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Click here to download KUSSMAUL AUTO CHARGE 12 091-165-24 (01) PDF MANUAL

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****** Page 1 ****** FILE: OBI -q 65-24 b.P7.O Rev a: 03/21/1 0 MFG INSTRUCTION MANUAL AUTO CHARGE 1 e AUTOMATIC BATTERY CHARGER FOR SYSTEMS MODEL #091-165-24 NOTE : This charger is designed for vehicles with a single 24VDC Battery Bank and Negative Ground. CAUTION This unit should not be exposed to water spray or rain a YEAR WARRANTY m KUSSMAUL ELECTRONICS CO., INC. 1 70 CHERRY AVE. , WEST SAYVILLE, N.Y. 1 796 Phone: 631-567-0314 Toll Free: 800-346-0857 1 Fax: 631-567-5826 Web: kussmaul.com E-Mail: sales@kussmaul.com

****** Page 2 ****** IMPORTANT SAFETY INSTRUCTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. SAVE THESE INSTRUCTIONS — This manual contains important safety and operating instructions for battery charger Model 091-165-24. Do not expose charger to rain or snow. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of fire, electric shock, or injury to persons. Wire Battery Charger; 115VAC, 60Hz Input Power per Figure 1 of this manual in accordance with ALL; National, Local and/or Underwriter requirements for a NEMA, 115VAC, 15 Ampere appliance. Portable extension cords on 115VAC Input or 24VDC Output should not be used unless absolutely necessary. Use of improper extension cord could result in a risk of fire and electric shock. If extension cord must be used; a) 115VAC input power cord shall comply with UL 1236 Edition 7, Table 11.1 “Acceptable Flexible Cords for Battery Chargers”. b) That extension cord is properly wired and in good electrical condition. c) Thatwiresize is large enough for ampere rating ofchargerasspecifiedinTable 52.1 of UL 1236 Edition 7, “Recommended Minimum AWG Size for Extension Cords for Battery Chargers”. Do not operate charger with damaged cord or plug — replace the cord or plug immediately. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman. Do not disassemble charger; take it to a qualified serviceman when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. 2

****** Page 3 ****** 10. WARNING – RISK OF EXPLOSIVE GASES a) WORKINGINVICINITYOFALEAD-ACID DANGEROUS. BAT- TERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THE CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. b) To reduce risk of battery explosion, follow these instructions and those pub- lished by battery manufacturer and manufacturer ofany equipment you intend to use in vicinity ofbattery. Review cautionary markings on these products and on engine. 11. PERSONAL PRECAUTIONS a) b) c) d) e) f) g) h) i) Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes. Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at least 1 0 minutes and get medical attention immediately. NEVER smoke or allow a spark or flame in vicinity of battery or engine. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short-circuit battery or other electrical part that may cause explosion. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short- circuit current high enough to weld a ring or the like to metal, causing a severe burn. Use charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low voltage electrical system other than in a starter-motor application. Do not use battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property. NEVER charge a frozen battery. 3

****** Page 4 ****** 12. PREPARING TO CHARGE a) Ifnecessarytoremove batteryfromvehicletocharge, always remove grounded terminal from battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc. b) Be sure area around battery is well ventilated while battery is being charged. Gas can be forcefully blown away by using a piece of cardboard or other nonmetallic material as a fan. c) Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes. d) Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. This helps purge excessive gas from cell. Do not overfill. For a battery without cell caps, carefully follow manufacturer’s recharging instructions. e) Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge. f) Determine voltage of battery by referring to vehicle owner’s manual and make sure that it matches the output rating ofthe charger. 13. CHARGER LOCATION a) b) c) d) e) Locate charger as far away from battery as VDC charge cables permit. Never place charger directly above battery being charged; gases from battery will corrode and damage charger. Never allow battery acid to drip on chargerwhen reading gravity orfilling battery. Do not operate charger in a closed-in area or restrict ventilation in any way. Do not set a battery on top of charger. 14. DC CONNECTION PRECAUTIONS a) Connect and disconnect DC outputwires only after interrupting 1 15VAC Input Power. Never allow wires to touch each other. b) Attachwiresto battery per Figure 1 ofthis manual. Foroptimal Battery Charger operation the DC charging connections require direct connection to battery undercharge. 4

****** Page 5 ****** 15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY: a) Position VAC and VDC cords to reduce risk of damage by hood, door, or moving engine part. b) Stay clear offan blades, belts, pulleys, and other parts that can cause injury to persons. c) Check polarityofbattery posts. POSITIVE (POS, P, +) battery post usually has larger diameter than NEGATIVE (NEG, N, -) post. d) For negative-grounded vehicle, connect POSITIVE (RED) wire from battery charger to POSITIVE (POS, P, +) ungrounded post of battery. Connect NEGATIVE (BLACK) wire to vehicle chassis or engine block away from battery. Do notconnectwire to carburetor, fuel lines, orsheet-metal body parts. Connect to a heavy gauge metal part of the frame or engine block. e) When disconnecting charger, turn any switches to off, disconnect AC cord, remove wire from vehicle chassis, and then remove wire from battery terminal. 5

****** Page 6 ****** 16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY: a) Check polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N, -) post. b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, battery post. c) Connect POSITIVE (RED) charger wire to POSITIVE (POS, P, +) post of battery. d) Position yourself and free end of cable as far away from battery as possible — then connect NEGATIVE (BLACK) charger wire to free end of cable. e) Do not face battery when making final connection. f) When disconnecting charger, always do so in reverse sequence of connect- ing procedure and break first connection while as far away from battery as practical. g) A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use. 17. The instructions fora battery charger shall include 16. (a) (g) as applicable to the particular charger. a) For all grounded cord-connected battery chargers: GROUNDING AND AC POWER CORD CONNECTION INSTRUCTIONS – Charger should be grounded to reduce risk of electric shock. b) For grounded , cord-connected battery chargers with an input rating less than 15 amperes and intended for use on a nominal 1 15VAC circuit only: 6

****** Page 7 ****** INTRODUCTION The Auto Charge 12 Battery Charger is a compact completely automatic charger designed for installation on vehicles with one (1) 24VDC Battery Bank. The Auto Charge 12 provides complete battery charging for a single 24VDC battery or single 24VDC battery bank. The voltage ofthe battery connected to the Auto Charge 12 is sensed via the charging cables so that the battery is charged according to it’s requirements. The maximum output ofthe charger is 6 Amperes DC. An ammeter provides continuous indication of the charger output. Construction of the Auto Charge 12 is extremely rugged to withstand the shock and vibration normally encountered by vehicle mounted equipment. The unit operates completely automati- cally and stops charging the batteries when they are fully charged. There is no trickle charge and therefore no dangerofovercharging and water boil-off. Any parasitic loads on the battery such as radio, lights, etc., will be supplied by current from the charger. The Auto Charge 12 incorporates an internal thermal safety device. Should the internal temperature ofthe Auto Charge 12 elevate beyond specification the chargerwill automatically shut down. The Auto Charge 12 will resume battery charging once the internal temperature has decreased to specification level. INSTALLATION The Auto Charge 12 Automatic Battery Charger should be installed in an area with adequate ventilation. Referto Installation Wiring Diagram, FIGURE 1 . 1 . Mount the charger using the four holes provided for this. 2. Connect the wiring from the battery bank to the Output Terminal Strip. 3. Connect the wiring to the battery. Ring lugs that have been securely crimped, or soldered, should be used. 4. Double check all wiring before proceeding. 5. Wire the 115VAC, 60Hz power to INPUT terminal strip. 6. POWER pilot light will light to show that the charger has power. 7

****** Page 8 ****** INSTALLATION WIRING DIAGRAM Optional Bar-graph Indicator 091-165-031 CAUTION:DISCONNECTSUPPLY BEFORE FUSE SERVICE 5 AMP POWER O 11014, 1 1 5VAC, 60Hz Input Power Line Neutral Ground Notes: Optional Economy Indicator O 091 -l I -102-24 1. 115VAC Input Power and Charger Output Power strain relief cover not shown for clarity. Refer to “Important Safety Instructions” section of this manual. 2. Charger output power connections, AWG 14, for 20 feet Maximum. Consult factory if longer length is required. 8

****** Page 9 ****** SPECIFICATION e OUTLINE SPECIFICATIONS: Input: 115/120VAC, 60 Hz, 5.0 Amps Input Fuse: 5 Amps, CAUTION: DISCONNECT SUPPLY BEFORE CHANGING FUSE Output: 26.50 VDC Output Fuse (Optional): 12 Amps Output Current: 6 Amps Charge Indicator: 0-8 amps 5% Weight: 10 lbs 9/32″ DIA 10 375 4.375 4.375 5.50 OUTLINE DRAWING II .375 9

****** Page 10 ****** INDICATOR INSTALLATION 1 . Locate Indicator in a convenient place on the vehicle. 2. Place the template in position and center punch in 4 places. 3. Drill holes as shown. 4. Cut out square hole. 5. Connect wiring to charger in accordance with the instructions in the charger installation instructions. 6. Install as shown. 7. Insert (4) #8-32 screws supplied and tighten. (CAUTION: Do not over tighten because you will bend the plastic bezel and break the watertight seal). 8-32 SCREW INDICATOR GASKET 3/1 DIA. 4 HOLES CUT OUT 2 1/1 61 x 3 1/21 HOLE TEMPLATE 3.900 TRUCK WALL #8-32 HEX NUT LOCK & FLAT WASHER o. 150 2 375 0.200 Hole Template may not be to Scale, please check dimensions before using. 10 File: Ind.cdr rev C: 3-31-10 do not shrink this art work

****** Page 11 ****** INSTALLATION RECORD e 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 liabilityfor damages of any kind to associated equipment arising from the installation and lor use ofthe Kussmaul Electronics Company, Inc. products. The purchaser, by the accep- tance ofthe 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. 11







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