KUSSMAUL 091-3510 User manual

INSTRUCTION MANUAL
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221
BOOK#091-35/10
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
AUTO CHARGE
35/10
AUTOMATIC BATTERY CHARGER
INPUT :120 volt, 50/60 Hz, 10 amps
OUTPUT: 35 AMPERES
MODEL #091-35/10
rev.A: 10-28-2004

Charge Controls & Electronic Remote Sensing
The Auto Charge 35/10 contains a precision voltage controller to maintain the
battery’s charge. Automatic electronic remote sensing measures the true battery
voltage, eliminating the need for the additional sense wires. The output current of
any charger is inherently a series of pulses whose frequency is determined by the
power line frequency. Therefore there are brief intervals during which no charging
currentflows. DuringthisbriefintervaltheAutoCharge35/10measuresandstores
the battery voltage. This battery voltage is compared to a standard and any error is
detected and used to control the charger output at the desired level. Their is no
“trickle charge” and therefore no danger of overcharging and water boil-off.
Introduction
The AUTO CHARGE 35/10 is a compact, completely automatic, single channel
battery charger designed for vehicles with a single battery system. The charger is
ruggedized to withstand the shock and vibration encountered by vehicle mounted
equipment.
The battery charger features:
• Electronic remote sensing of true battery voltages, eliminates the need
for sensing wires
• Automatic current limiting
• Built-in BATTERY SAVER
• Remote bar graph battery charge/condition indicator
• Power “ON” LED indicator
• BATTERY SAVER overload indicator

Automatic Current Limiting
When batteries are severely discharged, some battery chargers can be overloaded
due to the high charging current required. The Auto Charge 35/10 contains an
automaticcurrentlimit. Thiscircuitlimitstheoutputcurrenttotherated35amperes
when charging a deeply discharged battery or if the starter cranks the engine while
charging. The current limiter thus eliminates the need for an ignition interlock
circuit.
Battery Saver & Indicator
A 10 ampere BATTERY SAVER is built into the charger. When connected as
shown in the installation wiring diagram, loads on the battery such as radios and
rechargeable hand lights are automatically switched to the BATTERY SAVER
when power is applied to the charger. The BATTERY SAVER allows more efficient
charging by removing these loads. A BATTERY SAVER overload indicator alerts
the operator that the BATTERY SAVER load has exceeded 10 amperes.
WHEN A BATTERY SAVER OVERLOAD OCCURS:
a. Remove the loads for approximately two minutes
b. Reduce the load to 10 amperes or less
c. Reapply the load to the BATTERY SAVER
No fuses are required or provided as the BATTERY SAVER contains an automatic
circuit breaker.

KUSSMAUL ELECTRONICS COMPANY, INC.
170 CHERRY AVENUE, WEST SAYVILLE, NEW YORK, 11796-1221 USA
SINCE 1967, DESIGNERS OF INNOVATIVE PRODUCTS
TEL. In NY: TOLL FREE: FAX: [phone] 346-0857 631 567-582
6
CAUTION
This battery saver output is a full wave
rectified sine wave. The 12.5 volts D.C.
has a peak value of approximately 17.5
volts.
It is recommended that the loads are not
highly capacitive. A large capacitor on
the load terminal will "peak detect" the
output and create a voltage of
apporximately17volts.Thisvoltagemay
betoohighforthecomponentconnected.
It is suggested that the installed check
the output of the battery saver (when
operatingwithA.C.input)anddetermine
as each load is connected that the volt-
age does not rise.Any load that creates
an increase in voltage should not be
connectedtothebatterysaverbutrather
be connected directly to the battery.

Remote Battery Charge Condition Indicator
This remote indicator shows the charge condition of the battery in 10 levels from
“LOW CHARGE” to “FULLY CHARGED”. This device indicates a defective battery
when a bar graph does not rise to the “FULLY CHARGED” level after an extended
period of charging.
NOTE: If a battery is being discharged with an external load of 1.5 to 4
amperes across it’s terminals, the bar graph may move down 1
or 2 levels. This does not indicate a defective battery.
To avoid this, connect all external loads to the BATTERY SAVER
terminals.
Loads connected to the BATTERY SAVER will be powered either from
the BATTERY SAVER power supply when the A.C. power is “ON”, or
they will be connected to the battery when the A.C. power is “OFF”.

A.C. FUSE
POWER
INPUT
OUTPUT
LN
BATTERY SAVER
REMOTE
B.SBAT1
Battery Saver Loads
(10 amps max.).
When the charger
is disconnected from
120 volts AC the
Battery Saver loads
automatically are
connected to battery #1.
Chassis
Ground Chassis
Ground
+12Volts
Accessories
4
3
2
1
To 120 volts A.C.
Indicator
Auto Charge 35/10
CONNECTION DEFINITION WIRE SIZE
A.C. 120 VOLTS A.C. 14 AWG
COM GROUND LINE 8 AWG
BAT 1 POSITIVE CHARGING LEAD VEHICLE BATTERY 1 8 AWG
BATTERY SAVER POSITIVE OUTPUT 14 AWG
IMPORTANT: Wire size is for a maximum lenght of 10 feet. If longer, larger wiring is required.
Wire Chart
NOTE: Minimum wire size on char
g
er
output and ground is Smaller
gauge wire may cause overheating of
terminal. Use GS 7-13 eyelet over wire
to simplify insertion of wire into terminal
strip and to improve connection.
#8 AWG.
Strip insulation
15/32 so that
wire strands are
flush with end of
eyelet, 2 places,
Installation Wiring Diagram

Specifications:
Input: 120 volt, 50/60 Hz, 10 amperes
Input Fuse: 12 ampere, fast acting
Output: 12 volts D.C. 35 amperes Max.
Remote Sensing: Electronic, sense wires not required
Number of Charger Outputs: 1
Number of Battery Saver Outputs: 1
Battery Saver Output: 12 volts D.C., 10 amperes Max.
Indicators: Power: Red LED, indicates 120 volts power applied
Battery Saver Overload: Yellow LED, indicates Battery Saver
load greater than 10 amperes
Bar Graph: indicates charger output and state of charge of
battery
Weight: 22 lbs

INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
All products of Kussmaul Electronics Company Inc. are warranted to
be free of defects of material or workmanship. Liability is limited to repair-
ing 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 dam-
ages of any kind to associated equipment arising from the installation and
/or use of the Kussmaul Electronics Company, Inc. products. The pur-
chaser, 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.
WARRANTY