victron energy 77314-18 120 V Blue Smart IP67 Charger User Manual

Blue Smart IP67 Charger 120 V
User Manual

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for Blue Smart Charger models.

2. Use of an attachment not recommended or sold by Victron Energy may result in a risk of fire, electric shock, or injury to persons.

3. To reduce the risk of damage to the electric plug and cord, pull by the plug rather than the cord when disconnecting the charger.

4. An extension cord should not be used unless absolutely necessary. The use of an improper extension cord could result in a risk of fire and electric shock. If an extension cord must be used, make sure:
   a) That pins on the plug of the extension cord are the same number, size, and shape as those of the plug on the charger;
   b) that extension cord is properly wired and in good electrical condition; and
   c) that wire size is large enough for ac ampère rating of charger as specified in “Technical Specifications”

5. Do not operate the charger with a damaged cord or plug; contact your service agent or the manufacturer.

6. Do not operate the charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; contact your service agent or the manufacturer.

7. Do not disassemble the charger; contact your service agent or the manufacturer when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire.

8. To reduce the risk of electric shock, unplug the charger from the outlet before attempting any maintenance or cleaning. Turning off controls will not reduce this risk.

9. WARNING – RISK OF EXPLOSIVE GASES.
   a) BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY.
   b) Follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery.

10. PERSONAL PRECAUTIONS
    a) Consider having someone close enough by to your aid when you work near a lead-acid battery.
    b) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
    c) Wear complete eye protection and clothing protection. Avoid touching your eyes while working near a battery.
    d) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters the eye, immediately flood the eye with running cold water for at least 10 minutes and get medical attention immediately.
    e) NEVER smoke or allow a spark or flame in the vicinity of a battery or engine.
    f) Be extra cautious to reduce the risk of dropping a metal tool onto the battery. It might spark or short-circuit the battery or another electrical part that may cause an explosion.
    g) Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a lead-acid battery. A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a severe burn.
    h) Do not use the battery charger for charging dry-cell batteries that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to property.
    i) NEVER charge a frozen battery.

11. PREPARING TO CHARGE
    a) If it is necessary to remove the battery from a vehicle prior to charging, always remove the grounded terminal from the battery first. Make sure all accessories in the vehicle are off, so as not to cause an arc.
    b) Be sure that the area around the battery is well ventilated while the battery is being charged.
    c) Clean battery terminals. Be careful to keep corrosion from coming in contact with the eyes.
    d) add distilled water to each cell until battery acid reaches the level specified by the battery manufacturer. Do not overfill.
    For a battery without cell caps, such as valve-regulated lead-acid batteries, carefully follow the charging instructions of the manufacturer.
    e) Study all battery manufacturer’s specific precautions while charging and recommended rates of charge.
    f) Determine the nominal voltage of the battery by referring to the owner’s manual of the vehicle and make sure it matches the output rating of the battery charger.

12. CHARGER LOCATION
    a) Locate the charger as far away from the battery as DC cables permit.
    b) Never place charger directly above battery being charged; gases from battery will corrode and damage the charger.
    c) Never allow battery acid to drip on the charger when reading gravity or filling the battery.
    d) Do not operate the charger in a closed-in area or restrict ventilation in any way.
    e) Do not set a battery on top of the charger.

13. DC CONNECTION PRECAUTIONS
    a) Connect and disconnect the DC output terminals only after removing the AC cord from the electric outlet. Never allow terminals to touch each other.
    b) Attach terminals to battery and chassis as indicated in 14(e), 14(f), 15(b), and 15(d).

14. FOLLOW THE FOLLOWING STEPS WHEN THE BATTERY IS INSTALLED IN
    A VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:
    a) Position AC and DC cords to reduce the risk of damage to the hood, door, or moving engine part.
    b) Stay clear of fan blades, belts, pulleys, and other parts that can cause injury to persons.
    c) Check the polarity of battery posts. POSITIVE (POS, P, +) battery post usually has a larger diameter than NEGATIVE (NEG, N,–) post.
    d) Determine which post of the battery is grounded (connected) to the chassis. If the negative post is grounded to the chassis (as in most vehicles), see (e). If the positive post is grounded to the chassis, see (f).
    e) In case of a negative-grounded vehicle, connect the POSITIVE (RED) terminal from the battery charger to the POSITIVE (POS, P, +) ungrounded post of the battery. Connect the NEGATIVE (BLACK) terminal to the chassis or engine block of the vehicle, away from the battery. Do not connect the terminal to the carburetor, fuel lines, or sheet metal body parts. Connect to a heavy gauge metal part of the frame or the engine block. Connect the AC cord to the socket.
    f) In case of a positive-grounded vehicle, connect the NEGATIVE (BLACK) terminal from the battery charger to the NEGATIVE (NEG, N, –) ungrounded post of the battery. Connect the POSITIVE (RED) terminal to the chassis or engine block of the vehicle, away from the battery. Do not connect the terminal to the carburetor, fuel lines, or sheet metal body parts. Connect to a heavy gauge metal part of the frame or the engine block. Connect the AC cord to the socket.
    g) When disconnecting the charger, disconnect the AC cord, remove the terminal from the chassis of the vehicle, and finally remove the terminal from the battery terminal. h) See “charge algorithms” for the length of charge information.

15. FOLLOW THESE STEPS WHEN THE BATTERY IS OUTSIDE OF THE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE A BATTERY EXPLOSION. TO REDUCE THE RISK OF A SPARK NEAR THE BATTERY:
    a) Check the polarity of the battery posts. The POSITIVE (POS, P, +) battery post usually has a larger diameter than the NEGATIVE (NEG, N, –) post.
    b) Connect the POSITIVE (RED) charger terminal to the POSITIVE (POS, P, +) post of the battery.
    c) Do not face the battery when making the final connection.
    d) When disconnecting the charger, always do so in the reverse sequence of the connecting procedure and break the first connection while as far away from the battery as practical.
    e) A marine (boat) battery must be removed and charged on shore. To charge it on board requires equipment specially designed for marine use.

Quick user guide

The Blue Power IP67 chargers will charge and maintain lead-acid and Li-ion batteries, and supply users connected to the battery. In addition, the models with suffix (1+Si) feature a second current limited output which is always powered as long as 110 – 130 VAC is present on the input. This output can for example be used to prevent starting of a vehicle before unplugging the battery charger (start interrupt function).

Blue Smart version
Set up, monitor and update the charger (add new features when they become available) using Apple and Android smartphones, tablets, or other devices with the VictronConnect App.
VictronConnect is available to users of Windows PCs, macOS X, iOS, and Android phones, as well as tablets.
https://www.victronenergy.com/support-anddownloads/software#victronconnect- app

VictronConnect: Blue Smart IP67 charger pages
When the Blue Smart charger is powered-up it will be discoverable using the VictronConnect app on your device.
The ‘home’ page shows information about the battery voltage, charge current, and where your battery is in the charging cycle.
To access the Settings button click on the cog icon at the top right of the screen. From here you can choose a preset charge algorithm, you can select the charge current, and you can choose to employ the charge algorithm for a Li-ion battery when that is appropriate.

Installation and instructions for use

1. The battery charger must be installed in a well-ventilated area close to the battery (but, due to possible corrosive gasses not above the battery!)
2. Connect the ring terminals to the battery: the minus cable (black) to the minus (–) pole of the battery, the plus cable (red) to the plus (+) pole of the battery.
3. Plug the AC mains cable into the wall socket. The charge cycle will now start.

Two LEDs for status indication
Yellow LED: bulk charge (blinking fast), absorption (blinking slow), float (solid), storage (off) Green LED: power on

Safety regulations and measures

1. Install the charger according to the stated instructions

2. Connections and safety features must be executed according to the locally applicable regulations.

3. Warning: do not attempt to charge non-rechargeable batteries.

4. Warning: a BMS (Battery Management System) may be required to charge a Li-ion battery.

5. This appliance is not intended for use by persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety.
   Children should be supervised to ensure that they do not play with the appliance.

6. The charger is designed for lead-acid and Li-ion batteries 14-225Ah.
   Do not use it for any other purpose.

‘Must know’ features and facts

2.1 Ultra high efficiency “green” battery charger
With up to 95% efficiency, these chargers generate up to four times less heat when compared to the industry standard.
And once the battery is fully charged, power consumption reduces to 0.5 Watt, some five to ten times better than the industry standard.

2.2 Durable, safe, and silent
– Low thermal stress on the electronic components.
– Protection against ingress of dust, water, and chemicals.
– Protection against overheating: the output current will reduce as temperature increases up to 60°C (140°F), but the charger will not fail.
– The chargers are totally silent: no cooling fan or any other moving parts.

2.3 Reverse polarity protected
In case of a wrong polarity connection, the external ATO blade fuse will blow. Check the polarity of the cable and check the correct value before replacing the fuse.

2.4 Recovery function for fully discharged batteries
Most reverse polarity-protected chargers will not recognize, and therefore not recharge a battery that has been discharged to zero or nearly zero Volts. The Blue Smart IP67 Charger however will attempt to recharge a fully discharged battery with low current and resume normal charging once sufficient voltage has developed across the battery terminals.

2.5 Temperature compensated charging
The optimal charge voltage of a lead-acid battery varies inversely with temperature. The Blue Smart IP67 Charger measures ambient temperature during the test phase and compensates for temperature during the charging process. The temperature is measured again when the charger is in the low current mode during float or storage. Special settings for a cold or hot environment are therefore not needed.

2.6 Adaptive Battery Management
Lead-acid batteries should be charged in three stages, which are [1] bulk or constant-current charge, [2] absorption or topping charge, and [3] float charge.
Several hours of absorption charge are needed to fully charge the battery and prevent early failure to sulfation¹.
The relatively high voltage during absorption does however accelerate aging due to grid corrosion on the positive plates.
Adaptive Battery Management limits corrosion by reducing absorption time when possible, that is: when charging a battery that is already (nearly) fully charged.

2.7 Storage mode: less corrosion of the positive plates
Even the lower float charge voltage that follows the absorption period will cause grid corrosion. It is therefore essential to reduce the charge voltage even further when the battery remains connected to the charger for more than 48 hours.

2.8 Reconditioning
A lead-acid battery that has been insufficiently charged or has been left discharged for days or weeks will deteriorate due to sulfation¹. If caught in time, sulfation can sometimes be partially reversed by charging the battery with a low current up to a higher voltage.

Remarks:
a) Reconditioning should be applied only occasionally to flat plate VRLA (gel and AGM) batteries because the resulting gassing will dry out the electrolyte.
b) Cylindrical cell VRLA batteries build more internal pressure before gassing and will therefore lose less water when subjected to reconditioning. Some manufacturers of cylindrical cell batteries, therefore, recommend the reconditioning setting in case of cyclic application.
c) Reconditioning can be applied to flooded batteries to “equalize” the cells and to prevent acid stratification.
d) Some battery charger manufacturers recommend pulse charging to reverse sulfation. However, most battery experts agree that there is no conclusive proof that pulse charging works any better than constant voltage charging.
This is confirmed by our own tests.

2.9 Lithium-ion (LiFePO₄) batteries
Li-ion batteries do not suffer from sulfation.
But Li-ion batteries are very sensitive to under voltage or over voltage².
Li-ion batteries therefore often have integrated cell balancing and under- voltage protection (UVP) circuitry.
Some reverse polarity-protected chargers will not recognize a battery when the UVP has tripped.
The Blue Smart Charger will however automatically reset the UVP and start charging.
Important note:
NEVER attempt to charge a Li-ion battery when its temperature is below 0°C (32°F).

2.10 Low current mode
Some lead-acid batteries can overheat if charged with a current exceeding 0.3C (C is the capacity in Ah. A 12Ah battery for example should not be charged with a current exceeding 0.3 x 12 = 4A). The low current mode (charge currently limited to 4A or less, see technical specifications) should therefore be used to charge low-capacity lead-acid
batteries.
¹ For more information about batteries, please refer to our book ‘Energy Unlimited’ (downloadable from www.victronenergy.com), or http://batteryuniversity.com/learn/article/sulfation_and_how_to_prevent_it
² For more information about Li-ion batteries please see http://www.victronenergy.com/batteries/lithium-battery-12,8v/

Charge algorithms

3.1 Smart charge algorithm with optional reconditioning for lead-acid batteries Charge voltages at room temperature:
Charge voltages at room temperature:

MODE| ABS
V| FLOAT
V| STORAGE| RECONDITION
Max V@% of Inom
---|---|---|---|---
NORMAL| 14.4| 13.8| 13.2| 16.2@8%, max 1h
HIGH| 14.7| 13.8| 13.2| 16.5@8%, max 1h
LI-ION| 14.2| 13.5| 13.5| n. a.

For 24V chargers: multiply all voltage values by 2.

NORMAL (14.4V): recommended for flooded flat plate lead-antimony batteries (starter batteries), flat plate gel, and AGM batteries.
HIGH (14.7V): recommended for flooded lead-calcium batteries, Optima spiral cell batteries, and Odyssey batteries.

State of the art microprocessor controlled charge algorithm
Adaptive 5-stage charge characteristic: bulk – absorption –recondition – float – storage
The Blue Smart IP67 charger features a microprocessor-controlled ‘adaptive’ battery management system. The ‘adaptive’ feature will automatically optimize the process relative to the way the battery is being used.

1. BULK
   Charges the battery with maximum current until absorption voltage is reached. The battery will then be about 80% charged and is ready for use.

2. ABS – Absorption
   Charges the battery at constant voltage and with decreasing current until it is fully charged.
   See the table above for absorption voltage at room temperature.
   Adaptive battery management:
   The absorption time is short (minimum 30 minutes) if the battery was (nearly) fully charged and increases to 8 hours in case of a deeply discharged battery.

3. RECONDITION
   Optional reconditioning for deeply discharged lead-acid batteries.
   Reconditioning is applicable to the charge algorithms
   NORMAL and HIGH and can be selected with the App on your smartphone.
   When in RECONDITION mode the battery will be charged with a low current up to a higher voltage at the end of the absorption phase.
   During reconditioning the maximum current is equal to 8% of the nominal current until the maximum voltage is reached.
   Reconditioning is terminated after one hour or when the maximum voltage is reached, whichever comes first. See table.
   Example:
   For a 12/7 charger: the recondition current is 7 x 0.08 = 0.56A

4. FLOAT
   Keeps the battery at constant voltage and fully charged.

5. STORAGE
   Keeps the battery at reduced constant voltage to limit gassing and corrosion of the positive plates.
   Slow self-discharge is prevented by an automatic weekly refresh of the battery with a short absorption charge.

3.2 Lithium-ion (LiFePO₄) batteries
When charging a Lithium-ion battery, the Blue Smart IP67 Charger uses a specific charging algorithm for Lithium-ion batteries, to ensure optimum performance. Select LI-ION with the app on your smartphone.

3.3 When a load is connected to the battery
A load can be applied to the battery while charging, as long as the current draw is much lower than the rated output of the battery charger.
Reconditioning is not possible when a load is connected to the battery.

Remarks:
a) Disconnect all loads before attempting to recharge a very weak or fully discharged lead-acid battery. Loads may be reconnected once the bulk phase has started.
b) Disconnect all loads before attempting to recharge a Li-ion battery when the under-voltage protection (UVP) of the Li˗ion battery has tripped. Loads may be reconnected once the bulk phase has started.

3.4 Triggering a new charge cycle
A new charge cycle will start when:
a) The charger has reached float or storage, and, due to a load, current increases up to maximum current during more than four seconds.
b) The AC supply has been disconnected and reconnected.

3.5 Estimating charge time
A lead-acid battery is about 80% charged at the beginning of the absorption period.
The time T to 80% charged can be calculated as follows: T = Ah / I
Where:
I am the charge current (= charger output minus load current).
Ah is the amount of Ah to be charged.

A full absorption period of up to 8 hours is needed to charge the battery to 100%.
Example:
Charge time to 80% of a fully discharged 100Ah battery when charged with a 10A Blue Power Charger: T = 100 / 10 = 10 hours Charge time to 100%: 10 + 8 = 18 hours.
A Li-ion battery is more than 95% charged at the beginning of the absorption period and reaches 100% charge after approximately 30 minutes of absorption charge.

3.6 High internal resistance
When a battery reaches the end of its cycle- or float life, or when it dies prematurely due to sulfation or corrosion, capacity will dramatically drop and internal resistance will increase. The charger will not recognize such a battery during the test phase (it could as well be a nearly fully charged battery).
A very short bulk phase when charging a supposedly discharged battery does however indicate that the battery has reached the end of its useful life.
Remark: sulfation can sometimes be partially reversed by repeated application of the RECONDITION MODE.

3.7 Can be used as a power supply
The charger will supply DC loads when no battery is connected.

Technical specifications

Lithium-ion: 28.4 V
Charge voltage ‘float’| Normal: 13.8 V, High: 13.8 V
Lithium-ion: 13.5 V| Normal: 27,6 V, High: 27.4 V
Lithium-ion: 27.0 V
Charge voltage ‘storage’| Normal: 13.2 V, High: 13.2 V
Lithium-ion: 13.5 V| Normal: 26.4 V, High: 26.4 V
Lithium-ion: 27.0 V
Charge current| 7 / 13 / 17 / 25 A| 5 / 8 / 12 A
Charge current in low current mode| 2 / 4 / 6 / 10 A| 2 / 3 / 4 A
Charge characteristic| 5-stage adaptive
Temperature compensation (lead-acid batteries only)| 16 mV/°C (9mV/°F)| 32 mV/°C (18mV/°F)
Can be used as a power supply| Yes
Protection| Reverse reverse polarity (fuse), Output short circuit Over temperature
DC fuse, internal and not replaceable| n.a / n.a. / 25 / 35 A| n.a. / 15 / 20 A
DC fuse in DC cable – ATO blade (A)| 20 A (12/25: no fuse)| 20 / 10 / 15 A
Operating temp. range| -20 to +60°C (full rated output up to 40°C), 0 to + 140°F (full rated output up to 90°F)
Humidity| Up to 100%
Start interrupt option (Si)| Short circuit proof, current limit 0.5A, Output voltage: max one volt lower than the main output
ENCLOSURE
Material & Colour| Aluminum (blue RAL 5012)
Battery-connection| Black and red cable with M8 ring terminal 1.8 meter (6 feet)

12/7, 12/13, 24/5 -12 AWG   12/17, 12/25, 24/8, 24/12 – 9 AWG

120 V AC-connection| Cable of 1.8 meter (6 feet) with US NEMA 5-15 plug
Protection category| IP67
Weight| 12/7, 12/13, 24/5: 1.8kg (4lbs)

12/17, 12/25, 24/8, 24/12: 2.4kg (5.3lbs)

Dimensions (h x w x d)| 12/7, 12/13, 24/5: 85 x 211 x 60 mm 3.4 x 8.3 x 2.4 inches

12/17, 12/25, 24/8, 24/12: 99 x 219 x 65 mm  3.9 x 8.6 x 2.6 inches

STANDARDS
Safety| EN 60335-1, EN 60335-2-29 (UL1236 / CSA C22.2)
Emission| EN 55014-1, EN 61000-3-2
Immunity| EN 55014-2, EN 61000-3-3

Compliance Statement
This device complies with part 15 of the FCC rules. Operation is subject to the following two conditions.
(1) This device may not cause harmful interference.
(2) This device must accept any interference received, including interference that may cause undesired operation.”

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions.
(1) This device may not cause harmful interference.
(2) This device must accept any interference received, including interference that may cause undesired operation.
Contain FCC ID: SH6MDBT40
Contain IC ID: 8017A MDBT40
Frequency range: 2402 – 2480 MHz
Transmit power: -4dBm

Maintenance

The Blue Smart Charger is maintenance-free.
When cleaning the charger remove the plug from the power socket. Then use a damp cloth to clean the exterior.

Five-year limited warranty
This limited warranty covers defects in materials and workmanship in this product and lasts for five years from the date of original purchase of this product. The customer must return the product together with the receipt of purchase to the point of purchase.
This limited warranty does not cover damage, deterioration, or malfunction resulting from alteration, modification, improper or unreasonable use or misuse, neglect, exposure to excess moisture, fire, improper packing, lightning, power surges, or other acts of nature.
This limited warranty does not cover damage, deterioration, or malfunction resulting from repairs attempted by anyone unauthorized by Victron Energy to make such repairs.
Victron Energy is not liable for any consequential damages arising from the use of this product.
The maximum liability of Victron Energy under this limited warranty shall not exceed the actual purchase price of the product.

Victron Energy Blue Power

Distributor:

Serial number:

Version: 00
Date: August 7th, 2020
Victron Energy B.V.
De Paal 35, 1351 JG Almere
PO Box 50016, 1305 AA Almere, The Netherlands
General Phone: +31 (0)36 535 97 00
E-mail: sales@victronenergy.com

References

• BU-804b: Sulfation and How to Prevent it - Battery University
• Lithium Battery Smart 12,8V & 25,6V - Victron Energy
• Software - Victron Energy

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