KUSSMAUL 091-9-1200 User manual

INSTRUCTION MANUAL
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
INPUT :115 volt, 60 Hz, 10 amps
OUTPUT: 40 AMPERES
MODEL #091-9-1200
AUTO CHARGE
1200 PUMP PLUS
AUTOMATIC BATTERY CHARGER
FILE: 091-9-1200.P65
DATE: 11-1-2005
REV. C

Charge Controls & Electronic Remote Sensing
The Auto Charge 1200 Pump Plus contains a precision voltage controller to
maintain the battery’s charge. Automatic electronic remote sensing measures the
truebatteryvoltage,eliminatingtheneedfortheadditionalsensewires. Theoutput
current of any charger is inherently a series of pulses whose frequency is deter-
minedby thepower linefrequency. Therefore thereare briefintervals duringwhich
no charging current flows. During this brief interval the Auto Charge 1200 Pump
Plus measures and stores the battery voltage. This battery voltage is compared to
a standard and any error is detected and used to control the charger output to the
desired level. There is no “trickle charge” and therefore no danger of overcharging
and water boil-off.
INTRODUCTION
The AUTO CHARGE 1200 PUMP PLUS 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.
TheAUTOCHARGE1200PUMPPLUSoperatesan091-9aircompressor.Withthe
selector switch in the AC position the compressor runs only when the AC power is
applied. With the selector in the DC position the compressor will operate when the
AC power is ON or OFF. In either position the compressor operates from the
vehicle’s batteries, the charger automatically recharging the batteries as required.
The battery charger features:
• Electronic remote sensing of true battery voltage, eliminates the need
for sensing wires
• Automatic current limiting
• Remote Battery charge/condition indicator
• Power “ON” LED indicator

Automatic Current Limiting
When batteries are severely discharged, some batteries can be overloaded due to
the high charging current required. The Auto Charge 1200 Pump Plus contains an
automaticcurrentlimit. Thiscircuitlimitstheoutputcurrenttotherated40amperes
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 Charge Condition Indicator
This 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 charged with an external load of 4 to 10 amperes
across it’s terminals, the bar graph may move down 1 or 2 levels. This
does not indicate a defective battery.

Installation Wiring Diagram
AUTO CHARGE 1200
REMOTE DISPLAY
RED
BLKWHT
POWER
FUSE
COM VEHICLE
BATTERY
POSITIVE
AUTO
PUMP
Pressure
Switch
Auto Pump
Air Compressor
make sure
the Auto Pump
is mounted
vertically.
Note:
RED+12VOLTS
BLACK-12VOLTS
Chassis
Ground
Chassis
Ground
Chassis
Ground
WIRE SIZE CHART
CONNECTION DEFINITION WIRE SIZE
COM
VEHICLE
BATTERY
AUTO
PUMP
NEGATIVE CHARGING LEAD
POSITIVE CHARGING LEAD FOR BATTERY
POSITIVE OUTPUT FOR AUTO PUMP
8 AWG
8 AWG
14 AWG
IMPORTANT: WIRE SIZE IS
FOR A LENGTH OF 10 FEET.
IF WIRING IS TO BE LONGER,
6 AWG WIRING IS REQUIRED,
ADDITIONAL INFORMATION IS
AVAILABLE ON REQUEST.
INDICATOR
NOTE INDICATOR WIRING
PIN 1 OF INDICATOR MUST GO TO PIN 1
OF CHARGER, PIN 2 OF INDICATOR MUST
GO TO PIN 2 OF CHARGER AND SO FORTH
PLEASE CHECK CONNECTIONS AND COLOR
OF WIRES BEFORE PLUGGING IN.
USE 8 AWG
or larger on
Output & Gnd

1. Locate Indicator in a convenient place on the vehicle.
2. Place the template in position and center punch in 4 places.
3. Drill holes as shown.
5. Cut out square hole.
6. Connect wiring to charger using butt connector supplied.
7. Install as shown.
8. Insert 4 #6-32 screws and tighten, (CAUTION Do not overtighten because
you will bend the plastic bezel and break the watertight seal).
HOLE TEMPLATE
INDICATOR INSTALLATION

Specifications:
Input: 115 volt, 60 Hz, 10 amperes
Input Fuse: 15 ampere, fast acting
Output: 12 volts D.C. 40 amperes Max.
Remote Sensing: Electronic, sense wires not required
Indicators: Power: Red LED, indicates 115 volts power applied
Bar Graph: indicates charger output and state of charge of
battery
Weight: 21 lbs
Outline Dimensions, AUTO CHARGE 1200 PUMP PLUS

INSTALLATION RECORD & WARRANTY
Date Installed
Installed By
Vehicle Identification
Vehicle Owner
WARRANTY
AllproductsofKussmaul ElectronicsCompany Inc.are warrantedtobe
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
wasshipped.Equipmentis tobereturned,shippingchargesprepaidandwill
be returned, after repair, shipping charges paid.
KussmaulElectronicsCompany,Inc.shallhavenoliabilityfordamages
of any kind to associated equipment arising from the installation and /or use
ofthe KussmaulElectronics 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.