KUSSMAUL 091-92-12 User manual

INSTRUCTION MANUAL
3 YEAR WARRANTY
KUSSMAUL ELECTRONICS CO., INC.
170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221
FILE: IM_091-92-12_Rev_B
DATE: 09-15-04
TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: [phone]
BATTERY SAVER
LOW RIPPLE POWER SUPPLY / AUTOMATIC LOAD SWITCH
FOR 12VDC VEHICLE SYSTEMS
INPUT: 115 VOLTS, 50/60 Hz AC, 1.8 amps. RMS
OUTPUT: 13.2VDC, 10 AMPS DC, 130VA
MODEL #091-92-12

INSTALLATION
The 091-92-12 BATTERY SAVER is a power supply with a load power transfer function.
Loads connected to the BATTERY SAVER are powered by the vehicle’s battery when the
AC power to the 091-92-12 Battery Saver is OFF. When AC power is applied to the 091-
92-12 Battery Saver special circuitry within the Battery Saver transfers the load(s) to a
powersupplyinternaltothe091-92-12BatterySaver. TheBatterySaverpowersupplythen
provides low ripple 12VDC System power to Battery Saver load(s). Installation of a 091-
92-12BatterySavereliminatesthepowerdrainonavehiclebatteryandor abatteryunder-
charge ensuring all vehicle battery charger power is available to charge the battery.
The 091-92-12 Battery Saver is unique in that there is no interruption of power supplied to
the loads during power transfers. The feature makes the 091-92-12 Battery Saver ideal for
MDT (Mobile Data Terminal) and or 12VDC vehicle computer systems that may "re-boot"
during an input power interruption.
INTRODUCTION
1. Mount the BATTERY SAVER in a convenient location with 4 screws in the
mountingholesprovided. Becertainthatadequateventilationisavailableandthat
the unit is not subject to weather damage.
2. Connect the 115VAC input power to the BATTERY SAVER through a 3-wire line
cord as shown in INSTALLATION WIRING DIAGRAM, Figure 1.
3. ThelowvoltageconnectionsaremadethroughtheDCoutputconnector asshown
in INSTALLATION WIRING DIAGRAM, FIGURE 1.
1. Connect terminal 1 to the vehicle’s 12 volt battery (+).
2. Connect terminal 3 to the +12 volt electrical loads.
3. Connect terminal 4 to the vehicle ground or to the battery (-).
The installation is now complete. Loads connected to the Battery Saver will be powered
fromthevehiclebatterywhentheACpowertotheBatterySaverisOFFandfromtheBattery
Saver power supply when the AC power is ON.

TEST and OPERATION
The 091-92-12 Battery Saver system interface panel contains two (2) Green LEDs as
follows: Refer INSTALLATION WIRING DIAGRAM, Figure 1.
"LOAD POWER" LED: Illuminates when power is being supplied to the load(s) regardless
of the source of the power (Vehicle Battery or Battery Saver).
"BATT SVR PWR" LED: Illuminates when Battery Saver is receiving AC power and the
power supply internal to the Battery Saver is ON and functioning.
Installation Test
1. Remove AC power from the 091-92-12 Battery Saver.
2. Verify "LOAD POWER" LED is illuminated and loads are being powered by vehicle
battery (voltage at load is approximately equal to vehicle battery terminal voltage).
3. Apply AC power to 091-92-12 Battery Saver and verify:
1."LOAD POWER" LED remains illuminated
2. "BATT SVR PWR" LED illuminates approximately five (5) seconds after
application of AC power to Battery Saver.
3. Load voltage is between 13.2VDC and 13.4VDC
Operation
The 091-92-12 Battery Saver contains special circuitry that eliminates power delivery
"glitches" or interruptions during load power transfer(s) from:
*Vehicle Battery to Battery Saver: Five (5) second delay as Battery Saver power
supply stabilizes. Installation Test para. 3.2.
*Battery Saver to Vehicle Battery: No delay
The MINIMUM voltage at the load during any power transition is:
VehicleBatteryVDC-1.3VDCforaMAXIMUMof150milli-seconds(.150seconds).

INSTALLATION PRECAUTIONS
Refer Figure1, INSTALLATION WIRING DIAGRAM and Specifications & Outline
The091-92-12BatterySaverisACInputANDDCOutputover-currentprotectedasfollows:
115VAC 60Hz Input: 5 Ampere
DC Output: ATC, 10 Ampere
The ATC 10 Ampere DC OUTPUT FUSE internal to the Battery Saver is common to both
the Battery Saver Power Supply output AND the vehicle battery connection that supplies
powertotheloadwhentheBatterySaverisOFF(115VACtoBatterySaver-OFF). Current
OVERLOADING the Battery Saver in excess of 10 Amperes will:
Initiate current limiting of the Battery Saver Power Supply with a corresponding
reduction of the Battery Saver Power Supply terminal voltage when the Battery
Saver is ON until the DC OUTPUT FUSE open circuits.
OR
CausetheATC10AmpereDCOUTPUTFUSEtoopencircuitwhileaBatterySaver
connectedloadinexcessof10Amperesisbeingsuppliedbythevehiclebatterywith
the Battery Saver OFF.
Manage Battery Saver Connected Loads to 10 Amperes or less!

INSTALLATION WIRING DIAGRAM
FIGURE 1
115VAC INPUT
NL BATT SVR PWR
LOAD POWER
SYSTEM GROUND
BATT SVR DC OUT
12VDC BAT + IN
DC SYSTEM
115VAC,60Hz
LINE, AWG 18
NEUTRAL,AWG 18
EARTH,AWG 18
ACCESSORIES RADIOS HAND LIGHTS
+
12V VEHICLE
BATTERY
12V VEHICLE
GROUND
BATT SVR PWR
"ON" GREEN LED
LOAD PWR "ON"
GREEN LED
AC INPUT FUSE
* LOCATED UNDER COVER * LOCATED UNDER COVER
DC OUTPUT FUSE
and SPECIFICATIONS
* REFER TO INSTALLATION PRECAUTIONS
AIR INLET
KEEP CLEAR
SYSTEM INTERFACE 123
12 43
PANEL
SYSTEM CABLING CONNECTORS
SUPPLIED WITH 091-92-12 BATT SVR.
DC OUTPUT
CONNECTOR

SPECIFICATION & OUTLINE
SPECIFICATIONS:
Input Power: 115 volts AC., 50/60Hz, 1.8 Amperes RMS
Input Fuse: F1, 5 Ampere, fast acting, 5 X 20mm, Littlefuse
P/N 21605, inside enclosure
Output Voltage: 13.2 Volts, D.C. ( factory adjustable)
Output Ripple: 30 millivolts, AC., RMS
Output Current: 10 Amperes, D.C.
Electronic Current Limit: 10 Amperes D.C. from Battery Saver Power Supply
PleaserefertoInstallationPrecautions
Output Fuse: F2, 10 Ampere, fast acting Autofuse,
Littlefuse P/N 257010, inside enclosure
Please refer to Installation Precautions
Indicator(s): 1. LOAD POWER ON Green LED
2. BATTERY SAVER POWER SUPPLY ON Green LED
Size: 11.15" L x 5.75" W (air inlet grills) x 2.5" H
Mounting Hole Diameter: .191"
Weight: 2.5 lbs
2.50
11.75
3.50
5.75
OUTLINE DRAWING
9/32" DIA. 4 HOLES
11.15

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.
KussmaulElectronicsCompany,Inc.shallhavenoliabilityfordamagesofany
kind to associated equipment arising from the installation and /or use of the
KussmaulElectronicsCompany,Inc.products.Thepurchaser,bytheaccep-
tanceoftheequipment,assumesallliabilityforanydamageswhichmayresult
from its installation, use or misuse, by the purchaser, his or its employees or
others.