KUSSMAUL AUTO CHARGE 1000 PUMP-PLUS 091-9-1000 User manual

INSTRUCTION MANUAL
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796
4-16-2002
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
1 YEAR WARRANTY ON AIR COMPRESSOR
3 YEAR WARRANTY ON CHARGER
NOTE :
This charger is designed for
vehicles with single battery system
and negative ground.
INPUT :120 volt, 50/60 Hz, 3.5 amps
OUTPUT: 18 AMPERES
PUMP-PLUS
AIR COMPRESSOR / BATTERY CHARGER
AUTO CHARGE 1000
MODEL #091-9-1000
BOOK# 091-9-1000 pump plus-reva

Charge Controls & Electronic Remote Sensing
The Auto Charge 1000 Pump Plus 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 fre-
quency is determined by the power line frequency. Therefore their are brief
intervals during which no charging current flows. During this brief interval the
Auto Charge 1000 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 at the desired level. Their is no “trickle charge” and
therefore no danger of overcharging and water boil-off.
Automatic Current Limiting
When batteries are severely discharged, some battery chargers can be over-
loaded due to the high charging current required. The Auto Charge 1000 Pump
Plus contains an automatic current limit. This circuit limits the output current to
the rated 15 amperes 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.
Introduction
The AUTO CHARGE 1000 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. The Auto Charge 1000 Pump Plus operates an 091-9 air compres-
sor.WiththeselectorswitchintheACpositionthecompressorrunsonlywhentheACpower
isapplied.WiththeselectorswitchintheDCpositionthecompressorwilloperatewhenthe
ACpowerisonoroff.Ineitherpositionthecompressoroperatesfromthevehicle’sbatteries,
the Pump Plus automatically recharging the batteries as required.
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 battery charge/condition indicator

Battery Saver & Indicator
A 3 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 3 amperes.
WHEN A BATTERY SAVER OVERLOAD OCCURS:
a. Remove the loads for approximately two minutes
b. Reduce the load to 3 amperes or less
c. Reapply the load to the BATTERY SAVER
No fuses are required or provided as the BATTERY SAVER contains an electronic
overload interrupter.
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 charged 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”.

Installation Wiring Diagram
WIRE SIZE CHART
CONNECTION ITEM DEFINITION WIRE SIZE
COM BATTERY
COMMON NEGATIVE CHARGING LEAD FOR CHARGING BATTERIES
AND BATTERY SAVER LOAD
12 AWG
BAT 1 BATTERY
#1 POSITIVE CHARGING LEAD FOR BATTERY # 1 12 AWG
B.S. BATTERY
SAVER POSITIVE LEAD FOR BATTERY SAVER LOADS. 16 AWG
AUTO
PUMP+ AUTO
PUMP AUTO PUMP, POSITIVE 14 AWG
AUTO
PUMP- AUTO
PUMP AUTO PUMP, NEGATIVE 14 AWG
IMPORTANT : Wire size is
for a maximum length of 10
feet. If wiring is to be longer,
largerwiringisrequired.Ad-
ditional information is avail-
able on request.
BLK
BLK
RED
RED
NOTE:INDICATORWIRING,PIN1OF
INDICATOR MUST GO TO PIN 1 OF
CHARGER, PIN 2 OF INDICATOR TO
PIN 2 OF CHARGER AND SO FORTH.
PLEASECHECKCONNECTORSAND
COLOROFWIRESBEFOREPLUGGING
IN. Auto Charge 1000 Pump Plus
PUMP PLUS
1000
BATTERY SAVER
OVER LOAD
POWERPOWER
POWERPOWER
POWER
AUTOAUTO
AUTOAUTO
AUTO
PUMPPUMP
PUMPPUMP
PUMP
AUTOAUTO
AUTOAUTO
AUTO
PUMPPUMP
PUMPPUMP
PUMP
DCDC
DCDC
DC ACAC
ACAC
AC
++
++
+COMCOM
COMCOM
COM BAT 1BAT 1
BAT 1BAT 1
BAT 1 B.S.B.S.
B.S.B.S.
B.S.
POSITIVEPOSITIVE
POSITIVEPOSITIVE
POSITIVE
CHARGER
11
11
1
22
22
2
33
33
3
44
44
4
Auto Pump
Air Compressor
Note:
make sure
the Auto Pump
is mounted
vertical.
Pressure
Switch
Chassis
Ground
Range
Nut
Chassis
Ground
Chassis
Ground
+ 12 Volts
Accessories
Battery Saver Loads
(3 amps max.).
Whenthecharger
is disconnect from
120 volts AC the
Battery Saver loads
automatically are
connectedtobattery#1.

Specifications:
Input: 120 volt, 50/60 Hz, 3.5 amperes
Input Fuse: 6 ampere, fast acting
Output: 12 volts D.C. 15 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., 3 amperes Max.
Indicators: Power: Red LED, indicates 120 volts power applied
Battery Saver Overload: Yellow LED, indicates Battery Saver
load greater than 3 amperes
Bar Graph: indicates charger output and state of charge of
battery
Weight: 16 lbs
Outline Dimensions, AUTO CHARGE 1000

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

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 over tighten because
you will bend the plastic bezel and brake the watertight seal).
HOLE TEMPLATE
INDICATOR INSTALLATION