Instruction for operation of the automotive battery charger Vympel 325

Automatic charging and engine-start assist device for automotive accumulator batteries Vympel 325 Instruction for operation

Suitable for lead-acid starter batteries of general industrial purpose: traditional flooded WET, EFB accumulator batteries.

(!) WARNING! Before beginning work with the Vympel 325 charger, study the requirements of the present manual.
FAILURE TO FOLLOW THE CONNECTION ORDER MAY RESULT IN THE CHARGER’S FAILURE.

(!) WARNING! Explosive gases. Keep away from fire and sparks. During charging, an accumulator battery may emit explosive gases; therefore, all connections that may cause sparking and the charging of batteries must be performed in a well-ventilated area. Ensure adequate ventilation!

(!) WARNING! Observe the prescribed connection order of the charger (CU) to the battery (AB). GOST IEC 60335-2-29-2012, clause 7.12

(!) WARNING! The device is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and 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 play with the device.

PURPOSE

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

Automatic charging and engine-start assist device Vympel 325 monitors and limits the voltage on the battery under charge, preventing intensive gas evolution (boiling) and overcharge of the accumulator. Therefore, the device can be used to charge modern maintenance-free batteries and does not require disconnecting the accumulator battery from the vehicle onboard power system.

In addition, the automatic charger Vympel 325 may be used as a multi-purpose DC power source for supplying automotive equipment, power tools, halogen lamps, and other devices and instruments with a nominal supply voltage of 12 V DC and a current consumption not exceeding 20 amperes.

The Device may also be used in non-automatic mode for charging accumulators of any electrochemical system with a maximum end-of-charge voltage not exceeding 15 V.

Charging and engine-start assist device is intended for indoor use only; degree of water protection IP20 ingress protection (IP standard).

SAFETY REQUIREMENTS

Before operating the automatic charger , it is necessary to study this manual, as well as the rules for the care and operation of the battery. Before connecting the device to the mains, make sure the insulation of the power cord is intact (no damage). Do not allow chemically active liquids (gasoline, acid, etc.) or water to come into contact with the Device housing and the mains cord. When charging an accumulator, the device must be placed in a well-ventilated area. The gases and acid aerosol released during charging must not come into contact with the Device and mains cables.

(!) WARNING! Although the charger does not require user participation in the battery charging process, it is unacceptable to leave a connected charger unattended, as with any complex equipment, especially when powered by a garage electrical network.

TECHNICAL SPECIFICATIONS

DEVICE DESIGN

Structurally, the automatic charging and engine-start assist device is made in a plastic housing with ventilation louvers.

Located on the front panel of the Vympel 325 are:

1 – Ammeter scale
2 – Overheating indicator
3 – Power-on 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 architecture of the power stage provides high efficiency over a wide range of supply voltages, practically ideal output characteristics of a current generator and a voltage generator, 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 used. This circuit automatically reduces the output current when the internal temperature rises above the norm. In this case, manual current adjustment will not allow a value higher than the threshold set by the limiting circuit. When the normal temperature regime is restored, the manual adjustment range is also restored.

OPERABILITY CHECK

Remove the leads. Make sure that the product housing has no mechanical damage and that the insulation of the wires is intact. To check the operability of the automotive charger without accumulator battery, connect the device to the AC mains; the output terminals must remain open.

Make sure the “Mains” indicator is illuminated.

Set the current regulator to the leftmost position (minimum current). Short the output clamps or, for clarity, connect an automotive incandescent lamp of 55–110 W. By rotating the current regulator and observing the ammeter scale, make sure that the current is adjusted and the brightness of the lamp changes.

Attention! In the Orion-325 charger, the micro fan turns on automatically when the internal temperature rises or when the current exceeds 11 A. In short-circuit mode (output clamps shorted together), a slight hum or noise is possible.

To check the operability of the fan, connect the device to the mains, short the clamps, and turn the current regulator clockwise until the fan starts.

OPERATING PROCEDURE

CHARGING A 12 V BATTERY IN AUTOMATIC MODE

Failure to observe the connection order may lead to automatic charging and engine-start assist device Vympel 325 damage or to an explosion of gases emitted by the battery. Perform connection and disconnection of the Device 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 small spark, because there is a capacitor at the charger output that is charged by the battery at the moment the second clamp is connected to the battery terminal. To avoid ignition of the explosive mixture of battery gases or flammable fuel-oil vapors by a spark, it is recommended to perform the connection away from fuel lines and the battery. If the second clamp is connected directly to the negative battery terminal, use ventilation (airflow, draft, etc.) to disperse the cloud of explosive gases from the negative terminal.

(!) WARNING! The charger may be used to charge the battery without disconnecting the AB from the vehicle’s onboard network, if permitted by the vehicle’s operating manual.

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

2. Set the current regulator to the leftmost position (minimum current).

3. After verifying that the LED is lit, connect the device to the AC mains.

4. Current setting (interval I on the chart). Rotate the current regulator knob to set the current corresponding to the type and capacity of the battery being charged. The charging current value is displayed on the ammeter (Common recommendation: 0.1 of the battery capacity). The maximum current is set by turning the regulator fully clockwise.

Operating chart of the engine-start assist charger when charging an accumulator in automatic mode

Time intervals of the operating stages:
I – connection, setting of the charging current (common recommendation 0.1 of the battery capacity); II – charging process; III – final stage of charging; IV – float mode

Note:
The time intervals on the chart are schematic.

5. Charge of the accumulator battery B (interval II on the chart) in automatic mode at the current set by the adjustment knob. Upon the battery reaching a voltage of 15 V, the current automatically decreases (start of interval III on the chart). In this case, the charging current regulator will not allow a current higher than the threshold set by the automation.

(Spontaneous current reduction at the beginning of charging may indicate sulfate formation on the battery plates. By reducing the current, the Device automatically switches to a desulfation mode for the AB. Depending on the degree of plate degradation, desulfation may require 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 chart). The start of the reduction in the preset current indicates that the battery has reached 75–95% state of charge. For full completion of charging of the accumulator, 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 mode (interval IV on the chart). During the finishing stage, the automatic charger switches to float mode, in which the self-discharge of the AB is compensated by the required charging current.

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

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

USE OF THE DEVICE AS A MULTI-PURPOSE POWER SOURCE

The Automatic charging and engine-start assist device is a stabilized DC voltage source with load current limiting (stabilization). Therefore, it may be used to power any 15 V loads with a total current draw less than the value set by the manual current regulator. In case of overload or an accidental short circuit of the output leads, the charger will switch to protection mode.

USE OF THE DEVICE AS AN ENGINE-START ASSIST UNIT

To facilitate engine start, connect the charger to the battery, set the maximum current using the adjustment knob. In this way, revive the battery within 5–30 minutes and then, without disconnecting the Device from the battery, start the engine.

(!) WARNING! The charger may be used to charge the battery without disconnecting the AB from the vehicle’s onboard network, if permitted by the vehicle’s operating manual.

A battery activated by a start-assist charge is capable of delivering a significantly higher current during the first seconds of starter operation. This allows the viscous oil to be moved more easily, ensures good mixture formation and spark (or, in a diesel engine, ignition), and in most cases eliminates the need for an expensive starting unit; reducing cranking time decreases the load on the battery and extends its service life. If unsuccessful, repeat the procedure. The manufacturer recommends using more powerful models for this purpose (Vympel 415, Vympel-30, Vympel-40) or several chargers connected in parallel.

CHARGING AN ACCUMULATOR BATTERY OF OTHER ELECTROCHEMICAL SYSTEMS IN NON-AUTOMATIC MODE

Failure to observe the connection order may lead to Device failure. Non-automatic mode is a charging mode in which the battery voltage at the end of charging is lower than the voltage that the Device can generate. That is, the charger operates as a constant-current generator, without limiting the output voltage to a level safe for the battery. A typical example is charging a 6 V battery.

1 Verify that the end-of-charge voltage of the battery (specified in the battery passport) is less than 15 V.

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

3 Set the current regulator to the leftmost position (minimum current).

4 After confirming that the LED is on, connect the Device to the AC mains.

5 The Device operates in constant-current generator mode. In this mode, the charging current must be set using the regulator in accordance with the type and capacity of the battery, and the charging status must be monitored using commonly accepted methods (by voltage, by time and current, by electrolyte density, and so on).

6 After charging is complete, disconnect the Device from the mains and remove the clamps from the battery terminals. It is recommended to wipe the clamps and leads with a damp cloth and then a dry cloth to remove any electrolyte.

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

REVERSE POLARITY PROTECTION

The charger has 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 the event of incorrect polarity connection and will restore operability upon correct connection.

PREVENTIVE MAINTENANCE AND REPAIR

For prolonged operation of the Device, the following maintenance measures are recommended periodically:

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

More complex operations 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 a similarly qualified person.

The standard service life of the Device is 5 years.

(!) The manufacturer reserves the right to make changes to the device design and 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 EAEU Customs Union 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 quality are not accepted and warranty repair is not performed in the following cases:
    – the warranty card is missing
    – mechanical damage to the device is present
    – the factory seal is broken
    – the malfunction is caused by improper operation of the device
    – the product appearance has not been preserved, there is contamination, as well as traces of any other external influences

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