Automatic battery charging and pre-starting device with an analog ammeter for general-purpose, automotive, starter, traction EFB, WET Ag (silver), WET Ca/Ca (calcium) batteries

Vympel-20 Automatic Charger with Analog Ammeter for storage batteries 12 V, 6 V

WARNING! Before starting operation of the Vympel-20 device, carefully read the requirements of this operating instructions.

WARNING! Explosive gases. Keep away from fire and sparks. During battery charging, explosive gases may be released, therefore connection involving sparking and charging of batteries must be carried out in a well-ventilated area. Ensure adequate ventilation!

WARNING! Observe the correct sequence when connecting the charger to the battery. GOST IEC 60335-2-29-2012, section 7.12

FAILURE TO FOLLOW THE CONNECTION SEQUENCE MAY RESULT IN AN EXPLOSION OF GASES RELEASED BY THE BATTERY.

1. Make sure that the charger is not connected to the 220 V mains.

2. Connect the clamp of the device with red marking to the (+) terminal of the battery.

3. Connect the clamp of the charger with black marking to the (-) terminal of the battery.

WARNING! The device is not intended for operation by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they are under supervision or have been instructed on the use of the device by a person responsible for their safety. Children should be supervised to prevent them from playing with the device.

1. PURPOSE

The main purpose of the Vympel-20 charger is to charge starter automotive (12 V) and motorcycle (6/12 V) lead-acid batteries, traction, marine, and other batteries of various capacities, including fully discharged ones (to zero), in both fully automatic and non-automatic modes with the possibility of manual adjustment of the charging current, of the following types:

In automatic mode, the device controls and limits the voltage on the charged battery, preventing intensive gas formation (boiling) and overcharging of the battery. Therefore, the Vympel-20 charger can be used to charge modern maintenance-free batteries and does not require disconnection of the charged battery from the vehicle’s on-board network.

It is also possible to use the charger in non-automatic mode for charging batteries of any electrochemical system with a maximum voltage at the end of charge of less than 19 V.

The device is intended for indoor use only, with a degree of protection against water of IP20.

In addition, the Vympel-20 charger can be used as a multi-purpose DC power source for powering automotive equipment, power tools, halogen lamps, and other devices and appliances.

2. SAFETY REQUIREMENTS

Before starting operation of the device, read this manual as well as the rules for maintenance and operation of the battery. Before connecting the device to the mains, ensure the integrity (no damage) of the mains cable insulation. Do not allow chemically active liquids (gasoline, acid, etc.) or water to come into contact with the charger housing or mains cable. During battery charging, the device must be placed in a well-ventilated area, ensuring that emitted gases and acid aerosol do not come into contact with the charger or power cables.

WARNING!!! Although the Vympel-20 charger does not require your participation in the charging process, it is unacceptable to leave the connected charger unattended, as with any complex equipment, especially when powered from a garage mains supply.

3. TECHNICAL SPECIFICATIONS

4. DESIGN OF THE VYMPEL-20 CHARGER

The charger is housed in a plastic casing with ventilation slots.

The front panel contains:

1 – Ammeter scale

2 – Power indicator LED – "Network"; the LED changes its color depending on the position of the output voltage range switch:
14.8 V – green, 16 V – yellow, 19 V – red

3 – Overheating indicator; LED marked "T °C" indicates activation of the overheat protection

4 – Output voltage range switch

5 – Charging current control knob

The mains cable and output wires with alligator clips are stored in the rear compartment of the casing.

The electronic circuit of the charger is a high-voltage high-frequency converter with pulse-width modulation, equipped with a control circuit containing two feedback loops – for output current and voltage. This design of the power section provides high efficiency over a wide range of supply voltages, nearly ideal output characteristics for both current and voltage generators, reliable galvanic isolation, and excellent specific weight, size, and power characteristics.

An ammeter is used to indicate the charging current. A micro fan and output current limiting circuit protect the power section from overheating. This circuit automatically reduces the output current when the temperature inside the casing exceeds the permissible limit. In this case, manual current adjustment will not allow setting a current higher than that permitted by the limiting circuit. Once normal temperature is restored, the manual adjustment range is reinstated.

The Vympel-20 charger has reverse polarity protection implemented in the internal electronic circuit.

5. OVERHEAT INDICATION

When the maximum allowable internal temperature of the device is exceeded, the protection circuit reduces the charging current. The over-temperature indicator will light up. Once the temperature returns to normal, the current is restored and the charger resumes normal operation.

6. FUNCTIONAL CHECK

Remove the wires. Make sure the product casing is free from mechanical damage and that the wire insulation is intact.

To check the functionality of the charger without a battery, connect it to the AC mains. The output terminals must be open. The illumination of the "Network" LED indicates the presence of 220 V mains voltage.

Set the current control knob to the far left position (minimum current). Short the output clamps together or, for demonstration purposes, connect a 55–110 W automotive incandescent lamp to them. Rotate the current control knob to the right and observe the change in the current value on the ammeter and the brightness of the lamp. This confirms the current adjustment functionality.

WARNING! In short-circuit mode (output terminals shorted together), slight humming or noise may occur.

7. OPERATING PROCEDURE

7.1 CHARGING THE BATTERY IN AUTOMATIC MODE

7.1.1 Setting the voltage and current

(The Vympel-20 automatic charger must be disconnected from the battery)

1. Connect the charger to the AC mains.

2. Using the voltage selector switch, set the voltage in accordance with the table or the specifications of the battery.

REFER TO THE BATTERY SPECIFICATIONS FOR THE MAXIMUM ALLOWABLE FINAL CHARGING VOLTAGE.

3. Current setting (interval I on the graph). Short the output clamps together. Set the current corresponding to the type and capacity of the battery by turning the current control knob. (General recommendation: 0.1 of the battery capacity). Disconnect the output clamps.

4. Disconnect the device from the mains.

7.1.2 Connecting to the battery and charging

Failure to follow the correct connection sequence may result in an explosion of gases released by the battery. Connection and disconnection must be carried out according to GOST IEC 60335-2-29-2012, section 7.12 – “The battery terminal not connected to the chassis should be connected to the charger first; the other connection should be made to the chassis away from the battery and fuel line; then the battery charger should be connected to the mains. After charging, disconnect the battery charger from the mains; then disconnect it from the chassis; and finally from the battery.”

Explanation: The connection of the second clamp is always accompanied by a small spark because the charger output contains a capacitor, which is charged from the battery at the moment the second clamp is connected. To avoid ignition of the explosive mixture of battery gases or flammable fuel-oil vapors by the spark, it is recommended to make the connection away from fuel lines and the battery. If connecting the second clamp directly to the negative terminal of the battery, ventilation (airflow, draft, etc.) should be used to disperse the cloud of explosive gases from the negative terminal.

WARNING! The charger can be used to charge a battery without disconnecting it from the vehicle’s electrical system, if permitted by the vehicle’s operating manual.

1. Connect the charger clamp with red marking to the (+) battery terminal.

2. Connect the charger clamp with black marking to the (–) battery terminal.

3. Connect the charger to the AC mains.

Charger operation graph when charging lead-acid batteries in automatic mode

Time intervals of operation stages:
I – connection, setting the charging current;
II – charging process;
III – final charging stage;
IV – float mode

4. Charging the battery in automatic mode (interval II on the graph) with the current set by the adjustment knob. When the set voltage is reached, the current automatically decreases. In this case, the charging current control does not allow setting a current higher than that determined by the automation circuit.

Current reduction (interval III on the graph). The beginning of a reduction in the set current indicates that the battery has reached full charge. For complete charging, it may take from half an hour to several hours (depending on the type, capacity, and technical condition of the battery).

Note: The time intervals on the graph are schematic.

Float mode (interval IV on the graph). During the finishing stage, the charger switches to float mode, in which the self-discharge of the battery is compensated by the required charging current.

Spontaneous current reduction at the start of charging may indicate sulfation of the battery plates. By reducing the current, the charger automatically switches to battery desulfation mode. Depending on the degree of plate damage, desulfation may take from several minutes to several hours. During desulfation, the current will gradually and automatically increase to the value set by the current control knob.

The duration of float mode operation is unlimited and is even beneficial for older batteries, as after several dozen hours most batteries improve and restore their main characteristics – internal resistance and capacity.

5. After charging is complete, disconnect the charger from the mains and remove the clamps. It is recommended to wipe the clamps and wires with a damp cloth followed by a dry cloth to remove any electrolyte residue. It is advisable to then lubricate the clamps with any automotive grease to protect them from corrosion.

7.2 USING THE VYMPEL-20 CHARGER AS A MULTI-PURPOSE POWER SOURCE

The Vympel-20 charger is a source of stabilized DC voltage with current limiting (stabilization). Therefore, it can be used to power any consumers requiring 7.5 V / 15 V / 19 V, with a total consumption current lower than the value set by the manual current control. In case of overload or a short circuit of the output wires, the charger will switch to current stabilization mode.

7.3 CHARGING BATTERIES OF OTHER ELECTROCHEMICAL SYSTEMS AND VOLTAGES IN NON-AUTOMATIC MODE

Non-automatic mode is considered a charging mode in which the voltage on the battery at the end of charging is lower than the voltage that the charger can produce. In other words, the charger operates in constant-current generator mode without limiting the output voltage to a safe level for the battery.

1. To charge a 6 V battery in non-automatic mode, set the switch to the STANDARD 15 V position. Proceed to step 5.

2. To charge a 12 V battery in non-automatic mode, set the switch to the MANUAL 19 V position. Proceed to step 5.

3. To charge batteries of other electrochemical systems and voltages in non-automatic mode, set the voltage selector to a position where the charger voltage will be higher than the battery’s end-of-charge voltage (specified in the battery’s datasheet). Proceed to step 5.

4. Charging alkaline batteries. A feature of alkaline batteries is their higher charging voltage compared to lead-acid batteries of the same nominal voltage. Therefore, for full charging of an unsealed alkaline battery, set the mode switch to the 19 V position. The final charging voltage in the 19 V mode corresponds to a full charge for an unsealed general-purpose alkaline battery, meaning that such a battery will actually be charged in automatic mode.

A specific feature of alkaline batteries is intense gas release throughout the charging process, especially at the final stage. Therefore, it is not recommended to leave the battery connected for a long time at the final charging stage. It is also recommended to check the electrolyte level after each charge, topping up with distilled water if necessary.

WARNING! Charging sealed alkaline batteries requires strict voltage control according to the battery datasheet, as well as taking into account its temperature. The recommended charging current must also not be exceeded. Failure to follow these recommendations may result in destruction of the sealed alkaline battery with explosion and release of alkaline electrolyte.

5. Connect the charger clamps to the battery terminals, strictly observing polarity. The red clamp corresponds to positive, the black clamp to negative.

6. Set the current control knob to the far left position (minimum current).

7. Connect the charger to the 220 V AC mains.

8. Set the required charging current. The charger operates in constant-current generator mode. In this mode, set the charging current according to the type and capacity of the battery.

9. Charging occurs in non-automatic mode, and the state of charge must be monitored by common methods (voltage, time and current, electrolyte density, etc.).

10. After charging is complete, disconnect the charger from the mains and remove the clamps from the battery terminals. It is recommended to wipe the clamps and wires with a damp cloth followed by a dry cloth to remove any electrolyte residue. It is advisable to then lubricate the clamps with any automotive grease to protect them from corrosion.

The operating time of the charger in any of the listed modes is unlimited.

8. REVERSE POLARITY PROTECTION

The charger has reverse polarity protection implemented in the internal electronic circuit (without using fuses).

The device will automatically shut down in case of incorrect polarity connection and will restore operation when the correct connection is made.

9. MAINTENANCE

During long-term use of the charger, it is recommended to periodically perform the following maintenance:

1. Remove traces of corrosion and lubricate the alligator clamps.
2. Clean the ventilation louvers from dust using compressed air.
3. Check the integrity of the mains cable insulation.

The standard service life of the charger is 5 years.

The manufacturer reserves the right to make changes to the design and output specifications.

10. WARRANTY OBLIGATIONS

The product complies with the requirements of regulatory documents: GOST IEC 60335-2-29-2012; GOST 30805.14.1-2013; GOST 30805.14.2-2013; GOST 30804.3.2-2013; GOST 30804.3.3-2013 and has the Certificate of Conformity of the EAEU Customs Union KG 417/KLIA.027.RU.02.00172 dated 24.06.22.

The warranty period for the device is 12 months from the date of sale.

Claims regarding the quality of the device will not be accepted and warranty repairs will not be carried out in the following cases:
the warranty card is missing
there is mechanical damage to the device
the integrity of the factory seal has been violated
malfunction caused by improper operation of the device
the product’s original appearance is not preserved, with contamination or any other signs of external impact

In the event of a malfunction, if all requirements are met, warranty repair (exchange) of the device is carried out at the place of purchase. Post-warranty repairs are carried out at the following address: 192283, St. Petersburg, Zagrebsky Boulevard, Building 33, Letter "A".