User manual for operation automatic battery charger TOP AUTO AZU-108

Automatic Battery Charger TOP AUTO AZU-108.

1. Purpose and key features

1.1. The AZU-108 battery charger (hereinafter, the Charger) is intended for charging all types of lead–acid batteries (hereinafter, the Battery), including so-called “flooded”/WET lead–acid batteries, maintenance-free, valve-regulated (for uninterruptible power supplies), traction (for outboard motors), starter, hybrid, absorbed glass mat, batteries with plates alloyed with calcium and silver, most GEL batteries, as well as AGM batteries, EFB (enhanced flooded) batteries, and batteries for vehicles with START/STOP systems. The Charger is recommended for Batteries with a capacity from 3 to 150 Ah and a nominal voltage of 12 V. Charging higher-capacity Batteries will require more time.

1.2. Main properties of AZU-108:

• Efficient charging of the Battery and prevention of damage due to gentle automatic control of the charging process with an optimal balance of voltage and current.
• Digital voltmeter and ammeter.
• Charge-current regulator.
• Voltage regulator.
• Bracket for cable storage.
• Charging of maintenance-free Batteries.
• Charging of fully discharged Batteries.
• Charging the Battery without disconnecting or removing it from the vehicle.
• Charging calcium–calcium (Ca/Ca), silver–calcium (Ca/Ag), and other Batteries that require a charging voltage of 15 V or higher.
• Storage mode — maintaining Battery voltage with a low pulsed current after charging completes.
• Measurement of Battery voltage.
• Use as a power supply.
• Use as a jump-assist device.
• Protection against overload, reverse polarity, overheating, and short circuits.
• Indicator lights:
“Power” – green indicator
“Error” – red indicator (overheating, short circuit, reverse polarity)

2. Principal technical data and characteristics of AZU-108

2.1. Supply mains voltage, frequency 50–60±0.5 Hz, Volts: ~ 150?260
2.2. Electrical power drawn from the mains, not more than, Watts: 295
2.3. RMS current drawn from the mains during charging, not more than, Amperes: 1.0
2.4. Output voltage, Volts: 11–17.5 ± 0.2
2.5. Output current, Amperes: 0–10 ± 0.2
2.6. During operation, the enclosure temperature may rise up to, °C: 70
2.7. Product mass, kg: 0.850
2.8. Overall dimensions, mm: 165?140?95

3. Scope of supply

3.1. Battery charger: 1 pc.
3.2. Box: 1 pc.
3.3. Certificate (passport): 1 pc.

4. Design

4.1. The Charger consists of a steel housing containing a switched-mode DC converter and a controller that governs the Charger’s operating modes. The control panel includes a digital voltmeter and ammeter, a mains power switch, the “Power” indicator, a charge-current regulator, a voltage regulator, and the “Error” indicator. Two leads emerge from the housing with metal clamps at the ends, marked red (“+”) and black (“–”) for connection to the Battery terminals, and one lead with a plug for 220 V mains power.

A cable-storage bracket is located on the rear of the Charger.

5. Safety precautions

5.1. Before operating the Charger, read this manual as well as the care and operating instructions for the Battery being charged.

5.2. Charging a Battery releases flammable gases; therefore, charging must be performed in a well-ventilated area. Do not obstruct the ventilation openings of the Charger housing with foreign objects. Place the Battery and the Charger on non-combustible surfaces, at a safe distance from open flames and directed heat sources. Do not smoke near the Battery being charged! The Battery may be placed at the same level as or higher than, and to the side of, the Charger.

5.3. It is prohibited to charge damaged Batteries, Batteries with frozen electrolyte, or Batteries not intended to be charged by this Charger, e.g., 6 V Batteries or lithium-based Batteries.

5.4. Before connecting the Charger to the mains, ensure the housing is undamaged and the insulation of the mains cord and the Battery leads is intact. Also ensure the leads do not contact hot surfaces or sharp edges.

5.5. Prevent any liquids and small foreign objects from contacting the Charger housing and mains cord.

5.6. Do not operate the Charger outdoors or in humid environments. Degree of protection against water ingress: IP20.

5.7. Do not disassemble or repair the Charger. Repairs must be performed only by a qualified specialist.

5.8. During charging, the Charger’s enclosure temperature may exceed ambient temperature by no more than 40 °C.

5.9. Do not connect or disconnect the Battery to/from the Charger without first disconnecting the Charger from the AC mains.

5.10. Do not start the engine while the Battery is being charged.

5.11. The electrolyte is a corrosive substance. When connecting or disconnecting the Battery to/from the Charger, use protective goggles. Do not wear synthetic clothing. If acid contacts the skin or eyes, immediately rinse the affected area with running water and, if burning persists, seek medical attention.

5.12. This device is not intended for use by children or by individuals who cannot read or understand the manual, except when supervised by a responsible person who can ensure safe use of the device. Store and use the Charger in a place inaccessible to children and animals.

5.13. Do not leave the Charger operating unattended, especially when powered from a garage electrical network.

6. Operating procedure

6.1. Working with the Charger:

6.1.1. Before starting the charge, connect the Charger to the mains and, without connecting the Charger to the Battery, use the (V) regulator to set the voltage that will be the maximum for the Battery being charged. Voltage parameters are given in the table for selecting Battery charging and storage parameters. To check the Battery condition, connect the clamps to the Battery without connecting the Charger to the mains.

(!) WARNING!
Before using the Charger, verify the maximum permissible end-of-charge voltage in the Battery’s datasheet.

6.1.2. Connect the Charger clamps to the Battery terminals, observing polarity:
- red clamp “+” to the positive terminal of the Battery;
- black clamp “–” to the negative terminal of the Battery if the Battery is removed from the vehicle, or to the vehicle chassis (ground), away from fuel lines and the Battery, if the Battery is installed in the vehicle and connected to its electrical system.

Table No. 1 Selection of charging voltage and current, and storage voltage for various types of 12 V Batteries*

* Before use, check the maximum permissible end-of-charge voltage in the Battery’s datasheet.

6.1.3. Set the charge-current regulator (A) to the far-left position.

6.1.4. Connect the Charger to the ~220 V AC mains. Switch charging on with the “On/Off” switch; the “Power” indicator will light green.

• Depending on the Battery condition, the device will switch to one of the charging modes (see 6.3.).

• The charge current required for efficient Battery charging is 10% of the Battery’s capacity. For example, for a 50 Ah Battery this is 5 A. The time required for full charging depends on the degree of discharge and the Battery’s wear.

6.1.5. Set the required charging current using the regulator (turn clockwise). The maximum charging current is determined by the Battery condition; therefore, the regulator can only limit it.

6.1.6. The state of charge of the Battery is determined by the ammeter. The Battery is fully charged when it indicates approximately 0.5 A.

• If the ammeter reading decreases too quickly, the following factors may be the cause, indicating it may be advisable to replace the Battery or attempt recovery:
- the Battery plates may be sulfated;
- one or more cells may be shorted; in this case, electrolyte boiling may be observed in the functional cells.

• You may attempt to restore the Battery capacity by charging and discharging the Battery several times using an automotive lamp of approximately 50 W. It is recommended to monitor and correct the electrolyte density (for a fully charged Battery: winter — 1.29, summer — 1.27).

• If it is not possible to set the recommended charging current, the probable cause is sulfation of the plates. In this case, it is recommended to charge the Battery with a current of 0.03 of the rated capacity. This mode promotes dissolution of sulfate, but significantly increases charging time.

6.1.7. The “Error” indicator (red) signals faults: short circuit, reverse polarity, overheating. If a fault occurs, the Charger will stop charging and, after the fault is eliminated, will automatically resume operation.

6.1.8. Upon completion of charging, first disconnect the Charger from the mains and then remove the Charger clamps from the Battery terminals.

6.2. Using the Charger as a charging and jump-assist device (it is recommended to use more powerful chargers: 115, 315, 415)

6.2.1. Connect the Charger to the Battery (see 6.1.) and set the maximum current with the regulator (turn clockwise fully) and the voltage corresponding to the Battery type.
6.2.2. Charge the Battery for 5–30 minutes.
6.2.3. Without disconnecting the Charger from the mains or the Battery, start the engine.
6.2.4. If the attempt is unsuccessful, repeat 6.2.2 and 6.2.3.
6.2.5. Disconnect the Charger (see 6.1.8.).

• A Battery revitalized by charging will deliver a substantially higher current in the first seconds of starter operation. This will allow you to:
   — easily move the thickened engine oil,
   — produce rapid cranking for good air–fuel mixing and spark (compression ignition in a diesel),
   — avoid the need for an expensive dedicated jump-starter,
   — reduce Battery stress, extending its service life by shortening engine cranking time.

6.3. The Charger operates in three modes:

1. Constant-current charging mode (the Battery gains approximately 80% of capacity): Charging starts at the selected current (10% of Battery capacity or other value) and continues until the voltage reaches the value set by the voltage regulator; then, to prevent electrolyte boiling, the Charger automatically switches to the next mode.

2. Constant-voltage charging mode (current decreases smoothly): Charging is performed at the voltage set by the voltage regulator; the current gradually decreases to ≤0.5 A. The state of charge is determined by the ammeter. The Battery is fully charged when it indicates approximately 0.5 A.

3. Storage mode, manual (compensation of Battery self-discharge):
The storage-mode voltage is set manually, which enables selection of an optimal storage voltage based on the Battery type and characteristics. A “Voltage Table” with values for the main Battery types is located on the Charger housing (see Section 6, Table No. 1). Set the voltage corresponding to your Battery type and connect the Charger to the Battery. The Battery voltage is maintained at the selected level by a low pulsed current.