Kussmaul Electronics 091-9-1200 User Manual

FILE: 091-193-12.pmd
REV: B
REVISED BY: MFG
DATE: 2-14-2011

INSTRUCTION MANUAL

AUTO CHARGE

1200 PUMP PLUS

AUTOMATIC BATTERY CHARGER

MODEL #091-9-1200

INPUT: 115 volt, 50/60 Hz, 10 amps

OUTPUT: 40 AMPERES

3 YEAR WARRANTY

KUSSMAUL ELECTRONICS CO., INC.

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

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

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

INTRODUCTION

The AUTO CHARGE 1200 PUMP PLUS 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

• Electronic remote sensing of true battery voltage, eliminates the need for sensing
wires

• Automatic current limiting

• Remote Battery charge/condition indicator display

• LED status indicators

• Pump output with AC or DC mode rocker switch

FUNCTIONALITY

Charge Controls & Electronic Remote Sensing:

The Auto Charge 1200 Pump Plus 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 flows. Since there is
no charging current there is also no voltage drop between the charger and the battery. The
Auto Charge 1200 Pump Plus 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.

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 Pump Plus contains an
automatic current limit. The current limit feature limits the output current to 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.

Remote Battery Charge Condition Indicator:

This indicator shows the charge condition of the 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 its terminals, the
bar graph may move down 1 or 2 levels. This does not indicate a defective battery.

Pump Output:

The output terminal strip provides an additional output to accomodate a 12VDC air pump,
part # 091-9 air compressor. The air pump output works in conjunction with a front panel
mounted rocker switch. For normal operation, the rocker switch should be left in AC mode,
which means that the air pump works only when shoreline power is supplied to the charger.
With the switch in DC mode the compressor will operate when AC power is ON or OFF.
In either position the compressor operates from the vehicle's batteries, while the charger
automatically recharges the batteries as required.

LED Status Indicators:

• BATTERY CONNECTED: Indicates that a battery of proper polarity is connected
to the charger output terminals.

• 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.

• POWER: Indicates that AC voltage is present.

INSTALLATION

1. The Auto Charge 1200 Pump Plus should be installed in a well ventilated area.

2. Mount the charger with the four holes provided.

WIRING

1. Refer to Installation Wiring Diagram.

2. Kussmaul Electronics recommends installing an 80 amp fuse or circuit breaker
protection in line with the battery output. Note: Fuse or circuit breaker protection

should be placed near battery output terminal.

3. Double check all wiring before applying 115 AC volts to input terminal. Verify that
the battery voltage appears at the charger output terminals. Note: A minimum of
6 volts is required to start the charger.

4. Apply 115 volts (shoreline power) to input terminal and observe that the charger is
operating. The Remote Bar Graph need not be connected for the charger to
operate.

INSTALLATION WIRING DIAGRAM

Aut o Pump

Air Compressor

Note:
make sure
the Auto Pump
is mounted
vertical.

NOTE:

Pin 1 of indicator must go to Pin 1
of Remote Display on charger.
Pin 2 of indicator must go to Pin 2
of Remote Display on charger, and so forth.
Check connections and color of wires
before plugging-in.

AUTO CHARGE 1200

PUMP PLUS

Use 8 AWG

or larger on

Output & Gnd

VEHICLE
BATTERY

+

OUTPUT

AUTO

PUMP

+

COM

R

LN

INPUT

AUTO
PUMP

Press ur e

Switc h

CONNECTION

COM

VEHICLE

BATTERY

AUTO
PUMP

INPUT

BLK

BLK

BLACK

RED

RED

Range

Nut

WIRE SIZE CHART

DEFINITIO N

NEGATIVE CHARGING LEAD

POSITIVE CHARGING LEAD FOR BATTERY

POSITIVE OUTPUT FOR AUTO PUMP

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

Chassis

Ground

Optional -

80 Amp

Automatic Circuit Breaker

(part #: FUS-80-A)

WIRE SIZE

8 AWG

8 AWG

14 AWG

14 AWG

A.C. INPUT POWER

GROUND

NEUTRAL

LINE

Chassis

Ground

NOTE: Minimum wire size on charger
output and ground is For a length
of 10 feet or longer is required.

#8 AWG.

#6 AWG

Smaller gauge wire may cause overheating of
terminal. Use 2-966067 wire ferrule
over wire to simplify insertion of wire into
terminal strip and to improve connection.
Additional information is available upon request.

SPECIFICATIONS

Input Power: 115 volt, 50/60 Hz, 10 amperes
Input Fuse: 15 ampere, resettable, circuit breaker
Pump Fuse: 15 ampere, resettable, circuit breaker
Output Power: 12 volts DC, 40 amperes max
Remote Sensing: Electronic, sense wires not required
Status Indicators: Battery Connected, Fan On, and Power On
Charger Indicators: Remote Bar Graph indicator
Weight: 21 pounds

Outline Dimensions: AUTO CHARGE 1200 PUMP PLUS

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. 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.