INSTRUCTION MANUAL

PUMP PLUS 1000 PLC

AUTOMATIC SINGLE OUTPUT BATTERY CHARGER

Unit supplied with

one of these displays

MODEL #: 091-215-12-PP

INPUT: 120 Volt, 60 Hz, 3.5 Amps

OUTPUT BATTERY 1 and 2: 15 or 18 Amps

OUTPUT BATTERY SAVER: 3 Amps

File: IM_091-215-12-PP_revC.indd
Rev: C
Revisd By: SO, PG6,7&8
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Date: 05-13-2016 1 YEAR WARRANTY ON PUMP device for more information
3 YEAR WARRANTY ON CHARGER

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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IMPORTANT SAFETY INSTRUCTIONS

I. PERSONAL PRECAUTIONS:
1. Someone should be within range of your voice or close enough to come to your aid when you work near
a lead-acid battery.
2. Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
3. Wear complete eye and clothing protection. Avoid touching your eyes while working near a battery.
4. If battery acid contacts skin or clothing, wash immediately with soap and water. If battery acid enters
the eye, immediately flood eye with cold running water for at least 10 minutes and get medical attention
immediately.
5. NEVER smoke or allow a spark or flame in the vicinity of the battery or engine.
6. Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit
the battery or other electrical part and cause a fire or an explosion.
7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a
lead-acid battery. A lead-acid battery, when shorted, can produce a current sufficient to weld a ring or the
like metal causing a severe burn.
8. Use the battery charger for charging gel-cell, AGM and flooded lead-acid batteries only. Do not use the
charger for charging dry-cell batteries that are commonly used with home applications. These batteries
may burst and cause injury to persons and damage to property.
9. WARNING – RISK OF EXPLOSIVE GASES: Working in the vicinity of a lead-acid battery is dangerous.
Batteries generate explosive gases during normal battery operation.
II. CHARGER PRECAUTIONS:
1. NEVER charge a frozen battery.
2. Make sure the cord is located so that it will not be stepped on, tripped over, or otherwise subjected to
damage or stress.
3. Do not operate the charger with a damaged cord or plug; replace them immediately.
4. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged.
5. Do not disassemble the charger. Incorrect reassembly may result in a risk of electric shock and fire.
6. To reduce the risk of electric shock, disconnect the charger 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 should be well ventilated and free from excessive moisture, exhaust manifolds,
and battery fumes. For maximum performance, the charger should not be located in an area of extreme
high temperature. The charger is not waterproof. Do not mount the charger where there is a possibility of
water entering the unit. Evidence of water entry into the charger will void the warranty.
8. CAUTION: Do not attempt to increase battery bank capacity by splitting the output of one of the banks
with a diode-type battery isolator. The diode isolator lowers the charger voltage and results in under-
charging the batteries connected to it. If additional capacity is required it is preferable to add another
isolated or parallel battery.
III. GROUND AND AC POWER CORD CONNECTION:
1. The charger should be grounded via the AC power connection to reduce the risk of electrical shock.
2. The charger must be plugged into or wired to an outlet that is an over-current protected 3 prong outlet.
Alternatively, it may be routed through a separate dedicated fuse or circuit breaker on an AC distribution
panel with proper earth/safety ground. All wiring shall comply with UL recommendations, NEC or NFPA
standards and local ordinances. Never alter the AC cord or plug if provided. Any modification of the cord
must only be done by a qualified electrician. Improper cord/outlet connection may result in a risk of elec-
trical shock.
3. Observe color coding of the AC wiring as follows:
Black………....................... AC Hot or LINE (fused)
White…………................... AC Neutral
Green…….................…….. AC Ground (safety/earth)
4. CAUTION: (230 VAC applications only): If AC input is provided from a source consisting of two HOT or
LINE leads (phase-to-phase 230 VAC input voltage); an external fuse or circuit breaker must be used to
protect both hot leads.

170 Cherry Avenue Ph: 800-346-0857

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INTRODUCTION

The Pump Plus 1000 PLC with Parasitic Load Compensation (PLC) is a compact, microprocessor controlled,
completely automatic, single channel battery charger designed for vehicles with a single battery system. The
PLC charger is designed to withstand the shock and vibration encountered by vehicle mounted equipment. The
Pump Plus 1000 PLC is designed to power a 091-9-12V air compressor. A DIP switch is provided to select full-
time compressor operation (DC position) or only while AC power is applied (AC position).

FEATURES

I. PUMP PLUS 1000 PLC BATTERY CHARGER

• Electronic remote sensing of true battery voltage, eliminates the need for sensing wires
• Automatic current limiting
• Pump output with AC or DC mode dip switch
• Built-in Battery Saver output
• Accommodates Lead-Acid, Gelled Electrolyte, AGM and Odyssey® battery types
• Configurable for 3-Step or Float Charging
• 3 hour Safety Timer while in 3-Step mode
• Adjustable Parasitic Load Compensation (0-12 amperes)
• Power “ON” LED indicator
• System Status LED indicator
• Whisper quiet cooling fan

II. CHARGE CONTROLS & ELECTRONIC REMOTE SENSING

Pump Plus 1000 PLC contains a precision voltage controller to maintain the battery’s charge. Automatic
electronic remote sensing measures the true battery voltage, eliminating the need for additional sense wires.
The output current of the charger is a series of pulses whose frequency is determined by the power line fre-
quency. The Pump Plus 1000 PLC measures the battery voltage during brief intervals between pulses while
no charge current is flowing. The battery voltage is compared to a standard and any error is detected and
used to control the charger output at the desired level. There is no “trickle charge”, therefore, no danger of
overcharging and water boil-off.

III. AUTOMATIC CURRENT LIMITING

Some battery chargers can be overloaded due to the high charging current required when batteries are se-
verely discharged. The Pump Plus 1000 PLC contains an automatic current limiting circuit. This circuit limits
the output current to the rated 15 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.

IV. PLC - PARASITIC LOAD COMPENSATION

This new feature is designed specifically to meet the heavy duty requirements of emergency vehicles. Most
emergency vehicles have many parasitic loads on their systems (flash lights, gas detectors, computers,
monitoring systems and other items) that can trick a standard 3-step charger into over charging the batteries.
Parasitic load compensation allows you to input the total number of parasitic load amps on the vehicle. The
charger will then shift the absorption stage set-point so the battery voltage will drop to the float voltage when
the desired current is reached. In short the parasitic loads are invisible to the charger.

170 Cherry Avenue Ph: 800-346-0857

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WIRING AND SWITCH SETTINGS

I. BATTERY CHARGER WIRING INSTRUCTIONS

1. Refer to Installation Wiring Diagram I & 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 information is available upon request if
longer, larger wiring is required.
3. Torque DC output connector. Refer to Specifications.
4. Set the front panel switches for the appropriate battery type, charge method, safety timer value, battery
saver mode and parasitic load requirement. Refer to Sections III, IV, V, VI and VII.
5. Double check all wiring and switch settings before applying AC power to input terminal.
6. Apply AC power (shoreline power) to input terminal and observe that the charger is operating.
7. Verify that the battery voltage appears at the charger output terminals.

II. WIRING SPECIFICATIONS

Length of Wire to Battery (feet) 0-5 5 - 10* 10 - 20*

V. BAT +

V. BAT +

V. BAT +
PUMP +

PUMP +

PUMP +
B.S. +

B.S. +

B.S. +
COM

COM

COM
Battery Charger Connections

Wire # Gauge (awg) 14 14 14 16 14 12 12 16 12 10 10 16

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

III. BATTERY TYPE SELECTION SWITCHES

Switches 1 and 2 should be set to match the battery chemistry.

Lead-Acid - Both switches down (off) - factory default setting

Gelled Electrolyte (Gel Cell) - Switch 1 down (off) and Switch 2 up (on)
AGM - Switch 1 up (on) and Switch 2 down (off)
Odyssey® - Both switches up (on)

IV. FLOAT / 3-STEP CHARGE MODE SELECTION SWITCHES

Switch 3 should be set for the desired charging method, Float or 3-Step. When in 3-step mode, the safety timer
period is 3 hours. The safety timer period begins when AC power is applied to the charger. The absorption phase
of 3-step charging terminates when the safety timer expires, or when the PLC threshold setting is reached. If no
PLC settings are set, the threshold is 0.5A. The charger then switches to, and remains in, float mode while AC
power is applied.
Float Charge Only – Switch 3 down (off) - factory default setting
3-Step with 3 Hour Safety Timer - Switch 3 up (on)

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V. AUTO PUMP MODE SELECTION SWITCH

Switch 4 controls the Auto Pump operating mode.

AC – Switch 4 down (off) - factory default setting.
The compressor will operate only when AC power is applied to the battery charger.
DC – Switch 4 up (on).
The compressor will operate when the AC power is on or off. It is powered by the charger while AC
power is applied to the charger and from the vehicle’s battery when no AC power is applied.

VI. BATTERY SAVER SWITCH

A low ripple, current limited, 3 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 from the battery. Switch 5 enables the Battery Saver when set in the up
(on) position. If it is not required, turn the Battery Saver off by setting switch 5 down (off) position. This is the
factory default setting. A Battery Saver filter is not required.

WHEN A BATTERY SAVER OVERLOAD OCCURS:

a. Remove the loads for approximately two minutes

b. Reduce the load to 3 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.

VII. PARASITIC LOAD COMPENSATION SWITCHES (3-Step mode only)

Switches 6, 7 and 8 should be set to match the parasitic load on the battery (excluding any Battery Saver
load). These switches control the point at which the charger will terminate the absorption phase of the 3-step
charging cycle. The possible settings are 0, 1, 2, 4, 6, 8, 10 or 12 amperes. If there are no parasitic loads on
battery 1, or if they are all are on the Battery Saver, then set these three switches to the down (off) position.
This is the factory default setting.

VIII. REMOTE BATTERY CHARGE CONDITION INDICATOR (Standard equipment)

This remote indicator shows the charge condition of each 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 the 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. 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 by the
Battery Saver power supply when the AC power is “ON”, or they will be connected to the battery when the
AC power is “OFF”.

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
www.kussmaul.com sales@kussmaul.com
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170 Cherry Avenue Ph: 800-346-0857
West Sayville, NY 11796 Fax: 631-567-5826
www.kussmaul.com sales@kussmaul.com
6
INSTALLATION WIRING DIAGRAM
I. FOR STANDARD BAR GRAPH DISPLAY, 091-199-001
or OPTIONAL DELUXE STATUS CENTER, 091-194B-IND

Wiring Diagram shown is for a 10 foot installation

NOTE: Pin 1 of indicator must go to Pin 1
of Remote Display on charger.
Remote Pin 2 of indicator must go to Pin 2
Indicator
of Remote Display on charger, and
1
2
3
so forth. Check connections and
4
5
color of wires before plugging-in.

1 - RED 20AWG
2 - BLACK 20AWG
3 - WHITE 20AWG
4 - GREEN 20AWG
PUMP PLUS
1 1000 PLC 12345678

2
Auto Pump 3
Air Compressor 4 ON
LEAD FLOAT AC 0FF 0 - AUTO
1 AMPS
GEL 3-STEP DC 0N
OFF
INDICATOR SWITCH SHOWN AGM CHARGE AUTO BATTERY 2 AMPS
IN OFF POSITION MODE PUMP SAVER
ODY 4 AMPS
BATTERY 6 AMPS
PLC TYPE
8 AMPS
REMOTE
10 AMPS
OUTPUT
1 12 AMPS
PUMP BAT1 BS
2 + + + PARASITIC LOAD
COMPENSATION

SYSTEM POWER

G)
AW

40 Amp fuse or
G) Waterproof Circuit Breaker
(12

W Kussmaul Part #: 090-0040-0

RED (14AWG)

2A
K
G)

(1 Install near the battery.

AC

)
BLACK (14AW

G D
BL

AW RE
4
(1
Chassis
+ 12 Volts
D
RE Ground

BLK
BLK - 93.1
RED (12AWG)
BLK +
G)

BLK
BLACK (12AW

Y Battery Saver Loads

ER
15

RED TT (3 amps max.).

RED BA When the charger
RED
RED is disconnected from
120 volts AC the
Battery Saver loads
automatically are
Pressure BLACK (14AWG) connected to battery #1.
Switch

Accessories

WIRE SIZE CHART

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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II. FOR OPTIONAL WATERTIGHT DELUXE STATUS CENTER, 091-194B-IND-WT-XX

Wiring Diagram shown is for a 10 foot installation

NOTE: Pin 1 of indicator must go to Pin 1

1 - RED 20AWG
of Remote Display on charger.
2 - BLACK 20AWG Pin 2 of indicator must go to Pin 2
3 - WHITE 20AWG
4 - GREEN 20AWG of Remote Display on charger, and
so forth. Check connections and
color of wires before plugging-in.

Remote
Indicator 1 - RED 20AWG
2 - BLACK 20AWG
3 - WHITE 20AWG PUMP PLUS
4 - GREEN 20AWG
1 1000 PLC 12345678

2
Auto Pump 3
Air Compressor 4 ON
LEAD FLOAT AC 0FF 0 - AUTO
1 AMPS
GEL 3-STEP DC 0N
OFF
INDICATOR SWITCH SHOWN AGM CHARGE AUTO BATTERY 2 AMPS
IN OFF POSITION MODE PUMP SAVER
ODY 4 AMPS
BATTERY 6 AMPS
PLC TYPE
8 AMPS
REMOTE
10 AMPS
OUTPUT
1 12 AMPS
PUMP BAT1 BS
2 + + + PARASITIC LOAD
COMPENSATION

SYSTEM POWER

G) 40 Amp fuse or
W
G)

2A

Waterproof Circuit Breaker

AW

(1

Kussmaul Part #: 090-0040-0

RED (14AWG)

(12
G)

Install near the battery.

RE
BLACK (14AW

G)
AC

W
BL

4A
(1 Chassis

+ 12 Volts
D Ground
RE

BLK
BLK - 93.1
RED (12AWG)
BLK +
G)

BLK
BLACK (12AW

Y Battery Saver Loads

ER
15

RED TT (3 amps max.).

RED BA When the charger
RED
RED is disconnected from
120 volts AC the
Battery Saver loads
automatically are
Pressure BLACK (14AWG) connected to battery #1.
Switch

Accessories

WIRE SIZE CHART

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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SPECIFICATIONS

Input Power: 120 Volt, 60 Hz, 3.5 amperes

Input Fuse: 6 ampere, fast blow
Output Power - Bat : 15 amperes max (18 amperes if Battery Saver is turned off)
Battery Type Float V DC Absorbtion V DC
Lead-Acid 13.25 14.00
Gelled Electrolyte 13.50 14.25
AGM 13.50 14.40
Odyssey® 13.60 14.70
Output Power - Battery Saver: 13 Volts DC, 3 amperes max
Pump Output: 12 Amp Max
Remote Sensing: Electronic, sense wires not required
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
Brief Flash (once every 2 seconds) indicates 3-step boost mode operation
Cooling Fan: The whisper quiet cooling fan exhausts air from the rear of the charger. When the Battery Saver
is enabled, it is continuously on while AC power is applied to the charger. It turns on at 4 amperes of output
current and turns off at 3 amperes when the Battery Saver is disabled.
Torque: DC Output Connector: 15 in. lbs.
Remote Display Options: Bar Graph Display, Deluxe Status Center or Watertight Status Center
Output Waterproof Circuit Breaker (Optional): Bat 1 - 40 amperes, P/N: 090-0040-0
Output Buss Bar (Optional): 5 Studs, P/N: 002-3595-5
Weight: 11 pounds

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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OUTLINE DRAWING

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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OPTIONAL ACCESSORIES

I. GRAPH DISPLAY, MODEL #: 091-199-001

• 10-Segment LED display indicate the “state of charge”

and the general condition of the batteries

II. DELUXE STATUS CENTER, MODEL #: 091-194B-IND

• Indicator has a digital voltage and ampere display

• 5 segment bar graph display indicates output current
• 4 LED’s to show the condition of the batteries

III. WATERTIGHT DELUXE STATUS CENTER, MODEL #: 091-194B-IND-WT-XX

• Indicator has digital voltage and ampere display

• 5 segment bar graph display indicates output current
• 4 LED’s to show the condition of the batteries
• Indicator is housed in a watertight bezel
• Bezel is available in 6 different colors,
Red, White, Blue, Yellow, Gray, and Black
Specify color choice when ordering

IV. 40 AMP WATERPROOF CIRCUIT BREAKER, MODEL #: 090-0040-0

• Combines switching and circuit breaker function

• Compact size and surface mount 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

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
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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 Kuss-
maul 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.

170 Cherry Avenue Ph: 800-346-0857

West Sayville, NY 11796 Fax: 631-567-5826
www.kussmaul.com sales@kussmaul.com
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