Automatic charging and starter-assist device for automotive lead-acid starter WET EFB batteries, as well as alkaline traction batteries with a capacity of 3–240 Ah

Vympel - 30 Automatic charging and starter-assist device for lead-acid starter WET EFB (Ca/Ca calcium, Ag silver) batteries as well as alkaline traction batteries with a rated capacity of 3–240 Ah

ATTENTION! Before starting working with of the Vympel 30 charger, study the requirements of the present manual.

ATTENTION! Explosive gases. Keep away from fire and sparks. During charging, explosive gases may be released from the battery; therefore, connection actions that may produce sparking and the charging of batteries must be carried out in a well-ventilated room. Ensure adequate ventilation!

ATTENTION! Observe the connection sequence of the charger (CU) to the battery (SB). GOST IEC 60335-2-29-2012 clause 7.12

NONCOMPLIANCE WITH THE CONNECTION SEQUENCE MAY LEAD TO AN EXPLOSION OF GASES EMITTED BY THE BATTERY.

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

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

3. After making sure the “Mains” LED is lit, insert the charger plug into a 220 V outlet.

ATTENTION! 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 on the use of the device by a person responsible for their safety. Children must be supervised to prevent playing with the device.

1. PURPOSE

The primary purpose of the Vympel-30 charger (CU) is charging automotive starter lead-acid batteries (SB), traction, marine, and other batteries of various capacities, including fully discharged ones (to zero), both in fully automatic mode and in non-automatic mode with manual adjustment of the charging current, for the following types:

In automatic mode, the charger monitors and limits the voltage at the battery terminals, preventing intensive gas evolution (boiling) and overcharging. Therefore, the Vympel-30 can be used to charge modern maintenance-free batteries and does not require disconnecting the battery from the vehicle electrical system.

In addition, the CU may be used as a multi-purpose constant-current power source for automotive equipment, power tools, halogen lamps, and other devices and instruments. The CU can also be used in non-automatic mode to charge batteries of any electrochemical system with a maximum end-of-charge voltage below 19 V.

The devices are intended for indoor use; degree of protection against water IP-20 rating.

2. TECHNICAL SPECIFICATIONS

3. PRODUCT DESIGN

The CU is structurally made in a plastic housing with ventilation louvers.

Located on the front panel:

1 – Ammeter scale

2 – Power LED — “Mains”; the LED changes color depending on the position of the output-voltage range switch:
14.8 V — green, 16 V — yellow, 19 V — red

3 – Overheat indication; the LED marked “T °C” indicates the operation of thermal protection

4 – Output-voltage range switch

5 – Charging-current regulator.

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

The electronic circuit of the charger is a high-voltage high-frequency converter with pulse-width modulation control, with a control circuit containing two feedback loops for output current and voltage. This power topology provides high efficiency over a wide range of supply voltages, near-ideal output characteristics in current-generator and voltage-generator modes, reliable galvanic isolation, as well as high specific mass–dimension and power characteristics.

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

The CU has reverse-polarity protection implemented in the internal electronic circuit.

4. SAFETY REQUIREMENTS

Before operating the CU, read this guide and the battery care and operating 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 contact the charger housing and 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 be directed at the CU and its leads.

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

5. SERVICEABILITY CHECK

Remove the leads. Make sure the housing has no mechanical damage and the insulation of the leads is intact. To check CU serviceability without a battery, connect it to the AC mains. The output terminals must be open. Illumination of the “Mains” LED indicates the presence of 220 V supply voltage.

Set the current-setting potentiometer to the far left position (minimum current). Short the output clamps or, for clarity, connect an automotive incandescent lamp to them. By turning the current regulator clockwise and observing the change in the measured current on the ammeter, make sure the current is adjustable and the lamp brightness changes.

ATTENTION! The microfan switches on automatically when the internal temperature rises and/or the current exceeds 11 A.
In short-circuit mode (the output terminals shorted together) a slight hum or noise is possible.

6. OPERATING PROCEDURE

6.1 BATTERY CHARGING IN AUTOMATIC MODE

6.1.1 Setting voltage and current

(The Vympel-30 automatic charger must be disconnected from the battery)

1. Connect the CU to the AC mains.

2. Change the position of the voltage switch to set the voltage in accordance with the table or the battery data sheet.

CHECK THE MAXIMUM PERMISSIBLE END-OF-CHARGE VOLTAGE IN THE BATTERY DATA SHEET

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

3. Setting the current (interval I on the graph). Set the current appropriate to the battery type and rated capacity by turning the current regulator. (General recommendation is 0.1 of the battery capacity.)

Maximum current of 20 A is guaranteed only within the 0–16 V range; at higher voltages the current may decrease if the mains voltage is low.

4. Disconnect the device from the mains.

6.1.2 Connection to the battery and charging

Failure to follow the connection sequence may cause ignition of gases emitted 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 battery 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 small spark because there is a capacitor at the CU output that is charged from 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 this spark, the connection is recommended to be made away from fuel lines and the battery. If the second clamp is connected directly to the negative battery terminal, use ventilation (an air stream, draft, etc.) to blow the cloud of explosive gases away from the negative terminal.

ATTENTION! The CU can be used to charge a battery without disconnecting it from the vehicle electrical system if permitted by the vehicle operating manual.

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

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

3. Connect the CU to the AC mains.

4. Charging in automatic mode (interval II on the graph) proceeds with the current set by the regulator. When the battery reaches the set voltage, the current automatically decreases. In this case, the current regulator will not allow setting a current higher than that defined by the automation circuit.

Operating graph of the CU when charging lead-acid batteries in automatic mode

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

Note: The time intervals in the diagram are schematic.

Current decrease (interval III on the graph). The start of a decrease in the set current indicates that the battery has reached a high state of charge. For full topping charge, it may take another half hour to several hours (depending on the battery type, capacity, and technical condition).

Float mode (interval IV on the graph). During topping charge, the CU switches to float 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. By reducing the current, the CU automatically switches to a desulfation mode. Depending on the degree of plate sulfation, 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 float operation is not limited and is beneficial for batteries that are not new, since after several dozen hours most batteries improve and restore their main characteristics — internal resistance and usable 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 with a damp and then dry cloth to remove any electrolyte. It is advisable to lubricate the clamps with any automotive grease afterwards to protect against corrosion.

6.2 BATTERY CHARGING IN NON-AUTOMATIC (MANUAL) MODE

Charging in non-automatic mode differs in that the voltage at which the charging current begins to decrease is set deliberately higher than the maximum permissible end-of-charge voltage for the specific battery. Therefore, the state of charge must be monitored manually by conventional methods (by voltage, by time and current, by electrolyte density, etc.), and charging must be terminated in a timely manner. A typical example is charging a 6 V battery.

6.3 USING THE VYMPEL-30 CU AS A MULTI-PURPOSE POWER SUPPLY

The Vympel-30 charger is a stabilized DC voltage source with current limiting (stabilization). It can therefore be used to power any consumers requiring 14.8 V/16/19 V (Maximum current of 20 A is guaranteed only within the 0–16 V range; at higher voltages the current may decrease if the mains voltage is low.) with a total consumption current less than the value set by the manual current regulator. In the event of overload or accidental shorting of the output leads, the CU will switch to current-stabilization mode.

6.4 USING THE VYMPEL-30 CU AS A STARTER-ASSIST DEVICE

To facilitate engine starting, connect the CU to the battery (see section 6.1 Battery charging in automatic mode), set the current regulator to maximum. Thus, revive the battery for 5–30 minutes, and then, without disconnecting the CU, start the engine. A battery revived by pre-start charging can deliver a significantly higher current during the first seconds of starter operation. This makes it easier to move viscous oil, ensures good mixture formation with fast cranking and a spark (or, in a diesel engine, ignition), and in most cases eliminates the need for an expensive starting device; reducing cranking time also reduces battery stress and extends 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 not limited.

7. REVERSE-POLARITY PROTECTION

The Vympel-30 charger has electronic reverse-polarity protection. In the event of incorrect connection, the CU is disconnected from the battery; upon correct connection, operability is restored automatically.

8. PREVENTIVE MAINTENANCE

For long-term operation of the CU, it is recommended to periodically perform the following maintenance tasks:

1. Remove corrosion and lubricate the crocodile clamps.
2. Blow dust out of the ventilation louvers.
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 device design and output characteristics.

9. WARRANTY OBLIGATIONS

The product complies with the requirements of the standards: 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 a Certificate of Conformity of the Eurasian Economic Union CU EAEU 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 product performance are not accepted and warranty repair is not carried out in the following cases:
absence of a warranty card
    – mechanical damage to the device is present
    – violation of the factory seal integrity
    – malfunction caused by improper operation of the device
    – the commercial appearance of the device is not preserved, there is contamination, as well as traces of any other external impact

In case of malfunction, subject to all requirements, warranty repair (exchange) of the device is carried out at the place of purchase. Post-warranty repair is carried out at: 192283, Saint Petersburg, Zagrebsky Boulevard, building 33, letter “A”.