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WP-20
User Manual
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KUSSMAUL WP-20 User Manual

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Page 1
Waterproof Charger
with Remote Monitor
Model: WP-20
User’s Manual
Table of Contents Page
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Manual-WP20 As of March 2012
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 2
The WP-20 is a rugged, waterproof and sophisiticated three state lead-acid battery charger. With a wide operating temperature range (-10 ºC to 55 ºC) and UL/CSA1236 certication, this product is especially suited for emergency vehicle
and severe environments.
Charging operation, LEDs, and relay control signals are generated by an embedded microcontroller that contains soft-
ware. The charger precisely controls charging voltage and current to insure a complete recharge every time. The charger may be left connected indenitely to the battery, maintaining full charge at all times.
1) INSTALLATION
1-1) Location
• Do not mount directly over or under a battery or onto a carpeted, upholstered or varnished surface.
• Install in an area where all charger electrical cords will avoid hot surfaces such as exhaust pipes and moving parts
such as fan wheels.
• Operating temperature is -10 ºC (-14 ºF) to 55 ºC (131 ºF). Storage temperature is -30 ºC (-22 ºF) to 80 ºC (176 ºF)
• Provide as much surrounding cooling clearance as possible. At a minimum, maintain an 8 inch clearance around the
perimeter and top side of the charger.
• Never mount in the vicinity of explosives, pressurized cans or other ammable material.
1-2) Mounting
• Wear safety goggles, gloves and a long sleeve shirt when drilling mounting holes near a battery.
• In most cases, #10 stainless steel mounting bolts with aircraft nuts or nylocks or #10 screws provide for solid mounting.
2) ELECTRICAL
2-1) DC Wire Connections
• The charger should be used only with a lead-acid type battery.
• DC wire connections to the battery should be made before plugging in the AC cord. Do not remove DC connections
while the AC cord is plugged in.
• When installing in the bilge and or battery compartment of boats, open hatches and operate bilge blowers if any for ten minutes to remove any fumes and hydrogen gas. Be certain the area is ventilated for personal health and safety.
• Keep wire routing from the charger to the battery neat and secure by anchoring with cable tie to a solid surface every few inches, not to exceed 18” intervals.
• As is true with any device connected to a battery, an in-line fuse added to the positive lead to the battery is required (installer provided) and will provide further protection if the DC cord is somehow damaged.
• For a single 12 volt battery, connect the charger lead set to the battery as follows; the charger red lead is connected to the battery positive terminal and the black charger lead is connected to negative terminal of the battery. When charging two 6 volt batteries connected in series connect the red lead of the charger to the positive terminal of battery #1. Connected the negative terminal of battery #1 to the positive terminal of battery #2. Connect the black lead of the charger to the negative terminal of battery #2. All connections should be clean and tight. See installation
diagrams.
• When connecting two batteries in series it is imperative that the amount of discharge be equal for both batteries or excessive battery voltage during charge will be occur resulting in an overvoltaged battery. This will cause dangerous
battery out gassing and destruction.
2-2) Electrical Characteristics
AC Input Voltage Range: 90 - 132 VAC
AC Input Current: 6A rms Maximum Max. Charging Current: 22A (Fast Mode)
Charging Voltage (Absorption Mode): 14.1 VDC, 4 amps Float Voltage (Float Mode): 13.5 VDC
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 1
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 3
2-3) AC Wire Connections
Note: The WP-20 is equipped with a factory installed 6’ grounded AC cord. Though hook up is only a matter of plugging this cord into a suitable extension cord, please follow the following precautionary tips.
• Insure that the AC cord cannot reach moving parts, lids, hoods, etc. Secure with a cable tie to solid anchor point if necessary.
• The charger will operate properly with either 115 volts 50 Hz or 115 volts 60 Hz AC input. Never use 220 volt service
with this unit.
CAUTION: Never connect the AC plug into an electrical outlet when you are wet or barefoot.
2-4) Remote Panel
A battery condition/charger status panel, model EVM-12-1, is provided. It indicates when the charger is “ON” and provides
a bar graph indicator of battery condition. See diagram below for wiring instructions.
Figure 1: 12V Battery Wiring Diagram with EVM-12-1
Single 12V Battery Connection
Red Wire Black Wire
+
1 Amp Fuse
*
+ Red
-
- Black
EVM-12-1 Rear View
Remote Panel
Brown
Black
Blue
1
2 3
4 5
1 X 3 4 X
Plug-in
Connector
See section 4, Figure 2 for
AC Power Cord
AC Power Cord
WP-20
FAST
CHARGING
ABSOPTION
MODE
FLOAT
0-6 AMPS
CHARGING
6-14 AMPS
CURRENT
14 -20 AMPS
RELIABLE - RUGGED - 3STAGE- AUTOMATIC
120V/20 AMP INTELLIGENT BATTERY CHARGER
WATERPROOF
AC POWER ON
CHARGING
STATUS
DC OUTPUT ON
MAX DC OUTPUT: 15VDC 20 AMPS MAX AC INPUT: 120V 6A AMPS 50 /60 HZ
CAUTION: For use with 12VLead Acid b attery system s only. Consult factory for servi ce or a pplicat ion que stions
AC
REMOTE
INPUT
METER
TM
DC
OUPUT
panel wiring wiring instructions.
Blue/18AWG
Blue/18AWG
(“Charger On” Signal)
SAFETY INSTRUCTIONS
(“Charger On” Signal)
CAUTION: The following are important safety instructions. Save these instructions.
• Charge only lead acid, (maintenance free or rellable), or “gel-cell”/AGM rechargeable batteries. Other types of batteries may burst causing personal injury and damage
• Never smoke or allow sparks or ame in the vicinity of a battery.
• Someone should be within range of your voice and close enough to come to your aid when you are working
near a battery.
• Wear eye protection and clothing protection. Avoid touching eyes while working near a battery.
• Have plenty of fresh water and soap nearby in case battery acid contact’s skin, clothing or eyes.
• If battery acid contact’s skin or clothing, wash immediately with soap and water. If acid enters eyes, immediately ood
eyes with running cold water for at least ten minutes and get immediate medical attention.
• Never operate a charger with a damaged cord or plug. Wearing of AC and DC cords, accidentally nicking or cutting the
cords could result in sparking and cause injury.
• Never operate a charger that has been damaged in any way or try to disassemble. Return to factory when service or replacement is required. Incorrect reassembly may result in electrical shock or re
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 2
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 4
• Become familiar with all instructions, specications and cautionary markings on chargers, batteries and equipment
used. Only adults should install and operate the charger. Children should be kept out of reach of the charger and all batteries.
• When using an extension cord the WP-20 requires a quality grounded extension cord of at least 16 awg wire size for cords up to 50’ and a minimum of 14 awg for cords up to 150’.
• Never unplug a cord by pulling on the cord itself. Always grasp the plug when disconnecting the charger.
• Never charge a frozen battery. If the battery has an odor or is visibly damaged disconnect charger and consult factory.
• Study battery manufacturer’s precautions such as removing or not removing cell caps while charging.
• Keep batteries full. Add distilled water in each cell until it reaches levels specied by battery. Check battery uid levels
regularly.
• Keep battery terminals clean. Always unplug charger before cleaning and be careful to keep corrosion from coming in contact with eyes.
• Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short circuit high enough to weld a ring, etc. to metal, causing a severe burn.
3) THREE STATE CHARGE CYCLE
The WP-20 employs a three state charge routine. This is the charging procedure most lead-acid battery manufacturers recommend to
return full capacity efciently and extend battery life. Please refer to the gure Three State Charging Curve diagram.
3-1) Stage I: Constant Current Charging or Bulk Charge Mode
(Fast - Red LED Illuminates)
Assuming the battery is starting in a discharged state, the charging is operating in constant current mode, where the charger current is maintained
at a constant value and the battery voltage is allowed to rise as it is being recharged. Approximately 80% of battery capacity is returned in the
constant current region.
3-2) Stage II: Absorption Mode (Amber LED Illuminates)
When the battery voltage reaches approximately 2.33 volts per cell, or
14.0 volts for a 12V battery, the charger voltage is held constant at this level and the battery current is allowed to reduce. This voltage is maintained
until the charging current reduces substantially or two hours elapse.
3-3) Stage III: Float Mode (Green LED Illuminates)
Float mode is the nal stage of the charging routine. Float mode is where the voltage on the battery is maintained at approximately 2.20 volts per cell, or 13.25 volts for a 12V battery. This voltage will maintain the full charge condition in the battery without boiling out electrolyte or overcharging the battery.
3-4) Charger Operation
The WP-20 is fully automatic once installed properly. The indictor lights (LEDs) informs the user of the progress of the
charging cycle and conrms proper connections.
3-5) LED Indicators
Charging Mode: Indicates the mode of charge cycle.
• Red LED = Charging current LED (Red) indicates amount of current being accepted by the battery. Fast Bulk charge mode.
• Green LED = AC Power On LED (Green) indicates AC power is applied to the charger and is Float mode.
• Amber LED = Absorption charge mode.
Charging Status LED indicates the output is connected properly to the battery and is being charged.
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 3
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 5
3-6) Protection Modes
Over Temperature: The unit inhibits until it cools off and then restarts automatically. This is indicated by the AC Power and Float LEDs ashing. In very high ambient temperatures, it is possible for the non-auto reset thermal protection to activate. This is indicated by the AC power “ON” and 14-20 Amp charging current LEDs ashing. If this occurs the AC power should
be disconnected and reconnected once the charger has cooled off.
Over Voltage: Activates in the event of a regulation malfunction and inhibits the charger. An over voltage condition is indicated by the AC Power On and Fast LEDs ashing. If the over voltage persists then the factory should be consulted.
4) Remote Panel Monitor
4-1) Parts Required
22 to 18 gauge interconnect wire is required to connect the meter panel to the 12 volt battery. A 1 amp fuse is recom­mended on the positive (+) sense lead. A cut-out saw and drill are required to complete the installation along with some
hand tools.
4-2) Before Installation
Remove AC and DC power from the battery charger before attempting to make any connections; this will prevent any
shorting and accidental damage to the charger, wiring, and the EVM-12-1 monitor.
Figure 2: 12V Battery Wiring Diagram with EVM-12-1
Single 12V Battery Connection
AC Power Cord
AC Power Cord
WP-20
FAST
CHARGING
ABSOPTION
MODE
FLOAT
0-6 AMPS
CHARGING
6-14 AMPS
CURRENT
14 -20 AMPS
RELIABLE - RUGGED - 3STAGE- AUTOMATIC
120V/20 AMP INTELLIGENT BATTERY CHARGER
WATERPROOF
AC POWER ON
CHARGING
STATUS
DC OUTPUT ON
MAX DC OUTPUT: 15 VDC 20 AMPS MAX AC INPUT: 120V 6A AM PS 50/6 0 HZ
CAUTION: For use with 12 VLead A cid bat tery s ystems only. Consult factory for se rvice or appl icatio n quest ions
AC
REMOTE
INPUT
OUPUT
METER
TM
DC
Blue/18AWG
(“Charger On” Signal)
Red Wire Black Wire
+
Blue/18AWG
(“Charger On” Signal)
Remote Panel
Connector Terminal
-
EVM-12-1 Rear View
EVM-12-1 Rear View
1 Amp
*
Fuse
Remote Panel
#1 Batt +
#2 Not Used
#3 Batt -
#4 Charger On Sense
#5 Not used
Brown
Black
Blue
Plug-in
Connector
* Installer Provided
Connection
1
2 3
4 5
1 X 3 4 X
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 4
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 6
4-3) EVM-12-1 Installation
Locate a visable place to mount the meter panel, front panel of meter is waterproof, so it is ok to install in an area exposed
to the weather. Refer to last page of manual for proper cut-out and mounting screw dimensions.
See Figure 2 above for wiring diagram. Route the Blue wire from the WP-20 to the meter panel cut-out. This wire can
be extended if necessary. Connect the Blue wire to terminal #4 on the ve position EVM terminal block/connector. Note,
screw terminal #5 and #2 are unused.
Next, using a two conductor cable (recommended wire size: 18-22 AWG) connect one end to the EVM terminal block/ connector terminals as shown on the next page and the other end to a 12 VDC source - see wiring diagram above.
Install a 1 amp fuse on the +12 VDC wire rst before connecting to 12 VDC, as close to the source as possible.
Note: If the meter panel is in an exposed area, use gasket included or apply a bead of silicone to the ange underside of the panel, (see Fig. 1 or 2) to prevent water intrusion behind the pane. Reconnect AC power to the charger, this completes
the installation.
4-4) Operation
A) Battery and Charger Status Indicators
The EVM-12 panel enables you to monitor when the charger is on and the batteries’ state of readiness at a glance. Red, orange, and green bar LEDs indicate the batteries’ state of charger, and a blue ‘Charger On’ LED is illuminated whenever AC power is connected to the charger. Flashing red bars indicate when High or Low voltage is detected. The display has a sleep mode to conserve power, and gives periodic ashing indication of the battery voltage level even when the vehicle engine and charger are off. In the event battery voltage drops to a critical level, the display will automatically come out of
sleep mode into full operation to alert the operator.
Battery status bar graphs operate as follows: With a fully charged battery, all ve green bars will be lit indicating a battery voltage of over 13 volts. As the battery discharges, the green bars will go out one at a time until three remain lit, which is about 12.4 volts. As the state of charge drops further, the bars will change to orange, indicating the battery is getting low, which is below 12.4 volts. As the voltage of the battery drops lower, orange bars will illuminate. Once the battery is nearly discharged, the orange bars will go out and one red bar will remain illuminated. As the voltage continues to drop further, one red bar will begin to ash, indicating the battery is discharged to 11.2 volts and should be re-charged as soon as pos-
sible.
In the event that the battery voltage goes too high, over 15 volts, the entire 5 red segments will ash red to indicate an over voltage condition. If this should occur while the vehicle’s engine is in operation, it’s possible there is a fault within the alternator/charging system. This can be checked by shutting off the vehicle’s engine and observing if the battery status upper red bars quit ashing. If an over voltage indication is observed when the vehicle’s engine is not running disconnect power from the battery charger and observe the panel to verify that the blue ‘Charger On’ LED is out and the upper red LED bars have quit ashing and are now green. If so, the battery charger’s output voltage should be tested to insure it is
correct for the battery type selected.
B) Time-Out Feature/Sleep Mode
To conserve battery power, the EVM-12 has a time-out feature called ‘sleep mode’ which activates after a period of 48 hours if the charger and/or the vehicle is off and either battery voltage is below 13 volts. The meter will automatically come out of sleep mode whenever either battery(s) voltage is above 13 volts. When the meter is in the sleep mode, the LED segments will blink once every 2-3 seconds. The LED’s which blinks also indicates the voltage level of that battery. Therefore, it is possible to monitor the battery voltage even in sleep mode. Sleep mode reduces battery current drain. In the event that battery #1 or battery #2 voltage drops below 11.9 volts, the display will come out of sleep mode and the LED segment will illuminate to indicate the battery’s state of charge. If low battery condition is noticed, the battery should
be re-charged as soon as possible.
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 5
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 7
C) Start-Up Sequence Mode
The EVM cycles through a test mode when power is applied. The blue ‘Charger On’ LED will rapidly ash and each
segment of both bar graphs will light up sequentially starting from the bottom red bar, then changing to all yellow at the
second LED, and then changing to all green up to the fth bar.
Finally, all LED segments will change to ashing red, and then normal operation begins. As an option, test mode can be
initiated and the display reset by installing a momentary switch (normally closed) in line with battery #1 sense wire. When the switch is pushed, it will interrupt power to the meter which initiates the test mode and resets the meter. This can be used to take the meter out of sleep mode, if so desired.
4-5) Remote Panel Specications
Electrical
Input Voltage: 9-16 VDC (12 VDC vehicle battery systems), Negative Ground
Bar Graph Display Voltage
Output Reference
All 5 bars ash RED > 15V
All 5 bars GREEN between 13-15V
3-4 bars GREEN between 12.2 - 13.0V
2 bars YELLOW between 11.8 - 12.2V
1 bars RED between 11.2 - 11.8V
1 ashing RED < 11.2V
Mechanical
Case Size: 4.75” W x 3.125” H x 0.72” D” (with connector) Display case front: Waterproof
Rear panel gasket provided
5) Technical Assistance
If you have any questions about the proper operation of your WP-20 Charger or EVM-12-1 meter, please contact Kussmaul’s Technical Assistance: Phone: 631-567-0314, from the hours of 7:30 a.m to 5:00 p.m. weekdays, E.S.T.; Fax: 631-567-5826, anytime; or E-mail: sales@kussmaul.com, anytime
6) Warranty
All products of Kussmaul Electronics Company Inc. are warranted to be free of defects of material or workmanship. Liability is limited to repairing or replacing at our factory, without charge, any material or defects which become apparent in normal use within 3 years from the date the equipment was shipped. Equipment is to be returned, shipping charges prepaid and will be returned, after repair, shipping charges paid.
Kussmaul Electronics Company, Inc. shall have no liability for damages of any kind to associated equipment arising from
the installation and /or use of the Kussmaul Electronics Company, Inc. products. The purchaser, by the acceptance of the equipment, assumes all liability for any damages which may result from its installation, use or misuse, by the purchaser, his or its employees or others.
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 6
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
Page 8
7) Outline and Mounting Drawing
8) EVM-12-1 Mounting Diagram
170 Cherry Ave., West Sayville, New York 11796
www.kussmaul.com
Pg. 7
Phone: 800-346-0857
Fax: 631-567-5826
E-Mail: sales@kussmaul.com
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