INSTRUCTION MANUAL
AUTO CHARGE
1200
AUTOMATIC SINGLE OUTPUT BATTERY CHARGER
Unit supplied with
one of these displays
File: IM_091-187-12_revD.indd
Rev: D (Added AGM/FLD)
Revised By: PSS
Date: 3-26-2015
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
MODEL #: 091-187-12
INPUT: 120 Volt, 60 Hz, 10 Amps
OUTPUT: 40 Amps
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 1200 Remote is a compact, completely automatic, single channel battery charger
designed for vehicles with a single battery system. The charger is ruggedized to withstand the shock
and vibration encountered by vehicle mounted equipment.
FEATURES
I. AUTO CHARGE 1200 BATTERY CHARGER
• Electronic remote sensing of true battery voltage, eliminates the need for sensing wires
• Automatic current limiting
• LED status indicators
• Local and optional Remote Battery charge/condition indicator display
• NEW! Battery Selector Switch (Lead-Acid/AGM)
II. CHARGE CONTROLS & ELECTRONIC REMOTE SENSING
The Auto Charge 1200 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 1200 thus 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 1200 contains an automatic current limit. This circuit
limits the output current to the rated 40 amperes 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.
IV. LED STATUS INDICATORS
1. BATTERY CONNECTED: Indicates that a battery of proper polarity is connected to the charger
output terminals
2. FAN ON: Indicates that the fan is operating. Fan operates whenever output exceeds 10 amperes.
Fan turns off when output current decreases below 5 amperes
3. POWER: Indicates that AC voltage is present
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
3
IV. LOCAL BATTERY CHARGE CONDITION INDICATOR
This indicator shows the charge condition of each battery in 10 levels from “LOW CHARGE” to
“FULLY CHARGED”. This device indicates a defective battery when a bar graph does not rise to
the “FULLY CHARGED” level after an extended period of charging.
NOTE: If a battery is being charged with an external load of 4 to 10 amperes across, the bar graph
may move down 1 or 2 levels. This does not indicate a defective battery.
VI. BATTERY SELECTOR SWITCH
Used to select between Lead-Acid or AGM batteries. The selector switch is factory set to Lead-Acid.
WIRING
I. BATTERY CHARGER WIRING INSTRUCTIONS
1. Refer to Installation Wiring Diagram I. and II.
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. Make sure the position of the Battery Selector Switch matches the battery type. The switch is
factory to Lead-Acid. Switch to AGM when using AGM style batteries. Refer to Wiring Diagram
III.
4. Double check all wiring before applying AC power to input terminal.
5. Apply AC power (shoreline power) to input terminal and observe that the charger is operating.
6. Verify that the battery voltage appears at the charger output terminals. A minimum of 6 volts is
required to start the charger
II. WIRING SPECIFICATIONS
Length of Wire to Battery (feet) 0 - 5 < 5 - 10** < 10 - 20*
Battery Charger Connections
Wire Ferrule Used 091-TERFER812 091-TERFEB612 None
* Consult factory if length of wire to battery is longer than 20 feet
** Supplied with wire terminal hardware for 10 foot installation
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
V. BAT + COM - V. BAT + COM - V. BAT + COM -
8 8 6 6 4 4
sales@kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
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INSTALLATION WIRING DIAGRAM
I. FOR BAR GRAPH DISPLAY, 091-199-001 OR DELUXE STATUS CENTER, 091-194-IND
Wiring Diagram shown is for a 10 foot installation
Use 8 AWG
or larger on
Output & Gnd
OUTPUT
+
INPUT
LN
REMOTE
DISPLAY
BAT
FAN
PWR
4
3
2
1
Remote
Indicator
4 - GREEN 20AWG
3 - WHITE 20AWG
2 - BLACK 20AWG
1 - RED 20AWG
5
4
3
2
1
Strip insulation to 11/16”
Install P/N: 091-TERFEB612,
Wire Ferrule supplied, 2 places
80
Amp
Waterproof Circuit Breaker
Kussmaul Part #: 090-0080-0
Or lace near the batteryFuse, P
RED (6AWG)
RED (6AWG)
BLACK (6AWG)
+
BA
TT
A.C. INPUT POWER
GROUND
(Green 14AWG)
NEUTRAL (White 14AWG)
LINE (Black 14AWG)
AC CONNECTIONS TO THE
CHARGER SHALLCOMPLY
WITH UL RECOMMENDATIONS,
NEC, or NFPA STANDARDS
-
Y
R
E
5
II. FOR WATERTIGHT DELUXE STATUS CENTER, 091-194-IND-WT-XX
Wiring Diagram shown is for a 10 foot installation
Remote
Indicator
Use 8 AWG
or larger on
Output & Gnd
OUTPUT
+
INPUT
LN
4 - GREEN 20AWG
3 - WHITE 20AWG
2 - BLACK 20AWG
1 - RED 20AWG
BAT
FAN
PWR
4
3
2
1
REMOTE
DISPLAY
4 - GREEN 20AWG
3 - WHITE 20AWG
2 - BLACK 20AWG
1 - RED 20AWG
Strip insulation to 11/16”
Install P/N: 091-TERFEB612,
Wire Ferrule supplied, 2 places
80
Amp
Waterproof Circuit Breaker
Kussmaul Part #: 090-0080-0
Or lace near the batteryFuse, P
RED (6AWG)
RED (6AWG)
BLACK (6AWG)
+
A.C. INPUT POWER
GROUND
(Green 14AWG)
NEUTRAL (White 14AWG)
LINE (Black 14AWG)
AC CONNECTIONS TO THE
CHARGER SHALLCOMPLY
WITH UL RECOMMENDATIONS,
NEC, or NFPA STANDARDS
-
Y
R
E
T
T
A
B
6
BATTERY SELECTOR SWITCH
AGM / LEAD
Use a mini precision
slotted screwdriver to
select AGM or Lead-Acid
7
SPECIFICATIONS
Input Power: 120 Volt, 60 Hz, 10 Amperes
Input Fuse: 15 Ampere, resettable, circuit breaker
Output Power: 12 Volts DC, 40 Amperes Max
Remote Sensing: Electronic, sense wires not required
Torque: DC output connector: 20 in. lbs
LED Status Indicators: Battery Connected, Fan On, and Power On
Battery Selector Switch: (Lead-Acid / AGM): Lead-Acid Float = 13.25VDC; AGM Float = 13.50VDC
Hardware Pack Provided: (2) #6 AWG Blue Ferrules, P/N: 091-TERFEB612
Charger Indicators: Local Front Panel Bar Graph Indicator
Output Waterproof Circuit Breaker (Optional): 80 Amperes, P/N: 090-0080-0
Output Buss Bar (Optional): 5 Studs, P/N: 002-3595-5
Weight: 26 pounds
OUTLINE DRAWING
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
8
OPTIONAL ACCESSORIES
I. BAR GRAPH DISPLAY, MODEL #: 091-199-001
• 10-Segment LED display indicate the “state of charge”
and the general condition of the batteries
II. DELUXE STATUS CENTER, MODEL #: 091-194-IND
• Indicator has a digital voltage and ampere display
• 5 segment bar graph display indicates output current
• 4 LED’s to show the condition of the batteries
III. WATERTIGHT DELUXE STATUS CENTER, MODEL #: 091-194-IND-WT-XX
• Indicator has digital voltage and ampere display
• 5 segment bar graph display indicates output current
• 4 LED’s to show the condition of the batteries
• Indicator is housed in a watertight bezel
• Bezel is available in 6 different colors,
Red, White, Blue, Yellow, Gray, and Black
Specify color choice when ordering
IV. WATERPROOF CIRCUIT BREAKER, MODEL #: 090-0080-0
• Combines switching and circuit breaker function
• Compact size and surface mount con guration
• Protects high amperage circuits
• Latch arms resets breaker after overload
• Cannot be held in ON position if short remains on circuit
• Waterproof - Ideal for truck applications
V. E-Z SLIDE MOUNTING PLATE, MODEL #: 091-200-EZM
• Locking mounting system
• Ease the installation and the removal of larger sized chargers
that are in harder to access areas, such as under seats
170 Cherry Avenue
West Sayville, NY 11796
www.kussmaul.com
Ph: 800-346-0857
Fax: 631-567-5826
sales@kussmaul.com
9
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
10
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