Hello to all repairers. Today I’ll briefly talk about a simple repair of an automatic battery charger “ Orion PW 700» .
When first turned on in the presence of the owner, the unit showed the battery voltage on the dial indicator, the LEDs “Voltage” and “Current” displayed “gibberish” and the charging process was not carried out.
After opening, a radiator with a diode assembly had fallen off the board and a second one with the same assembly was found hanging on one leg side by side. Smiled and delighted.
Initial opening of ROM Orion PW 700
The diode assembly fell off
An external inspection of the board did not reveal anything special, except for swollen power capacitors and sticky liquid underneath them.
Swollen capacitors
To make it convenient to use the board, I removed all the interfering wires.
Bottom view of the electronic board
Two power transistors, after desoldering, turned out to be normal, all other semiconductor elements without desoldering from the board, the short ones, did not show up.
Original transistors are ok
One of the diode assemblies with the legs torn off showed a breakdown, the second was alive.
Broken diode in the first diode assembly
Second serviceable assembly with torn off legs
Just to be sure, the fireman checked all the electrolytes with an ESR meter, fortunately there weren’t many of them. They were also normal.
And at this time, the fussy owner, at my instigation, with optimism and rapture, scoured electronics friends and workshops in search of conductors and diode assemblies. I brought two new condensers and... a disassembled one computer unit power supply, with the words: “They told you to rip out the diode assemblies from here and, if necessary, transyuks, although they are not very suitable. They said that there was no big difference, these would do for him.” And so it happened, the only difference was in the tension, i.e. the original ones are 100V - and the replacement is 45V. In terms of current, everything matched. Fortunately, the device’s charge does not rise above 14V.
I just had to do a little bit of soldering and testing. I soldered it in, started the device through a 220Vx65W current light bulb, and it worked.
Initial check
I tested it with a load of a 12Vx100W light bulb, it worked like a charm. I tested it on an old battery - the charging current was decreasing and the voltage on the battery was increasing. See photo.
I noticed that the cooling cooler was working a bit slow. I took it apart, cleaned it, lubricated it, reassembled it, checked it was working - everything was good!
Cleaned and lubricated cooler
Lubricated and assembled cooler
Don't be surprised by the photo that the radiators are strangely thin. Thanks to the cooler, the need for monster radiators a priori disappears.
The ROM arrived with some kind of sticky liquid spilled on it in some places, possibly electrolyte.
Leaks under capacitors
I washed the board with alcohol, washed the case under warm running water and soap, dried it, assembled it, started it up, it works, hooked up the battery, tested it, everything works, the charge is on.
Attention! Follow the order of connecting the starter-charger (hereinafter referred to as the ROM) to the battery. GOST R IEC60335-2-29-98.
Connecting with the wrong polarity causes large emergency currents to flow (even when the ROM is disconnected from the network) and is accompanied by severe sparking, melting and spattering of molten metal. This can cause burns, fire, destruction of the battery (hereinafter - AB) or burnout of the ROM circuit.
- Set the mode switch to the desired mode position.
- Connect the ROM clamps to the AB terminals, strictly observing the polarity. A plus corresponds to a red or light color of the clamp marking. Minus - black or dark color of the clamp markings.
- After making sure that the built-in voltmeter shows the voltage at the terminals, connect the ROM to the AC mains.
Attention! The appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities or life experience or knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children must be supervised to prevent them from playing with the device.
PURPOSE
The main purpose of this starting-charger (ROM) is to help the battery when starting the engine. Specifications This ROM allows it to be used as a starting device to assist the battery when starting the engine of cars and trucks.
This ROM is also used to charge 12 V automobile batteries (AB), including completely discharged ones (to zero), of any type and with a capacity of more than 45 A/h in full automatic mode.
You can use the ROM in non-automatic mode to charge the battery of any electrochemical system with a maximum voltage at the end of the charge less than 15 V.
The device is intended to be used only indoors, water protection degree IP20.
SAFETY REQUIREMENTS
Before using the ROM, you must study this manual, as well as. Before connecting the device to the network, make sure that the insulation of the power cord is intact (no damage). Do not allow chemically active liquids (gasoline, acid, etc.) and water to come into contact with the ROM housing and the power cable. When charging, the battery should be placed in a well-ventilated area. In this case, the gases and acid aerosol released by the battery should not get on the ROM and network wires.
Pay special attention to the correct connection to the battery! Connecting with the wrong polarity causes large emergency currents to flow (even when the ROM is disconnected from the network) and is accompanied by severe sparking, melting and spattering of molten metal. This can cause burns, fire, destruction of the battery or burnout of the ROM circuit itself.
ATTENTION! Despite the fact that the ROM does not require your participation in the process of charging the battery, it is unacceptable to leave the connected ROM unattended, like any complex equipment, especially when powered from a garage electrical network.
SPECIFICATIONS
* current depends on the network voltage and the condition of the batteryOutput characteristics of ROM Orion PW 700 in modes: start and charge
PRODUCT DEVICE
Structurally, the ROM is made in a plastic case with louvers for ventilation.
On the front panel there are:
- - Pointer voltmeter
- - Start/Charge mode switch
- - Two-color LED "Current" - indicates the flow of charging current:
Green color - low current in charging mode
Red color - high inrush current
ATTENTION! When making measurements, it is necessary to take into account that the pointer voltmeter measures the voltage not at the crocodiles, but at the output of the circuit to the output wires. Therefore, the voltmeter readings at starting currents will be overestimated by about 1.5-2 volts compared to the voltage on the crocodiles.
The electronic ROM circuit is a push-pull high-voltage high-frequency converter with a control circuit containing three circuits feedback by voltage, current and temperature.
This design of the power part ensures high efficiency over a wide range of supply voltages, generates the output characteristics necessary for an automatic charger, ensures reliable galvanic isolation, as well as high specific weight, size and power characteristics. Output current limiting circuit monitors temperature power circuit converter and, when the temperature rises above normal, reduces the current value, thereby reducing the internal heat generation.
Explanations: overheating is possible if the free flow of cooled air through the blinds is disrupted, for example by dust or an instruction manual placed on top of the ROM, and an uneven surface on the bottom (the legs create a gap for ventilation). Or operating the device in conditions of elevated ambient temperatures.
The voltage and current feedback circuit provides protection against short circuits of the output terminals, turns off the generation of charging current when the battery voltage reaches 14.9-15.1 V, and re-enables the generation of charging current when the voltage decreases to 13.6-14.0 V. The selected thresholds for turning on and off the charging current allow the car owner, without going into the intricacies of electrochemical processes, to guarantee a full charge of the battery without monitoring and servicing the charging process. The essence of the chosen charging method is as follows: as the battery is charged, the concentration polarization of the electrodes increases. The electrode potentials reach values at which noticeable gas evolution begins. Further maintenance of a large (or rather excessive) charging current is pointless and harmful, since real speed charge accumulation is limited by the speed of ion movement, which decreases with increasing accumulated charge. All current in excess of useful current is spent on the decomposition of water into hydrogen and oxygen, heating the battery and corrosion of the plates.
The processor built into the ROM calculates, based on three parameters (voltage, current, temperature), the threshold for turning off the charge when the concentration polarization of the electrodes is maximum and the process of intense gas formation has not yet begun. The charge is turned off and the ROM goes into standby mode. During this time, ions penetrate from the surface into the thickness of the plates, thereby reducing the concentration polarization to a value at which it is advisable to resume the flow of charging current. The processor turns on the charge until the next shutdown. Thus, the ROM, having provided the battery with the main amount of charge, goes into periodic shutdown mode and then turns on. The longer the pause between charging cycles, the more fully charged the battery is. The degree of charge when the machine is first turned off (the red “Current” indicator goes out) depends on the technical condition of the battery. For a new battery it is higher than for a used one. Therefore, the first shutdown occurs when the battery reaches 70% to 95% of its full capacity. If you leave the ROM on for a long time, the battery will gain 100% charge without boiling over or overheating. Moreover, the initial sulfation of the plates will be eliminated, and the internal resistance of the battery (the main characteristic of the starter battery) will decrease. Long-term practice has shown: regular use of a charger with this operating algorithm (regardless of the winter-summer season) allows you to increase the service life of the battery to 7-8 years or more, since in most cars the battery is never fully charged, and long-term (chronic) undercharging causes irreversible processes that worsen the basic parameters of the battery.
OPERATIONAL CHECK
Straighten the wires. Make sure that the product body has no mechanical damage and that the wire insulation is intact.
To check the functionality of a charger without a battery, you must connect it to an alternating current network, the output terminals must be open. Set the switch to the “Charge” position.
A sign of serviceability is a short blinking of the “Current” indicator and fluctuations of the voltmeter needle in the region of 10-15 V (this is the idle mode). If you close the output terminals in this mode, the device will go into protection mode against short circuit. When the terminals are opened, the device returns to idle mode.
OPERATING PROCEDURE
Charge 12 V battery in automatic mode
ATTENTION!
4. The battery will be charged automatically with a current of 12-16A. When the voltage on the battery reaches 14.9-15.11 V, the ROM will automatically turn off the current and wait until the voltage on the battery decreases to 13.6-14.0 V due to the drop in the excess charging overvoltage. After this, the charging current will turn on again and the cycle will repeat again.
5. End of charge. The higher the charge level of the battery, the shorter the charging periods will be and the longer the shutdown periods. The voltmeter needle fluctuates between 13.5-15 V. In this mode, the ROM and battery can operate indefinitely. Overcharging and harmful effects on the battery will not occur. Moreover, after staying in this mode for more than 12 hours, most batteries restore or significantly improve their characteristics. The onset of sulfation is removed, the structure of the electrodes is improved, the internal resistance is reduced, and the starting current is increased.
6. Upon completion of charging, disconnect the ROM from the network and remove the clamps from the battery terminals. It is recommended to wipe the clamps and wires with a damp and then a dry cloth to remove any electrolyte that may have accumulated. It is advisable to lubricate any clamps after this to protect against corrosion.
ATTENTION! Despite the fact that the ROM does not require your participation in the process of charging the battery, it is unacceptable to leave the connected ROM unattended, like any complex equipment, especially when powered from a garage electrical network.
Using ROM as a trigger
ATTENTION! Failure to follow the connection order may result in failure of the ROM or battery.
1. Set the mode switch to the “Charge” position.
2. Connect the ROM clamps to the AB terminals, strictly observing the polarity. A plus corresponds to a red or light color of the clamp marking. Minus - black or dark color of the clamp markings.
3. After making sure that the built-in voltmeter shows the voltage at the terminals, connect the ROM to the AC mains.
4. If the battery voltage is low, it is recommended to pre-charge the battery.*
5. Set the mode switch to the “Start” position.
6. Start the engine. If unsuccessful, repeat the procedure. It is not recommended to turn the starter for more than 30 seconds to avoid overheating of the starter. Restarts are recommended after 2-5 minutes. The device automatically switches to start-up mode when the battery voltage drops below 12 V. The ROM provides a starting current of 70-80 A depending on the network voltage and the condition of the battery.
_______________________________________________________________
Attention! The ROM can provide a starting current (without overheating the ROM) of 70-80 A for no more than 1-3 minutes (depending on the ambient temperature). Next, the device will automatically switch to the “Charge” mode (in this case, the “Current” LED will glow green), and will return to the “Start” mode after 3-5 minutes of operation in the “Charge” mode (after the internal temperature has decreased). Next, the device will switch between these modes, maintaining an acceptable temperature of the power part.
7. When you do not turn on the car starter, the ROM charges the battery.
8. Upon completion of charging, disconnect the ROM from the network and remove the clamps from the battery terminals.
Charging batteries of other electrochemical systems in non-automatic mode.
ATTENTION! Failure to follow the connection order may result in failure of the ROM or battery.
A non-automatic mode is considered to be a charging mode in which the voltage on the battery at the end of the charge is less than the voltage that the ROM can create (14.9-15.1 V).
1. Make sure that the voltage on the battery at the end of the charge (indicated in the battery passport) is less than 14.9-15.1 V.
2. Set the mode switch to the "Charge" position.
3. Connect the ROM clamps to the AB terminals, strictly observing the polarity. A plus corresponds to a red or light color of the clamp marking. Minus - black or dark color of the clamp markings.
4. After making sure that the built-in voltmeter shows the voltage at the terminals, connect the ROM to the AC mains.
5. The ROM operates in current generator mode, providing charge to the battery.
6. End of charge. It is necessary to control the degree of charge using generally accepted methods (voltage, time and current, electrolyte density, etc.).
7. Upon completion of charging, disconnect the ROM from the network and remove the clamps from the battery terminals.
The operating time of the ROM in any of the listed modes is unlimited.
PREVENTIVE CARE AND REPAIR
- Remove traces of corrosion and lubricate alligator clips.
- Blow off dust from the blinds.
- If noise occurs, lubricate the microfan bearing with any engine oil (this does not require disassembling the ROM).
The standard service life of the ROM is 5 years.
More complex work involving disassembling the ROM case, such as replacing the power cord if it is damaged, should be performed by the ROM manufacturer or its agent or similarly qualified person.
WARRANTY
The product meets the requirements regulatory documents: GOST R 52161.2.29-2007; GOST R 51318.4.1-2006 r. 4; GOST R 51318.14.2-2006 r.r. 5, 7; GOST R 51317.3.2-2006 r.r. 6, 7; GOST R 51317.3.3-2008 and the State Standard of the Russian Federation issued the certificate ROSS RU.ML03.VO1490. The manufacturer guarantees the operability of the device subject to all requirements set forth in the operating instructions.
The warranty period for the device is 12 months from the date of sale. During warranty period The manufacturer repairs the product free of charge, that is, for nothing. Without presenting a warranty card, in case of mechanical damage, as well as if the malfunction is caused by improper operation, claims regarding the quality of the device’s operation will not be accepted and warranty repairs will not be performed. In the event of a malfunction, subject to all requirements, repair (exchange) of the device is carried out at the point of sale.
ROM PW700 designed to start a car engine, as well as charge 12V car batteries of any capacity in automatic mode. Double overheat protection: electronic circuit and microfan. Ability to charge a completely discharged battery.Start Charger Designed to start the engine when the battery is discharged or at low air temperatures.
Features of Orion PW700 starting chargers
- These are automatic start-up chargers that themselves control the state of charge of the battery and promptly change the start and charge mode.
- Starting chargers Orion use high-frequency (pulse) energy conversion in the power circuit, this makes it possible to reduce the weight and overall dimensions of the devices.
- An additional feature of the starter chargers is forced ventilation with a built-in microfan. Moreover, all ROMs Orion have an (emergency) internal temperature control circuit.
- Output characteristics of starting chargers Orion allow you to charge rechargeable cells and batteries of any capacity with a minimum voltage from 0V to 12V with any degree of discharge.
Technical data
Reviews
Reviews
Orion PW700
Yuri (03/20/2015 00:15:58)
A neighbor gave me a non-working Orion PW700 (mixed the wires). It’s good that I found the diagram on your website. We managed to repair it, but based on the results of the inspection, the Orion PW700 discovered a discrepancy with the battery charging rules. The charging current should not exceed 1/10 of its capacity in a/h. My battery is 60 a/h. On the Orion PW700, the current exceeds this value by 2 times, which causes the electrolyte to boil. How do you comment on my remark.
Pennant PW700 is a starter-charger that was created for starting engines cargo and passenger vehicles, as well as for charging 12-volt car batteries any capacity and type in non-automatic and automatic mode.
Versatility of use
Unlike its analogues, the Vympel PW700 has the ability to charge 12-volt batteries of any capacity and any electrochemical systems. Also with this device you can charge completely discharged batteries.
The starting current of the PW700, which is equal to 80 A, will allow you to start the vehicle engine even with a very discharged battery and at very low air temperatures.
To ensure that the presented device can operate for a long time, Orion specialists have endowed it with two-level overheat protection.
This is a system that consists of a special electronic circuit and a built-in device microfan. So, when the temperature inside the PW700 case reaches the maximum point when the device can fail, output current limiting circuit will reduce the value of the latter, thereby reducing the heat generation inside the device.
Compact body
Thanks to the fact that in this device Using high-frequency (pulse) energy conversion in a power circuit, Orion developers were able to create a device that is relatively light in weight and small in size.
Long period of operation
When developing the Vympel PW700, modern technical solutions and imported components were used, which, if used correctly, will allow this device to operate for a long period of time.
Due to the fact that the level of moisture protection of the device is equal to the IP20 standard, the device must be used in a place well protected from moisture, within permissible temperatures and without disrupting the free circulation of air in the device’s blinds.
Peculiarities:
Designed to start engines of cars and trucks and to charge 12-volt batteries of any capacity and type in automatic or non-automatic mode
Starting current 80 A
Operating current 15 A
Double overheat protection (electronic circuit and built-in microfan)
Ability to charge completely discharged batteries
Pointer voltmeter