INSTRUCTION MANUAL
AUTO CHARGE 12 HO
AUTOMATIC SINGLE OUTPUT BATTERY CHARGER
File: IM_091-170-xx_revd.indd
Rev: D
Revised By: MFG
Date: 10-23-2013
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
MODEL #: 091-170-6
MODEL #: 091-170-12
MODEL #: 091-170-24
3 YEAR WARRANTY
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device for more information
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
IMPORTANT SAFETY INSTRUCTIONS
I. PERSONAL PRECAUTIONS:
1. Someone should be within range of your voice or close enough to come to your aid when you work near
a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye and clothing protection. Avoid touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If battery acid enters
the eye, immediately ood eye with cold running water for at least 10 minutes and get medical attention
immediately.
5. NEVER smoke or allow a spark or ame in the vicinity of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit
the battery or other electrical part and cause a re or an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
lead-acid battery. A lead-acid battery, when shorted, can produce a current sufcient to weld a ring or the
like metal causing a severe burn.
8. Use the battery charger for charging gel-cell, AGM and ooded lead-acid batteries only. Do not use the
charger for charging dry-cell batteries that are commonly used with home applications. These batteries
may burst and cause injury to persons and damage to property.
9. WARNING – RISK OF EXPLOSIVE GASES: Working in the vicinity of a lead-acid battery is dangerous.
Batteries generate explosive gases during normal battery operation.
II. CHARGER PRECAUTIONS:
1. NEVER charge a frozen battery.
2. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to
damage or stress.
3. Do not operate the charger with a damaged cord or plug; replace them immediately.
4. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged.
5. Do not disassemble the charger. Incorrect reassembly may result in a risk of electric shock and re.
6. To reduce the risk of electric shock, disconnect the charger from the AC source before attempting any
maintenance or cleaning.
7. LOCATION OF CHARGER: The charger should be mounted on a wall, vehicle oor, ventilated compartment or other suitable surface as close to the batteries to be charged as possible. Do not block the charger’s fan or air intakes. Do not mount the charger directly over the batteries as fumes may cause exces-
sive corrosion. The area should be well ventilated and free from excessive moisture, exhaust manifolds,
and battery fumes. For maximum performance, the charger should not be located in an area of extreme
high temperature. The charger is not waterproof. Do not mount the charger where there is a possibility of
water entering the unit. Evidence of water entry into the charger will void the warranty.
8. CAUTION: Do not attempt to increase battery bank capacity by splitting the output of one of the banks
with a diode-type battery isolator. The diode isolator lowers the charger voltage and results in undercharging the batteries connected to it. If additional capacity is required it is preferable to add another
isolated or parallel battery.
III. GROUND AND AC POWER CORD CONNECTION:
1. The charger should be grounded via the AC power connection to reduce the risk of electrical shock.
2. The charger must be plugged into or wired to an outlet that is an over-current protected 3 prong outlet.
Alternatively, it may be routed through a separate dedicated fuse or circuit breaker on an AC distribution
panel with proper earth/safety ground. All wiring shall comply with UL recommendations, NEC or NFPA
standards and local ordinances. Never alter the AC cord or plug if provided. Any modication of the cord
must only be done by a qualied electrician. Improper cord/outlet connection may result in a risk of elec-
trical shock.
3. Observe color coding of the AC wiring as follows:
Black………....................... AC Hot or LINE (fused)
White…………................... AC Neutral
Green…….................…….. AC Ground (safety/earth)
4. CAUTION: (230 VAC applications only): If AC input is provide from a source consisting of two HOT or
LINE leads (phase-to-phase 230 VAC input voltage); an external fuse or circuit breaker must be used to
protect both hot leads.
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
2
INTRODUCTION
The Auto Charge 12 HO, Model 091-170, is a high output fully automatic battery charger for vehicles
with a single battery system. A patented “Sample & Hold” circuit is utilized to detect the actual battery
voltage. This eliminates the error due to the current flowing in the charging wires and assures that the
battery is charged to the precise float voltage. A current limiter prevents overloading the charger when
charging a deeply discharged battery or driving large parasitic loads. The charger is ruggedly constructed
to assure reliable operation when mounted in a vehicle.
FEATURES
I. AUTO CHARGE 12 HO BATTERY CHARGER
• Electronic remote sensing of true battery voltage, eliminates the need for sensing wires
• Automatic current limiting
• Optional Remote Battery charge/condition indicator display
• Power “ON” LED status indicator
II. CHARGE CONTROLS & ELECTRONIC REMOTE SENSING
The Auto Charge 12 HO contains a precision voltage controller to maintain the battery’s charge.
Automatic electronic remote sensing measures the true battery voltage, eliminating the need for the
additional sense wires. The output current of any charger is inherently a series of pulses whose
frequency is determined by the power line frequency. Therefore, there are brief intervals during
which no charging current ows. Since there is no charging current there is also no voltage drop
between the charger and the battery. The Auto Charge 12 HO measures and stores the true battery
voltage. This battery voltage is compared to a reference voltage, any error detected is then used to
control the charger output at the desired level. There is no “trickle charge” and therefore no danger
of overcharging and water boil-off.
III. AUTOMATIC CURRENT LIMITING
When batteries are severely discharged, some battery chargers can be overloaded due to the high
charging current required. The Auto Charge 12 HO contains an automatic current limit. The current
limit feature limits the output current to the max. amperes of the charger output when charging a
deeply discharged battery or if the starter cranks the engine while charging. The current limiter thus
eliminates the need for an ignition interlock circuit.
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
3
IV. LED STATUS INDICATOR
1. POWER: Indicates that AC voltage is present
WIRING
I. BATTERY CHARGER WIRING INSTRUCTIONS
1. Refer to Installation Wiring Diagram.
2. Refer to Wiring Specications to determine the recommended wire size and maximum lengths.
Using a smaller gauge may cause overheating of the terminal. Additional information is available
upon request if longer, larger wiring is required.
3. Double check all wiring before applying AC power volts to input terminal.
4. Apply AC power (shoreline power) to input terminal and observe that the charger is operating.
5. Verify that the battery voltage appears at the charger output terminals.
II. WIRING SPECIFICATIONS
1. For Model #: 091-170-6
Length of Wire to Battery (feet) 0 - 5 < 5 - 10** < 10 - 20*
Battery Charger Connections
* Consult factory if length of wire to battery is longer than 20 feet
BAT + COM BAT + COM BAT + COM
12 12 10 10 8 8
2. For Model #: 091-170-12
Length of Wire to Battery (feet) 0 - 5 < 5 - 10** < 10 - 20*
Battery Charger Connections
* Consult factory if length of wire to battery is longer than 20 feet
BAT + COM B AT + COM BAT + COM
12 12 10 10 8 8
3. For Model #: 091-170-24
Length of Wire to Battery (feet) 0 - 5 < 5 - 10** < 10 - 20*
Battery Charger Connections
* Consult factory if length of wire to battery is longer than 20 feet
BAT + COM BAT + COM BAT + COM
14 14 12 12 10 10
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
4
INSTALLATION WIRING DIAGRAM
I. FOR MODEL #: 091-170-6, SHOWN WITH OPTIONAL BAR GRAPH DISPLAY, 091-199-001
Wiring Diagram shown is for a 10 foot installation
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
5
II. FOR MODEL #: 091-170-12, SHOWN WITH OPTIONAL BAR GRAPH DISPLAY, 091-199-001
Wiring Diagram shown is for a 10 foot installation
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
6
III. FOR MODEL #: 091-170-24, SHOWN WITH OPTIONAL BAR GRAPH DISPLAY, 091-199-001
Wiring Diagram shown is for a 10 foot installation
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
7
SPECIFICATIONS
Model
Number
091-170-6 6.62 20 115 50/60 2 25 4 40 16
091-170-12 13.25 20 11 5 50/60 2 25 8 40 16
091-170-24 26.50 12 11 5 50/60 2.5 15 5 24 16
Output
Float Voltage
(Vdc)
Output
Current
(Amps)
Input
Voltage
(Vac)
Input
Frequency
(Hz)
Input
Current
(Amps)
Current
Meter
(Amps)
Input
Fuse
(Amps)
Output
Fuse
(Amps)
Weight
(lbs.)
OUTLINE DRAWING
6.75
AUTO CHARGE
12.00
12.75
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
4.75
9/32" DIA. 4 HOLES
4.25
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
8
INSTALLATION RECORD
DATE INSTALLED _______________________________________________________
INSTALLED BY _________________________________________________________
VEHICLE IDENTIFICATION _______________________________________________
VEHICLE OWNER _______________________________________________________
WARRANTY POLICY
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 Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
9
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