Kussmaul Electronics 091-168-12 User Manual

FILE: 091-168-12 rev a.pmd
REV A: 4/30/2007

INSTRUCTION MANUAL

AUTO CHARGE

SD 150

AUTOMATIC BATTERY CHARGER

MODEL #091-168-12

INPUT: 115 VOLTS, 50/60 Hz

OUTPUT: 50 AMPERES

3 YEAR WARRANTY

KUSSMAUL ELECTRONICS CO., INC.

170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221

Phone: [phone] Toll Free: 800-346-0857 Fax: [phone]

Web: www.kussmaul.com E-Mail: [e-mail]

INTRODUCTION

The Auto Charge SD 150, Model 091-168-12, is a state of the art, high output completely

automatic single channel battery charger specifically designed for recharging and maintaining

the multiple batteries as found in modern emergency vehicles. The charger contains many

features that enhance performance and provide the vehicle user with self-diagnostics of the

chargers operation.

1. The charging protocol is a modifed 3-step configuration. Whenever the vehicle is

powered from a shore line the charger charges the battery at a "boost" rate of 14.25 volts

for approximately 1.5 hours. At the completion of the boost phase the output voltage

switches to the float rate of 13.25 volts.

2. An external dual bar graph indicator displays the chargers actual output voltage and

current.

3. An analog meter on the front of the charger also indicates charger output.

4. Output voltage of the charger is constant voltage, controlled by the patented "Sample

and Hold" circuitthat eliminates the voltage drop in the charging wires and current limited

to protect the charger and the batteries.

5. Maximum charger output current is limited to 50 amperes.

6. The charger is reverse polarity protected to prevent damage if the output wires are

inadvertently reversed.

SELF DIAGNOSTIC DISPLAY

The charger contains self diagnostic circuits whose outputs are displayed on a 10 LED display.

These aid in charger installation, servicing, and troubleshooting and are as follows

RESET

BATTERY CONNECTION

R

E SD

CHARGER

POWER

EQUALIZED

HI RESISTANCE

HI TEMPERATURE

HI VOLTAGE

LOW VOLTAGE

SHUTDOWN

CHARGER INOP.

FAN ON

SELF DIAGNOSTIC DISPLAY (cont.)

POWER:

BATTERY CONNECTION:

EQUALIZE:

HI RESISTANCE:

HI TEMPERATURE:

Indicates that A.C. input power is present.

Indicates that a battery of proper polarity is connected to the
charger output terminals.

Indicates that the charger is in the boost mode and is charging the
battery at 14.25 volts. This is a temporary condition that lasts for
approximately 1.5 hours after the start of charging. When EQUAL­IZE light is OFF, charger is in FLOAT mode and charging at 13.25
volts.

Indicates a high resistance in the D.C. output, either the positive
or ground connection. This requires service - either clean the
connections on the D.C. output terminal strip, or at the other end
of those wires. If cleaning and tightening does not correct the
problem, increase the wire size.

Indicates a high temperature internal to the charger. Temperature

HI VOLTAGE:

sensors are located on the D.C. output wires close to the terminal
strip. Hi Temperature will shut down the charger and sound an
alarm. The alarm buzzer is periodic 10 seconds ON and 10
seconds OFF. A RESET switch is provided above the LED
Display to restart the charger after cool down. Alternatively the
shutdown is reset when the A.C. power is removed from the
charger.

Indicates that the charger output has exceeded 15.0 volts. This will
sound the alarm buzzer and shut the charger down. Pressing the
RESET switch will reset the HI VOLTAGE alarm and restart the
charger. If the high voltage was temporary, the charger will operate
normally. If unable to reset an internal malfunction is indicated.

SELF DIAGNOSTIC DISPLAY (cont.)

LOW VOLTAGE:

SHUTDOWN:

CHARGER INOP.:

FAN ON:

Indicates that a low output voltage has been detected. This may be
due to excessive load on the charger - Check ammeter indication.
If due to discharged battery, charger output current will be high and
LOW VOLTAGE indicator will be extinguished when battery is
recharged. If indicator is due to high parasitic loads then these

must be reduced to permit the charger to recharge the batteries.

Indicates that the charger is shutdown either due to HI VOLTAGE
or to HI TEMPERATURE. This indicator illuminates simultaneously
with the alarm buzzer.

Indicates an inoperative charger creating a low output current and
a low output voltage. Probably requires charger servicing.

Indicates that the fan is operating. Fan operates whenever output

current exceeds 8 amperes.

INSTALLATION

1. The Auto Charge SD 150 should be installed in an area with adequate ventilation.

2. Mount the charger with the four holes provided.

3. Wire the charger in accordance with figure 1.

4. Double check all wiring. Verify that the battery voltage appears at the charger output

terminals - see figure 1. Battery voltage must appear at the charger output terminals, a

minimum of 6 volts is required to start the charger.

5. Apply 115 volts to input terminal and observe that the charger is operating. The Bar Graph

need not be connected for the charger to operate.

INSTALLATION WIRING DIAGRAM

RESET

POWER

EQUALIZED

HI RESISTANCE

HI TEMPERATURE

HI VOLTAGE

LOW VOLTAGE

SHUTDOWN

CHARGER INOP.

FAN ON

FUSE

BATTERY CONNECTION

AUTO CHARGE SD

R

AUTOMATIC BATTERY CHARGER

A.C. Input
Power

Black

White

Green

INPUT

LN

Strip insulation to
11/16” and install
wire ferrule
supplied, 2 places

+

OUTPUT

T

A

B

Amps

Volts

GND

+12V

REMOTE

5

4

3

2

1

Y

R

E

T

IMPORTANT: Minimun wire size on charger output and ground is #6 AWG for a maximum
length of 25 feet. If wiring is to be longer, #4 AWG wire is required. Smaller gauge wire may
cause overheating of terminal. Additional information is available upon request.

NOTE: Use two(2) TERFEB612 Wire Ferrules over wire to simplify insertion of wire into
terminal strip and improve connection.

SPECIFICATIONS & OUTLINE

Specifications:
Input Power: 115 VAC, 50/60 Hz, 15 Amps
Input Over Current Protection: Fuse; 20 Amp, Slow-Blow
Output Power: 12 to 14.25 VDC, 50 Amperes Current Limited
Charge Indicator: 75 Amperes
Weight: 28 Pounds

Figure 2

Outline Drawing

8-32 SCREW

INDICATOR INSTALLATION

INDICATOR

GASKET

HOLE TEMPLATE

#8-32 HEX NUT

TRUCK WALL

LOCK & FL AT WASH ER

Hole Template may not be to Scale, please check dimensions before using.

File: Ind.cdr rev C: 3-31-10 do not shrink this art wo rk

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 or others.