FILE: IM_091-128-XX-XX-(XXX)(XX)_revA.P65
REV: A
REVISED BY: PSS
DATE: 07-19-13
INSTRUCTION MANUAL
R
AUTO CHARGE
3 STEP
AUTOMATIC BATTERY CHARGER
MODEL #091-128-XX-XX-(XXX)(XX)
170 Cherry Ave.
West Sayville, NY 11796
www.kussmaul.com
3 YEAR WARRANTY
Phone: 631-567-0314
Fax: 631-567-5826
sales@kussmaul.com
INTRODUCTION
The Auto Charge-3 STEP CHARGER, Model 091-128-XX-XX-(XXX)(XX) is a compact,
completely automatic single channel battery charger designed specifically for periodic
charging. Of rugged construction, the charger is made to withstand the shock and
vibration encountered in vehicle mounted equipment. Utilizing components, which meet
international safety standards, makes this charger ideal for worldwide applications.
BATTERY CHARGER FEATURES
Completely automatic operation, charges battery on demand
Output Voltage regulated, eliminates overcharging battery
Output Voltage, temperature compensated (optional)
Output, current limited to protect charger from overloading
A 5-LED display indicating charge state and faults
Reverse polarity protection
INSTALLATION
The 3 STEP CHARGER should be installed in an area with adequate ventilation.
Mount the charger using the four holes provided.
Connect wiring from the battery to the output terminal strip.
Double check battery wiring. Verify that the battery voltage appears at the charger
output terminals (See Figure 2).
PRINCIPLES OF OPERATION
A three-step lead acid battery charger operates in the three stages described below:
1) A discharged battery is recharged at a constant current (bulk charge) until its voltage reaches an overcharge level of 2.42 volts per cell (approximately 14.5 vdc for a
12V battery). At this time the charger will switch to Finish Charge. The battery
accepts 75-85% of its capacity during bulk charge.
2) This overcharge voltage is now maintained constant at 2.42 volts per cell (absorp-
tion or finish charge) until the charge current tapers down to {battery capacity/35}
amperes. For the 12 volt, 40 ampere charger this current is 6 amperes. The battery
accepts 15-25% of it capacity during absorption charge.
3) Once the charge current reaches the tapered down value (see above), the voltage is
set to a float voltage of 2.24 volts per cell (approximately 13.4 vdc for a 12V battery), and maintained at float charge. The battery is maintained at full charge during
float charge, and the green indicator labeled “Battery Charged” is illuminated.
Figure 1 depicts the above described operation. Note that the term “absorption charge”
is used interchangeably with “finish charge”. Upon application of AC power, the charger
is placed into bulk charge. When the charger switches to finish charge, a timer starts.
In the event that the charge current did not taper down to approximately C/35 amperes
after 2 ½ hours, the charger will automatically go to float charge, and a timeout will be
indicated. This timeout indicator can indicate an old or leaky battery, or it can indicate
that the charger is undersized for the battery being charged.
A battery fault indicator is provided to indicate the absence of a battery, a battery connected with reverse polarity, or a battery with an open circuit terminal voltage of less
than 1.35 volts per cell.
TEMPERATURE COMPENSATION
Temperature compensation is provided as an optional feature. A temperature probe is
provided which can be placed in the air surrounding the battery or bonded to the battery
case.
THREE STAGE CHARGING CURVE
BATTERY
CURRENT
BATTERY
VOLTA GE
FLOAT
STAGE
ABSO RPTION STAGE
Voltage Increasing
Current Constant
Voltage Constant
Current Decreasing
Voltage Constant
Full Charge Maintained
STAGE I
CONSTANT CURRENT
(BULK)
STAGE II
CONSTANT VOLTAGE
(ABSORPTION)
STAGE III
CONSTANT VOLTAGE
(FLOAT)
TIME
Figure 1
AUTO CHARGE
FUS E
BATTE RY FA ULT
TIME OU T
BUL K C HAR GE
FINIS H C HA RGE
BATTE RY C HARGED
3 STE P AUTO MATIC B ATTERY CHA RGER
BAT
+
#2 #1
TEMP. SENSEOUTPUT
L
N
INP UT
CHARGING WIRE SIZE
VOLTS AWG
12
24
32
36
48
72
96
120
8
10
12
12
12
14
14
14
+
-
THERMISTOR (OPTIONAL)
BATTERY
BLACK
GREEN
WHITE
A.C. INPUT
POWER
Figure 2
INSTALLATION WIRING
S
P
ECIFI
CATIONS
:
Input Power & Fuse:
Output Power:
Charge Indicator:
Mode Indicators:
Recommended Battery Size:
Weight:
Temperature Compensation:
See Chart
See Chart
See Chart
Battery Fault, Timeout, Bulk Charge & Battery Charged
See Chart
28 pounds
Add suffix “TC” to Model Number shown in table
Model Number Definition:
091-128-XX-XX-XXX-XX
Add “TC” suffix to Temperature Compensated Units
Input Voltage, (not necessary to specify for standard 115 volt model)
Output Current
Output Voltage
Model
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Figure 3
OUTLINE DRAWING
INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
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.
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 employes or others.
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