BOOK# 091-12DV-HO INSTRUCTION MANUAL AUTO CHARGE 12HO DV AUTOMATIC BATTERY CHARGER MODEL #091-12HO DV NOTE : This charger is designed for vehicles with a single battery system INPUT :120/230 volt, 50/60 Hz 3 YEAR WARRANTY KUSSMAUL ELECTRONICS CO., INC. 170 CHERRY AVE., WEST SAYVILLE, N.Y. 11796-1221 TEL: in NY 631-567-0314 TOLL FREE: 800-346-0857 FAX: 631-567-5826 1.0 INTRODUCTION This manual describes the installation and wiring for the Auto-Charge 12HO DV Automatic Battery Charger. It is suggested that the installer read the entire instructions to become familiar with the tasks involved before starting. 2.0 VEHICLE WIRING INSTALLATION The installation of the vehicle wiring provides a direct connection between the battery and the Auto-Charge 12HO DV Automatic Battery Charger. The battery is automatically charged at constant voltage. For deeply discharged batteries or if the charger is operated while thevehicle is started, a current limiter automatically limits the output to 20 amperes. Input power may be either 115 volts or 230 volts, 50 or 60 Herz. A recessed voltage selector switch is provided on the end panel near the output terminal strip. The Auto-Charge 12HO DV uses remote sensing and therefore four wires are necessary to connect to the battery. Two wires charge the battery while an additional two wires detect the battery voltage. These connections are made on the output terminal strip. 3. AUTO-CHARGE 12HO DV INSTALLATION The Auto-Charge 12HO DV Automatic Battery Charger should be installed in an area with adequate ventilation. A power cord is supplied for connection to the input power source. A switch on the end panel of the charger selects either 115 volts or 230 volts. Set this switch to the proper position to correspond to the input voltage before applying power to the charger. 1. Mount the charger using the four holes provided. See figure 1. 2. Connect the wiring from the batteries to the Output Terminal Strip. Spade lugs that have been securely crimped or soldered should be used 3. Connect the wiring to the batteries. Ring lugs that have been securely crimped or sol dered should be used. 4. Double check all wiring before proceeding. 5. Wire the A.C. power line to the power source and check the position of the Voltage Selec tor Switch. NOTE DO NOT APPLY 230 VOLTS TO THE CHARGER WITH THE SELECTOR SWITCH IN THE 115 VOLT POSITION SERIOUS DAMAGE MAY RESULT 6. The pilot light will light to show that the charger has power. 7. The ammeter will indicate how much current is flowing to the battery. A charging current limit of 20 amperes is factory set. 4.0 SPECIFICATIONS Input: 230 volts/115 volts, 50/60 Hz, switch selectable Output Volts: Adjustable, 13.25 volts nominal Output Current: 0 - 20 Amps, D.C., Current Limited Charge Indicator: 0 - 25 Amps. Weight: 13 pounds Size: 12.75 x 6.73 x 4.25 inches SPARE PARTS LIST PART NUMBER B091-349 3596 SPW405-S B-511-2 A091-15-017 EM 5822 2150-A1 LM3900 IP15WB-1K LM7812 2N4401 1N4004 1N914 1N751 779 11Z2101 V802 210.51/250 DESCRIPTION Assembly, Control Board Transformer,Power Transformer,Power,PC mount Rectifier Bridge Sense Resistor Assembly Meter, 0-25 Amp D.C. Light,Indicator,Neon Integ.Circuit, Quad Op Amp Potentiometer,trimming,1K Integ.Circuit, Volt Reg Transistor, NPN Diode, Rectifier Diode, Signal Diode, 5.1V Zener Line Cord Transformer, Trigger Switch, Voltage Select INSTALLATION WIRING DIAGRAM WIRE SIZE CHART CONNECTION ITEM DEFINITION WIRE SIZE BATBAT+ BATTERY NEGATIVE CHARGING LEAD NEGATIVE FOR BATTERIES BATTERY POSITIVE CHARGING LEAD POSITIVE FOR BATTERY # 1 12 AWG 12 AWG 16 AWG 16 AWG IMPORTANT: Wire size is for a maximum length of 20 feet. If wiring is to be longer, larger wiring is required. Additional information is available on request. NOTE: The sense leads must be connected to the battery for the charger to operate. NOTE: Sense leads are shown connected to battery. For installations that do no permit a 4 wire connection the positive sense terminal may be connected to the "Battery +" terminal and the negative sense terminal may be connected to the "Battery -" terminal. This eliminates the remote sensing feature. SENSE NEGATIVE NEGATIVE VOLTAGE SENSE SENSE LEAD. DETECTS VOLTAGE _ SENSE + POSITIVE POSITIVE VOLTAGE SENSE SENSE LEAD. DETECTS VOLTAGE SPECIFICATION & OUTLINE SPECIFICATIONS: Input: 115/230V 50/60Hz, 4 amps Output: see chart Output Current: see chart Charge Indicator: 0-25 amps 5% Weight: 22 lbs SPECIFICATION CHART MODEL # 091-12HO-DV-6 091-12HO-DV-12 091-11HO-DV-24 091-12HO-DV-32 091-12HO-DV-36 091-12HO-DV-48 AMPS 20 20 12 10 8 6 VOLTAGE 6 12 24 32 36 48 6.75 AUTO CHARGE 12.00 12.75 4.75 9/32" DIA. 4 HOLES 4.25 OUTLINE DRAWING 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. 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 ...