File: IM_091-139-2-12_revC.pmd
REV C
03-30-2012
INSTRUCTION MANUAL
AUTO ISOLATOR I
AN AUTOMATIC LOSSLESS BATTERY ISOLATOR
FOR DUAL BATTERY SYSTEMS
MODEL# 091-139-2-12
BATTERY VOLTAGE: 12 VDC
OUTPUT: 12 VOLTS, 3 AMPS
BATTERY PARALLELING SOLENOID: 200 AMPS
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826 EMAIL:Sales@Kussmaul.com
INTRODUCTION
A
R
The Model 091-139-2-12 AUTO ISOLATOR I system is a lossless isolator replacement for the
conventional diode isolator. Designed to be installed in a vehicle with one or more Main
batteries that must be isolated from one or more auxiliary batteries. The system consists of
a voltage detector and controller Model 091-139-CONT-12 and a separate 200-ampere rated
solenoid, Model 091-139-SOL-12HO for switching the batteries. In addition to maintaining
battery isolation the AUTO ISOLATOR I may parallel the batteries on engine starting if the
auxiliary battery has sufficient charge to assist in the cranking. A block diagram of the system
appears in figure 1.
STARTE
PUSH BUTTON
STARTER
SOLENOID
MAIN
BATTERY
MAIN BATTERY SENSE
AUXILIARY BATTERY SENSE
STARTER
ISOLATOR
MAIN
BATTERY
VOLTAGE
DETECTOR
AUX.
BATTERY
VOLTAGE
DETECTOR
ALTERNATOR
UXILIARY
BATTERY
POWER
IGNITION
SWITCH
PARALLELING
SOLENOID
DRIVER
TIMER
SOLENOID
Figure 1
Block Diagram
SYSTEM OPERATION
The system receives its power from the ignition switch. With the switch “OFF” all the power
is removed from the system and the solenoid is deenergized.
As soon as the operator turns the ignition “ON”, the system is powered and detects the voltage
of the main and auxiliary batteries. If the auxiliary battery voltage is 12.4 volts or greater,
(indicating sufficient charge) cranking the engine will cause the paralleling solenoid to be
energized. A 10-second timer will maintain the paralleling solenoid if the engine doesn’t start
immediately and must be cranked a second time. When the engine starts the alternator output
raises the battery voltage. This increase in voltage is detected and the paralleling solenoid is
held energized charging both batteries.
If when the engine is started the auxiliary battery voltage is below 12.0 volts the paralleling
solenoid is not energized while cranking. As soon as the engine starts, the alternator raises
the main battery voltage and the solenoid is energized charging both batteries.
Upon engine shutdown the ignition switch is placed in the “OFF” position. Power is removed
from the Auto Isolator and the solenoid is deenergized.
INSTALLATION
A
A
Install the 091-139-CONT-12 Controller is a suitable location protected from the weather and
engine heat. The 091-139-SOL-12HO Solenoid may be mounted in the engine compartment
or at a location to minimize the length of the battery cables. Install wiring per figure 2.
THIS LINE ENERGIZES THE
SOLENOID AT ENGINE START
IF THE AUXILI ARY BATTERY
HAS SUFFICIENT VOLTAGE
TO PROVI DE A BOOST
THIS LINE SUPPLIES
THE POWER TO OPERATE
THE SYSTEM
UTO ISOLATOR I CONTROLLER
091-139-CONT12
+12VOLT
FROM
IGNITION
SWITCH
1 2 3 4 5 6 7 8
PA RAL LE L IN G
SOLENOID
SENSE LINE, CONNECT
DIRECTLY TO BATTERY
MAIN
BATTERY
LL WIRES #16 AWG EXCEPT AS NOTED
SENSE LINE, CONNECT
DIRECTLY TO BATTERY
#2 AWG MIN.
+12VOLT
FROM
STARTER
AUXILIA RY
BATTERY
Figure 2
AUTO ISOLATOR I
Model 091-139-12
INSTALLATION WIRING
CALIBRATION
The voltage setpoints may be altered in the field to suit particular customer requirements.
Adjustments are provided to adjust the main battery voltage at which the paralleling solenoid
is energized. An additional adjustment permits adjusting the voltage below which the auxiliary
battery will not be paralleled for starting boost.
CW INCREASES VOLTAGE
INDICATOR ILLUMINATED WHEN MAIN
BATTERY VOLTAGE IS ABOVE SETPOINT
13.0 VOLTS
AUXILIARY BATTERY VOLTAGE ADJUST
MAIN BATTERY VOLTAGE ADJUST
MAIN AUX.
R6
C6
R7
C1
U1
C2
+
R9
R8
U3
OUTPUT
I2
Q1
CR3
CR4
CR1
R3
CI1 R10
R2
J1
VCC+
CR2
INDICATOR ILLUMINATED WHEN
AUXILIARY BATTERY VOLTAGE IS
ABOVE SETPOINT, 12.4 VOLTS
R4
MAIN
R15
R13
R18
C7
R19
U2
GND
R17
R21R1
U5
KUSSMAUL ELECTRONICS CO
R16
AUX
BAT.
OK
I1
U4
C3
AUX.
BAT.
OK
I4
R20
R12
R11
+
C4
C5
ILLUMINATES DURING
ENGINE CRANKING
I3
STARTER
B091-139-002
MAIN
87654321
MEASURE AUX. BAT. VOLTAGE HERE
MEASURE MAIN BAT. VOLTAGE HERE
Figure 3
VOLTAGE ADJUSTMENTS
AUTO ISOLATOR 1
SPECIFICATION AND OUTLINE
CONTROLLER, Model 091-139-CONT12
Volts to parallel, normal operation: 13.0 volts, field adjustable
Volts to parallel , start boost: 12.4 volts, field adjustable
Battery load: .000125 amps.
Output current: 3 amps
Weight: .4 lbs.
SOLENOID, Model 091-139-SOL-12HO
Volts: 12 volts D.C.
Coil current: .45 amps
5.10
3/16" DIA.
OUTLINE, AUTO ISOLATOR I CONTROLLER, 091-139-CONT12
3.60
4,50
2.95
1.55
3.30
2.80
OUTLINE, AUTO ISOLATOR I SOLENOID, 091-139-SOL-12HO
INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
WARRANTY
All product 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
employees others.
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