FILE: 091-139-002 DATE: 04-23-01 REV.A: 2/24/04 INSTRUCTION MANUAL AUTO ISOLATOR I AN AUTOMATIC LOSSLESS BATTERY ISOLATOR FOR DUAL BATTERY SYSTEMS MODEL# 091-139-2-12 BATTERY VOLTAGE: 12 VDC OUTPUT: 12 VOLTS, 3 AMPS BATTERY PARALLELING SOLENOID: 200 AMPS 3 YEAR WARRANTY INTRODUCTION The Model 091-139-2-12 AUTO ISOLATOR I system is a lossless isolator replacement for the conventional diode isolator. Designed to be installed in a vehicle with one or more Main batteries that must be isolated from one or more auxiliary batteries. The system consists of a voltage detector and controller Model 091-139-CONT-12 and a separate 200-ampere rated solenoid, Model 091-139-SOL-12HO for switching the batteries. In addition to maintaining battery isolation the AUTO ISOLATOR I may parallel the batteries on engine starting if the auxiliary battery has sufficient charge to assist in the cranking. A block diagram of the system appears in figure 1. STARTER PUSH BUTTON STARTER SOLENOID ALTERNATOR MAIN BATTERY AUXILIARY BATTERY MAIN BATTERY SENSE AUXILIARY BATTERY SENSE PARALLELING SOLENOID POWER IGNITION SWITCH STARTER ISOLATOR SOLENOID DRIVER MAIN BATTERY VOLTAGE DETECTOR AUX. BATTERY VOLTAGE DETECTOR TIMER Figure 1 Block Diagram SYSTEM OPERATION The system receives its power from the ignition switch. With the switch "OFF" all the power is removed from the system and the solenoid is deenergized. As soon as the operator turns the ignition "ON", the system is powered and detects the voltage of the main and auxiliary batteries. If the auxiliary battery voltage is 12.4 volts or greater, (indicating sufficient charge) cranking the engine will cause the paralleling solenoid to be energized. A 10-second timer will maintain the paralleling solenoid if the engine doesn't start immediately and must be cranked a second time. When the engine starts the alternator output raises the battery voltage. This increase in voltage is detected and the paralleling solenoid is held energized charging both batteries. If when the engine is started the auxiliary battery voltage is below 12.0 volts the paralleling solenoid is not energized while cranking. As soon as the engine starts, the alternator raises the main battery voltage and the solenoid is energized charging both batteries. Upon engine shutdown the ignition switch is placed in the "OFF" position. Power is removed from the Auto Isolator and the solenoid is deenergized. INSTALLATION Install the 091-139-CONT-12 Controller is a suitable location protected from the weather and engine heat. The 091-139-SOL-12HO Solenoid may be mounted in the engine compartment or at a location to minimize the length of the battery cables. Install wiring per figure 2. AUTO ISOLATOR I CONTROLLER THIS LINE SUPPLIES THE POWER TO OPERATE THE SYSTEM 091-139-CONT-12 THIS LINE ENERGIZES THE SOLENOID AT ENGINE START IF THE AUXILIARY BATTERY HAS SUFFICIENT VOLTAGE TO PROVIDE A BOOST +12VOLT FROM GNITION SWITCH PARALLELING SOLENOID 12345678 +12VOLT FROM STARTER Note: Red Dot SENSE LINE, CONNECT DIRECTLY TO BATTERY SENSE LINE, CONNECT DIRECTLY TO BATTERY MAIN BATTERY NOTE POLARITY OF FLYBACK DIODE #2 AWG MIN. AUXILIARY BATTERY ALL WIRES #16 AWG EXCEPT AS NOTED Figure 2 AUTO ISOLATOR I Model 091-139-12 INSTALLATION WIRING CALIBRATION The voltage setpoints may be altered in the field to suit particular customer requirements. Adjustments are provided to adjust the main battery voltage at which the paralleling solenoid is energized. An additional adjustment permits adjusting the voltage below which the auxiliary battery will not be paralleled for starting boost. INDICATOR ILLUMINATED WHEN MAIN BATTERY VOLTAGE IS ABOVE SETPOINT 13.3 VOLTS CW INCREASES VOLTAGE AUXILIARY BATTERY VOLTAGE ADJUST MAIN BATTERY VOLTAGE ADJUST INDICATOR ILLUMINATED WHEN AUXILIARY BATTERY VOLTAGE IS ABOVE SETPOINT, 12.0 VOLTS R15 MAIN AUX. R6 I1 R19 R8 C6 R9 OUTPUT R7 R18 VCC C7 R13 MAIN BAT. OK I4 AUX. BAT. OK R20 R11 R12 R4 C1 + U3 R17 GND U2 U4 R3 + U1 I2 C2 R1 Q1 CR3 CR4 U5 R21 C3 C5 KUSSMAUL ELECTRONICS CO CI1 R10 MAIN AUX R16 C4 I3 ILLUMINATES DURING ENGINE CRANKING STARTER + CR1 R2 CR2 J1 1 2 3 4 B091-139-002 5 6 7 8 MEASURE AUX. BAT. VOLTAGE HERE MEASURE MAIN BAT. VOLTAGE HERE Figure 3 VOLTAGE ADJUSTMENTS AUTO ISOLATOR 1 SPECIFICATION AND OUTLINE CONTROLLER, Model 091-139-CONT12 Volts to parallel: 13.3 volts, field adjustable Battery load: .000125 amps. Output current: 3 amps Weight: .4 lbs. SOLENOID, Model 091-139-SOL-12HO Volts: 12 volts D.C. Coil current: .65 amps Contact rating: 200 amps 5.10 3/16" DIA. 2.95 4,50 1.55 OUTLINE, AUTO ISOLATOR I CONTROLLER, 091-139-CONT12 3.60 3.30 2.80 OUTLINE, AUTO ISOLATOR I SOLENOID, 091-139-SOL-12HO INSTALLATION RECORD & WARRANTY Date Installed________________________________________ Installed By___________________________________________ Vehicle Identification_________________________________ Vehicle Owner________________________________________ 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 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 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. ...