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****** Page 1 ****** FILE: -BOA. PMD DATE: 07-ao-og REV. a INSTRUCTION MANUAL LOAD MANAGER MARK II A START-UP AND SHUT DOWN LOAD SEQUENCER AND AUTOMATIC LOAD SHEDDING SYSTEM WITH INTEGRAL RELAYS FOR a LOADS MODEL #091 -soA INPUT: 12VOLTS, D.C. OUTPUT LOAD: ao AMPERES, MAXIMUM a YEAR WARRANTY KUSSMAUL ELECTRONICS CO., INC. 70 CHERRY AVE. , WEST SAYVILLE, N.Y. 1 TEL: 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826 EMAIL: Sales@Kussmaul.com
****** Page 2 ****** INTRODUCTION The Load Manaqer Mark II is a device which: 1 . Sequentially energizes and deenergizes relays which are mounted inside the unit at approximately 1 /2 second intervals in order to reduce transients in a vehicle’s electrical system. 2. Detects when the vehicle’s electrical load is greater than the output of the alternator. When this occurs, loads are sequentially deenergized until the alternator output is equal to the load. The Load Manaqer Mark II contains the followinq features: 1 . An electrical input which changes the Load Manager Mark II from an automatic load shedding device to operation only as an automatic load sequencer. 2. An automatic override ofthe Load Manager Mark II which operates all the relays simultaneously by connecting one input to ground. 3. An adjustable time delay from 2 to 16 seconds which prevents load shedding until the timeout occurs. This timer starts when the Load Manager Mark II detects an overload. If the battery voltage returns to normal before the timeout, the timer is reset and no loads are shed. 4. An indicator panel which includes a Power ON LED indicator and a Load Reduce indicator. This provides the vehicle’s driverwith the information that the Load Manager Mark II is in operation and that the loads are in the process of being shed. 5. I nternally mounted relays that eliminate the need to supply separate relays in the vehicle. The loads are wired to the relay contacts at the top of the unit using standard 1/4″ quick disconnect terminals. Each relay output is rated at 30 amperes maximum at 12 volts.
****** Page 3 ****** LOAD MANAGER PROGRAMMING Recognizing that priorities may change after an installation is made, the Load Manager Mark II is designed so that the sequence of load removal may be easily altered. At installation, the highest priority load is wired to relay KI which is operated by terminal 3. The second highest priority load is wired to relay K2, which is operated byterminal 4. A total of 8 relays, decreasing in priority are operated by terminals 5, 6, 7, 8, 9, & 13. See Figure 4 – Schematic, Installation. Upon start-up, when the Load Manager Mark II operates as a sequential loading device, the loads are applied in priority order with the highest priority first. When the Load Manager feature is enabled and excessive electrical loads cause a drop in battery voltage, the Load Manager Mark II will deenergize loads at approximately 2 second intervals starting with the lowest priority. Loads will be removed until the voltage sensed returns to normal. The exact interval between load removals depends on the degree of the overload and the capacity of the batteries. With only a slight overload and large batteries the time interval is extended. After installation the user may vary the priority by altering the switch setting from the BASIC SETTI NGS illustrated on Figure 3 Relay Wiring Connections. Caution: There are 5 switches, each with 5 levers. Only one lever on each switch my be in the “ON” Position. Each switch controls the operation ofa relay. The actuation sequence ofa particular relay is controlled by the individual levers of each switch. Lever #5 is the lowest priority, while lever #1 is the highest. It is thus possible to arrange the relay operating priority for the 5 lowest priority relays. NOTE The Load Manager Mark II contains the load switching relays. The manual switches wired by the installer control the 12 volt supply to these relays. THE RELAY CONTACT CAPACITY IS 30 AMPS. DO NOT EXCEED.
****** Page 4 ****** LOAD MANAGER SETTINGS The standard setting on Load Manager Mark II may not be optimum for all applications. The Configuration Switch , S6, sets the initial time delay and the initial shed voltage for the unit. On the Configuration Switch, levers 1-3 are used for time settings. Levers 5 and 6 are for voltage settings. To prevent false voltage readings, the Load Manger Mark II, delays the shedding or adding of loads. The initial delay time is factory set for four seconds. By adjusting levers 1-3 on the Configuration Switch, the user may vary the initial time delay from 2 to 16 seconds. Figure 1 below indicates how to alter the initial delay time. Lever 1 Lever 2 Lever 3 Time Delay on Factory Setting off on off on off on off on on off off on on off off Figure 1 on on on on off off off off 2±.5 sec 4±5 sec 6±5 sec 8±5 sec 10±5 sec 12±5 sec 14±5 sec 16±.5 sec Configuration Switch, S6, InitialTime Delay Settings Subsequent time delays for additional load shedding is factory set for 2 seconds and is not adjustable. Load Reduce will start at the Initial Shed Voltage. The Factory Setting, for the Initial Shed Voltage, is 12.3VDC. For the first load to go off, the voltage must be 12.3 VDC or lower for the duration of the time delay. Recovery, that is reapplication of a load will not occur until the voltage is .2 VDC hig her than the shed voltage. A time delay prevents the instantaneous operation ofthe output relay. After shedding the first load the Load Manager waits 2 seconds before making a decision to shed more loads. Ifthe sensed voltage is .2 volts less than that at the previous shed point and maintains this lower voltage for 2 seconds, the next load will be shed. This continues until sufficient loads are shed so that there is no further decrease in sensed voltage. Figure 2 below indicates the switch settings required to vary the Initial Shed Voltage. Loads are reapplied when the voltage rises and is maintained for a suitable time. Switch 4 Switch 5 Initial Shed Voltage Factory Setting on off on off on on off off Figure 2 12.30±-1 12.15±.1 12.00±.1 11.85±-1 Configuration Switch S6, Threshold Voltage Setting CAUTION Changes to Configuration Switch, S6, will only take effect during power up. Remove power from pin one of Load Manager and reapply to change the setting on the Load Manger Mark II.
****** Page 5 ****** CU co CD Note 1 . Wire COM. Terminal of each relay individually to a +12V supply using a wire size appro- priate for the current load. 2. Relay Current is 30 Amperes Maximum
****** Page 6 ****** 0 o 10 o z O 0 Ilo cu (D z lååå Ilo Jeöeuen peon eluado 01 leu6!S cu II ayon *Note: Relays KI , K2, and K3 will sequence “ON” and “OFF”, but will not shed loads.
****** Page 7 ****** 14 13 12 11 10 2.13 Figure NC. NC. NC Lowest Priority 6.10 6.52 5.50 CONIPCIS AELAYKB 5.90 Mark 6.30 Highest Priority KI S, Outline Drawing, Load Manager Drawing # : eoen.so-ooe
****** Page 8 ****** 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.
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