KUSSMAUL 091-11 Series User manual

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INSTRUCTION MANUAL
AUTO CHARGE 11
AUTOMATIC BATTERY CHARGER
MODEL #091-11-XX
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
3 YEAR WARRANTY
NOTE :
This charger is designed for vehicles with
dual batteries and negative ground.
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
FILE: 091-11-UL.p65
DATE: 8-12-2002
REV. E
U.L. Configuration
CAUTION
This unit should not be exposed to water spray or rain

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IMPORTANT SAFETY INSTRUCTIONS
1. SAVETHESEINSTRUCTION–Thismanualcontainsimportantsafetyandoperat-
inginstructionsforbatterychargerModel091-11-xx
2. Donotexposechargertorainorsnow.
3. Useofanattachmentnotrecommendedorsoldbythebatterychargermanufacturer
mayresultinariskoffire,electricshock,orinjurytopersons.
4. Toreduce riskofdamageto electricplugandcord, pullbyplugrather thancord
whendisconnectingcharger.
5. Anextensioncordshouldnotbeusedunlessabsolutelynecessary. Useofim-
properextensioncordcould resultinariskof fireandelectricshock. Ifextension
cordmust beused,make sure:
a) Thatpinsonplugofextensioncordarethesame number,size,andshapeas
thoseofplugoncharger.
b) Thatextensioncordisproperlywired andingood electricalcondition;and
c) That wire size is large enough for ac ampere rating of charger as specified in
Table 50.1 of UL 1236, 3/27/02
6. Do not operate charger with damaged cord or plug – replace the cord or plug
immediately.
7. Do not operate charger if it has received a sharp blow, been dropped, or otherwise
damagedinanyway;takeittoaqualifiedserviceman.
8. Donot disassemble charger; takeit to a qualifiedserviceman when service or
repairisrequired. Incorrectreassembly may result in a risk of electric shock orfire.
9. Toreduceriskofelectricshock,unplugchargerfromoutletbeforeattemptingany
maintenanceorcleaning.

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10. Warning – RISK OF EXPLOSIVE GASES
a) WORKINGINVICINITYOFALEAD-ACIDBATTERYISDANGEROUS.
BATTERIESGENERATEEXPLOSIVEGASESDURINGNORMALBAT-
TERYOPERATION. FORTHISREASON,ITISOFUTMOSTIMPOR-
TANCETHATEACHTIMEBEFOREUSINGTHECHARGER,YOUREAD
THISMANUALANDFOLLOWTHEINSTRUCTIONSEXACTLY.
b) Toreduceriskofbatteryexplosion,followtheseinstructionsandthose
publishedbybatterymanufacturerandmanufacturerofanyequipmentyou
intendtouseinvicinityofbattery. Reviewcautionarymarkingonthese
productsandonengine.
11. PERSONALPRECAUTIONS
a) Someoneshouldbewithinrangeof yourvoiceorcloseenoughtocome to
youraidwhenyouworknearalead-acidbattery.
b) Haveplentyoffreshwaterandsoapnearbyincasebatteryacidcontacts
skin,clothing,oreyes.
c) Wearcompleteeyeprotectionandclothingprotection. Avoidtouchingeyes
whileworkingnearbattery.
d) Ifbatteryacidcontactsskinorclothing,washimmediatelywithsoapand
water. Ifacidenterseye,immediatelyfloodeyewithrunningcoldwaterforat
least10minutesandgetmedicalattentionimmediately.
e) NEVERsmoke or allow a spark or flame invicinity ofbatteryorengine.
f) Beextra cautious to reduceriskofdroppinga metal toolontobattery. It
mightsparkorshort-circuitbatteryorotherelectricalpartthatmaycause
explosion.
g) Removepersonalmetalitemssuchasrings,bracelets,necklaces,and
watcheswhenworkingwithalead-acidbattery. Alead-acidbatterycan
produceashort-circuitcurrenthighenoughtoweldaringortheliketometal,
causingasevereburn.
h) Usecharger forchargingaLEAD-ACIDbattery only. Itisnotintendedto
supplypowertoalowvoltageelectricalsystemotherthaninastarter-motor
application. Donotusebatterychargerforchargingdry-cellbatteriesthat
arecommonlyusedwithhomeappliances. Thesebatteriesmayburstand
causeinjurytopersonsanddamagetoproperty.
i) NEVERchargeafrozenbattery.

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12. PREPARINGTOCHARGE
a) Ifnecessarytoremovebatteryfromvehicletocharge,alwaysremove
groundedterminalfrombatteryfirst. Makesureallaccessoriesinthevehicle
are off, so as not to cause an arc.
b) Besureareaaroundbatteryiswellventilatedwhilebatteryisbeingcharged.
Gascan beforcefullyblownaway by usingapieceof cardboardorother
nonmetallicmaterialasafan.
c) Cleanbatteryterminals. Becarefultokeepcorrosion fromcomingin contact
witheyes.
d) Adddistilledwaterineach cell until battery acid reaches level specified by
batterymanufacturer. Thishelpspurgeexcessivegasfromcell. Donot
overfill. Forabatterywithoutcellcaps,carefullyfollowmanufacturer’sre-
charginginstructions.
e) Studyallbatterymanufacturer’sspecificprecautionssuchasremovingornot
removingcellcapswhilechargingandrecommendedratesofcharge.
f) Determinevoltageofbatterybyreferringtovehicleowner’smanualand
makesurethatitmatchestheoutputratingofthecharger.
13. CHARGERLOCATION
a) Locatecharger as far awayfrombattery as dc cables permit.
b) Neverplacechargerdirectlyabovebatterybeingcharged;gasesfrom
batterywillcorrodeanddamagecharger.
c) Neverallowbatteryacidtodriponchargerwhenreadinggravityorfilling
battery.
d) Donot operatechargerin aclosed-inarea orrestrictventilation inanyway.
e) Donot set a battery on top of charger.
14. DCCONNECTIONPRECAUTIONS
a) Connectanddisconnectdcoutputwiresonlyafterinterruptingpowerand
removingaccordfromelectricoutlet. Neverallowwirestotoucheachother.
b) Attachwires to battery and chassis as indicatedin 15(e),15(f),16(b),and
16(d).
15. FOLLOWTHESESTEPS WHEN BATTERYISINSTALLEDIN VEHICLE. A

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SPARKNEARBATTERYMAYCAUSEBATTERYEXPLOSION. TOREDUCE
RISKOF ASPARKNEARBATTERY:
a) Position ac and dc cords to reduce risk of damage by hood, door, or moving
enginepart.
b) Stayclearoffanblades,belts,pulleys,andotherpartsthatcancauseinjury
topersons.
c) Checkpolarityofbatteryposts. POSITIVE(POS,P,+)batterypostusually
haslargerdiameterthanNEGATIVE(NEG,N,-)post.
d) Determinewhichpostofbatteryisgrounded(connected)tothechassis. If
negativepost is grounded to chassis(asin most vehicles), see (e). Ifposi-
tivepostisgroundedtothe chassis, see (f).
e) Fornegative-groundedvehicle,connectPOSITIVE(RED)wirefrombattery
chargertoPOSITIVE(POS,P,+)ungroundedpostofbattery. Connect
NEGATIVE(BLACK)wiretovehiclechassisorengineblockawayfrom
battery. Donotconnectwiretocarburetor,fuellines,orsheet-metalbody
parts. Connecttoaheavygagemetalpart of the frame or engine block.
f) Forpositive-groundedvehicle,connectNEGATIVE(BLACK)wirefrom
batterychargertoNEGATIVE(NEG,N,-)ungroundedpostofbattery. Con-
nectPOSITIVE(RED)wiretovehiclechassisorengineblockawayfrom
battery. Donotconnectwiretocarburetor,fuellines,orsheetmetalbody
parts. Connecttoa heavy gage metal part oftheframeorengineblock.
g) Whendisconnectingcharger,turnanyswitchestooff,disconnectACcord,
removewirefromvehiclechassis,andthenremovewirefrombatterytermi-
nal.
h) Seeoperatinginstructionsforlengthofchargeinformation.
16. FOLLOWTHESE STEPS WHEN BATTERYIS OUTSIDE VEHICLE. A SPARK
NEARTHEBATTERYMAYCAUSEBATTERYEXPLOSION. TOREDUCERISK
OFASPARKNEARBATTERY:
a) Checkpolarityofbatteryposts. POSITIVE(POS,P,+)batterypostusually
hasalargerdiameterthanNEGATIVE(NEG,N,-)post.
b) Attachatleasta24-inch-long6-gauge(AWG)insulatedbatterycableto
NEGATIVE(NEG,N,-)batterypost.

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c) ConnectPOSITIVE(RED)chargerwiretoPOSITIVE(POS,P,+)postof
battery.
d) Positionyourselfand free end of cable as far awayfrom battery aspossible
–then connect NEGATIVE(BLACK)chargerwireto free endofcable.
e) Donotfacebatterywhenmakingfinalconnection.
f) Whendisconnectingcharger,alwaysdosoinreversesequenceofconnect-
ingprocedureandbreakfirstconnectionwhileasfarawayfrom batteryas
practical.
g) Amarine (boat)batterymustbe removed andchargedonshore. To charge
itonboardrequiresequipmentsspeciallydesignedformarineuse.
17. Theinstructions for a battery chargershallinclude(a)– (g) as applicable tothe
particularcharger.
a) Forallgroundedcord-connectedbatterychargers:
GROUNDINGANDACPOWERCORDCONNECTIONINSTRUCTIONS-
Chargershould be groundedto reduce risk ofelectric shock. Charger is
equippedwithanelectriccordhavinganequipment-groundingconductorand
agroundingplug. Theplugmustbepluggedintoanoutletthatisproperly
installedandgroundedinaccordancewithalllocalcodesandordinances.
DANGER–Never alter AC cord orplugprovided – if it willnotfitoutlet, have
properoutletinstalledbyaqualifiedelectrician. Improperconnectioncan
resultinariskofanelectricshock.
b) Forgrounded,cord-connectedbatterychargerswithaninputratingless
than15amperesandintendedforuseonanominal120-voltcircuit:
Thisbatterychargerisforuseonanominal120-voltcircuit,andhasaground-
ingplugthatlooks like the plug illustrated insketchAinFigure 50.1. A tempo-
raryadapter, whichlookslike theadapterillustratedin sketchesBandC, may
beused to connect thisplug to a two-polereceptacleas shown in sketchB if a
properlygroundedoutletisnotavailable. Thetemporaryadaptershouldbe
usedonlyuntilaproperlygroundedoutletcanbeinstalledbyaqualified
electrician.

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DANGER– Before usingadapterasillustrated, be certainthatcenterscrew
ofoutletplateis grounded. Thegreen-coloredrigidearor lugextendingfrom
adaptermustbeconnectedto a properly grounded outlet – make certainit is
grounded. Ifnecessary,replaceoriginaloutletcoverplatescrewwithalonger
screwthatwillsecureadapterearorlugtooutletcoverplate andmakeground
connectiontogroundedoutlet.

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INTRODUCTION
TheAutoCharge 11 Battery Charger is acompact completelyautomaticchargerdesigned
for installation on vehicles with two batteries. Two individual chargers are provided to
chargethetwobatteries. Voltageissensedseparatelyforeachbatterysothateachbattery
ischargedaccordingtoitsrequirements.Thetotaloutputtothetwobatteriesis10amperes.
An ammeter provides continuous indication of the charger output.
ConstructionoftheAutoCharge11isextremelyruggedtowithstandtheshockandvibration
normally encountered by vehicle mounted equipment. The unit operates completely
automatically and stops charging the batteries when they are fully charged. There is no
trickle charge and therefore no danger of overcharging and water boil-off. Any parasitic
loads on the battery such as radio, lights, etc., are automatically supplied with current by
the charger.
INSTALLATION
TheAutoCharge11AutomaticBatteryChargershouldbeinstalledinanareawithadequate
ventilation.
1. Mount the charger using the four holes provided for this.
2. Connect the wiring from the batteries to the Output Terminal Strip.
3. Connect the wiring to the batteries. Ring lugs that have been securely crimped, or
soldered, should be used.
4. Double check all wiring before proceeding.
5. Wire the A.C. power to power input terminal strip.
6. Pilot light will light to show that the charger has power.

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INSTALLATION WIRING DIAGRAM
IMPORTANT: Charger output wire size is 14 awg. Wire size is for a maximum length of 20
feet. If wiring is to be longer, larger wiring is required. Additional information is available on
request.
FUS E
5 AMP
POW ER
IN P U T
OU T P U T
LN
BAT 1 BAT 2
REMOTE
Optional Bar-Graph
Indicator
091-11-127
Optional Economy
Indicator
091-11-102-XX
Yellow
Black
Red
Chassis
Ground
Chassis
Ground
Chassis
Ground
Ground
Neutral
Line
A.C. Input Power

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SPECIFICATIONS:
Input: see chart
Output: see chart
Output Current: see chart
Charge Indicator: 0-15 amps 5%
Weight: 12 lbs
SPECIFICATION & OUTLINE
Model # Output Current Output Voltage Input Voltage Input Current Input Fuse
091-11-6 10 Amps 6 120, 50/60 Hz 2.5 Amps 3 Amp
091-11-12 10 Amps 12 120, 50/60 Hz 2.5 Amps 3 Amp
091-11-24 5 Amps 24 120, 50/60 Hz 2.5 Amps 3 Amp
091-11-6-230 10 Amps 6 230, 50/60 Hz 1.3 Amps 1.6 Amp
091-11-12-230 10 Amps 12 230, 50/60 Hz 1.3 Amps 1.6 Amp
091-11-24-230 5 Amps 24 230, 50/60 Hz 1.3 Amps 1.6 Amp