KUSSMAUL 091-12DV User manual

INSTRUCTION MANUAL
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221
BOOK# 091-12-1
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
AUTO CHARGE 12 DV
AUTOMATIC BATTERY CHARGER
NOTE :
This charger is designed for
vehicles with single batteries
either negative or positive ground
INPUT : 115/230 volt, 50/60 Hz
MODEL #091-12DV-12

INTRODUCTION
This manual describes the installation and wiring for the Auto-Charge 12DV Automatic
Battery Charger. It is suggested that the installer read The entire instructions to become
familiar with the tasks involved before starting.
INSTALLATION
The installation of the vehicle wiring provides a direct connection between the battery
and the Auto-Charge 12DV Automatic Battery Charger. The battery is automatically
charged at constant voltage. For deeply discharged batteries or if the charger is operated
while the vehicle is started, a current limiter automatically limits the output to 12
amperes. Input power may be either 115 volts or 230 volts, 50 or 60 Hz. A recessed
voltage selector switch is provided on the end panel near the output terminal strip.
The Auto-Charge 12DV uses remote sensing and therefore four wires are necessary to
connect to the battery. Two wires charge the battery while an additional two wires detect
the battery voltage. These connections are made on the output terminal strip.
The Auto-charge 12DV Automatic Battery Charger should be installed in an area with
adequate ventilation. A power cord is supplied for connection to the input power source.
A switch on the end panel of the charger selects either 115 volts or 230 volts. Set this
switch to the proper position to correspond to the input voltage before applying power to
thecharger.
1. Mount the charger using the four holes provided. See figure 1.
2. Connect the wiring from the batteries to the Output Terminal Strip. Spade lugs that
have been securely crimped or soldered should be used
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 line to the power source and check the position of the Voltage
Selector Switch.
6. The pilot light will light to show that the charger has power.
7. The ammeter will indicate how much current is flowing to the battery. A charging
current limit of 12 amperes is factory set.
*************NOTE*************
DO NOT APPLY 230 VOLTS TO THE CHARGER WITH
SELECTOR SWITCH IN THE 115 VOLT POSITION SERJOUS
DAMAGE MAY RESULT

INSTALLATION WIRING DIAGRAM
NOTE:Thesenseleads must be
connected to the battery for the
charger to operate.
IMPORTANT: Wire size is for a
maximumlengthof20feet.Ifwiring
is to be longer, larger wiring is re-
quired.Additionalinformationisavail-
able on request.
WIRE SIZE CHART
CONNECTION ITEM DEFINITION WIRE SIZE
BAT-
BATTERY
NEGATIVE NEGATIVE CHARGING LEAD FOR BATTERIES 14 AWG
BAT+
BATTERY
POSITIVE POSITIVE CHARGING LEAD FOR BATTERY # 1 14 AWG
SENSE
-
NEGATIVE
SENSE NEGATIVE VOLTAGE SENSE LEAD. DETECTS VOLTAGE 16 AWG
SENSE
+
POSITIVE
SENSE POSITIVE VOLTAGE SENSE LEAD. DETECTS VOLTAGE 16 AWG

SPECIFICATION & OUTLINE
SPECIFICATIONS:
Input: 230/115V 50/60Hz, switch selectable
Output Volts: Adjustable, 13.25 volts nominal
Output Current: 0-12 amps, D.C., Current Limited
Charge Indicator: 0-15 amps
Weight: 16 lbs
AUTO CHARGE
4.25
12.75
4.75
6.75
OUTLINEDRAWING
9/32" DIA. 4 HOLES
12.00

SPARE PARTS LIST
PART NUMBER DESCRIPTION
B091-349 Assembly, Control Board
2480 Transformer,Power
SPW405-S Transformer, Power, PC Mount
B-511-2 Rectifier Bridge
A091-15-017 Sense Resistor Assembly
EM 5822 Meter, 0-15 Amp D.C.
2150-A1 Light, Indicator, Neon
LM3900 Integ. Circuit, Quad Op Amp
IP15WB-1K Potentiometer,trimming, 1K
LM7812 Integ. Circuit, Volt Reg
2N4401 Transistor, NPN
1N4004 Diode, Rectifier
1N914 Diode, Signal
1N751 Diode, 5.1V Zener
779 Line Cord
11Z2101 Transformer,Trigger
V802 210.51/250 Switch, Voltage Select

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. 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 the purchaser, his or its
employees or others.