Automatic transformer-based charging and starting device for automotive batteries ZU-120M-3 LLC NPP "Oboronpribor" Ryazan. User Manual

Transformer-based Charging Device ZU-120M-3 User Manual

Due to improvements in circuit design, construction, and manufacturing technologies of the charging device, the manufacturer reserves the right to introduce changes in the circuit and construction of the device.

General Instructions

1. The charging device ZU-120M-3 is intended for charging automotive lead-acid accumulator batteries with a nominal voltage of 12V and a capacity from 50 to 120 Ah.

2. The C.D. ZU-120M-3 operates from an alternating current mains with a frequency of 50 Hz and a voltage of 220V.

3. Conditions of operation: indoors in ventilated areas at temperatures from minus 10°C to plus 35°C and relative humidity up to 85%.

4. The charging device must not be used to recharge non-rechargeable batteries.

(!) 5. Mandatory requirements for the device, aimed at ensuring the safety of life, health, and property of the population, as well as environmental protection, are set out in Section 4.

2. Technical Data of ZU-120M-3

2.1 Nominal voltage of the charged battery: 12V.
2.2 Nominal direct output current (charging current): (9±0.5) A
2.3 Nominal power consumption of the device at maximum charging current of 4A, not more than 80 W.
2.4 Automatic disconnection voltage of the charged battery: 14.2–14.5 V
2.5 Weight of the device including connection cables, not more than 3 kg.
2.6 Overall dimensions of the device: 290 x 145 x 100 mm.
2.7 Service life of the device: not less than 6 years.
2.8 Degree of electric shock protection: II.
2.9 Operation of the device is prohibited if the power cord is damaged.

3. Package Contents

The delivery set includes:
- Charging device with connection cables – 1 pc.
- Clamps for connection to the battery – 2 pcs.
- Packaging for the charging device – 1 pc.
- User guide user manual – 1 pc.

4. Safety Requirements

4.1 When operating the charging device, the requirements of this manual must be observed.

4.2 It is prohibited to remove the casing of the device during operation.

4.3 It is prohibited to carry out any repair of the emergency shutdown system of the charging device.

4.4 It is prohibited to short-circuit or block the mechanical protective shutdown device.

4.5 During charging of accumulator batteries, explosive gases are released. Ventilate the premises periodically.

4.6 Place the charging device at a distance of about 1 meter from the battery being charged.

4.7 Disconnect the charging device from the power supply before connecting or disconnecting the battery.

4.8 Remember that a battery left charging unattended for a long time poses a hazard.

5. Device Structure

5.1 The device consists of a housing to which the transformer and other electrical circuit components are attached at the base.

5.2 On the front panel of the device 55A there are: a two-position charging current switch and a charging current indicator with a measurement range from 0 to 10 A.

5.3 On the rear panel there are: the protective shutdown device, wires with output terminals “+” (red) and “–” (black), and a power cord with type Y attachment.

6. Preparation for Operation

6.1 Place the charging device at a distance of about 1 meter from the battery to be charged.

6.2 Connect the red clamp to the “+” terminal of the battery, the black clamp to the “–” terminal.

6.3 After connecting the charging device to the battery, assess its condition using the E.M.F. indicator.

The following cases are possible:

Battery in emergency condition. E.M.F. less than 11V. Possible failure of one of the cells. Charging with the device is prohibited.

Battery in good condition, discharged. E.M.F. greater than 11.3 V but less than 12.3 V. Begin charging. Expected charging time not less than 8–10 hours.

Battery in working condition, charged (or discharged by no more than 50%). Battery E.M.F. greater than 12.3 V. Recharge the battery if necessary.

(!) Note: the E.M.F. indicator may show underestimated values if the battery was discharged with high currents immediately prior to connection. It is necessary to wait several minutes for the recovery of the rest voltage.

6.4 After performing the above operations and connecting the device to the AC mains, it is ready for operation.

(!) *When charging the battery without removing it from the vehicle, disconnect the “+” terminal of the battery from the vehicle electrical system; do not disconnect the “–” terminal from the chassis ground. Connect the red clamp of the device to the “+” terminal of the battery, and the other lead to the vehicle chassis ground away from the engine, fuel system, and battery.

7. Operating Procedure

7.1 After completing the operations described in Section 6, the charging device is connected to the power supply and the charging process begins.

7.2 When the switch is set to the “4A” position, the charging current (monitored on the ammeter) may range within (4±1) A, depending on the degree of battery discharge.

7.3 When the switch is set to the “9A” position, the charging current (monitored on the ammeter) may range within (9±2) A, depending on the degree of battery discharge.

7.4 It is not recommended to charge or recharge the battery with an increased current (more than 10% of the battery capacity). Follow the recommendations of the battery manufacturer.

7.5 Charging completion is determined by time (about 8 hours) and a decrease of the charging current to (1–2) A. At the end of the cycle, when the battery is charged up to 90% of its actual capacity, the voltage at its terminals exceeds (14.3–14.5) V – the fourth LED of the device, marked “14”, lights up. The final degree of battery charge is determined by the electrolyte density.

7.6 After completing charging, disconnect the device from the power supply and detach the clamps from the terminals of the accumulator. The unit is ready for storage.

8. Maintenance

It is necessary to keep the connecting clamps clean, since contact with acid causes corrosion and disrupts electrical conductivity during the charging process. It is recommended to lubricate the clamps with grease such as “Litol”, which significantly reduces the likelihood of corrosion.

9. Storage Rules

9.1 The charging device in its packaging must be stored indoors at temperatures from minus 50°C to plus 50°C, with relative humidity not exceeding 85%.

9.2 The charging device without packaging may be stored in dry rooms at temperatures from minus 10°C to plus 50°C, with relative humidity not exceeding 60%.

10. Possible Malfunctions and Troubleshooting Methods

*Protective shutdown – in the event of a short circuit or incorrect battery connection (“reverse polarity”), the bimetallic fuse is triggered within a few seconds. To restore operability, reset the fuse to its original position.

11. Manufacturer’s Warranty

The manufacturer guarantees proper operation of the device for 12 months from the date of sale, provided the operating rules are observed.

In case of manufacturing defects, contact the manufacturer LLC “NPP OBORONPRIBOR” at: Ryazan, ul. Voennykh Avtomobilistov, 10.

During the warranty period, malfunctions not caused by violation of the operating rules are rectified free of charge.

If the warranty card does not contain the date of sale with the store’s stamp, the warranty period is calculated from the date of manufacture of the device.

Comments and suggestions should be sent to the manufacturer’s address.

(!) Attention!
The device is equipped with overheating protection. If the temperature threshold is exceeded during battery charging, protective shutdown is activated. The device resumes operation automatically after the temperature decreases.

Technical Specifications:

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