KUSSMAUL AUTO CHARGE 12 User manual

TM
AUTO CHARGE 12
INSTALLA TION GUIDE & MANUAL
Visit: www.evpeurope.com
Call: [phone]
E-mail: [email protected]om
EVP Ltd, Unit 4, Benford Court, Lower Cape, Warwick, CV34 5DA
Company Registration Number: 9121263
VAT number: 196484653
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS – This manual contains
important safetyand operating instructions for battery charger
Model 091-165-12.
2. Do not expose charger to rain or snow.
3. Use of an attachment not recommended or sold by the
battery charger manufacturer may result in a risk of fire,
electric shock, or injury to persons.
4. Wire Battery Charger; 115VAC, 50/60Hz Input Power per
Figure 1 of this manual in accordance with ALL; National, Local
and/or Underwriter requirements for a NEMA, 115VAC, 15
Ampere appliance.
5. Portable extension cords on 115VAC Input or 12VDC
Output should not be used unless absolutely necessary. Use
of improper extension cord could result in a risk of fire and
electric shock. If extension cord must be used;
a) 115VAC input power cord shall comply with UL 1236 Edition
7, Table 11.1 “Acceptable Flexible Cords for Battery Chargers”.
b) That extension cord is properly wired and in good electrical
condition.
c) That wire size is large enough for ampere rating of charger
as specified in Table 52.1 of UL 1236 Edition 7, “Recommended
Minimum AWG Size for Extension Cords for Battery Chargers”.
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
damaged in any way; take it to a qualified serviceman.
8. Do not disassemble charger; take it to a qualified serviceman
when service or repair is required. Incorrect reassembly may
result in a risk of electric shock or fire.
9. To reduce risk of electric shock, unplug charger from outlet
before attempting any maintenance or cleaning.
10. WARNING – RISK OF EXPLOSIVE GASES
a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS
DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES
DURING NORMAL BATTERY OPERATION. FOR THIS
REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME
BEFORE USING THE CHARGER, YOU READ THIS MANUAL
AND FOLLOW THE INSTRUCTIONS EXACTLY.
b) To reduce risk of battery explosion, follow these
instructions and those published by battery manufacturer and
manufacturer of any equipment you intend to use in vicinity
of battery. Review cautionary marking on these products and
on engine.
11. PERSONAL PRECAUTIONS
a) Someone should be within range of your voice or close
enough to come to your aid when you work near a lead-acid
battery.
b) Have plenty of fresh water and soap nearby in case battery
acid contacts skin, clothing, or eyes.
c) Wear complete eye protection and clothing protection.
Avoid touching eyes while working near battery.
d) If battery acid contacts skin or clothing, wash immediately
with soap and water. If acid enters eye, immediately flood
eye with running cold water for at least 10 minutes and get
medical attention immediately.
e) NEVER smoke or allow a spark or flame in vicinity of battery
or engine.
f) Be extra cautious to reduce risk of dropping a metal tool
onto battery. It might spark or short-circuit battery or other
electrical part that may cause explosion.
g) Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with a lead-acid battery.
A lead-acid battery can produce a shortcircuit current high
enough to weld a ring or the like to metal, causing a severe
burn.
MODEL #091-165-12
NOTE : This charger is designed for vehicles with a single battery and negative ground.
CAUTION: This unit should not be exposed to water spray or rain

TM
AUTO CHARGE 12, 091-165-12
INSTALLA TION GUIDE & MANUAL
Visit: www.evpeurope.com
Call: [phone]
E-mail: [email protected]om
EVP Ltd, Unit 4, Benford Court, Lower Cape, Warwick, CV34 5DA
Company Registration Number: 9121263
VAT number: 196484653
h) Use charger for charging a LEAD-ACID battery only. It is not
intended to supply power to a low voltage electrical system
other than in a starter-motor application.
Do not use battery charger for charging dry-cell batteries that
are commonly used with home appliances. These batteries may
burst and cause injury to persons and damage to property.
i) NEVER charge a frozen battery.
12. PREPARING TO CHARGE
a) If necessary to remove battery from vehicle to charge,
always remove grounded terminal from battery first. Make
sure all accessories in the vehicle are o, so as not to cause
an arc.
b) Be sure area around battery is well ventilated while battery
is being charged. Gas can be forcefully blown away by using a
piece of cardboard or other nonmetallic material as a fan.
c) Clean battery terminals. Be careful to keep corrosion from
coming in contact with eyes.
d) Add distilled water in each cell until battery acid reaches
level specified by battery manufacturer. This helps purge
excessive gas from cell. Do not overfill.
For a battery without cell caps, carefully follow manufacturer’s
recharging instructions.
e) Study all battery manufacturer’s specific precautions such
as removing or not removing cell caps while charging and
recommended rates of charge.
f) Determine voltage of battery by referring to vehicle owner’s
manual and make sure that it matches the output rating of the
charger.
13. CHARGER LOCATION
a) Locate charger as far away from battery as VDC charge
cables permit.
b) Never place charger directly above battery being charged;
gases from battery will corrode and damage charger.
c) Never allow battery acid to drip on charger when reading
gravity or filling battery.
d) Do not operate charger in a closed-in area or restrict
ventilation in any way.
e) Do not set a battery on top of charger.
14. DC CONNECTION PRECAUTIONS
a) Connect and disconnect dc output wires only after
interrupting 115VAC Input Power. Never allow wires to touch
each other.
b) Attach wiresto battery perFigure 1 of this manual. For optimal
Battery Charger operation the DC charging connections
require direct connection to battery under charge.
15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN
VEHICLE. A SPARK NEAR BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR BATTERY:
a) Position VAC and VDC cords to reduce risk of damage by
hood, door, or moving engine part.
b) Stay clear of fan blades, belts, pulleys, and other parts that
can cause injury to persons.
c) Check polarity of battery posts. POSITIVE (POS, P, +)
battery post usually has larger diameter than NEGATIVE (NEG,
N, -) post.
d) For negative-grounded vehicle, connect POSITIVE (RED)
wire from battery charger to POSITIVE (POS, P, +) ungrounded
post of battery. Connect NEGATIVE (BLACK) wire to vehicle
chassis or engine block away from battery.
Do not connect wire to carburetor, fuel lines, or sheet-metal
body parts. Connect to a heavy gage metal part of the frame
or engine block.
e) When disconnecting charger, turn any switches to o,
disconnect AC cord, remove wire from vehicle chassis, and
then remove wire from battery terminal.
16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE
VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE
BATTERY EXPLOSION. TO REDUCE RISK OF A SPARK NEAR
BATTERY:
a) Check polarity of battery posts. POSITIVE (POS, P, +)
battery post usually has a larger diameter than NEGATIVE
(NEG, N, -) post.
b) Attach at least a 24-inch-long 6-gauge (AWG) insulated
battery cable to NEGATIVE (NEG, N, -) battery post.
c) Connect POSITIVE (RED) charger wire to POSITIVE (POS,
P, +) post of battery.
d) Position yourself and free end of cable as far away from
battery as possible – then connect NEGATIVE (BLACK)
charger wire to free end of cable.
e) Do not face battery when making final connection.
f) When disconnecting charger, always do so in reverse
sequence of connecting procedure and break first connection
while as far away from battery as practical.
g) A marine (boat) battery must be removed and charged on
shore. To charge it on board requires equipments specially
designed for marine use.
17. The instructions for a battery charger shall include 16. (a) –
(g) as applicable to the particular charger.
a) For all grounded cord-connected battery chargers:
GROUNDING AND AC POWER CORD CONNECTION
INSTRUCTIONS - Charger should be grounded to reduce risk
of electric shock.
b) For grounded, cord-connected battery chargers with an
input rating less than 15 amperes and intended for use on a
nominal 115VAC circuit only.

Notes:
INSTALLATION WIRING DIAGRAM
1. 115VAC Input Power and Charger Output Power strain relief cover not shown for
clarity. Refer to "Important Safety Instructions" section of this manual.
2. Charger output power connections, AWG 14, for 20 feet Maximum. Consult factory
if longer length is required.
OUTPUT
INPUT
LN
FIGURE 1
CAUTION: DISCONNECT SUPPLY
BEFORE FUSE SERVICE
Optional Economy
Indicator
Optional Bar-Graph
Indicator
091-165-016
091-11-102-12
REMOTE
5 AMP
FUSE
POWER
lac
Yellow
R d
AWG 16 X 3
B
e
k
TYPE SJ
NOTE 1
Line
Neutral
Ground
AWG 14
NOTE 1,2
25A
Fuse
TM
Visit: www.evpeurope.com
Call: [phone]
E-mail: [email protected]om
EVP Ltd, Unit 4, Benford Court, Lower Cape, Warwick, CV34 5DA
Company Registration Number: 9121263
VAT number: 196484653
INTRODUCTION
The Auto Charge 12 Battery Charger is a compact completely
automatic charger designed for installation on vehicles with
one (1) battery. The Auto Charge 12 provides complete battery
charging for a single 12VDC battery or single 12VDC battery
bank. The voltage of the battery connected to the Auto
Charge 12 is sensed via the charging cables so that the battery
is charged according to it’s requirements. The maximum
output of the charger is 12 Amperes DC. An ammeter provides
continuous indication of the charger output.
Construction of the Auto Charge 12 is extremely rugged to
withstand the shock and vibration 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-o. Any parasitic loads
on the battery such as radio, lights, etc., will be supplied by
current from the charger.
The Auto Charge 12 incorporates an internal thermal safety
device. Should the internal temperature of the Auto Charge
12 elevate beyond specification the charger will automatically
shut down. The Auto Charge 12 will resume battery charging
once the internal temperature has decreased to specification
level.
INSTALLATION
The Auto Charge 12 Automatic Battery Charger should
be installed in an area with adequate ventilation. Refer to
Installation Wiring Diagram, FIGURE 1
1. Mount the charger using the four holes provided for this.
2. Connect the wiring from the battery to the Output
Terminal Strip.
3. Connect the wiring to the battery. Ring lugs that have
been securely crimped, or soldered, should be used.
4. Double check all wiring before proceeding.
5. Wire the 115VAC, 50/60Hz power to INPUT terminal strip.
6. POWER pilot light will light to show that the charger has
power.
AUTO CHARGE 12, 091-165-12
INSTALLA TION GUIDE & MANUAL
FIGURE 1: Installation Wiring Diagram
CAUTION: Disconnet supply before
fuse service

TM
Visit: www.evpeurope.com
Call: [phone]
E-mail: [email protected]om
EVP Ltd, Unit 4, Benford Court, Lower Cape, Warwick, CV34 5DA
Company Registration Number: 9121263
VAT number: 196484653
AUTO CHARGE 12, 091-165-12
INSTALLA TION GUIDE & MANUAL
Notes:
INSTALLATION WIRING DIAGRAM
1. 115VAC Input Power and Charger Output Power strain
relief cover not shown for clarity. Refer to “Important Safety
Instructions” section of this manual.
2. Charger output power connections, AWG 14, for 20 feet
Maximum. Consult factory if longer length is required.
SPECIFICATION & OUTLINE
Input: 115/120VAC, 50/60 Hz, 2.5 Amps
Input Fuse: 5 Amps,
CAUTION: DISCONNECT SUPPLY BEFORE CHANGING FUSE
Output: 13.25 VDC
Output Fuse (Optional): 25 Amps
Output Current: 12 Amps
Charge Indicator: 0-15 amps 5%
Weight: 10 lbs
Regulatory Approvals
Recognized Component, Battery Chargers, Automotive Type
(BBGQ2) File E225909
1. UL1236 Standard for Battery Chargers
2. Canadian Standards Association, Standard for Battery
Chargers, C22.2 No. 107.2
3. Federal Specification for Emergency Medical Care Vehicles,
KKK-A-1822E
INDICATOR INSTALLATION
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.
4. Cut out square hole.
5. Connect wiring to charge in accordance with the
instruction in the charger installation instructions.
6. Install as shown.
7. Insert (4) #8-32 screws supplied and tighten. (Caution: do
not over tighten because you will bend the plastic bezel
and break the watertight seal).
WARRANTY
All products 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 ordefects 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 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.
9
SPECIFICATIONS:
Input: 115/120VAC, 50/60 Hz, 2.5 Amps
Input Fuse: 5 Amps, CAUTION: DISCONNECT SUPPLY BEFORE CHANGING FUSE
Output: 13.25 VDC
Output Fuse (Optional): 25Amps
Output Current: 12 Amps
Charge Indicator: 0-15 amps 5%
Weight: 10 lbs
SPECIFICATION & OUTLINE
11.375
10.375
4.375 4.375
5.50
9/32" DIA.
OUTLINE DRAWING
Regulatory Approvals
Recognized Component, Battery Chargers, Automotive Type (BBGQ2)
File E225909
1. UL1236 Standard for Battery Chargers
2. Canadian Standards Association, Standard for Battery Chargers, C22.2 No. 107.2
3. Federal Specification for Emergency Medical Care Vehicles, KKK-A-1822E

TM
Visit: www.evpeurope.com
Call: [phone]
E-mail: [email protected]om
EVP Ltd, Unit 4, Benford Court, Lower Cape, Warwick, CV34 5DA
Company Registration Number: 9121263
VAT number: 196484653
AUTO CHARGE 12, 091-165-12
INSTALLA TION GUIDE & MANUAL
10
#8-32 HEX NUT
TRUCK WALL
GASKET
INDICATOR
LOCK & FLAT WASHER
8-32 SCREW
INDICATOR INSTALLATION
HOLE TEMPLATE
File: Ind.cdr rev C: 3-31-10 do not shrink this art work
Hole Template may not be to Scale, please check dimensions before using.
Hole Template may not be to Scale, please check dimensions before using.