Manual for operation of the automotive battery charger Vympel 265

Automatic charger for automotive storage batteries Vympel 265 Manual for operation

Suitable for lead–acid starter batteries of general technical purpose: traditional flooded WET type, Enhanced Flooded Battery (EFB).

(!) WARNING! Before beginning use of the Vympel 265 charger, study the requirements of the present manual.
FAILURE TO OBSERVE THE CONNECTION SEQUENCE MAY RESULT IN DAMAGE TO THE CHARGER.

(!) WARNING! Explosive gases. Keep away from flame and sparks. During charging, explosive gases may be released from the storage battery; therefore, any connection accompanied by sparking and the charging of storage batteries must be performed in a well-ventilated area. Ensure adequate ventilation!

(!) WARNING! Observe the sequence of connecting the charger (Chg) to the battery (SB). GOST IEC 60335-2-29-2012, cl. 7.12

(!) WARNING! The device is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lacking experience and knowledge, unless supervised or instructed in the use of the device by a person responsible for their safety. Children must be supervised to prevent playing with the device.

PURPOSE

The principal purpose of this starter-assist device (hereinafter the Device) is the charging of automotive and motorcycle 12 V batteries (6 V in non-automatic mode), including fully discharged units (down to zero), of any type and capacity, in a fully automatic mode with the option of manual adjustment of the charging current. The charging time depends on the battery capacity and its state of discharge.

The automatic starter-assist device Vympel 265 monitors and limits the voltage on the charged battery, preventing intensive gas evolution (boiling) and overcharge of the storage battery. Therefore, the starter-assist device Vympel 265 can be used to charge modern maintenance-free batteries and does not require disconnecting the charged batary from the vehicle onboard network.

In addition, the charger may be used as a multi-purpose direct-current power source to supply automotive equipment, power tools, halogen lamps, and other devices and instruments with a nominal supply voltage of 12 V direct current and a current consumption not exceeding 7 amperes.

The Device may also be used in non-automatic mode for charging storage batteries of any electrochemical system with a maximum end-of-charge voltage not exceeding 14.8 V.

The automatic starter-assist device Vympel 265 is intended for indoor use only; the degree of protection against water is IP20 ingress protection.

SAFETY REQUIREMENTS

Before commencing operation of the charger Vympel 265, it is necessary to study this manual as well as the rules for the care and operation of the accumulator. Before connecting the device to the mains, ensure the integrity (absence of damage) of the mains cord insulation. Prevent chemically active liquids (gasoline, acid, etc.) and water from getting onto the housing of the Device and the mains cord. During charging of the storage battery, the device must be located in a well-ventilated area. The gases released and the acidic aerosol must not be directed onto the Device and the mains leads.

(!) WARNING! Although the charger does not require your involvement during the battery charging process, it is inadmissible to leave a connected charger unattended, as with any complex equipment, especially when powered from a garage electrical network.

TECHNICAL SPECIFICATIONS

PRODUCT DESIGN

Structurally, the automatic charger Vympel 265 is executed in a plastic housing equipped with ventilation louvers.

Located on the front panel of the Vympel 265 are:

1 – Ammeter scale
2 – Overheating indicator
3 – Power LED “Mains”
4 – Charging current control knob

The mains cord and output leads with clamps are placed in the rear compartment of the housing.

The electronic circuit of the charger is a push-pull high-voltage high-frequency converter with pulse-width modulation, with a control circuit containing two feedback loops for output current and voltage.

This power-stage design provides high efficiency across a wide range of supply voltages, near-ideal output characteristics in both current-source and voltage-source modes, reliable galvanic isolation, as well as high specific mass-dimensional and power characteristics.

An ammeter is used to indicate the charging current. To protect the power stage from overheating, a micro-fan and an output-current limiting circuit are employed. This circuit automatically reduces the output current when the internal temperature exceeds the norm. In this case, manual current adjustment does not allow setting a current higher than that determined by the limiting circuit. When the normal temperature regime is restored, the range of manual adjustment is recovered.

OPERABILITY CHECK

Remove the leads. Make sure the device housing has no mechanical damage and the insulation of the leads is intact. To check the operability of the starter-assist charger without a battery, connect the device to an AC mains supply with the output terminals left open.

Ensure that the “Mains” indicator is illuminated; this indicates that the charger is operating and outputs 14.8 V at its terminals.

Set the current regulator to the far left position (minimum current). Short the output clamps together or, for clarity, connect an automotive incandescent lamp rated 55–110 W. By turning the current regulator and observing the ammeter scale, make sure that the current is adjustable and the lamp brightness varies.

Attention! In the Orion-265 charger, the micro-fan switches on automatically when the internal temperature rises or when the current exceeds 11 A. In short-circuit mode (the output clamps shorted together), a slight hum or noise is possible.

To check the operability of the fan, plug the device into the mains, short the terminals, and rotate the current regulator clockwise until the fan starts.

OPERATING PROCEDURE

CHARGING A 12 V BATTERY IN AUTOMATIC MODE

Failure to observe the connection sequence may lead to failure of the automatic charger or to an explosion of gases released by the battery. Connect and disconnect the Device in accordance with the requirements of GOST IEC 60335-2-29-2012, clause 7.12 — “The battery terminal not connected to the chassis shall be connected to the battery charger first; the other connection shall be made to the chassis away from the battery and the fuel line; then the battery charger shall be connected to the supply mains. After charging, the battery charger shall be disconnected from the supply mains; then the connection to the chassis shall be removed; then from the battery.”

Clarification: Connecting the second clamp is always accompanied by a small spark, since a capacitor is present at the output of the charger, which is charged by the SB at the moment the second clamp is attached to the SB terminal. To avoid ignition of an explosive mixture of battery gases or a flammable fuel-oil mixture by the spark, the connection is recommended to be made away from fuel lines and the SB. If the second clamp is connected directly to the negative terminal of the SB, ventilation (airflow, draft, etc.) should be used to remove the cloud of explosive gas mixture from the negative terminal.

(!) WARNING! The Vympel-265 charger may be used to charge a battery without disconnecting the SB from the vehicle onboard network, if permitted by the vehicle’s operation manual.

1. Connect the Device clamps to the storage battery terminals, strictly observing polarity. The positive terminal corresponds to a clamp with red or light-colored marking. The negative terminal corresponds to a clamp with black or dark-colored marking.

2. Set the current regulator to the far left position (minimum current).

3. After ensuring that the LED is illuminated, connect the starter-assist device to the 220 V AC mains.

4. Current setting (interval I on the graph). By turning the current control knob, set the current corresponding to the type and capacity of the battery being charged. The charging current value is indicated on the ammeter (the generally accepted recommendation is 0.1 of the battery capacity). The maximum current is set by turning the regulator fully clockwise to the stop.

Operating graph of the automotive charger during charging of a storage battery in automatic mode

Time intervals of the stages:
I — connection, setting of charging current (generally accepted recommendation is 0.1 of the battery capacity); II — charging process; III — final stage of charging; IV — float (buffer) mode

Note:
The time intervals on the graph are schematic in nature.

5. Charging of the battery B (interval II on the graph) in automatic mode proceeds with the current set by the control knob. Upon reaching 15 V at the SB, the current is automatically reduced (the beginning of interval III on the graph). In this case, the current regulator does not allow setting a current higher than that determined by the automation circuit.

(Spontaneous reduction of current at the beginning of charging may indicate the presence of sulfation of the SB plates. By reducing the current, the Device automatically switches to a desulfation mode for the accumulator. Depending on the degree of plate degradation, 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 regulator.)

Current reduction (interval III on the graph). The onset of a reduction in the preset current indicates that the battery has reached 75–95% state of charge. For complete topping-up of the storage battery, an additional period from half an hour to several hours may be required (depending on the type, capacity, and technical condition of the battery).

Float (buffer) mode (interval IV on the graph). During the finishing stage, the charger Vympel 265 switches to float mode, in which the self-discharge of the accumulator is compensated by the required charging current.

The duration of operation in float mode is not limited and is beneficial for batteries that are not new, since after several tens of hours most batteries improve and restore their main characteristics — internal resistance and capacity.

6. Upon completion of charging, disconnect the Device from the mains and remove the clamps from the accumulator terminals. It is recommended to wipe the clamps and leads with a damp and then a dry cloth to remove any electrolyte residue. It is advisable thereafter to lubricate the clamps with any automotive grease for corrosion protection.

USE OF THE DEVICE AS A MULTI-PURPOSE POWER SOURCE

The automatic charger Vympel 265 is a stabilized direct-voltage source with limitation (stabilization) of load current. Therefore, it can be used to supply any loads requiring 14.8 V whose total current consumption is lower than the value set by the manual current regulator. In case of overload or accidental shorting of the output leads, the charger will switch to protection mode.

CHARGING A ACCUMULATOR OF OTHER ELECTROCHEMICAL SYSTEMS IN NON-AUTOMATIC MODE

Failure to observe the connection sequence may result in failure of the Device. Non-automatic mode is considered a charging mode in which the end-of-charge voltage on the battery is lower than the voltage that the Device can provide. That is, the charger operates in constant-current source mode without limiting the output voltage to a level safe for the SB. A typical example is charging a 6 V SB.

1 Ensure that the end-of-charge voltage for the battery (specified in the battery’s datasheet) is lower than 15 V.

2 Connect the Device clamps to the battery terminals, strictly observing polarity. The positive terminal corresponds to a clamp with red or light-colored marking. The negative terminal corresponds to a clamp with black or dark-colored marking.

3 Set the current regulator to the far left position (minimum current).

4 After ensuring that the LED is illuminated, connect the Device to the AC mains.

5 The Device operates in constant-current generator mode. In this mode, it is necessary to set, using the regulator, the charging current corresponding to the type and capacity of the battery being charged, and to control the state of charge by generally accepted methods (by voltage, by time and current, by electrolyte density, and so on).

6 Upon completion of charging, disconnect the charger from the mains and remove the clamps from the SB terminals. It is recommended to wipe the clamps and leads with a damp and then a dry cloth to remove any electrolyte residue.

The operating time of the Device in any of the listed modes is not limited.

REVERSE-POLARITY PROTECTION

The charger is equipped with reverse-polarity protection. It is implemented in the internal electronic circuit of the charger (without the use of fuses).

(!) The device will automatically switch off in case of incorrect polarity connection and will restore operability when correctly connected.

PREVENTIVE MAINTENANCE AND REPAIR

During long-term operation, it is recommended to periodically perform the following maintenance activities:

1. Remove traces of corrosion and lubricate the crocodile clamps.
2. Clean the ventilation louvers from dust by blowing out.
3. Check the integrity of the mains cord insulation.

More complex work involving disassembly of the Device housing, for example replacement of the mains cord in case of damage, must be performed by the manufacturer of the Device or its agent, or by a similarly qualified person.

The standard service life of the Device is 5 years.

(!) The manufacturer reserves the right to make changes to the design of the device and to the output characteristics.

WARRANTY OBLIGATIONS

The product complies with the requirements of the 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 Eurasian Economic Union KG 417/KLIA.027.RU.02.00172 dated 24.06.22.

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

Claims regarding device performance are not accepted and warranty service is not provided in the following cases:
    – the warranty card is absent
    – the device has mechanical damage
    – the integrity of the factory seal is violated
    – the malfunction is caused by improper operation of the device
    – the commercial appearance of the device is not preserved, contamination is present, as well as traces of any other external influences

In case of malfunction, provided that all requirements have been met, warranty repair (exchange) of the device is carried out at the place of sale. Post-warranty repair is carried out at: 192283, Saint Petersburg, Zagrebsky Boulevard, building 33, block “A”.