BOOK#091-35/10 rev.A: 10-28-2004 INSTRUCTION MANUAL AUTO CHARGE 35/10 AUTOMATIC BATTERY CHARGER MODEL #091-35/10 INPUT :120 volt, 50/60 Hz, 10 amps OUTPUT: 35 AMPERES 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 Introduction The AUTO CHARGE 35/10 is a compact, completely automatic, single channel battery charger designed for vehicles with a single battery system. The charger is ruggedized to withstand the shock and vibration encountered by vehicle mounted equipment. The battery charger features: · Electronic remote sensing of true battery voltages, eliminates the need for sensing wires · Automatic current limiting · Built-in BATTERY SAVER · Remote bar graph battery charge/condition indicator · Power "ON" LED indicator · BATTERY SAVER overload indicator Charge Controls & Electronic Remote Sensing The Auto Charge 35/10 contains a precision voltage controller to maintain the battery's charge. Automatic electronic remote sensing measures the true battery voltage, eliminating the need for the additional sense wires. The output current of any charger is inherently a series of pulses whose frequency is determined by the power line frequency. Therefore there are brief intervals during which no charging current flows. During this brief interval the Auto Charge 35/10 measures and stores the battery voltage. This battery voltage is compared to a standard and any error is detected and used to control the charger output at the desired level. Their is no "trickle charge" and therefore no danger of overcharging and water boil-off. Automatic Current Limiting When batteries are severely discharged, some battery chargers can be overloaded due to the high charging current required. The Auto Charge 35/10 contains an automatic current limit. This circuit limits the output current to the rated 35 amperes when charging a deeply discharged battery or if the starter cranks the engine while charging. The current limiter thus eliminates the need for an ignition interlock circuit. Battery Saver & Indicator A 10 ampere BATTERY SAVER is built into the charger. When connected as shown in the installation wiring diagram, loads on the battery such as radios and rechargeable hand lights are automatically switched to the BATTERY SAVER when power is applied to the charger. The BATTERY SAVER allows more efficient charging by removing these loads. A BATTERY SAVER overload indicator alerts the operator that the BATTERY SAVER load has exceeded 10 amperes. WHEN A BATTERY SAVER OVERLOAD OCCURS: a. Remove the loads for approximately two minutes b. Reduce the load to 10 amperes or less c. Reapply the load to the BATTERY SAVER No fuses are required or provided as the BATTERY SAVER contains an automatic circuit breaker. CAUTION This battery saver output is a full wave rectified sine wave. The 12.5 volts D.C. has a peak value of approximately 17.5 volts. It is recommended that the loads are not highly capacitive. A large capacitor on the load terminal will "peak detect" the output and create a voltage of apporximately 17 volts. This voltage may be too high for the component connected. It is suggested that the installed check the output of the battery saver (when operating with A.C. input) and determine as each load is connected that the voltage does not rise. Any load that creates an increase in voltage should not be connected to the battery saver but rather be connected directly to the battery. SINCE 1967, DESIGNERS OF INNOVATIVE PRODUCTS KUSSMAUL ELECTRONICS COMPANY, INC. 170 CHERRY AVENUE, WEST SAYVILLE, NEW YORK, 11796-1221 USA TEL. In NY: 631 567-0314 TOLL FREE: 800 346-0857 FAX: 631 567-5826 Remote Battery Charge Condition Indicator This remote indicator shows the charge condition of the battery in 10 levels from "LOW CHARGE" to "FULLY CHARGED". This device indicates a defective battery when a bar graph does not rise to the "FULLY CHARGED" level after an extended period of charging. NOTE: If a battery is being discharged with an external load of 1.5 to 4 amperes across it's terminals, the bar graph may move down 1 or 2 levels. This does not indicate a defective battery. To avoid this, connect all external loads to the BATTERY SAVER terminals. Loads connected to the BATTERY SAVER will be powered either from the BATTERY SAVER power supply when the A.C. power is "ON", or they will be connected to the battery when the A.C. power is "OFF". Installation Wiring Diagram Auto Charge 35/10 BATTERY SAVER POWER A.C. FUSE Indicator OUTPUT INPUT L N BAT1 B.S 4 3 2 1 REMOTE +1 2V olts To 120 volts A.C. Strip insulation 15/32 so that wire strands are flush with end of eyelet, 2 places, Chassis Ground Chassis Ground Accessories Bat te ry S aver L o ad s (10 amps max.). When the charger is disconnected from 120 volts AC the B at t e r y S a ve r lo a d s automatically are connected to battery #1. NOTE: Minimum wire size on charger output and ground is #8 AWG. Smaller gauge wire may cause overheating of terminal. Use GS 7-13 eyelet over wire to simplify insertion of wire into terminal strip and to improve connection. Wire Chart CONNECTION DEFINITION WIRE SIZE A.C. 120 VOLTS A.C. 14 AWG COM GROUND LINE 8 AWG BAT 1 POSITIVE CHARGING LEAD VEHICLE BATTERY 1 8 AWG BATTERY SAVER POSITIVE OUTPUT 14 AWG IMPORTANT: Wire size is for a maximum lenght of 10 feet. If longer, larger wiring is required. Specifications: Input: 120 volt, 50/60 Hz, 10 amperes Input Fuse: 12 ampere, fast acting Output: 12 volts D.C. 35 amperes Max. Remote Sensing: Electronic, sense wires not required Number of Charger Outputs: 1 Number of Battery Saver Outputs: 1 Battery Saver Output: 12 volts D.C., 10 amperes Max. Indicators: Power: Red LED, indicates 120 volts power applied Battery Saver Overload: Yellow LED, indicates Battery Saver load greater than 10 amperes Bar Graph: indicates charger output and state of charge of battery Weight: 22 lbs 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. ...