KUSSMAUL AUTO CHARGE LOW PROFILE LPC-7 (01) PDF MANUAL


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****** Page 1 ****** RKUSSMAUL ELECTRONICS CONTENTS Section V) VII) VIII) 170 Cherry Ave. West Sayville, NY 11796 AUTO CHARGE Low Profile Series INSTALLATION/OPERATION MANUAL Model: LPC-7 Topic GENERAL INFORMATION IMPORTANT SAFETY INSTALLATION A) Materials Provided B) Location C) Mounting Page D) d.c. Output Wiring………………………………… .. E) a.c. Input Wiring F) Gel-Cell/Lead-Acid Selector Switch OPERATION A) Three Stage Charge Regimen B) Start-U C) Constant Versus Occasional Use D) Proper Load Sizing E) Operation with Engine F) Operation as a d.c. Power Supply SPECIFICATIONS…………………………………………………………… TROUBLESHOOTING WARRANTY INFORMATION BATTERY CARE TIPS RKUSSMAUL ELECTRONICS kussmaul.com 11 14 M-LPC7 As of June 2012 Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 2 ****** GENERAL INFORMATION Your Low Profile Series Battery Charger represents a new phase in charger design and performance, employing “smart” switching circuitry which puts batteries through the optimum three-step charge process, adapts for gel-cell or lead-acid batteries, is rated for continuous duty and is housed in a rugged stainless steel case. Following is a brief listing of some of the more important features/options of your Low Profile Charger. Each is fully detailed later in this manual: * Three step “smart” charging: bulk, absorption, float * Gel cell/lead-acid switch selects optimum charge/float voltages based on battery type * Dual output banks charge independently based on demand * “Universal” 115/230V a.c., 50-60 Hz input—can be used anywhere in the world * Charger Status indicator light—changes color according to output * Current limiting prevents damage from overload * Load activated cooling fan allows continuous operation at full-rated output * Use as a power supply without in-line battery; allows continued use of d.c. powered electronics (when a.c. is available) in the event that batteries must be taken off-line or removed. * “Float” selector switch protects batteries when charging under continuous load * Rugged stainless steel case * Carries the CE mark. In addition, your Low Profile Charger carries a full three year warranty against defects in materials or work- manship from the date of purchase. Careful attention to these instructions should help you to enjoy years of trouble-free service. IMPORTANT SAFETY INSTRUCTIONS 1 . SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the Low Profile Battery Charger. 2. Before using this battery charger, read all instructions and cautionary markings on (1) the battery charger (2) the battery, and (3) any product powered by the battery. 3. CAUTION To reduce the risk of injury, charge only 6 cell lead-acid rechargeable batteries (flooded, AGM, gel or sealed). Other types of batteries may burst, causing personal injury and damage. 4. Do not expose charger to rain or spray. 2 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 3 ****** 5. Use of an attachment not recommended or sold by KUSSMAUL may result in a risk of fire, electric shock or injury to persons. 6. To reduce the risk of damage to the electric plug and cord (if plugged into an a.c. outlet), pull by plug rather than cord when disconnecting the charger. 7. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to damage or stress. 8. An extension cord should not be used. Use of an improper cord could result in a risk of fire and electric shock. 9. Do not operate the charger with a damaged cord or plug; replace them immediately. 10. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged; take it to a qualified serviceman. 11 . Do not disassemble the charger; take it to a qualified serviceman when service or repair is necessary. Incorrect reassembly may result in a risk of electric shock and fire. 12. To reduce the risk of electric shock, disconnect the charger from a.c. source before attempting any maintenance or cleaning. WARNING—RISK OF EXPLOSIVE GASES 1. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT BEFORE INSTALLING AND USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. 2. To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer and by the manufacturer of any equipment you intend to use in the vicinity of the battery. Review all cautionary markings on these products. 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 protection 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 flood the eye with running cold water for at least 10 minutes and get medical attention immediately. 5. NEVER smoke or allow a spark or flame in the vicinity of the battery or engine. 3 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 4 ****** 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 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 can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn. 8. Use the battery charger for charging gel-cell, AGM or flooded lead-acid batteries only. Do not use the 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. 9. NEVER charge a frozen battery. PREPARING TO CHARGE 1. Be sure the area around the battery is well ventilated. 2. Clean battery terminals. Be careful to keep corrosion from coming in contact with eyes. 3. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer. This helps purge excessive gas from cells. Do not overfill. For a battery without cell caps, carefully follow manu- facturer’s recharging instructions. 4. Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and recommended rates of charge. GROUNDING AND a.c. POWER CORD CONNECTION 1 . The charger should be grounded to reduce the risk of electric shock. Ill) INSTALLATION A) Materials Provided The LPC-7 charger is provided completely assembled and ready for installation. The installer must provide mounting hardware and d.c. output wiring. Proper sizes and gauges for the hardware and wire are noted in Sections C and D following. 4 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 5 ****** B) Location The charger should be mounted on a wall, bulkhead or other suitable mounting surface as close to the bat- teries to be charged as possible. Do not mount the charger directly over the batteries as battery fumes may cause excessive corrosion. The charger is ignition protected so it is acceptable to locate the unit in an area where ignition protected equipment is required. The area should be well ventilated and free from excessive moisture, exhaust manifolds and battery fumes. Vertical mounting is preferred. However, horizontal mounting is acceptable where absolutely necessary. Do not mount the charger where water, spray or condensation can occur, as this will shorten charger life. It should not be located where there is a possibility of dust or debris being drawn into the unit through the fan. A minimum of 2′ clearance around the charger is recommended for proper cooling. If the charger is located in an extreme heat area, such as an unventilated engine compartment, and maxi- mum operating temperature is exceeded, an automatic thermal protection circuit will shut the charger off. Although it will return to service automatically after cooling sufficiently, thermal cycling will shorten the life of the charger. If this condition occurs repeatedly, the charger should be relocated. For optimum performance and longer life the charger should not be located in an area of extreme high temperature. C) Mountinq The charger may be mounted on either a metal or non-metal surface. Four # 10 screws (self taping sheet metal or machine screws, depending on mounting surface) with wash- ers, are required to mount the charger. IMPORTANT: Although the charger is constructed of materials and in a manner which makes it high- ly resistive to the corrosive effects of moisture in the environment, 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. D) d.c. Output Wiring Note: Only qualified service personnel should access the output terminals of the charger. The installer must provide output wires for attaching the charger to the battery. Use the table below to deter- mine the correct gauge wire, based on the length of the wire run from the charger to the batteries. Length of Wire from Charger to Batteries (in feet) Minimum Wire Gauge AWG #14 #12 #10 *Based on N.E.C. Minimum Wire Size Chart ENSURE THAT LEADS ARE PROPERLY FUSED AT THE BATTERY. 5 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 6 ****** Typical d.c. wiring configurations are illustrated in FIGURES 1 and 2. The LPC-7 uses a Euro style outlet terminal block that accepts a stripped wire end. Loosen the terminal screw by turning couterclock wise, strip approximately 1/4″ of insulation from the wire end. Instert into terminal block and tighten down terminal screw. FIGURE 1: Simple d.c. Wirinq (Preferred Method) o BANK t Warning: Utilize bottom terminals only for output wiring IMPORTANT: Install fuses on battery hot leads at battery to protect charging leads FIGURE 2: Wiring With Batterv Switch Warning: Utilize bottom unsrtR BANK 1 terminals only for output wiring 6 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com euss -tav Buss Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 7 ****** An Important Note about the DC Output Fuse: DC output wiring is protected by an externally mounted ATC blade-type output fuse. The fuseholder is located on the bottom of the unit. To remove the fuse for checking or replacing simply pinch the fuse between thumb and forefinger and pull firmly down- ward. The current limiting circuit of the Low Profile charger should prevent the fuse from blowing under normal op- erating conditions. If the fuse blows, this may indicate a reverse polarity hook-up or an internal short. If the battery is connected to the charger backwards, the fuse should blow to prevent a dangerous short circuit, however damage to the internal components is possible, as well. If, after replacing this fuse, it blows again upon application of power, return the charger to an electronics service professional or to the factory for a thorough inspection. Always replace the fuse with another of the same type and value: ATC 10 amp. E) a.c. Input Wiring/Voltage Selection For the convenience of the installer an a.c. power cord has been factory installed. It is a three-conductor stranded type, 18 AWG. The cord is terminated with a plug suitable for standard USA outlets and uses stan- dard USA color coding of conductors. The LPC-7 operates within a “universal” range of 82-132 or 176-264V a.c., 47-63 Hz input. Input voltage selection is made via a slide switch on the bottom of the charger. It is factory set for 115V. For 230V a.c. ap- plications use a ball point pen or similar tool to slide the switch into the 230V position. a.c. input for the charger must be routed through a fuse or circuit breaker on an a.c. distribution panel with proper safety/earth chassis ground in accordance with all applicable local codes and ordinances. Color coding of the installed a.c. cord is as follows: Black a.c. Hot (fused) White………………………………a.c. Neutral Green a.c. Ground (safety, earth) If the plug on the factory-installed cord is unsuitable for the available outlet it may be cut off and replaced. Pay careful attention to color coding of the wires as noted above. Do not attempt to replace the entire cord by removing the charger cover. Evidence of entry into the charger will void the warranty. A note about the a.c. input fuse: The a.c. input of your charger is protected by an input fuse which is located inside the unit. Due to the current limiting characteristic of the charger, it is highly unlikely that this fuse will blow unless there is some other malfunction within the charger. This fuse is not user-replaceable. Contact the factory if you suspect a blown input fuse. (See Troubleshooting section.) F) Setting the Gel-Cell Flooded/AGM Switch According to most battery manufacturers, the ideal charge regimen for gel-cell and flooded (wet) lead-acid or AGM (Absorbed Glass Mat) batteries differs somewhat. The gelled electrolyte in a sealed battery may be lost or damaged by high voltage and, once lost, cannot be replaced as it can with a wet lead acid battery. Manufacturers of gel-cells usually recommend an ideal charge voltage which is slightly lower for a gel-cell than a lead-acid battery. (The charge regimen recommended for AGM batteries is typically similar to that of flooded lead-acid batteries.) 7 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 8 ****** However, when the charger is in the float voltage mode over lengthier periods of time, gelled electrolyte in a sealed battery is not susceptible to evaporation, as is the non-immobilized electrolyte of a wet lead acid battery. This evaporation can be accelerated by the applied voltage. Consequently, the ideal float voltage is slightly higher for a gel-cell than a lead-acid or AGM battery. The ideal charge/float regimen has been programmed into the Low Profile Charger for either sealed gel-cell or flooded lead-acid/AGM batteries. Simply make the proper selection for your battery type via the slide switch on the front of the charger, prior to turning the unit on. Note: A wide variety of batteries are now available which do not conform to conventional descriptions as “gel-cell” or “lead-acid”. You are advised to consult the manufacturer of your particular battery as to proper charging regimen, and use the battery type selection switch setting which most closely conforms to the rec- ommended voltages. See the SPECIFICATIONS section for the actual preset charge and float voltages for each model. IV) OPERATION A) Three Stage Charge Regimen The Low Profile Battery Charger utilizes the three stage charge regimen which is widely recommended by battery manufacturers for allowing the fastest possible recharge time without loss of batteries’ electrolyte (gel or liquid) which may be caused by sustained charging at higher voltages. This three stage regimen is initiated each time a.c. is first applied, when drained batteries are most likely to be encountered, and proceeds slowly or quickly through each stage depending on the battery’s relative state of charge. Note: The Charge Cycle Select switch on the front pane/ must be in the “Charge” position for the three stage cycle to occur. In the “Float” position, the charger will have a fixed output voltage which depends on the setting of the Battery Type Selector. (See Specifications section for output voltages. See also the warning about the switch setting at the end of this section.) During the first two stages (referred to collectively as the “Charge” stage) the indicator light on the front panel will glow red. When charging is complete and the charger has switched to the “Float” stage, the indi- cator will glow green. The charge regimen proceeds as follows: 1) Bulk Phase: When batteries are significantly discharged the charger responds initially by delivering a high amount of d.c. current, at or near the charger’s maximum rated output, in order to rapidly replenish them. It is during this stage that charging current is maintained at a high level as battery voltage increases. Bulk charging continues until battery voltage reaches the “charge” voltage level (where batteries are at about 75-80% of capacity). At this point the charger switches to the second stage. 2) Absorption Phase: During this second stage of the charge cycle, battery voltage is maintained at the “charge” voltage level. Output current begins to taper off as the battery plates become saturated. Charge voltage is maintained until the current sensing circuit detects that output current has tapered to about 5-15 % of charger rating. At this point the batteries are at about 95 % of full charge and the Phase Three charger 8 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 9 ****** switches to the third and final stage of the charge cycle. 3) Float Phase: For extended battery life, the LPC-7 then automatically switches to a lower float voltage level. This float charge keeps batteries at peak condition without overcharging. The charger may be left in this stage for lengthy periods of time without attention (though periodic checks of electrolyte level in flooded batteries is recommended). It is not necessary or recommended to shut the charger off when this stage is reached. A typical three stage charging cycle is illustrated in FIGURE 3. FIGURE 3: Typical Charger Output Graph (into battery without load) 50 25 100% 14.2 75 13.0 12.0 11.0 10.0 o o MODE AhQS TIME A WARNING ABOUT THE CHARGE CYCLE SELECT smrcH.• Whenever a load of approximately 3 amps or more is applied, the charger will go into the elevated voltage “Charge” mode, as indicated by the glowing red indicator on the front panel. (See specifications for actual charge/float voltages.) Battery electrolyte may be damaged or lost by extended exposure to this higher voltage. If there is a d.c. load on the battery system of 3 amps or more for periods lasting 8 hours or more, it is stæn.glu recommended that the Charge Cycle Select switch on the front panel be placed in the “Float” posi- tion. B) Start up 1) Before powering up your charger, check for tight electrical connections to each battery in your system. Switch off any d.c. loads on the batteries. Apply a.c. power. Observe the Charger Status indicator on the front panel. If it glows red and stays red for a while, it is an indication that the batteries are in a relatively low state of charge. The charger, sensing this, is supplying high current to the batteries. If the indicator glows red briefly, then switches to green it is an indication that the batteries are at or nearing full charge, and the charger has switched to the “Float” (maintenance) mode. 2) After the indicator has switched to green, apply a load to the charger by switching on some lights, a pump or some other d.c. appliance. Observe the indicator. As current is demanded from the battery system, the charger will automatically increase its output in response to the increased load demand and the charger will switch to the higher current (and higher voltage) “Charge” mode. As long as the load current exceeds ap- proximately 3 amps, the charger will remain in the charge mode (unless the Charge Cycle Select switch is put into the “Float” position). 9 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 10 ****** C) Constant Versus Occasional Use In general, it is recommended that the charger be left connected continuously to the a.c. distribution system so that it will be in operation whenever a.c. is available. This will maintain batteries at peak voltage and will automatically compensate for the natural self-discharge of the battery system. When a load is applied to the battery system the charger’s output will automatically increase to supply the current which would otherwise draw battery voltage down. Repeatedly allowing batteries to become completely discharged before recharging will greatly shorten their life. Leaving the charger on continuously will prevent this. While the output regulation of the charger will minimize battery gassing and water loss, monthly checks of the electrolyte level (for wet lead acid batteries) are still strongly recommended. Some water loss is an inevitable aspect of the charging process, and maintaining the correct electrolyte level in your batteries is the most important thing you can do to assure their maximum performance and long life. D) Proper Load Sizing The LPC-7 is rated for continuous duty at 7 amps. While the charger cannot be damaged by overloads that exceed this continuous rating, excessive load demands may draw battery voltage down faster than the charger can resupply it. If battery voltage continues to drop and the output current is at maximum while the charger is in service, check to see that your average d.c. loads are not exceeding the charger’s rated output. E) Operation With Engine It is perfectly acceptable to allow the charger to remain on when the engine is started and while it is running. The current limit feature of the Low Profile Charger will protect against any damage due to the high current demands of engine cranking. Output diodes will prevent any back-feed of current into the charger from the alternator while the engine runs. As the alternator starts to charge the battery, the charger output will decrease. When the battery voltage exceeds the rated output voltage of the charger it will shut off and stay off as long as the batteries are in this high state of charge. If the battery voltage should drop below the charger’s rated output voltage it will auto- matically return to service. F) Operation as a d.c. Power Supply (stand-alone d.c. power source) Most battery chargers are not suitable for powering electronic devices directly, without a battery attached to the output, as the high ripple and pulsing d.c output ( i.e., rectified a.c. output) can interfere with the opera- tion of the device. However, the LPC-7 employs a circuit that produces an extremely well-filtered d.c. output. Therefore it is able to power virtually any d.c. powered device (within the unit’s rating) without the battery at- tached in-line (if, for instance, the battery must be removed for any purpose and a.c. is still available). All but the most sensitive d.c. powered electronic devices will function as normally as if powered by a battery. When using the LPC-7 as a regulated power supply without battery in-line, place the Charger Cycle select switch in the “FLOAT” position for maximum regulation. 10 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 11 ****** V) SPECIFICATIONS Model: Input VAC (50-60 Hz.): Input Amps @ Full Load: @115VAC 2 @ 230 VAC 1 Output Voltage (Nominal VDC): Output Amps (Continuous): Output Banks: 2 Battery Capacity (Amp-Hours): Weight (Lbs./Kg.): Compliances: LPC-7 82-132 or 164-264 12 7 14-70 3.2/1.5 Carries the CE Mark Temperature Rating: -1 OOC to +600C; Derate linearly from 100% @ 500C to 60% @ 600C Nominal Output Voltages at Gel/Flooded Switch Settings: Settinq Charge @ 50 % load Flooded/AGM 14.0-14.2V d.c. Gel-Cell 13.8-14.OV d.c. Float @ .5 amp load 13.4V d.c 13.6V d.c. Protection: Input/Output Fuses, Current Limiting, Thermal Protection, Forced Air Cooling Case Dimensions (Inches): O ø.219×4 O 8.265 6.750 2.468 2.225 11 170 Cherry Ave. West Sayville, NY 11796 o 3.850 4.500 4.930 o 0000 00000 000000 000000 0000 o RKUSSMAUL ELECTRONICS kussmaul.com O 8.615 Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 12 ****** TROUBLESHOOTING Note: The LPC-7 charger incorporates a self-contained a.c. to d.c. conversion module which utilizes numerous automatic protection circuits. The a.c. input fuse which protects internal wiring is housed inside the charger with the module. Under most circumstances the fuse will fail only if the charger has an internal fault. Hence, it is not intended to be user-replaceable and any condition which has caused a blown a.c. fuse will likely require repair of other internal circuitry by a qualified technician. If an apparent charger fault cannot be corrected using any of the recommendations in this section, the charger should be returned to the factory or place of purchase for inspection and repair or replacement. PROBLEM A. Batteries not coming up to full charge B. Charger continues to charge at 3 amps or more does not taper back C. No charger output, even when all connections have been checked, a.c. is applied to the charger, and d.c. load is applied to the batteries D. Reverse polarity connection has caused charger to have no output 12 170 Cherry Ave. West Sayville, NY 11796 POSSIBLE CAUSE 1. Extremely discharged batteries requiring long recharge time 2. Charger limiting its output due to overload or over-temperature conditions 1. d.c. load connected to batteries drawing current (not a problem condition) 2. Bad cell in one of the batteries to which the charger is connected Blown input fuse or other internal defect d.c. output fuse and other inter- nal components likely blown RKUSSMAUL ELECTRONICS kussmaul.com SOLUTION 1. Turn off all d.c. loads and allow charger 24-48 hours to recharge batteries 2. Reduce d.c. load and/or determine cause of over- temperature condition (see section Ill-B, Location) 1 . Turn off main battery switch to d.c. electrical panel or turn of all d.c. loads if you wish to confirm charger will output minimal amperage to fully charged batteries 2. Check for shorted cell in wet lead-acid batteries using a hydrom- eter. Refer to manufacturer for testing maintenance-free batteries Return to servicing dealer for failure analysis or contact KUSSMAUL for Return Authorization Number Replace output fuse with like type and value. If still no output, return to servicing dealer for failure analysis or contact KUSSMAUL for Return Authorization Number Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 13 ****** E. High voltage measured across charger output terminals VII Warranty Information Batteries not connected to charger. It is normal to read 1/2 volt higher across any output bank when no batteries are connected. Check for tight connection of charging leads to batteries 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 purchaser, his or its employees or others. 13 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 14 ****** VIII) BATTERY CARE TIPS Regular maintenance and proper care will assure you reliable service from the most depended upon and sometimes most neglected items, your batteries and battery charger. KUSSMAUL battery chargers are designed to keep your batteries fully charged but your batteries also need proper regular maintenance to provide a maximum life of service. ALWAYS READ AND FOLLOW THE BATTERY MANUFACTURER’S INSTRUCTIONS Battery Installation Batteries must be securely mounted to prevent them from falling over when the vehicle or boat is in motion. A loose battery can do serious damage. Batteries should be mounted in a battery box to contain any acid spill. Batteries give off a certain amount of hydrogen gas when they are charging. When concentrated, this gas is highly explosive. Therefore make sure they are in an accessible place with adequate ventilation for any hydrogen gas discharge. Cleaning Batteries Dirt and electrolyte salts can build up on the top of your batteries. This accumulation conducts electricity stored in the battery and can cause the battery to discharge by itself. Therefore, at least twice a year, it is a good idea to disconnect the battery cables and scrub the battery with a baking soda solution. Rinse with fresh water and dry with a clean cloth. You may wish to purchase a set of terminal post corrosion prevention rings. These are alkali-saturated felt rings that slip over the battery post to reduce corrosion. Do not apply grease to any part of the battery terminals, but you may use an occasional light spray of silicone lubricant. Routine Checks and Maintenance Batteries should periodically be “exercised” (slowly discharged and then recharged) to keep them in top condition. New batteries may need to be exercised before they will be capable of their full rating. If your batteries are not the sealed type, distilled water should be added to them whenever needed. The electrolyte should cover the plates by about 1/2″, allowing a small air space at the top. Do not fill the cells up to the filler cap as this could cause the battery to sputter out electrolyte when it is being charged. Only distilled water should be used never plain tap water. Tap water contains chemicals and elements that can alter the properties of the electrolyte, including specific gravity. Some chemicals may also create an insulating coating on the battery plates which will retard current flow. The rate that water is lost by the battery is dependent on several factors; battery condition, ambient temperature, battery use, charge voltage, etc. It is normal for batteries which are not maintenance-free to require topping off about once a month. A battery’s state of charge may be monitored by checking the specific gravity or by open circuit voltage. You may use the following table to evaluate the condition of your batteries: 14 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com

****** Page 15 ****** Battery Condition Table Specific Gravity Measured by Hydrometer 1.265 1.225 1.190 1.155 1.120 Open Circuit Voltage 12 Volt System 12.6 or more 12.4 12.2 12.0 11.7 or less State of Discharge @ 800 F Fully Charged 25 % Discharged 50 % Discharged 75 % Discharged 100 % Discharged * Note: Wait at least 5 minutes after charging or discharging before checking specific gravity or open circuit voltage. The battery’s voltage needs to stabilize in order to get an accurate reading. Troubleshooting Your Battery System If your battery will not accept or hold a charge, one of the following conditions may exist: 1. A BAD BATTERY. You may have a battery with an open or shorted cell, a battery without any “life” left. Check by charging the battery until all cells have a specific gravity of 1.225 or greater at 800 F. If you are unable to obtain 1.225 in each cell, replace the battery. 2. A BAD BATTERY CHARGER. If the battery open circuit voltage is low and/or the hydrometer indicates your batteries are low, the battery charger should be providing current to the batteries. If it is not, check the input fuse and check to see that you have charging voltage on the output with no battery attached. Note: You will not get an accurate voltage reading on the output of the charger with no batteries attached. This is checked merely to ensure that you do not have an open circuit on the output. The battery charger has a thermal power reduction circuit to protect the charger from overheating. If you suspect this is the case, refer to the INSTALLATION section for information about proper charger location. 3. ELECTRICAL LEAKAGE. You may have a previously unsuspected source of current drain from the battery. To check for a leakage of this sort, disconnect the battery ground cable and connect an ammeter between the negative battery post and ground. If you have a reading over .1 amp, there is a source of current drain from the batteries which must be located and removed. 15 170 Cherry Ave. West Sayville, NY 11796 RKUSSMAUL ELECTRONICS kussmaul.com Phone: 800-346-0857 E-mail: sales@kussmaul.com


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