DUI BlueHeat User manual

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DUI BLUEHEAT™ OWNER’S MANUAL
Congratulations on purchasing a DUI BlueHeat™ System. It has been carefully
manufactured to exacting standards using high quality materials.When
properly used, it will make your diving more comfortable and enjoyable. DUI’s
BlueHeat™ is intended for use by certified divers trained in the use of
drysuits, or individuals under the direct supervision of a qualified instructor.
Even if you are experienced with the use of other electrically heated products,
it is the users responsibility to read and follow the information contained in
this manual. It includes many important safety techniques and information that
can help you extend the useful life of your BlueHeat™ System. ailure to
follow the information contained in this manual and information attached to
BlueHeat™ products may result in serious injury or death and will void all
product warranties. Diving Unlimited International, Inc., it's distributors and
agents shall not be liable for any injury, death or damages as a result of a user
failing to follow the instructions contained in this manual.
If the owner’s manual is unavailable or lost, you can download a copy from the
DUI website at www.DUI-Online.com or a copy may be obtained by
contacting DUI at:
DIVING UNLIMITED INTERNATIONAL, INC.
1148 Delevan Drive
San Diego, CA 92102-2499 USA
800-325-8439
619-236-1203
619-237-0378 ax
[e-mail]
Manual Part# 292245
Meets EN 14225 part 3

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TABLE O CONTENTS
UNCONTROLLED I PRINTED QSP-711-101
Definitions..............................................................3
CustomerSupport .......................................................3
ImportantSafetyInformation ..............................................4
ImportantSafetyPrecautions ..............................................6
Intended Use and unction of the BlueHeat™ System . . . . . . . . . . . . . . . . . . . . . . . . . .7
LinerSizeChart .........................................................7
BlueHeat™SystemOverview ..............................................7
BlueHeat™ Smart Battery System (SBS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SBS™BatteryPack......................................................12
SBS™Controller .......................................................14
SBS™Modes ..........................................................16
ValvePortInstallation....................................................17
BlueHeat™Liner .......................................................18
AccessoryWiringHarness ................................................19
DivePreparation........................................................21
PreDiveCheckandInspection ............................................22
DivingtheBlueHeat™System.............................................23
EmergencyProcedures...................................................25
PostDiveCare .........................................................26
Appendix..............................................................27
Why Li ePO4Batteries................................................27
O-ringCareandMaintenance ..........................................28
ResponsibleDiverCode .................................................30
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DE INITION O IMPORTANT WORDS USED
IN THIS MANUAL
Throughout this manual, we will use certain words to call your attention to
conditions, practices, or techniques that may directly affect your safety. Pay
particular attention to information introduced by the following signal words:
!!! DANGER !!!
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
!! WARNING !!
Indicates a potentially hazardous situation, which if not
avoided, could result in death or serious injury.
! CAUTION !
Indicates a potentially hazardous situation, which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CUSTOMER SUPPORT
If any portion of this manual is unclear, or if you are unable to obtain
satisfactory answers from your dive store or instructor, contact DUI at:
800-325-8439
619-236-1203
ax 619-237-0378
[e-mail]
www.DUI-Online.com
BLUEHEAT™ SYSTEM__________

IMPORTANT SA ETY IN ORMATION
!!! DANGER !!!
The BlueHeat™ liner, accessory gloves and socks are
designed to be used in a dry environment under a
drysuit. In the event the drysuit becomes flooded, the
entire BlueHeat™ System should be turned off.
!!! DANGER !!!
Never use the BlueHeat™ liner, accessory gloves or
socks under a wet suit or semi-dry suit.
!! WARNING !!
Follow all instructions and safety precautions. Improper
use or misuse of the BlueHeat™ System could result in
serious injury or death.
!! WARNING !!
Improper use or abuse of the BlueHeat™ System in
combination with a drysuit could result in loss of
buoyancy control, including uncontrolled descents and
uncontrolled rapid ascents, resulting in drowning,
decompression sickness, air embolism, injury or death.
!! WARNING !!
Improper use or abuse of the BlueHeat™ System could
result in exposure to thermal hazards, including
rapid body overheating (hyperthermia) or
cooling (hypothermia), resulting in stroke or seizure,
injury or death.
!! WARNING !!
Improper use or abuse of this BlueHeat™ System could
result in burns.
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!! WARNING !!
Ice diving (diving in water 40°F (5°C) or less) is
extremely hazardous. Do not engage in ice diving
unless you have been thoroughly trained
and specially equipped.
Read this entire manual before using the BlueHeat™ System even if you have
experience using other heated systems. Keep the manual for future reference.
If you resell or loan the BlueHeat™ System to someone, be sure that this
manual accompanies it and that it is read and understood before the
BlueHeat™ System is used.
ailure to follow all warnings and instructions for use and maintenance of the
BlueHeat™ System may result in serious injury or, in extreme situations,
death.
This manual is supplied to the original purchaser of a BlueHeat™ System. If
you have any questions about the use or maintenance of your BlueHeat™
System, or if you need another copy of this manual, contact DUI:
Diving Unlimited International, Inc.
1148 Delevan Drive, San Diego, CA 92102-2499 USA
800-325-8439
619-236-1203
619-237-0278 ax
[e-mail]
www.DUI-Online.com
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IMPORTANT SA ETY PRECAUTIONS
BLUEHEAT™ AND DRYSUIT GUIDELINES
The BlueHeat™ System is designed to be used under a drysuit.The following
drysuit safety practices should be followed.These safety practices have been
adopted and endorsed by several manufacturers of drysuits, including DUI:
• Complete a drysuit diving course from an instructor and stay current by
practicing your skills often.
• Use a buoyancy compensation device for surface flotation and back up.
Never use a drysuit as a buoyancy device.
• Know your equipment and emergency procedures.
• Practice your drysuit diving skills under controlled conditions until they
become second nature.
• Dive with a dive partner who understands your drysuit system.
• Use the correct amount of insulation for the water temperature in which
you are diving and exercise rate.
• Do not weight yourself heavier than neutral buoyancy with an empty tank.
Your weighting should allow you to make a safety stop at ten feet upon
completion of your dive with a tank containing 500 psi (34 Bar) of air or
less.
• Check your valves, zipper and seals before each dive.
• Perform preventive maintenance and repairs on your drysuit and valves
regularly, or have them serviced by a qualified individual.
• Know your limitations and do not exceed them.
• Water or air temperatures below 70° (21°C) constitute cold water diving.
• Water or air temperatures below 40° (5°C) constitute ice diving. Ice diving
is very dangerous and requires special training.
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INTENDED USE AND UNCTION O THE
BLUEHEAT™ SYSTEM
DUI’s BlueHeat™ System is designed to provide the diver with supplemental
heat greatly extending the divers comfort range.The BlueHeat™ liner,
accessory gloves and socks provide a very minimal amount of insulation when
not energized and therefore the liner and accessory socks are designed to be
used in combination with standard drysuit insulated undergarments that are
suitable for the diving environment.
LINER SIZE CHART (INCHES)
Liner Sizing XS SM LXL XXL
Height 64-67 66-69 68-71 70-73 72-75 74-77
Chest 32-34 35-37 38-40 41-43 44-43 47-49
Waist 30-31 33-35 36-38 39-41 42-44 45-47
Hips 29-31 32-34 35-37 38-40 41-43 44-46
Spine to Wrist 27-28 28-29 29-30 30-31 31-32 32-33
loor to Crotch 32-33 33-34 34-35 35-36 36-37 37-38
BLUEHEAT™ SYSTEM OVERVIEW
The BlueHeat™ System is intended to provide the diver with supplemental
heating (active insulation), extending the diver’s comfort range.The
BlueHeat™ System is not intended to be a replacement for insulated
undergarments.
BlueHeat™ System consists of the following:
• Smart Battery System (SBS™) - Housing, Battery & Controller
• Liner
• Port and Bulkhead Connector
• Smart Charger
• O-ring Kit
• Carrying bag
BlueHeat™ System Accessories
• Gloves
• Socks
• Wiring Harness for Accessory Gloves & Socks
• Replacement Battery Pack
• Replacement Charger
• Lights
• O-ring Kit
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BLUEHEAT™ SMART BATTERY SYSTEM (SBS™)
The BlueHeat™ Smart Battery System is built around a Lithium Iron
Phosphate (Li ePO4) core battery pack. Its capacity is 12.8 Volts, 12.5 Ahr
(Amp-hour) or 160 Wh (Watt-hr). See the appendix for more detailed
information on the Li ePO4battery.
SBS™ Physical Canister Properties
• Height 13-1/2” (34.3 cm)
• Width 5-3/4‘’ (14.6 cm) at the latches and 4-1/4” inches (10.8 cm) overall.
• Depth 3-5/8” inches (9.2 cm)
• Weight 9-1/4 lb (4.19 kg)
• Weight in fresh water negative 2-3/8 lb (-1.07 kg)
• Maximum operating depth 410 ft (125m)
SBS™Materials
• Cap:Anodized aluminum.This System may be used in an air environment.
• Canister: Glass filled polycarbonate
SBS™ ports on cap (See FIG. 1)
• BlueHeat™ garment & accessory port:The garment & accessory port is 4
pin EO style female wet connect connector on a 36” (91 cm) cable.
• Controller Port: Dry connector.The controller should only be removed from
the SBS™ cap outside the water.After removing the controller, remember
to install the port plug on the SBS™ cap and on the controller connector.
ailure to use the port plugs will result in flooding the housing.
• Accessory Light Port: Dry connector.The light head should only be removed
from the SBS™cap outside the water. After removing the light head
remember to install the port plug on the SBS™ cap and on the light head
connector. ailure to use the port plugs will result in flooding the housing.
• Secondary Power Port:A 12 volt port is provided for ganging or daisy
chaining more than one battery canister together to extend the range of the
dive.This port can be equipped with a common EO connector which will
allow connecting multiple SBS™ canisters. (Custom ordered from DUI)
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Mounting the SBS™ Canister (See FIG. 2)
• The SBS™ housing is equipped with three 2 inch (50 mm) belt slots to
facilitate different mounting options.
• Using the top slot, the SBS™ can be mounted on your waist belt as in a
typical canister light.
• Use any of the slots on the SBS™ with your BC’s tanks strap(s).
• Three mounting slots allows for the greatest flexibility when mounting to
single and twin cylinders and CCRs depending on your configuration.
IG. 1
IG. 2

Opening the SBS™ Canister
1.The SBS™ should be dry and free of moisture before opening it.The
SBS™ should only be opened in a dry environment.
2. Undo the two locking stainless steel latches
3. Pull the SBS™ cap off by using your hands and applying even force. Be
careful not to pull on the wires between the battery pack and SBS™ cap
once open.
4. Disconnect the battery pack from the SBS™ cap.
5. Be careful not to damage the O-ring, O-ring surfaces on the cap and/or
sealing surfaces on the canister.
einstalling the Battery Pack into the SBS™
1.Take the time to inspect the O-rings on the SBS™ cap before every dive.
The O-rings should be free of grit or dirt and should not have any signs of
damage.
2. Remove the O-rings from the cap and wipe them down with a clean cloth
before every dive.The O-rings should be lubricated lightly with silicone
grease, any regulator grease or Dow 111 equivalent.The O-ring groove on
the cap should also be free of any dirt or debris. Be careful not to damage
the sealing surface on the cap or canister body. Insert the battery pack
with connector on top into the canister body. Connect the battery pack
to the SBS™ cap.
3. Orientate the SBS™ cap so that the wires will lay flat. See IG. 4.
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IG. 3

4.Align the SBS™ cap and canister body and firmly press the cap into the
canister with both hands.
5. Close and latch the two stainless steel locking latches.
!!WARNING!!
Use only DUI’s BlueHeat™ charger with
DUI’s BlueHeat™ battery pack. Use of an improper
charger could result in damaging the battery pack or
fire and explosion.
!!WARNING!!
Use only DUI’s BlueHeat™ battery pack with DUI’s
SBS™ battery canister. Use of improper batteries could
result in damaging the battery pack or full SBS™.
!!WARNING!!
During transport, the cap should always be
attached to the canister to prevent accidentally
nicking on either surface.
!!!CAUTION!!!
Change any O-ring if you see wear or cracking. Best
practice is to change O-rings once a year. Remember to
lubricate your O-rings with a light coat and wipe them
off. Lubricant should be a silicone grease, any regulator
grease or Dow 111 equivalent. Leaving excess lubrication
attracts dirt and increases wear to an O-ring.
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IG. 4

SBS™ Care and Maintenance
The outside of the SBS™ should be rinsed with fresh running water and all
dirt and salt residue removed.
SBS™ Storage
1.When storing your SBS™ for extended periods of time, remove the
SBS™ cap and battery pack from the canister.
2.The SBS™ should be stored in a cool, dry place.
SBS™ BATTERY PACK
Charging the Battery Pack
DUI’s SBS™ utilizes Lithium Iron Phosphate (Li ePO4) batteries which can
provide years of consistent use. However, even the best batteries are only as
good as the manner in which they are maintained. Batteries should always be
charged as soon as possible after use and not left to sit for long periods in a
discharged state.
While Li ePO4batteries do not experience the reduced discharge effect
known as “memory,” they can be damaged if left at low voltage levels.The
charger provided with your BlueHeat™ System will charge the batteries to
capacity and automatically stop charging.
Batteries tend to slowly discharge over time especially if exposed to extreme
heat or cold.Your DUI BlueHeat™ charger is designed to top off the battery
pack to a full charge when left connected to the battery during storage.You
can store your battery pack connected to your battery charger if you plan to
use your BlueHeat™ within a few weeks or top it off the day before your
dive. If the battery is going to be left unused for several weeks or months, fully
charge the battery, disconnect the battery from the charger, and top off the
battery prior to the next use. If the battery is to be stored without use for a
long period, top it off with a recovery charge every six months.
Charging Steps:
1. Plug in the charger and verify that it is receiving power. DUI’s battery
charger will work with 110/220.You should see a green light on the
charger. Plug the battery pack into the charger and verify that the light
turns red.
2.Allow the battery pack to charge until the red light turns green.A normal
charge cycle should be around 4 hours. Allow the battery pack to cool for
10 minutes before use.
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!!WARNING!!
Do not charge the SBS™ battery pack while
in the SBS™ housing.
!!WARNING!!
Use only DUI’s charger with DUI’s BlueHeat™ battery
pack. Use of an improper charger could result in
damaging the battery pack or cause a
fire and/or explosion.
!!WARNING!!
Do not overcharge DUI’s BlueHeat™ battery pack past
14.6 volts.This is controlled by DUI’s charger
provided with each SBS™.
Battery Pack Lifespan
Your SBS™ battery pack should provide you with years of trouble free
performance.The anticipated life of a battery pack is measured by the number
of charge and discharge cycles it can tolerate.The life of a battery pack will
depend on many factors including the storage temperature, the discharge of
the battery pack, and the charging efficiency. If well cared for, the SBS™
battery pack should provide nominally 1,000 cycles while retaining over 70%
of its capacity.
Please see the recommendations below for other ways of increasing the
battery pack’s life.
1. Use only DUI’s Lithium Iron Phosphate (Li ePO4) battery packs with your
BlueHeat™ SBS™. It is very important that the Lithium Iron Phosphate
(Li ePO4) battery packs be charged with DUI’s charger.
2. Do not allow the battery pack to discharge deeply (below 8.4 volts).This
is managed by the protection circuit in each battery. Charging your battery
every six months will prevent this from taking place.
3. Do not allow the batteries to sit in a discharged state.
4. Do not expose the batteries to extreme temperatures below -10° C (14° )
or above 45° C (113° ).
5. Batteries must be removed from canister for charging.

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SBS™ CONTROLLER
The SBS™ Controller provides the diver with control at their fingertips.You
can control zone A and B independently. Zone A is for the liner. Zone B is for
the accessory gloves and socks.The SBS™ Controller will also display your
battery packs capacity.The SBS™ Controller has the ability to control selected
light heads when plugged into the SBS™ canister. Please check online at
http://www.dui-online.com/heat/Lights.html for compatible lights and SBS™
configuration.
Installing the SBS™ Controller onto the SBS™ Cap:
1. Unscrew and remove the waterproof covers from the controller’s
connector and the SBS™ cap. Make sure to save the covers.They should
be used anytime the controller is removed from the SBS™ cap.
2. Check the O-rings on the SBS™ Controller for any damage. Replace as
needed. Match the pins on the Controller with the SBS™ cap and press
the connectors together then thread the locking ring until snug.This
connection should not be broken in the water. It will cause the housing to
leak.This connector is a dry connector only.
!!WARNING!!
All changing of attachments or caps must be done in a
dry environment. Failure to do so will result in the
flooding of the SBS™ battery housing.
Your SBS™ Controller can be attached to the diver in
multiple ways (See FIG. 6)
1.Attach a snap hook at the end (as indicated)
2.Attach to a retractor
3. Install wrist bungees to the four mounting holes provided (as indicated)
IG. 5

Control Features (See FIG. 7)
1.There are two separately controlled heating zones (A & B)
a.A = Liner torso heating
b. B = Accessory gloves and/or socks
2. Each zone control has 4 power levels
a. Off
b. 50%
c. 75%
d. 100%
3. Each zone control has a LED visual indicator of the current power level
selected
4. Battery level (capacity) indicator uses 4 LEDs to show you how much
battery power remains
5.The controller also has the capacity to turn power on and off to your light
head
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IG. 6
IG. 7

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SBS™ MODES
The SBS™ has 3 different modes that a diver can switch between to best meet
their needs. Switching between modes is easy but can only be done when you
first connect the battery pack to the cap.After connecting the battery pack to
the cap, you have 10 seconds to momentarily press the “A” or “B” buttons 4
times to enter into “change mode”.When in “change mode” the LED on
buttons “A” and “B” will be red.The battery level LEDs will display which mode
you are in and if SBS™ Saver is turned on.The position of the green LED lets
you know which mode you are in and the red LED on the right lets you know
if SBS™ Saver is turned on. Momentarily pressing the “A” button will allow you
to switch between the 3 modes. Momentarily pressing button “B” is to turn
on/off SBS™ Saver. Please read below for details on SBS™ Saver.The controller
will automatically save and exit after 5 seconds without a button being pressed.
Mode 1
When in mode 1, button “A” will control the liner and button “B” will control
the socks and gloves. Both circuits have 4 power settings (off, 50%, 75%, 100%)
and cycle every time the button is momentarily pressed. Mode 1 is the default
mode and the SBS™ is already configured for this.
In mode 1 the circuit that is used for a light is always on and meant for lights
that have their own on and off switch on them.
Mode 2
When in mode 2, button “A” will control the liner and button “B” will control
the socks and gloves. Both circuits have 4 power settings (off, 50%, 75%, 100%)
and cycle every time the button is momentarily pressed.
In mode 2 the circuit that is used for a light is also controlled by the controller.
Pushing button “A” or “B” for a long press (3 seconds) will turn the light circuit
on and then return the display back to the liner socks/gloves power setting.
Pushing button “A” or “B” for a long press again will cycle the power off and
back on triggering your light to medium if your light supports it. Pushing button
“A” or “B” for a long press again will turn the light circuit off.
Mode 3
When in mode 3, button “A” will control the liner, socks and gloves. Button “B”
will control the light circuit. Button “A” has 4 power settings (off, 50%, 75%,
100%) and cycle every time the button is momentarily pressed. Button “B” has
3 settings (On, Medium** Off). In this mode the liner, socks and gloves will
always be at the same power setting.
** Please check online at http://www.dui-online.com/heat/Lights.html for compatible
lights and SBS™ configuration.
Battery Level LED’s
Battery Level LED’s
Battery Level LED’s

SBS™ Saver
SBS™ Saver extends your battery so you don’t have to worry about running
out of power for your light and heating.This System has two steps. First, when
your battery starts to get low, it switches your liner, socks and gloves to 50%
thus doubling your time and extending your comfort. Second, when you have
just minutes left and are running a light, the SBS™ Saver turns the heating off
and dedicates the remaining power to your light.
SBS™ Saver is designed to help extend your comfort and make managing your
battery life easy.The diver always has the ability to override SBS™ Saver and
turn components back on by simply activating that zone again.
VALV PORT INSTALLATION
The BlueHeat™ port is to be installed underneath the drysuit inflation valve.
It is designed to work with an Apeks inlet valve.The installation of the
BlueHeat™ port should be done by an individual familiar with the removal and
installation of drysuit valves. Installation of the electric suit port should be
done with silicone sealant. Use Dow Corning 732 multi-purpose sealant or
equivalent.
An accessory port is available as an added accessory for divers that do not
want to put the port under the inflation valve and instead place the port in a
different location.
1. Loosen the existing inlet valve by firmly applying pressure to both sides of
the inlet valve and turning the valve backing counter-clockwise.
2. Once the valve is loosened remove the backing and carefully pull the front
inlet valve off the suit. Remove all silicone from the overlay and base suit
fabric.
3.Apply a small bead of silicone on the flat surface of the electric suit port
next to the male threads.The bead should go completely around the electric
suit port.
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Battery Level L D’s
FIG. 8

4. Insert the electric suit port into the valve hole on the suit. Make sure to
align the suit port so that the wet connector is facing the direction that you
will be mounting your SBS™.
5.Thread the valve backing on. Be sure not to twist the electrical wiring. Make
sure the overlay fabric and suit fabric are flat and do not twist during
tightening. Hand tighten only; over tightening could cause the electric suit
port to leak.
6. Make sure the O-ring is in the groove on the top of the suit port before
installing the valve.When installing the inlet valve only hand tighten the
valve.
7. Leak check the suit to ensure the installation is water/air tight.
!! WARNING !!
Improper installation could result in a water leak or
flood of the drysuit. Check the installation for any
leaks prior to your dive.
BLU H AT™ LIN R
The BlueHeat™ Liner is a two layer, breathable garment.The material is an
anit-microbial stretch fleece/lycra designed to remove moisture from the skin.
The inside, next-to-skin material is soft and comfortable.The outside material
is smooth allowing your primary insulation jumpsuit to easily slide over the
surface.The Liner contains four 20 watt heating pads for a total of 80 watts of
heat.These heating pads are made of breathable materials to support natural
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FIG. 9
FIG. 10

moisture transport.The combination of stretch materials is critical in the
design of the Liner so that it places and holds the heating pads close and
evenly over the surface of the skin.The Liner configuration prevents “ride up”
which can generate hot spots due to folds in the heating pads.
The heating pads are made with stainless steel MicroWire® which has up to
150% to 200% more tensile strength over typically used elements made of
copper, aluminum, nickel-chromium alloys, etc. Combined with the superior
flex strength, this makes it ideal for the demands of diving. In addition, stainless
steel-based MicroWire® has low thermal inertia meaning that temperature
changes happen rapidly. Low thermal inertia makes the System easier to
control as it responds quickly once activated. Each of the four heating pads has
a high limit thermal control board which keeps the maximum pad temperature
less than 120º (49ºC).
The Liner also has conduits in the arms and legs for the accessory wiring
harness for the accessory gloves and socks.
!! WARNING !!
The fit of the liner is critical. If the liner is too big, the
four heating pads may not sit evenly over the surface of
the diver resulting in a hot spot and potentially a burn.
!! WARNING !!
Do not use DUI’s BlueHeat™ Liner, Gloves or Socks
with any other battery system than DUI’s SBS™.
Failure to do so may cause damage to the
garment and/or a burn.
ACCESSORY WIRING HARNESS
The accessory wiring harness facilitates the use of BlueHeat™ gloves and
socks.The harness can be easily added when gloves and socks are in use or
removed when gloves and socks are not in use to eliminate bulk.
Size Chart
Height Spine to wrist
Small 5’0”-5’4” 25”-26”
Medium 5’5”-5’10” 27”-28”
Large 5’11”-6’3” 29”-30”
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