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WIRING

I.  BATTERY CHARGER WIRING INSTRUCTIONS

1. 

Refer to Installation Wiring Diagram I and II.

2. 

Refer  to  Wiring  Specifications  to  determine  the  recommended  wire  size  and  maximum 

lengths. Using a smaller gauge may cause overheating of the terminal.  Additional informa-

tion is available upon request if longer, larger wiring is required.

3. 

Double check all wiring before applying AC power to input terminal.

4.  Apply AC power (shoreline power) to input terminal and observe that the charger is oper-

ating. 

5.  Verify that the battery voltage appears at the charger output terminals. A minimum of 9 

volts is required to start the charger.

II.  WIRING SPECIFICATIONS

170 Cherry Avenue

West Sayville, NY 11796

www.kussmaul.com

Ph: 800-346-0857

Fax: 631-567-5826

[email protected]

6

091-89-12

Length of Wire to Battery (feet)

Battery Charger Connections

CO

M -

BA

T 1

+

BA

T 2

+

B.S

. +

CO

M -

BA

T 1

+

BA

T 2

+

B.S

. +

CO

M -

BA

T 1

+

BA

T 2

+

B.S

. +

Wire # Gauge (awg)

8

8

8

14

6

6

6

14

4

4

4

14

Wire Ferrule Used

091-

TE

RF

ER

812

091-

TE

RF

ER

812

091-

TE

RF

ER

812

091-

TE

RF

EB

148

091-

TE

RF

EB

612

091-

TE

RF

EB

612

091-

TE

RF

EB

612

091-

TE

RF

EB

148

no

ne

no

ne

no

ne

091-

TE

RF

EB

148

0-5

5 - 10**

10 - 20*

* Consult factory if length of wire to battery is longer than 20 feet

** Supplied with wire terminal hardware for 10 foot installation

Summary of Contents for AUTO CHARGE 4000

Page 1: ... LOW PROFILE CHARGER AUTOMATIC DUAL OUTPUT BATTERY CHARGER INSTRUCTION MANUAL INPUT 120 Volt 50 60 Hz 5 Amps OUTPUT 45 Amps MODEL 091 89 12 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com Unit supplied with this display ...

Page 2: ...ger from the AC source before attempting any maintenance or cleaning 7 LOCATION OF CHARGER The charger should be mounted on a wall vehicle floor ventilated compart ment or other suitable surface as close to the batteries to be charged as possible Do not block the char ger s fan or air intakes Do not mount the charger directly over the batteries as fumes may cause exces sive corrosion The area shou...

Page 3: ...t terminal is voltage regulated and internal circuitry provides for constant power during loaded situations Using high frequency switching technology the output terminal voltage is compared to a reference voltage any error detected is then used to control the charger output at the desired level There is no trickle charge and therefore no danger of overcharging and water boil off III AUTOMATIC CURR...

Page 4: ...tus VII COOLING FAN The AC 4000 LPC is fan cooled and automatically cycles on and off depending on output current When the fan is on air is circulated and exhausted through the right side The fan cycles briefly when power is applied in order to verify that it is functioning OPERATION I BATTERY TYPE SELECTION SWITCHES Switches 1 and 2 should be used to match the battery chemistry Units are shipped ...

Page 5: ... equipment 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 the bar graph does not rise to the FULLY CHARGED level after an extended period of charging NOTE If a battery is being charged with an external load of 1 5 to 4 amperes across its terminals the bar graph may move down 1 or 2 levels ...

Page 6: ...ery voltage appears at the charger output terminals A minimum of 9 volts is required to start the charger II WIRING SPECIFICATIONS 170 Cherry Avenue West Sayville NY 11796 www kussmaul com Ph 800 346 0857 Fax 631 567 5826 sales kussmaul com 6 091 89 12 Length of Wire to Battery feet Battery Charger Connections COM BAT 1 BAT 2 B S COM BAT 1 BAT 2 B S COM BAT 1 BAT 2 B S Wire Gauge awg 8 8 8 14 6 6 ...

Page 7: ...SYSTEM R OUTPUT BAT1 AUX AUTO CHARGE 4000 50 Amp Waterproof Circuit Breaker Kussmaul Part 090 0050 0 Or Fuse Place near the battery RE D 8A WG R E D 8 A W G BLACK 8AWG BATTERY 3 IEC Power Cord 16 3AWG Supplied with unit AC Connections shall RED 12AWG To 12 Volt Accessories 1 RED 20AWG 2 BLACK 20AWG 3 WHITE 20AWG 4 GREEN 20AWG BAT2 RE D 8 AW G RE D 8A WG BATTERY Buss Bar 002 3595 5 Kussmaul Part Or...

Page 8: ...F POSITION DIP SWITCH SETTINGS Legend on front panel of charger This is what the dip switch should look like when setting it to the legend on the front panel of the charger ON 1 2 3 4 5 6 7 8 DC LEAD AGM ODY AC AUX BATTERY TYPE GEL 9 ...

Page 9: ...ess Termination LED Status Indicators Power Green LED Indicates 120 Volt AC power applied System Yellow LED Fast Flash 5 times per Second indicates battery reverse polarity Slow Flash once per second indicates no battery is connected Solid On indicates charger is in current limit normal operation Solid Off indicates normal operation Hardware Pack Provided 1 3 ft IEC cord Charger Indicators Options...

Page 10: ... configuration Protects high amperage circuits Latch arms resets breaker after overload Cannot be held in ON position if short remains on circuit Waterproof Ideal for truck applications III E Z SLIDE MOUNTING PLATE MODEL 091 200 EZM Locking mounting system Ease the installation and the removal of larger sized chargers that are in harder to access areas such as under seats 170 Cherry Avenue West Sa...

Page 11: ...aterial 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 Kuss maul Electronics Compan...

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