Phoenix Charger - Battery charger VICTRON ENERGY - Free user manual and instructions

USER MANUAL Phoenix Charger VICTRON ENERGY

victron energy GB NL F D I DK ΕΛ N P E S Specs

Copyrights 1999, 2000, 2001 Victron Energy B.V. All Rights Reserved This publication or parts thereof, may not be reproduced in any form, by any method, for any purpose. VICTRON ENERGY B.V. MAKES NO WARRANTY, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, REGARDING THESE VICTRON ENERGY PRODUCTS AND MAKES SUCH VICTRON ENERGY PRODUCTS AVAILABLE SOLELY ON AN “AS – IS” BASIS. IN NO EVENT SHALL VICTRON ENERGY B.V. BE LIABLE TO ANYONE FOR SPECIAL, COLLATERAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN CONNECTION WITH OR ARISING OUT OF PURCHASE OR USE OF THESE VICTRON ENERGY PRODUCTS. THE SOLE AND EXCLUSIVE LIABILITY TO VICTRON ENERGY B.V., REGARDLESS OF THE FORM OF ACTION, SHALL NOT EXCEED THE PURCHASE PRICE OF THE VICTRON ENERGY PRODUCTS DESCRIBED HEREIN. For conditions of use and permission to use this manual for publication in other than the English language, contact Victron Energy B.V. Victron Energy B.V. reserves the right to revise and improve its products as it sees fit. This publication describes the state of this product at the time of its publication and may not reflect the product at all times in the future.2 victron energy GB NL F D I DK ΕΛ N P E S Specs

• Review related documentation of this product to familiarise yourself with safety markings and instructions before you operate the equipment.

• This product has been designed and tested in accordance with international standards. Only use the equipment for the intended purpose of application.

• WARNING: RISK OF ELECTRIC SHOCK. The product is used in conjunction with a permanent energy source (battery). Even if the equipment is switched off, dangerous electrical voltages may appear at the in- and/or output terminals. Always disconnect AC power and battery before maintaining or servicing the product. A Ground Fault Circuit Interruptor (GFCI) must be installed in the AC supply circuit.

• There are no user-serviceable parts inside. Do not remove the frontplate or operate the product without the frontplate fitted. Refer all servicing to qualified personnel.

• Never use the product in locations where there is danger of gas- or dust explosions. Consult your supplier to ensure that the product is intended for use in conjunction with the battery. Always apply the battery manufacturer’s safety instructions.

• Caution: never carry heavy loads without assistance.

• Explosive gases can be generated during charging of a lead-acid battery. Prevent open flame and sparks. Take care of sufficient ventilation during charging.

• Never try to recharge non-rechargeable batteries.

• The on/off switch at the front panel of this battery charger does not isolate the main circuits.

• A double-pole switch with a minimum contact distance of 3mm must be incorporated in the fixed mains input wiring of the installation Installation

• The installation of this product must be performed by qualified personnel.

• Always refer to the installation section in the operator’s manual before applying power to the equipment.

• This is a Safety Class I product (provided with a protective earthing terminal). An uninterruptible safety earth ground must be provided at the AC in/output terminals. An additional grounding point is located at the outside of the product. Whenever it is likely that the grounding protection has been impaired, the product must be made inoperative and secured against any unintended operation; refer to qualified service personnel.

• Make sure that fuses and circuit breakers are provided in the connecting wires. Never replace a safety component by a different type. Consult the manual for determining the correct component.

• Make sure that all cables and wiring in the installation are anchored such that the conductors are relieved from strain and twisting.

• Before applying power, verify that the available power source matches the configuration settings of the product as described in the manual.

• Ensure that the environmental conditions are suitable for operation of the equipment. Never operate the product in a wet or in a dusty environment.

• Always allow enough free space around the product for ventilation and make sure that ventilation vents are not blocked.

• Be sure that the demanded power does not exceed the capacity of the product.

• This device is a continuous duty automatic charger for rechargeable open, sealed and gel lead acid batteries (max. 12 x 2V cells)

• For supply connection use wires suitable for at least 75°C (167°F).

• CAUTION: Replace defective cords or wires immediately. Transport and storage

• When storing or transporting the product make certain that mains power and battery leads are disconnected.

• No liability can be accepted for any transport damage when equipment is shipped in non- original packaging.

• Store the product in a dry location, storage temperature must be between –20°C and 60°C.

• Refer to the battery manufacturer manual concerning transport, storage, charging, recharging and disposal of the battery.3 victron energy

DESCRIPTION Technology The Phoenix Charger is a fully high-frequency switched battery charger. The input is electronically powerfactor corrected by the first powerstage. The next stage gives provision for galvanic isolation and a perfect DC voltage at the output terminals. A very accurate charging state of the battery is guaranteed because the charging process is microcontroller regulated. The internal electronic parts are protected against moisture and dirt by means of a special coating, which assures a long lifetime of your battery charger. Two high-capacity batteries and an additional low- capacity battery can be charged with this charger. Adaptive Charging The new Phoenix Charger uses the Adaptive Charging Characteristic. The Adaptive Charging Characteristic distinguishes from other charging characteristic on several topics. The main 3 topics are Rapid Charging, Battery Safe Mode and All Season Mode. Generally speaking the Phoenix Charger will adapt to the connected batteries. Rapid charging In the first stage, the bulk phase, of the charging cycle the batteries are charged with higher current then traditional charging methods. The bulk phase will stop at the point where the battery voltage will be 14,4V or 28,8V. From here the absorption phase will start. Based on the measured bulk time the length of the absorption time will be calculated. For this the charger micro-controller will monitor several parameters of the battery. BatterySafe mode But what if your battery needs a higher absorption voltage? The charger will gradually raise the applied voltage to the battery until it reaches the set absorption voltage. This phase we call the BatterySafe Mode. It will safe your battery from destruction by overcharging. The Phoenix Charger is temperature compensated. The charger will recalculate different values based on the battery temperature. All Season mode For periods were you do not use your batteries and the mains is applied to the charger, the Phoenix Charger will reduce its float voltage. By doing this we reduce the gassing in your battery so they will not run dry after a longer period of not using your battery. To keep your batteries in shape the Phoenix Charger will raise the applied voltage once a week. This we call the repetitive absorption. Operation The battery charger charges the battery with a 4- stage adaptive charging characteristic, see specifications at the back for details. It can remain connected to the battery continuously, without increased gas formation, caused by overcharging, taking place. The charger can be used for different types of batteries but the default settings are for Sonnenschein A200 dryfit gel batteries. See specifications for other pre-programmed battery types. For use with other types of batteries please contact your battery supplier to inform you about the right charging voltages. If necessary let the Phoenix Charger be readjusted. The full charging current of the Phoenix Charger is divided in two main outputs. An extra output with limited charge capacity is available to charge a starter battery for example. The charger is protected against short-circuit at the outputs and too high ambient temperature. Temperature sensor The Phoenix Charger is factory shipped with a temperature sensor. Its function is to measure the battery temperature and adjust the charging voltages accordingly. By this means superiour charging is achieved and a longer lifetime of the battery is assured. Voltage sense Using the Voltage sense connection will compensate the battery cable loss.4 victron energy GB NL F D I DK ΕΛ N P E S Specs

Controls The Phoenix Charger will start charging by switching it ON with the switch at the front panel. One of the LED’s at the front will indicate the progress of charge state:

Battery is less then 80% charged.

Battery is approximately charged for 80%. If Bulk LED is illuminating as well the set absorption voltage has not yet been reached (Battery Safe Mode). Battery is fully charged and will be kept charged with trickle charge.

An output fuse is defective or the ambient temperature of the charger is too high.

The Phoenix Charger will stop charging by switching it OFF with the switch at the front panel. Equalize a traction set This is done at a higher voltage than most DC- equipment can handle so all consumer electronics should be disconnected before equalizing the battery.

• Put the charger in off position. Switch ON-OFF- ON within 2 seconds.

• You’ll see all the LED’s flashing 5 times. After the 5th time all LEDs illuminate in sequence:

• Bulk –switch OFF-ON when this LED lights up. Now the charger increases its voltage up to 1 Volt above Absorption voltage for a 12V model or 2 Volts for a 24V model. The maximum current in this mode is limited to ¼ of the adjusted maximum charge current. The charger will stay in this mode for 1 hour and then switches to Float mode. Equalizing will only work with an already charged battery. If the battery voltage remains too low (see specs) for > 60 seconds the charger switches to Bulk mode and continues charging according normal charging characteristic. Force to Absorption mode for fixed time In certain circumstances it can be desirable to charge the battery occasionally with Absorption voltage for a fixed time.

• Put the charger in off position. Switch ON-OFF- ON within 2 seconds.

• You’ll see all the LED’s flashing 5 times. After the 5th time a sequence starts:

• Absorption –switch OFF-ON when this LED lights up. Now the charger will stay in Absorption mode for the default or adjusted fixed Absorption time. Remote control The Phoenix Charger can be remote controlled optionally. With the Phoenix Charger Control all indicators can be seen and additionally the charging current. With this remote control it is possible to temporarily limit the charging current. This could be useful in case of a low current mains connection in combination with other utility equipment. TROUBLESHOOTING Problem

Failure LED illuminates The output fuses are defect Return the product to your dealer The ambient temperature of the charger is too high Put the charger in a cool and well ventilated environment Charger does not function The mains voltage is not ok Measure the mains voltage and make it within specs The input fuse is defect Return the product to your dealer The battery doesn’t get fully charged A bad battery connection Check the battery connections The Absorption voltage is wrongly adjusted Consult your battery supplier and electrician and have the charging voltage adjusted The float voltage is wrongly adjusted

The battery capacity is too large Make sure the charger matches the battery capacity The output fuses are defect Return the product to your dealer The battery is being overcharged The Absorption voltage is wrongly adjusted Consult your battery supplier and electrician and have the charging voltage adjusted The float voltage is wrongly adjusted A single battery cell is defect Replace the battery or the defect cell Too small a battery Consult your battery supplier and electrician and have the charging current adjusted The ambient temperature of the battery is too high Consult your electrician and let him connect a temperature sensor

WARNING: Qualified personnel only

Location The Phoenix Charger must be installed in a dry, well-ventilated area. Too high an ambient temperature has the consequence of lower output, shorter life or a complete shutdown of the Phoenix Charger. The Phoenix Charger is suitable for floor and wall mounting. However, for optimum cooling, a vertical position is recommended. The cables between the Phoenix Charger and the battery must be kept as short as possible to minimise cable losses. Required tools and cables

• Crosshead screwdriver no. 2 phillips.

• Battery cables and external fuse: Model

12/30 16 mm² 40 AT 12/50 25 mm² 60 AT 24/16 10 mm² 20 AT 24/25 16 mm² 30 AT Cables longer then 6 m are not recommended. Cable eyes with M6 holes should be used. For supply connection use wires suitable for at least 75°C (167°F). CAUTION: Replace defective cords or wires immediately. Connection sequence

• Disconnect battery cables from the battery.

• Remove the frontplate.

• Remove carfuses if placed.

• Connect the housing of the charger to ground. The housing is fitted with an M4 ground screw for this purpose.

• Connect the accompanying temperature sensor to the +T-sense and –T-sense and mount the M8 cable-eye to one of the battery clamps. The connector is located on the front PCB.

• Voltage sense is recommended. Connect 0.75 mm² wires to +V-sense and –V-sense and use a 5 AT fuse near the battery for protection. The connector is located on the front PCB.

• Connect the starter battery (if present) to the Trickle-charge connector located near the minus- output bolt. Use a 25 AT carfuse near the battery for protection.

• If used, the Phoenix Charger Control panel can be connected by means of a standard 8-pole communication cable with 8-pole communication connector. The maximum length is 100 m.

• Connect battery cables to the charger. Note that there’s only one “minus”- output to connect both battery minus poles. Use a fuse according the table near the battery for protection.

• Connect battery cables to the battery.

• Watch if the POLARITY LED does NOT illuminate.

• If it does reverse battery cables

• Put the car fuses in their sockets

• Connect the AC-in by means of a 3-core cable of

2.5 – 4 mm² flexible core to the AC-in terminal

block. Note that a real PE-connection is strictly necessary.

victron energy Adjustments without remote panel

WARNING: Always check with your battery

supplier if the choosen charge characteristic is suitable for your battery and application

Remove the frontplate and disconnect battery and Voltage sense and Temperature sense and connect a digital voltmeter to – and +1 output. Bulk-current

While switching on keep both the pushbuttons

Release pushbuttons.

Bulk LED is flashing alternately with Failure LED.

Reading as follows: Discard first digit of DVM then multiply by 10, i.e: 22.50V => ….2.50 => 25 Amps 15.00V => .....5.00 => 50 Amps

Switch the charger Off to store. Absorption and Float voltage

While switching on keep the pushbutton

pushed for Absorption voltage and

Release pushbuttons.

Absorption or Float LED is flashing alternately with Failure LED.

Reading on voltmeter as is.

Switch the charger Off to store.

Please note that in adjust-mode the Temperature sense compensation is not taken into account.

Warning: If the charger is not switched Off

after an adjustment the new value will not be stored but will remain on the outputs. After 4 hours the charger continues the normal sequence with the old values. This can be useful if a forced high voltage is wanted to get some life in an assumed ‘dead’ battery. Return to factory settings

Switch the charger on.

pushed while switching off.

The factory settings are restored. When ready

Connect battery and if applicable Voltage sense and Temperature sense.

Adjusting maximum Bulk current

Adjusting Float voltage

Adjusting Absorption voltage

Restoring defaults8 victron energy Adjustments with remote panel Phoenix Charger Control

WARNING: Always check with your battery

supplier if the choosen charge characteristic is suitable for your battery and application

Remove the frontplate and connect the Phoenix Charger Control panel to the 8-pin modular jack.

Disconnect battery, Voltage sense and Temperature sense. A voltmeter is not required but may be useful.

While switching on keep one of the pushbuttons

LED indicators on remote panel read the value as follows: LED flashing = 1 step LED on = 2 steps 1 bar flashing = 9 steps Left bar is [step x10], right bar is [step x1]. To read the Float and Absorption adjustment the lowest value in the table has to be added: 12 V models 24V models Bulk 0 – 50 A/30A;step 1A 0 – 25 A / 16 A; step 1 A Abs 12.00 – 16.00 V; step 0.1 V 24.00 – 32.00 V; step 0.1 V Float 12.00 – 16.00 V; step 0.1 V 24.00 – 32.00 V; step 0.1 V Rep. Abs. int. 0 – 45 days; step 1 day ; def.= 7 days Rep. Abs. time 0 – 72 qu. of an hour; step 1 qu.; def = 4 qu. Max. Abs. time or Fixed Abs. time 1 – 8 hrs ; default = 4 hrs. Characteristic 1 = Fixed: Fixed Abs. time. default = 4 hrs. Rep. Abs. int. default = 1 day Rep. Abs. time. default = 2 qu. 2 = Adaptive 3 = Adaptive with BatterySafe mode (default) Battery type default = 1 Abs. Volt age Float Voltage / Reduced Float Max.Abs. time 0: User defined 1: Sonnenschein Dryfit A200 gel 14.4 V 28.8 V 13.8 V/

26.0 V 6 hrs. 3: Semitraction

Turn the knob to another adjust-mode to store or switch Off to escape.

Switch Off and On to start normal charging sequence.

Warning: If the knob is not turned after an

adjustment the charger will not store this adjustment. If the Float or Absorption voltage was adjusted and the charger is not switched off this voltage will remain on the outputs.

The optimum absorption voltage of flat plate lead acid batteries depends on mechanical and chemical properties. Batteries with high antimony doping can general be charged with a lower absorption voltage than batteries with low antimony doping, like the Victory carbon fibre battery. (See the book "Electricity on board" at www.victronenergy.com )

Repeated Absorption time = 4 quarters of an hour

Characteristic = 1. Fixed mode

Repeated Absorption interval = 7 days

Maximum Absorption time = 4 hrs.

Battery type = 1. Gel

Max. Bulk current = 25 amps9 victron energy After 4 hours the charger continues the normal sequence with the old value. This could be useful if a forced high voltage is wanted to get some life in an assumed ‘dead’ battery. Return to factory defaults

Switch the charger on.

pushed while switching off.

The factory defaults are restored.

Replace the frontplate.10 victron energy GB NL F D I DK ΕΛ N P E S Specs

Maximum Absorptionstid = 4 timer

GB NL F D I DK ΕΛ N P E S Specs

• Retire o painel frontal.

@ Vin=230Vac/Vout=24Vdc/Ta=25°C Short circuit current 50 Adc 30Adc 25 Adc 16 Adc Adjustment range 1 - 50 Adc 1 - 30 Adc 1 - 25 Adc 1 - 16 Adc Maximum trickle charge current 4 Adc 4 Adc Current/voltage stability ±1% Output fuse 4x 20 A carfuse 2x 20 A carfuse Battery leakage current when charger is switched off <2 mA Recommended battery capacity 200 - 400 Ah 100 - 200 Ah 100 - 200 Ah 45 - 100 Ah Environment EMC EEC 89/336 Emission EN55014 (1993) EN61000-3-2 EN61000-3-3 Immunity EN55104 (1995) Safety EN60335-2-29 (1991) Vibration IEC68-2-6 : 10 - 150 Hz / 1.0 G Shock IEC68-2-29: 1000 times XYZ +/- 10 G / 16 ms Operating temperature 0-40°C Transport & storage temperature -20 - +60°C Relative humidity max. 95% non condensing Noise < 45 dB (A) Ventilation Combined convection / forced-air Connections Mains connector connection block provision for 4 mm² Output +1/+2 battery connection M6 bolts Trickle charge connection connection block provision for 1.5 mm² Earthing M4 screw Temperature sensor connection block provision for 1.5 mm² Voltage sense connection block provision for 1.5 mm² Remote panel / RS485 RJ45 connector Mechanical Cabinet Aluminium IP21, RAL5012 (blue) epoxy coated Size (h x w x d) 350 x 200 x 110 (mm) Weight 3.8 kg Weight including box 4.9 kg91 victron energy

20% 40% 60% 80% 100% 120% Time Amps Charge voltage

Time Volts Figure 1: Adaptive charging: Bulk-mode: Entered after a reset or if the battery voltage becomes 1.3V resp. 2.6V (for 12V and 24V charger) lower than Float voltage. Constant current is applied until the battery has reached 14.4V resp. 28.8V (for 12V and 24V charger, temperature compensated). Battery Safe mode: The applied voltage to the battery is raised gradually until the set Absorption voltage is reached. The Battery Safe Mode is part of the calculated absorption time. Absorption-mode: Absorption voltage is applied until {actual-Bulk-Ah*5 / max.adjusted-Bulk-current} (in hours) is reached. Usually {actual-Bulk-Ah*5} = {max.adjusted-Bulk-current * Bulk-hours *5}, but the actual-Bulk-current can be limited by ambient temperature, or remote-control.The maximum time in Absorption mode is the Maximum Absorption time set with control panel. Float-mode: Float voltage is applied to keep the battery fully charged and to protect it against self discharge. After one day of Float charge a reduced Float charge is applied. This is 13V resp. 26V (for 12V and 24V charger, temperature compensated). This will limit water loss to a minimum when the battery is stored for the winter season. After an adjustable time (default = 7 days) the charger will enter Repeated Absorption-mode for an adjustable time (default = 4 quarters ). Bulk-hours Absorption time 1 day 7 days 7 days Float reduced Float reduced Float

1 hour Repeated Absorption 5 x Bulk-hours or Max. Absorption time Battery Safe mode92 GB NL F D I DK ΕΛ N P E S Specs

U in A m p s Figure 3: Maximum output current vs. input voltage: Output voltage = 12.0V / 24.0V

Battery temperature Volts

Volts Figure 2: Temperature compensation Default output voltages for Float and Absorption are at 20°C. In adjust mode temperature compensation does not apply. Tamb = 25°C Tamb = 40°C93 victron energy Default factory settings: Repeated Absorption interval 7 days Repeated Absorption time 4 quarters of an hour Maximum Absorption time 4 hrs Characteristic: Default = 3 1 = Fixed Absorption time Repeated Absorption interval Repeated Absorption time 4 hrs 1 day 2 quarters 2 = Adaptive 3 = Adaptive with Battery Safe Mode

Battery type: Default = 1 Abs. Voltage Float Voltage / Reduced Float

Factory defaults can always be restored by your authorized Victron Energy dealer. Acting sequence is described in the installation part of the manual.94 GB NL F D I DK ΕΛ N P E S Specs