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INSTRUCTION MANUAL

KUSSMAUL ELECTRONICS CO., INC.

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

FILE: IM_091-127-XXX-YY-TC-HL-UV_Rev_A.P65

Date: 06-24-03

TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826

AUTO CHARGE

3 STEP

AUTOMATIC BATTERY CHARGER

3 YEAR WARRANTY

MODEL #091-127-XXX-YY-(ZZZ)(WW)

XXX - 12, 24, 32, 36, 48, 72, 96, 120 and 144 VDC

YY - 8, 10, 15, 20, 27, 30, 40 and 80 Amps

ZZZ -115VAC 60Hz, 230VAC 60Hz, 230VAC 50Hz

WW - TC, HL and UV Options

Summary of content (10 pages)

PAGE 1
FILE: IM_091-127-XXX-YY-TC-HL-UV_Rev_A.P65 Date: 06-24-03 INSTRUCTION MANUAL AUTO CHARGE R 3 STEP AUTOMATIC BATTERY CHARGER MODEL #091-127-XXX-YY-(ZZZ)(WW) XXX - 12, 24, 32, 36, 48, 72, 96, 120 and 144 VDC YY - 8, 10, 15, 20, 27, 30, 40 and 80 Amps ZZZ -115VAC 60Hz, 230VAC 60Hz, 230VAC 50Hz WW - TC, HL and UV Options 3 YEAR WARRANTY KUSSMAUL ELECTRONICS CO., INC. 170 CHERRY AVE., WEST SAYVILLE, N.Y.
PAGE 2
INTRODUCTION The Auto Charge-3 STEP CHARGER, Model 091-127-XXX-YY-(ZZZ)(WW) is a compact, completely automatic single channel battery charger designed specifically for periodic charging. Refer to Specifications section of this manual for Model Number Composition. Of rugged construction, the charger is made to withstand the shock and vibration encountered in vehicle mounted equipment. Utilizing components, which meet international safety standards, makes this charger ideal for worldwide applications.
PAGE 3
PRINCIPLES OF OPERATION A three-step lead acid battery charger operates in the three stages described below: 1) A discharged battery is recharged at a constant current (bulk charge) until its voltage reaches an overcharge level of 2.48 volts per cell. At this time the charger will switch to Finish Charge. The battery accepts 75-85% of its capacity during bulk charge. 2) This overcharge voltage is now maintained constant at 2.
PAGE 4
UNDER VOLTAGE Under Voltage signaling is provided as an optional feature. It is supplied as relay contact closures internal to the charger in accordance with the following specifications. Interface Voltage and Current Rating: per NEMA Classification for AWG 18 wire and Customer Interface distance. Consult Factory for Under Voltage "Set-Point" threshold and signal hysteresis characteristics for Under Voltage signaling equipped models. Consult Factory for field adjustment of Under Voltage Set-Point threshold.
PAGE 5
THREE STAGE CHARGING CURVE ABSORPTION STAGE BATTERY CURRENT FLOAT STAGE BATTERY VOLTAGE Voltage Increasing Current Constant STAGE I CONSTANT CURRENT (BULK) Voltage Constant Current Decreasing Voltage Constant Full Charge Maintained STAGE II CONSTANT VOLTAGE (ABSORPTION) STAGE III CONSTANT VOLTAGE (FLOAT) Figure 1 TIME
PAGE 6
NOTE: This charger is designed to have it’s output voltage compensated for changes in Temperature. A switch on the circuit board selects whether the unit is operated in the compensated or uncompensated mode. WHEN IN THE TEMPERATURE COMPENSATED MODE THE THERMISTOR MUST BE CONNECTED. Operation without the thermistor while in the compensated mode will result in loss of voltage control and overcharging of the battery.
PAGE 7
Specifications Input Power:& Fuse: See Chart Output Power: See Chart Charge Indicator: See Chart Mode Indicators: Battery Fault, Time-out, Bulk Charge, Finish Charge, and Battery Charged Recommended Battery Size: See Chart Weight: 65 pounds Temperature Compensation: Add suffix “TC” to Model Number shown in Table below Output Current Select: Add suffix "HL" to Model Number for selectable output current levels. Under Voltage: Add suffix "UV" to Model Number for Under Voltage signaling option.
PAGE 8
OUTLINE DRAWING
PAGE 9
TST-110-01-T-S CONNECTOR FAR SIDE SWITCH S1 PLACE IN T/C POSITION WHEN INSTALLING THERMISTOR FIGURE 3 THERMISTOR INSTALLATION SWITCH SETTING
PAGE 10
INSTALLATION RECORD & WARRANTY Date Installed Installed By Vehicle Identification Vehicle Owner WARRANTY All product 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. Kussmaul Electronics Company, Inc.