Kussmaul Electronics 091-171 User Manual

IM_091-171-12

REV A, 06-26-2008

INSTRUCTION MANUAL

EMS

ADD-A-BAT

AUTOMATIC BATTERY CHARGER

& AUTOMATIC LOSSLESS BATTERY

ISOLATOR FOR DUAL BATTERY SYSTEMS

MODEL #091-171

INPUT: 115 Volt, 60 hz, 4.7 Amps

OUTPUT: 12 Volt, 20 Amps

battery system.

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: [phone] EMAIL:[e-mail]

INTRODUCTION

Many vehicles come from the factory with only a single battery. Often, especially in emergency
or police vehicles, a considerable number of electrical accessories are installed. This creates
an extreme burden on the battery and results in an unreliable system. In addition to a larger
alternator, it is often desirable to install a second battery. This additional battery can then be
dedicated to the accessory loads and the original battery is then used only for vehicle
operation.

The Model 091-171-12 Add-A-Bat is designed to simplify the installation of a auxiliary battery.
The Add-A-Bat consists of an automatic battery charger, a high current solenoid switch and a
Bar Graph display. The automatic battery charger recharges and maintains the batteries
whenever the vehicle is connected to a 115 volt AC source. The high current solenoid connects
the two batteries so that the alternator charges both when the engine is running while the display
indicates the voltage of each battery and the charger output current.

The accessory loads may be wired to auxiliary battery and thus are completely isolated from
the main vehicle battery. Whenever the vehicle is plugged into “shore power” the battery
charger recharges and maintains the two batteries separately. When the engine is running the
solenoid is energized connecting the two batteries to charge them simultaneously from the
alternator. Thus, a vehicle parked with the engine not running or with insufficient alternator
output, will have its solenoid de-energized and the accessories will only drain the auxiliary
battery. The main vehicle battery is protected and will always be available for engine starting.

Construction of the Add-A-Bat is extremely rugged to withstand the shock and vibration
normally encountered by vehicle mounted equipment. The unit operates completely automatically
and stops charging the batteries when they are fully charged.

There is no trickle charge and therefore no danger of overcharging and water boil-off. Any
parasitic loads on the battery such as radio, lights etc. are automatically supplied with current
from the charger.

BLOCK DIAGRAM

STARTER

ALTERNATOR

MAIN BATTERY SENSE

POWER

STARTER

ISOLATOR

STARTER

SOLENOID

STARTER

MAIN

BATTERY

PARALLELIN G

SOLENOID

IGNITION

SWITCH

SOLEN OID

DRIVER

MAIN
BATTERY
VOLTAGE

DETECTOR

AND

CHARGER

AUX.

BATTERY
VOLTAGE

DETECTOR

AND

CHARGER

TIMER

AUXILIARY BATTERY SENSE

Figure 1

ADD-A-BAT Block Diagram

AUXILIARY

BATTERY

SYSTEM OPERATION

The Add-A-Bat in addition to the dual independent automatic battery charger contains a
solenoid controller. The solenoid controller receives its power from the ignition switch. With
the switch “OFF” all the power is removed from the system and the solenoid is de-energized.

As soon as the operator turns the ignition switch “ON” the system is powered and detects the
voltage of the main and auxiliary batteries. If the auxiliary battery is 12.4 volts or greater,
(indicating sufficient charge) cranking the engine will cause the paralleling solenoid to be
energized. The engine is cranked with the two batteries in parallel yielding a faster start. A 10
second timer will maintain the 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
so that the solenoid remains energized and both batteries are charged.

If when the engine is started the auxiliary battery 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 shut down the ignition switch is placed in the “OFF” position. Power is removed
from the solenoid controller and the solenoid is de-energized. The batteries are thus isolated.

INSTALLATION

The Add-A-Bat should be installed in an area with adequate ventilation. The solenoid must be
installed as close as possible to the two batteries in order to limit the voltage drop in the high
current cables. The bar graph display should be located in a convenient place for the operator.

1. Mount the charger and solenoid using the holes shown in the outline drawing.

2. Connect the wiring from the batteries to the output terminal strip. Ferrule lugs that
have been securely crimped or soldered should be used.

3. Wire the indicator per the diagram.

4. Double check all wiring.

5. Turn on 115 volt AC power and note that power indicator is illuminated.

6. Note that charger output is 13.25 volts for each battery when batteries are fully charged.
Output volts may be lower while charging.

7. With both batteries fully charged, crank engine and note that the solenoid is energized
during cranking cycle.

INSTALLATION WIRING DIAGRAM

8 AMP FUSE

115 VAC,

AWG 16
MINIMUM

Line

Neutral

Ground

FUSE

INPUT

LN

0

BAT 1 BAT 2

+

+

.
N

I
M

E
R

I

W
G

W
A

2
1

#

OUTPUT

.

N

I
M

E
R

I
W

G

W
A

2
1

#

THIS LINE ENERGIZES THE
SOLENOID AT ENGINE START
IF THE AUXILIARY BATTERY
HAS SUFFICIENT VOLTAGE
TO PRO VID E A BOOST

2

5

10

9
8
7
6
5
4
3
2
1

REMOTE

+12VOLT
FROM
STARTER

TH IS L INE SUPP LIE S
T HE P OWE R TO OPE RATE
THE SYSTEM

+12VOLT
FROM
IGNITION
SWITCH

Chassis

Ground

#12 AWG WIRE MIN.

091-171-IND

#16 AWG WIRE MIN.

#16 AWG WIRE MIN.

Chassis

Ground

MAIN

BATTERY

#2 AWG MIN.

Chassis

Ground

AUXILIARY

BATTERY

FIGURE 2

IMPORTANT:
NOTE: Wire size is for a maximum length of 20 feet. If wiring is to be longer, larger
wiring is required. Additional information is available on request.

SPECIFICATION

BATTERY CHARGER when connected to shore line, Model 091-171

Input: 115 volt, 60Hz, 4.7 Amps
Input breaker: 8 Amp fuse breaker
Output: 12 V supplies 20 Amps max
Weight: 18 lbs

BATTERY CHARGER when connected to battery, Model 091-171

Volts to parallel: 13.3 volts, field adjustable
Battery load: .000125 Amps
Output current: 3 Amps

SOLENOID, Model 091-139-SOL-12HO

Volts: 12 volts D.C.
Coil Current: .65 Amps
Contact Rating: 200 Amps

OUTLINE

Solenoid

3.60

3.30

Battery Charger

6.75

AUTO CHARGE

12.00

4.75

2.80

12.75

9/32" DIA. 4 HOLES

4.25

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
employees or others.