Three-mode automatic charging and pre-start device for automotive lead-acid starter WET and EFB batteries, as well as alkaline traction batteries with a capacity of 3–240 Ah

Vympel-27 / Vympel-37 Three-mode automatic charging and pre-start device

Suitable for lead-acid starter traditional WET (flooded), EFB (Ca/Ca calcium, Ag silver) storage batteries, as well as alkaline traction and other batteries with a capacity of 3–240 Ah.

(!) ATTENTION! Before starting work with the Vympel-27 / Vympel-37 charger, study the requirements of the present manual.

(!) ATTENTION! Explosive gases. Keep away from fire and sparks. During charging of a storage battery, explosive gases may be released; therefore, connection operations that may cause sparking and the charging of batteries must be performed in a well-ventilated area. Ensure adequate ventilation!

(!) ATTENTION! Observe the connection order when connecting the charger (CU) to the battery (BAT). GOST IEC 60335-2-29-2012, cl. 7.12

(!) ATTENTION! The device is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lacking experience or knowledge, unless they are 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.

FAILURE TO OBSERVE THE CONNECTION ORDER MAY LEAD TO AN EXPLOSION OF GASES RELEASED BY THE BATTERY.

1. PURPOSE

The primary purpose of the Vympel-27 / Vympel-37 charger (CU) is charging automotive lead-acid starter storage batteries (BAT), traction, marine and other 12 V batteries of various capacities, including completely discharged ones (down to zero), of the following types:

(!) The charging voltage in the non-automatic (manual) mode is 16 V.

In automatic mode, the charger monitors and limits the voltage on the battery being charged, preventing intensive gas formation (boiling) and overcharging. Therefore, the Vympel-27 / Vympel-37 can be used to charge modern maintenance-free batteries and does not require disconnecting the battery from the vehicle’s onboard network.

The CU may also be used in non-automatic mode to charge batteries of any electrochemical system with a maximum end-of-charge voltage below 18 V. The CU allows adjustment of charging current and voltage to charge batteries of different types.

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

The devices are intended for indoor use. Degree of water protection: IP-20.

2. TECHNICAL SPECIFICATIONS

3. PRODUCT DESIGN

Structurally, the CU is made in a plastic enclosure with ventilation louvers. The mains cord and output leads with clamps are stowed in the rear compartment of the enclosure.

Located on the front panel are:

1 – Segment LCD indicator
2 – Output voltage range selector: 14.2 V / 14.8 V / 18 V
3 – Charging current adjustment knob.

The electronic circuit of the charger is a high-voltage, high-frequency converter with pulse-width modulation and a control circuit comprising two feedback loops for output current and voltage. This design of the power section ensures high efficiency over a wide range of input voltages, nearly ideal output characteristics of the current and voltage generators, reliable galvanic isolation, and superior specific mass-dimensional and power characteristics.

An LCD indicator is used to display the charging current. To protect the power section from overheating, a micro-fan (Vympel-37 only) and an output-current limiting circuit are employed. This circuit automatically reduces the output current when the internal temperature rises above normal. In this case, manual current regulation does not allow setting a current higher than the limit imposed by the protection circuit. When the normal temperature regime is restored, the manual adjustment range is recovered.

4. SAFETY REQUIREMENTS

Before operating the CU, read this manual as well as the battery care and operation rules. Before connecting the device to the mains, make sure the insulation of the mains cord is intact (no damage). Do not allow chemically active liquids (gasoline, acid, etc.) or water to get on the charger housing or the mains cord. During charging, the battery must be placed in a well-ventilated area. The gases and acid aerosol emitted by the battery must not come into contact with the CU or the mains cord.

(!) ATTENTION! Although the CU does not require your involvement during the charging process, it is unacceptable to leave the connected CU unattended, as with any complex equipment, especially when powered from a garage power supply.

Handle the CU carefully. Do not disassemble or drop it; do not bend the mains cord and output leads to avoid damaging the insulation; avoid mechanical and thermal effects.

Do not use the CU if its housing is damaged, the plug contacts are bent, there are other mechanical damages, or the CU has been exposed to moisture and has not been completely dried. Keep the CU away from sources of intense heat and direct sunlight.

Do not attempt to repair the CU yourself. Do not disassemble the CU, as you may damage it or be injured. If the CU is faulty or damaged, contact the seller or the manufacturer.

Storing the CU in dusty, gassy, humid, or heavily contaminated rooms is not permitted—it may lead to corrosion, damage to the electronic circuitry, and short circuits inside the device.

Do not use the CU in locations containing flammable and explosive substances, explosive gases, organic dust (wood, grain, paper, etc.), flammable vapors and aerosols, etc., since sparking that inevitably occurs when connecting the clamps to the battery terminals may lead to an explosion or fire.

The CU does not contain precious metals or their alloys. Disposal shall be carried out in accordance with standard practice of the country of operation.

5. OPERABILITY CHECK

Remove the leads. Make sure the product housing has no mechanical damage and the insulation of the leads is intact. To check CU operability without a battery, connect it to the AC mains. The output terminals must be open.

By changing the position of the voltage selector, make sure the output voltage is adjustable. Set the voltage selector to the 14.2 V position.

Make sure the LCD indicator displays the voltage and charging current values. With the terminals open, the current value must be zero.

Set the potentiometer of the current to the far left position (minimum current). Short the output clamps or, for clarity, connect a 55–110 W automotive incandescent lamp to them. By turning the current control knob clockwise and observing the change in the flowing current on the LCD indicator, make sure the current is adjustable and the lamp brightness changes.

(!) ATTENTION! The micro-fan turns on automatically as the internal temperature rises and/or when the current increases above 11 A.
In short-circuit mode (output terminals shorted together), slight humming or noise is possible.

6. OPERATING PROCEDURE

6.1 CHARGING A BATTERY IN AUTOMATIC MODE

6.1.1 Setting voltage and current

(The automatic charger Vympel-27 / Vympel-37 must be disconnected from the battery; output clamps are open)

1. Connect the CU to the AC mains.

2. By changing the position of the voltage selector, set the voltage in accordance with the table or the battery datasheet.

(!) BECOME ACQUAINTED WITH THE MAXIMUM PERMISSIBLE END-OF-CHARGE VOLTAGES IN THE BATTERY SPECIFICATION

Charging voltage in non-automatic (manual) mode: 16/19 V

3. Setting the current (interval I on the graph). Set the current corresponding to the type and capacity of the battery being charged by turning the current control knob. (Common recommendations: 0.1 of the battery capacity.)

4. Disconnect the device from the mains.

6.1.2 Connecting to the battery and charging

Failure to follow the connection order may lead to an explosion of gases released by the battery. Perform connection and disconnection of the CU in accordance with GOST IEC 60335-2-29-2012, clause 7.12 – “The battery terminal not connected to the chassis shall be connected to the charger first; the other connection shall be made to the chassis away from the battery and fuel line; then the battery charger shall be connected to the supply. After charging, the battery charger shall be disconnected from the supply; then the charger shall be disconnected from the chassis; then – from the battery.”

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

(!) ATTENTION! The CU can be used to charge a battery without disconnecting it from the vehicle’s onboard network if permitted by the vehicle’s operating manual.

CU operating 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 – buffer mode

(!) Note: The time intervals in the graph are schematic.

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

2. Connect the CU clamp with black marking to the (?) battery terminal.

3. Connect the CU to the AC mains. The CU will start charging the battery in automatic mode.

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

Current reduction (interval III on the graph). The beginning of a decrease in the set current indicates the battery has reached charge. For full topping-up of the battery, an additional half hour to several hours may be required (depending on the type, capacity, and technical condition of the battery).

Buffer mode (interval IV on the graph). During the topping-up process, the CU switches to buffer mode, in which the battery self-discharge is compensated by the required charging current.

Spontaneous current reduction at the beginning of charging may indicate sulfation of the battery plates. Upon reducing the current, the CU automatically switches to the 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 regulator.

The duration of operation in buffer mode is unlimited 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.

5. Upon completion of charging, disconnect the CU from the mains and remove the clamps. It is recommended to wipe the clamps and leads first with a damp and then a dry cloth to remove any electrolyte. If possible, lubricate the clamps with any automotive grease to protect against corrosion.

6.2 CHARGING A BATTERY IN NON-AUTOMATIC (MANUAL) MODE

Charging in non-automatic mode differs in that the voltage at which the charging current begins to decrease is deliberately set higher than the maximum permissible end-of-charge voltage for the specific battery. Therefore, the state of charge must be monitored manually by generally accepted methods (by voltage, by time and current, by electrolyte density, etc.), and charging must be disconnected in a timely manner.

6.3 USING THE VYMPEL-27 / VYMPEL-37 AS A MULTI-PURPOSE POWER SOURCE

The Vympel-27 / Vympel-37 is a stabilized DC voltage source with current limiting (stabilization). It can therefore be used to power any consumers requiring 14.2 / 14.8 / 18 V with a total current consumption less than the value set by the manual current regulator. In the event of an overload or a fault shorting the output leads, the CU will switch to current stabilization mode.

6.4 USING THE VYMPEL-27 / VYMPEL-37 AS A PRE-START DEVICE

To facilitate engine starting, connect the CU to the battery (see section 6.1 Charging a battery in automatic mode) and set the maximum current using the adjustment knob. Thus, revive the battery over 5–30 minutes and then, without disconnecting the CU, start the engine. A battery revived by pre-start charging is capable of delivering a substantially higher current in the first seconds of starter operation. This allows easy overcoming of viscous oil, ensures good mixture formation with faster cranking and a strong spark (in a diesel – ignition), and in most cases avoids the need for an expensive jump starter; the reduced cranking time also lowers the load on the battery, prolonging its service life.

If unsuccessful, repeat the procedure. The manufacturer recommends using more powerful models for this purpose (VYMPEL-40, VYMPEL-57) or several CUs connected in parallel.

Operating time of the CU in any of the listed modes is unlimited.

7. INFORMATION DISPLAY

7.1 WELCOME SCREEN

When the device is connected to a 220 V mains supply, information about the CU model number and firmware version is displayed once.

(!) The displays switch in a loop at short time intervals.

7.2 PARAMETERS DISPLAY

The screen displays the current current and voltage.

7.3 STATISTICS DISPLAY

The screen displays charging time, ampere-hours delivered to the battery, and state of charge percentage.

The state of charge is determined using an estimation algorithm and allows forecasting of the time remaining to full charge of the battery.

7.4 SETUP DISPLAY

When the position of the voltage selector and/or current adjustment knob is changed, the “SETUP” message will appear on the screen; the value being set will flash for several seconds.

(!) Transition to this display occurs instantly when the current regulator knob or voltage selector is moved.

8. VOLTAGE SETTING

1. The device must be switched to idle mode (output clamps not connected).

2. By changing the position of the selector, make a preliminary voltage setting.

3. Wait until the flashing of the set value stops and the “SETUP” message disappears.

10. CHARGE COMPLETION

(!) ATTENTION! The appearance of the message “CHARGE COMPLETE” on the charger screen is for reference only.

The message may appear in the following cases:

• The battery is ready for operation
• The battery is not connected to the charger (for example, poor contact of the clamps on oxidized terminals)
• The charging parameters do not correspond to the type of battery being charged
• The battery is sulfated or faulty

The CU’s electronic circuit monitors voltage and current during charging. If the voltage at the CU clamps has stabilized and the current does not exceed 10% of the value set at the beginning of charging, the CU considers such a battery charged. The message “CHARGE COMPLETE” will be displayed.

11. OVERHEAT PROTECTION

An output-current limiting circuit is used to protect the power section from overheating. This circuit automatically reduces the output current when the internal temperature rises above normal.

The “t°C” caption and the alarm icon will flash on the screen. After the internal temperature decreases, the source will return to normal operation.

12. REVERSE POLARITY PROTECTION

The Vympel-27 / Vympel-37 charger has electronic reverse polarity protection. In case of incorrect connection, the CU disconnects from the battery; the “PER” caption and the alarm icon flash on the screen. After disconnecting the CU clamps from the battery, CU operability is automatically restored.

13. DIGITAL VOLTMETER

The CU can be used as a digital voltmeter. To do this, connect the CU clamps to the battery terminals, observing the polarity: red clamp to (+), black clamp to (?).

(!) Voltmeter measurement range: 8.5 – 23 V, accuracy 8.5–23 V ±0.1 V

(!) ATTENTION! In “VOLTMETER” mode, the device must be disconnected from the 220 V mains. Connecting the mains supply automatically switches the CU to charging mode.

14. PREVENTIVE MAINTENANCE

For prolonged operation of the CU, it is recommended to periodically perform the following maintenance operations:

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

Standard service life of the CU – 5 years.

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

15. 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 an EAEU Customs Union Certificate of Conformity KG 417/KLIA.027.RU.02.00172 dated 24.06.22.

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

Claims regarding device performance are not accepted and warranty repair is not provided in the following cases:
    – absence of a warranty card
    – presence of mechanical damage to the device
    – violation of the integrity of the factory seal
    – malfunction caused by improper operation of the device
    – loss of the product’s marketable condition, contamination, as well as traces of any other external impacts

In case of malfunction, provided all requirements are met, warranty repair (replacement) is carried out at the place of purchase. Post-warranty repair is carried out at: 192283, Saint Petersburg, Zagrebsky Boulevard, building 33, lit. “A”.