INSTRUCTION MANUAL AUTO ISOLATOR I AN AUTOMATIC LOSSLESS ISOLATOR FOR DUAL SYSTEMS MODEL #: 091-139-2-12 VOLTAGE: 12 VDC OUTPUT: 12 VOLTS, 3 AMPS PARALLELING : 200 AMPS File: IM-091-139-2-12 Rev: revc Revised By: Date: 3-30-2012 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. PUSH BUTTON ALTERNATOR SENSE AUXILIARY SENSE PARALLELING AUXILIARY POWER IGNITION SWITCH ISOLATOR DRIVER VOLTAGE DETECTOR AUX. VOLTAGE DETECTOR TIMER Figure 1 Block Diagram 2
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 de-energized. 3
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. THIS LINE SUPPLIES THE POWER TO OPERATE THE SYSTEM AUTO ISOLATOR I CONTROLLER 091-139-CONT12 THIS LINE ENERGIZES THE AT ENGINE START IF THE AUXILIARY HAS SUFFICIENT VOLTAGE TO PROVIDE A BOOST +12VOLT FROM IGNITION SWITCH PARALLELING 1 2 3 4 5 6 7 8 +12VOLT FROM SENSE LINE, CONNECT DIRECTLY TO SENSE LINE, CONNECT DIRECTLY TO #2 AWG MIN. AUXILIARY ALL WIRES #16 AWG EXCEPT AS NOTED Figure 2 AUTO ISOLATOR I Model 091-139-12 INSTALLATION WIRING 4
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. CW INCREASES VOLTAGE AUXILIARY VOLTAGE ADJUST VOLTAGE ADJUST INDICATOR ILLUMINATED WHEN VOLTAGE IS ABOVE SETPOINT 13.0 VOLTS INDICATOR ILLUMINATED WHEN AUXILIARY VOLTAGE IS ABOVE SETPOINT, 12.4 VOLTS C1 + U1 + C2 R6 OUTPUT C6 R9 U3 R3 R1 I2 CR3 CR4 Q1 R7 J1 R8 R15 VCC CR2 R18 C7 CI1 R10 CR1 R2 AUX. U5 R13 R17 R19 GND R21 U2 R4 I1 U4 C3 AUX. BAT. BAT. OK I4 OK R20 R11 C4 + R12 C5 KUSSMAUL ELECTRONICS CO I3 AUX R16 B091-139-002 ILLUMINATES DURING ENGINE CRANKING 1 2 3 4 5 6 7 8 MEASURE AUX. BAT. VOLTAGE HERE MEASURE BAT. VOLTAGE HERE Figure 3 VOLTAGE ADJUSTMENTS AUTO ISOLATOR 1 5
SPECIFICATION AND OUTLINE CONTROLLER, Model 091-139-CONT12 Volts to parallel, normal operation: Volts to parallel, start boost: Battery load:.000125 amps. Output current: 3 amps Weight:.4 lbs. 13.0 volts, field adjustable 12.4 volts, field adjustable, Model 091-139-SOL-12HO Volts: 12 volts D.C. Coil current:.45 amps 5.10 3/16" DIA. 2.95 4,50 OUTLINE, AUTO ISOLATOR I CONTROLLER, 091-139-CONT12 1.55 OUTLINE, AUTO ISOLATOR I, 091-139-SOL-12HO 6
INSTALLATION RECORD DATE INSTALLED INSTALLED BY VEHICLE IDENTIFICATION VEHICLE OWNER WARRANTY POLICY 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. 7