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Phoenix Smart IP43 Charger

5. Installation

In this section:

5.1. Mounting

The Phoenix Smart IP43 Charger range is designed to be wall mounted using the flanges which protrude from either side of the base.

Before mounting, the following aspects should be considered to identify/provide a suitable and safe location:

  1. Install the charger in a location with good natural airflow/ventilation; in case airflow is a restricted, consider adding a cooling fan.

  2. Ensure there is sufficient unobstructed space around the charger; a minimum clearance of 100mm above and below is recommended.

  3. Install the charger on a non-flammable substrate and ensure there are no heat-sensitive items in the immediate vicinity; it is normal for the charger to become hot during operation.

  4. Install the charger in a location where it is protected from environmental conditions such as water, high moisture and dust, and also located well away from any flammable liquids or gasses.

  5. Do not install or place/operate the charger on top of the battery, directly above the battery, or in a sealed compartment with the battery; batteries can emit explosive gasses.

  6. Do not cover or place any other items on top of the charger.

Mount the charger vertically with terminals facing down; secure using the 4 mounting holes/slots on the base.

To aid installation, it is recommended to 'hang' the unit using the 2 upper screws and then add the 2 lower screws, before fully securing all 4 screws.

Use well fitting pan/flange head screws to secure the unit, ensure that the screw thread outer diameter is a clearance fit within the flange holes/slots (~5mm max OD).

Refer to the drawing below for mounting dimensions:

Drawing_-_Installation_-_PSC.png

5.2. Wiring

Connect DC cabling between the charger's BATTERY terminals and the battery/batteries or DC system distribution bus; all LEDs will illuminate briefly when DC power is connected.

  1. Ensure that the DC system is fully shut down (all DC loads and charge sources off/isolated) prior to disconnection of any existing battery/DC system distribution bus cabling and connection of the charger to the battery terminals/DC system distribution bus.

  2. Use flexible multi stranded copper cable with sufficient cross sectional area, inline with an appropriate fuse or circuit breaker; refer to the 'Installation - Cable and fusing' section for more information.

  3. Ensure that wiring polarity is correct; use red cabling for the + (positive) connections and black cabling for the - (negative) connections.

  4. Refer to the 'Installation - Schematics' section for wiring schematic diagrams; wiring configuration for most typical installations are shown.

Connect any required communication cabling (VE.Direct) and/or control wiring (remote on/off and/or programmable relay).

Connect the AC power cable to a mains power outlet; all LEDs will illuminate briefly when the charger is powered up, then the LED indicating the charge state will illuminate.

Image_-_LED_charge_state_-_PSC.png

5.2.1. Cable and fusing

To enable proper and safe operation it is important to select and use suitably rated DC cabling, combined with a suitably rated inline fuse or circuit breaker.

Cable type/specification selection should consider the following aspects:

  1. Select/use high quality flexible copper power cable; the conductors must be multi-stranded copper cable and the diameter of each individual strand must not exceed 0.4mm (0.016 inch) or a surface area of 0.125mm² (AWG26).

    Image_-_Max_strand_diameter.png

    In case cable with a thicker strand diameter was used, the contact area with the terminations/connections will be insufficient and cause excessive resistance. A high resistance joint will generate heat when operating under load and subsequently result in severe overheating or potentially a fire.

    It is recommended to use cable with a flexibility class of 5 or higher (according to VDE 0295, IEC 60228 and BS6360).

  2. Select/use power cable with high quality insulation:

    1. The cable/insulation voltage rating must be well in excess of the maximum operating voltage. Power cable with a 0.6/1kV voltage rating is recommended.

    2. The cable/insulation temperature rating must be well in excess of the maxumum expected operating temperature and account for heat generated within the cable itself. Power cable with a maximum operating temperature rating of at least 90°C (194°F) is recommended.

  3. Select/use power cable with adequate conductor cross sectional area:

    1. The cable conductor must have sufficient cross sectional area to prevent overheating when operating continuously at maximum operating current.

    2. The cable conductor must have sufficient cross sectional area to safety withstand the fault current required to blow the fuse / trip the circuit breaker (not just the maximum operating current).

    3. The cable conductor must have sufficient cross sectional area to prevent excessive voltage drop between the charger and battery/batteries, this is related to maximum operating current and cable length.

      It is recommended to size cable gauge/cross sectional area for a maximum of ~0.5V and ~3% voltage drop at maximum operating current.

Refer to the table below for the recommended fuse/circuit breaker rating and minimum cable gauge/cross sectional area in relation to cable length (one way length between charger and battery/batteries):

5.2.2. Remote on/off

The Phoenix Smart IP43 Charger is equipped with remote on/off terminals, these terminals enable charging to be turned on or off remotely dependent on their state.

There are 3 options to turn the Phoenix Smart IP43 Charger on using the remote terminal(s):

  1. Interconnect / short the L and H terminals (factory default is a shorting link between L and H). The L and H terminal can be interconnected /shorted via a switch, relay or other external device, like a battery management system (BMS).

  2. Pull the H terminal to a high voltage level; when the voltage on the H terminal is above 2.9V (connected to battery positive for example) the charger will turn on. The H terminal can be connected to a high voltage level via a switch, relay or other external device, like a battery management system (BMS).

  3. Pull the L terminal to a low voltage level; when the voltage on the L terminal is below 3.5V (connected to battery negative for example) the charger will turn off. The L terminal can be connected to a low voltage level via a switch, relay or other external device, like a battery management system (BMS).

To turn the Phoenix Smart IP43 Charger off using the remote terminal(s), both terminals need to have an open circuit relative to each other and be left floating (no connection to a high or low voltage level).

5.2.3. Programmable relay

The Phoenix Smart IP43 Charger is equipped with a programmable relay, the relay can be used for external control based on the selected relay mode (Alarm, Remote control, or Charging) and operational conditions.

There are 3 programmable relay terminals:

  1. NO (Normally open)

  2. C (Common)

  3. NC (Normally closed)

Schematic - Relay.png

When the relay is switched off there is a closed circuit between C and NC, and an open circuit between C an NO.

When the relay is switched on there is a closed circuit between C and NO, and an open circuit between C an NC.

Wire the relay terminals to an external device as necessary in order to achieve the desired signal/control.

Notice

Note: The programmable relay function only works when AC input power is available and charging is enabled. If charging is disabled by any means (the remote on/off terminals, via VictronConnect or a GX device) the programmable relay functionally will also be disabled.

5.2.4. Schematics