FILE: IM_091-127-XXX-YY-TC-HL-UV_Rev_A.

P65
Date: 06-24-03

INSTRUCTION MANUAL

AUTO CHARGE
3 STEP
AUTOMATIC BATTERY CHARGER

MODEL #091-127-XXX-YY-(ZZZ)(WW)
XXX - 12, 24, 32, 36, 48, 72, 96, 120 and 144 VDC

YY - 8, 10, 15, 20, 27, 30, 40 and 80 Amps

ZZZ -115VAC 60Hz, 230VAC 60Hz, 230VAC 50Hz

WW - TC, HL and UV Options

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: 631-567-5826

Downloaded from www.Manualslib.com manuals search engine

 INTRODUCTION
The Auto Charge-3 STEP CHARGER, Model 091-127-XXX-YY-(ZZZ)(WW) is a compact,
completely automatic single channel battery charger designed specifically for periodic
charging. Refer to Specifications section of this manual for Model Number Composition.
Of rugged construction, the charger is made to withstand the shock and vibration
encountered in vehicle mounted equipment. Utilizing components, which meet international
safety standards, makes this charger ideal for worldwide applications.

BATTERY CHARGER FEATURES

Completely automatic operation, charges battery on demand
Output Voltage regulated, eliminates overcharging battery
Output Voltage, temperature compensated (Option)
Output, current limited to protect charger from overloading
A 5-LED display indicating charge state and faults
Reverse polarity protection
Under voltage signaling (Option)
Selectable HIGH/LOW Output Current (Optionl)

Refer to Specifications section of this manual to incorporate "Options" in Model Number

Composition.

INSTALLATION
The 3 STEP CHARGER should be installed in an area with adequate ventilation.
Mount the charger using the four holes provided.
Connect wiring from the battery to the output terminal strip.
Double check battery wiring. Verify that the battery voltage appears at the charger
output terminals (See Figure 2).

Downloaded from www.Manualslib.com manuals search engine

 PRINCIPLES OF OPERATION
A three-step lead acid battery charger operates in the three stages described below:

1) A discharged battery is recharged at a constant current (bulk charge) until its voltage
reaches an overcharge level of 2.48 volts per cell. At this time the charger will switch
to Finish Charge. The battery accepts 75-85% of its capacity during bulk charge.

2) This overcharge voltage is now maintained constant at 2.48 volts per cell (absorption
or finish charge) until the charge current tapers down to {battery capacity/35}
amperes. For the 12 volt, 80 ampere charger this current is 11.9 amperes. The battery
accepts 15-25% of it capacity during absorption charge.

3) Once the charge current reaches the tapered down value (see above), the voltage is
set to a float voltage of 2.24 volts per cell, and maintained at float charge. The battery
is maintained at full charge during float charge, and the green indicator labeled “Battery
Charged” is illuminated.

Figure 1 depicts the above described operation. Note that the term “absorption charge” is
used interchangeably with “finish charge”. Upon application of AC power, the charger is
placed into bulk charge. When the charger switches to finish charge, a timer starts. In the
event that the charge current did not taper down to approximately C/35 amperes after 2 ½
hours, the charger will automatically go to float charge, and a time-out will be indicated. This
time-out indicator can indicate an old or leaky battery, or it can indicate that the charger is
undersized for the battery being charged.

A battery fault indicator is provided to indicate the absence of a battery, a battery connected
with reverse polarity, or a battery with an open circuit terminal voltage of less than 1.35 volts
per cell.

TEMPERATURE COMPENSATION
Temperature compensation is provided as an optional feature. A temperature probe is
provided which can be placed in the air surrounding the battery or bonded to the battery
case.

SELECTABLE OUTPUT CURRENT

Selectable output current level is provided as an optional feature. It is normally supplied as
a current output level "HIGH" and "LOW" front panel switch selectable setting. Unless
otherwise specified the "HIGH" current setting refers to unit maximum output currrent as
specified in Specifications section of this manual. The "LOW" current setting is 40% +/- 5%
of the maximum current ouput. Consult factory for additional information on this option.

Downloaded from www.Manualslib.com manuals search engine

 UNDER VOLTAGE
Under Voltage signaling is provided as an optional feature. It is supplied as relay contact
closures internal to the charger in accordance with the following specifications.

Interface Voltage and Current Rating: per NEMA Classification for AWG 18 wire and
Customer Interface distance.

Consult Factory for Under Voltage "Set-Point" threshold and signal hysteresis character-
istics for Under Voltage signaling equipped models. Consult Factory for field adjustment of
Under Voltage Set-Point threshold.

UV RELAY: Refer to Figure 2

Energized [COM makes NO] when battery terminal voltage is ABOVE Under Voltage Set-
Point plus signal hysteresis.

De-energized [COM makes NC] when battery terminal voltage is EQUAL to or BELOW
Under Voltage Set-Point.

Downloaded from www.Manualslib.com manuals search engine

 THREE STAGE CHARGING CURVE

ABSORPTION STAGE
BATTERY
CURRENT

FLOAT
STAGE

BATTERY
VOLTAGE

Voltage Increasing Voltage Constant Voltage Constant

Current Constant Current Decreasing Full Charge Maintained
STAGE I STAGE II STAGE III TIME
CONSTANT CURRENT CONSTANT VOLTAGE CONSTANT VOLTAGE
(BULK) (ABSORPTION) (FLOAT)

Figure 1

Downloaded from www.Manualslib.com manuals search engine

 NOTE: This charger is designed to have it’s output voltage compensated for changes in
Temperature. A switch on the circuit board selects whether the unit is operated in the
compensated or uncompensated mode. WHEN IN THE TEMPERATURE COMPENSATED
MODE THE THERMISTOR MUST BE CONNECTED. Operation without the thermistor
while in the compensated mode will result in loss of voltage control and overcharging
of the battery.

UV RELAY Customer Interface

(Optional)

White
COM
Green
NC
Black
NO

OUTPUT
CURRENT
HIGH/LOW
SWITCH
(OPTIONAL)

A.C. POWER

- +
BATTERY

THERMISTOR
(OPTIONAL)

Figure 2

INSTALLATION WIRING

Downloaded from www.Manualslib.com manuals search engine

 Specifications
Input Power:& Fuse: See Chart
Output Power: See Chart
Charge Indicator: See Chart
Mode Indicators: Battery Fault, Time-out, Bulk Charge, Finish Charge, and Battery Charged
Recommended Battery Size: See Chart
Weight: 65 pounds
Temperature Compensation: Add suffix “TC” to Model Number shown in Table below
Output Current Select: Add suffix "HL" to Model Number for selectable output current levels.
Under Voltage: Add suffix "UV" to Model Number for Under Voltage signaling option.
Fifty (50) Hz Operation: 230VAC input power operation only. Add "/50" as suffix to 230
in Model Number for 50Hz operation. Example: 091-127-XXX-YY-230/50.

Model Number Composition:

091-127-XXX-YY-ZZZ-WW
Options: TC, HL, UV
Input: Omit for 115VAC 60Hz
230 for 230VAC 60Hz
230/50 for 230VAC 50Hz
Output Amperes
Output Volts, DC
Model Number Input Power Input Fuse Output Charge Recommended
091-127-XXX-YY VAC, Freq,, Current Amps, Type XXX Volts, YY Amps Indicator Battery Size

091-127-12-80 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 12 Volts, 80 Amps 100 Ampere 300 to 600 ampere-hours

091-127-24-40 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 24 Volts, 40 Amps 50 Ampere 150 to 300 ampere-hours

091-127-32-30 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 32 Volts, 30 Amps 50 Ampere 110 to 220 ampere-hours

091-127-36-27 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 36 Volts, 27 Amps 50 Ampere 100 to 200 ampere-hours

091-127-48-20 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 48 Volts, 20 Amps 25 Ampere 75 to 150 ampere-hours

091-127-72-15 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 72 Volts, 15 Amps 25 Ampere 50 to 100 ampere-hours

091-127-96-12 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 96 Volts, 12 Amps 25 Ampere 45 to 90 ampere hours

091-127-120-10 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 120 Volts, 10 Amps 25 Ampere 40 to 80 ampere hours

091-127-144-8 115 Volts 60 Hz, 20 Amps 25 Amp Slow Blow 144 Volts, 8 Amps 25 Ampere 40 to 80 ampere hours

091-127-12-80-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 12 Volts, 80 Amps 100 Ampere 300 to 600 ampere-hours

091-127-24-40-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 24 Volts, 40 Amps 50 Ampere 150 to 300 ampere-hours

091-127-32-30-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 32 Volts, 30 Amps 50 Ampere 110 to 220 ampere-hours

091-127-36-27-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 36 Volts, 27 Amps 50 Ampere 100 to 200 ampere-hours

091-127-48-20-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 48 Volts, 20 Amps 25 Ampere 75 to 150 ampere-hours

091-127-72-15-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 72 Volts, 15 Amps 25 Ampere 50 to 100 ampere-hours

091-127-96-12-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 96 Volts, 12 Amps 25 Ampere 45 to 90 ampere hours

091-127-120-10-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 120 Volts, 10 Amps 25 Ampere 40 to 80 ampere hours

091-127-144-8-230 230 Volts 60 Hz, 10 Amps 15 Amp Slow Blow 144 Volts, 8 Amps 25 Ampere 30 to 60 ampere hours

Downloaded from www.Manualslib.com manuals search engine

 OUTLINE DRAWING

Downloaded from www.Manualslib.com manuals search engine

 TST-110-01-T-S CONNECTOR
FAR SIDE

SWITCH S1
PLACE IN
T/C POSITION
WHEN INSTALLING
THERMISTOR

FIGURE 3
THERMISTOR INSTALLATION SWITCH SETTING

Downloaded from www.Manualslib.com manuals search engine

 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 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.

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.

Downloaded from www.Manualslib.com manuals search engine