Reya Dolphin Pro 24V40A, Dolphin Pro 24V60A, Dolphin Pro 12V60A, Dolphin Pro 24V100A, Dolphin Pro 12V90A Operating And Users Manual

OPERATING AND USERS MANUAL
DOLPHIN PRO
Battery charger
UK
24V40A
REYA Code : 399160
24V60A
REYA Code : 399170
REYA Code : 399180
12V60A
REYA Code : 399140
12V90A
REYA Code : 399150
SAFETY PRECAUTIONS
TO PREVENT ANY RISK OF ELECTRIC SHOCK OR FIRE, READ THIS MANUAL CAREFULLY BEFORE INSTALLING THE EQUIPMENT.
In the event of any problems or misunderstan­dings, please contact REYA.
This equipment is not designed for use by people (including children) with diminished physical, sen­sorial or mental capacities, or people without ex­perience or knowledge of such equipment, unless they have received prior instruction in the use of the equipment from a person responsible for their safety or are under the supervision of such a per­son. Ensure that children are supervised in order to prevent them playing with the device.
This equipment contains components that may cause electric arcs or sparks, when connecting cables, for example.
To prevent any risk of re or
explosion, do not install this equipment close to
ammable materials, liquids or gases.
Installation precautions.
To prevent any risk of irreversible damage to the equipment, ensure that you comply scrupulously with the following recommendations.
4This device must not be installed close to a heat source.
4It must not be installed in an airtight or badly-ventilated compartment.
4The ventilation inlets must not be obstructed.
4Clearance of at least 10 cm must be allowed
around the housing to guarantee adequate convection.
4This device must not be exposed to running wa­ter, water spray and dust of any kind.
4We recommend securing the device in a ver­tical position, with the cable outlet pointing downwards.
4You are formally prohibited from making mechanical alterations to the housing, including making additional holes, for example.
4Under no circumstances should this device be seen as a toy. It should therefore, quite clearly, not be left in the hands of a child.
Connection precautions.
To prevent any risk of electric shock or irreversible damage to the equipment, you should comply strictly with the following recommendations.
4The installation to which this device is connected must comply with the applicable regulations.
4This device is designed to be connected to 220-240V 50Hz or 100-120V 60Hz single phase circuits. 115V / 230V selection is automatic. 220-240V only for 24V100A version.
4The mains power line must feature a cut-off device with differential protection, to protect individuals against electric shocks. Refer to the device’s electricity consumption characteristics to select the size and type of circuit breaker.
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SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
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4Prior to commencing connection, the mains ca­ble gland in the packaging must be assembled and correctly attached to the housing (using the nut provided), in the hole designed for this purpo­se.
4For safety reasons, the device’s EARTH terminal (PE “Protective Earth” terminal), must be connec­ted to the system’s physical earth (yellow & green wire of the mains cable). Refer to the wiring dia­gram for more information.
4To prevent parasite heating, ensure that the ca­ble cross-sections are correct and the connectors are properly tightened.
IMPORTANT : This device is not protected against battery polarity reversals. A battery connection error automatically causes the battery fuses to blow as well as irreversible damage to the circuit board.
Activation precautions.
To prevent any risk of electric shock on ac­tivation or during operation, the protective cover must be correctly positioned and screwed into the housing.
This device complies with the applicable regulations governing transmitted interference and immunity from external disturbances (see
EMC paragraph in the Technical specications
section).
When in operation, take particular care that this device is not subjected to conducted or ra­diated interference at levels higher than the legal limits otherwise malfunctions may occur (e.g.: de­vice too close to a powerful transmitter).
In other respects, this device transmits conducted and radiated interference at levels that comply with the applicable regulations. Ensure that other sensitive equipment used in the vicinity is compa­tible with this device otherwise malfunctions may occur.
Device serial number
The serial number appears on the grey or white sticker on one side of the device. This number is
aligned vertically and comprises a rst number
indicating the year of manufacture (e.g.: 12 for
2012), a letter indicating the month of manufac­ture (e.g.: C for the month of March), as well as
a 5-gure number that is the product’s individual
serial number.
Important Note on the choice of charge curve
It is important to note that the use of an inappropriate charging cycle for the battery technology may extensively impair or even damage the latter.
This is particularly true for cycles where the charge voltages are higher than the levels recommended by the battery manufacturers.
Example: A serious risk of overheating the batteries and releasing gases that are harmful to users’ health.
Curve no. 9 is compatible with a LiFeSo4 battery provided that the battery is equipped with BMS-type battery protection (Battery Management System) within the actual battery. In this case, refer to the battery manufacturer’s recommendations for the choice of charging cycle.
SAFETY PRECAUTIONS
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CONTENTS of the BOX
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Maintenance precautions
To prevent any risk of electric shock during maintenance operations, ensure that the following recommendations are scrupulously observed before performing any maintenance on the device:
4All maintenance operations must only be
carried out by a suitably qualied technician.
4In the event of damage to the mains leads and/or batteries, these may only be replaced by
a qualied person, to avoid any danger.
4The mains power supply must be disconnected (cable or switch).
4 The -DC or -BAT supply on the battery must also be disconnected to prevent any transfer of power.
4To allow the high voltage capacitors to discharge (on the circuit board), wait for 5 minutes before carrying out any work inside the housing.
4The fuses must be replaced by fuses with strictly identical characteristics and performance levels.
RECEIPT OF THE PRODUCT
Contents of the packaging
4The charger.
4Its user manual.
4Its mains cable gland
accompanied by its mounting nut (to be installed on the housing prior to connection).
4Its battery temperature sensor
(24V100A version only)
Checking
Check the product’s identi­cation label, attached to one
side of the product, to ensure that the technical details actually meet your needs (mains supply voltage, charger capacity, etc.).
Installation introduction
The charger is attached using 4 x 4mm Ø screws
(not supplied), to a “robust” mounting or wall.
Ideally, the product should be in a vertical position, with the cable outlet pointing downwards. Clearance of at least 10 cm must be allowed around the device to guarantee optimum convection, in particular along the sides allowing the air needed for ventilation to
ow in and out.
The circulation and convection direction of the air inside the charger is from right to left, viewed from the front of the product (see photo below).
GENERAL CHARACTERISTICS
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CONNECTIONS
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CONNECTIONS
CONNECTIONS
To gain access to the charger’s connections, the front hatch must be removed. To do this, simply unscrew the screw on the front hatch. The hatch is removed by rotating it.
Prior to commencing connection, the mains cable gland must be positioned and attached to the housing in the hole designed for this purpose (hole on the left, when viewed from the front of the product).
The plastic nut supplied with the cable gland allows it to be attached to the housing. This nut is positioned on the inside of the housing. Ensure the correct tightening torque is applied.
DETAILS OF CONNECTIONS
Ventilation direction
Mains cable gland
cool
warm
Front hatch
CONNECTIONS
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CONNECTIONS
UK
Marking Functionalities
L1 AC mains phase, 10mm2 max
(wire colour code: brown or black)
N AC mains neutral, 10mm2 max
(wire colour code: blue, white or red)
PE AC mains earth, 10mm2 max
(wire colour code: green & yellow or green)
-DC battery negative (common), pin M8 (wire colour code: black)
+DC1 Main battery positive, pin
M8 (wire colour code: red)
+DC2 Auxiliary battery 2 positive, pin
M8 (wire colour code: red)
+DC3 Auxiliary battery 3 positive, pin
M8 (wire colour code: red)
CHARGE SELECT
Charge curve and battery char­ging mode selector, 10 positions (from 0 to 9)
BATTERY FUSES Battery protection fuses (on the
–DC supply)
EXT COM1 External communication bus
(CAN bus) (for an external digital display or communication between chargers)
EXT COM2 External communication bus
(CAN bus) (for an external digital display or communication between chargers)
INT COM Communication bus for a digital
display built into the charger
TEMP SENSOR Battery temperature sensor (2
non-polarised wires, no direction) positioned on the positive terminal of the main battery
REPLAY Dry alarm contact
Example of connection on the basis of 3 distinct sets of batteries
Important
Check the quality of connections and proper tightening of connections.
CONNECTIONS CONNECTIONS
UK
AC CABLES AND CIRCUIT BREAKER
AC wiring
Check the quality of connections and proper tightening of connections. For mains power, preferably use a HO7RNF-type industrial cable. Ensure that you comply with the following recommendations.
AC circuit breaker
The AC mains power line must feature a cut-off
device with differential protection, to specically
protect individuals against electric shocks. The circuit breaker’s sensitivity must be 30mA. Its current capacities comply with the charger’s power consumption. Comply with the following recommendations in this respect.
N.b. : The charger has an internal protection fuse on the L1 supply, in the event of a general fault on the circuit board in particular. Due to the irrever­sible nature of this fault, the fuse is not accessible for maintenance of any kind.
DC CABLES AND FUSES
DC wiring
Check the quality of connections and proper tightening of connections. Battery cables must be as direct and short as possible. Each battery output can provide the charger’s full amperage and all the cables must have identical cross-sections. Ensure that you comply with the following recommended cross-sections.
These chargers are equipped with airtight grommets with “automatic” opening.
Simply pressing the central section of the
membrane is sufcient to allow the cable to
pass through the grommet.
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Charger capacity
220-240V AC 50Hz Length < 5m (16ft)
100-120V AC 60Hz Length < 5m (16ft)
12V 60A 2.5mm2 / AWG13 4mm2 / AWG11
12V 90A 2.5mm2 / AWG13 4mm2 / AWG11
24V 40A 2.5mm2 / AWG13 4mm2 / AWG11
24V 60A 2.5mm2 / AWG13 4mm2 / AWG11
24V 100A 4mm2 / AWG11 6mm2 / AWG9
Charger capacity
Length < 2m (6ft)
Length between 3 and 5m (10 to 16ft)
12V 60A 25mm2 / AWG3 35mm2 / AWG2
12V 90A 35mm2 / AWG2 50mm2 / AWG0-1
24V 40A 16mm2 / AWG5 20mm2 / AWG4
24V 60A 25mm2 / AWG3 35mm2 / AWG2
24V 100A 35mm2 / AWG2 50mm2 / AWG0-1
Charger capacity
Mains power 220­240V 50Hz
Mains power 100­120V 60Hz
12V 60A 8A – 30mA 16A – 30mA
12V 90A 8A – 30mA 16A – 30mA
24V 40A 8A – 30mA 16A – 30mA
24V 60A 10A – 30mA 20A – 20mA
24V 100A 20A – 30mA
-
CHARGE CURVE SELECTION
The up-to-date digital electro­nics, based on an RSC microcontroller, monitor the charging process by optimi­sing, the voltage, current and recharging time parameters, on the basis of the initial char­ge level of the batteries, using the exclusive “scanning charge” function.
CONNECTIONS CONNECTIONS
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AC CABLES AND CIRCUIT BREAKER
DC fuses
When maintaining the charger’s internal fuses, these must be replaced by fuses with strictly iden­tical characteristics and performance levels. Risks of irreversible damage to the equipment.
It is essential and highly recommended that you install, as close as possible to each positive out­put on the battery, a fuse to protect connections,
specically in the event of a short circuit and/or
overheating of the battery cables, as the result of damage to the protective sleeves, for example.
The performance and usable life of batteries are thereby maximised.
By virtue of fully automated charging cycles, the batteries are protected against surges, providing a permanent connection for the charger. Selection of the charging program takes place on installation using the “CHARGE SELECT” dial on the charger board.
The position of the arrow indicates the number of the program selected (e.g.: program No. 1 in the photograph above). Selection is made using a
small at-head screwdriver.
CAUTION
It is important to note that the use of an inappropriate charging cycle for the battery technology may extensively impair or even damage the latter.
This is particularly true for cycles where charge voltages are higher than the levels recommen­ded by the battery manufacturers.
A serious risk of overheating the batteries and releasing gases that are harmful to users’health.
Curve no. 9 is compatible with a LiFeSo4 battery, provided that the battery is equipped with BMS-type battery protection (Battery Management System) within the actual battery. In this case, refer to the battery manufacturer’s recommendations for the choice of charging cycle.
Charger capacity
Internal charger fuse (–DC supply)
External battery fuse (+BAT supply for each battery)
12V 60A
3 x 25A 32V rapid (mini automotive fuse)
80A 32V rapid
12V 90A
4 x 30A 32V rapid (mini automotive fuse)
100A 32V rapid
24V 40A
3 x 25A 32V rapid (mini automotive fuse)
60A 32V rapid
24V 60A
3 x 25A 32V rapid (mini automotive fuse) 80A 32V rapid
24V 100A
5 x 30A 32V rapid (mini automotive fuse)
150A 32V rapid
SETTINGS SETTINGS
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PROGRAMME PHASE 12V 24V
0
Open lead
V. BOOST V. FLOAT
14,4V 13,2V
28,8V 26,4V
1
Airtight lead
V. BOOST V. FLOAT
14,2V 13,6V
28,4V 27,2V
2
Lead calcium
V. BOOST V. FLOAT
14,8V 13,8V
29,6V 27,6V
3
«Delphi» type
V. BOOST V. FLOAT
15,4V 13,8V
30,8V 27,6V
Charge curve
5
Winte­ring Open lead
V. BOOST V. FLOAT
14,4V 13,2V
28,8V 26,4V
Charge curve
7
GEL & AGM
V. BOOST V. FLOAT
14,4V 13,8V
28,8V 27,6V
Charge curve
8
Power supply
V. FLOAT 13,6V 27,2V
Charge curve
9
LiFeSo4 + inte­grated BMS
V. FLOAT 14,4V 28,8V
Charge curve
6
Winte­ring Airtight lead
V. BOOST V. FLOAT
14,2V 13,6V
28,4V 27,2V
Charge curve
4
«Op­tima» type
V. BOOST V. MAX V. FLOAT
14,8V 15,5V 13,8V
29,6V
31.0V 27,6V
Charge curve
OPERATION OPERATION
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BATTERY TEMPERATURE SENSOR
The temperature sensor allows the charging voltage to be adjusted depending on the battery temperature.
It therefore allows the usable life of batteries to be increased, mainly in the event that the ambient temperature in the battery area is high.
This sensor is screwed onto the main battery’s positive terminal (a service battery as a general rule). The 2 wires are connected to the “TEMP SEN­SOR” connector on the charger board (in no par­ticular direction).
The compensation level is around +/-25mV per °C for a 24V battery and between +/-12mV per °C for a 12V battery (see curves below).
LED DISPLAY
The PRO charger is equipped with a local multifunction LED display, which, among other things, shows the details of the key stages of the battery charging process.
BOOST phase : the battery is in its recharging phase, reaching a level of charge of close to 80%. This recharging phase is limited to a period of 6 hours.
ABSORPTION phase : The voltage is maintained and the amperage is reduced until the battery returns to a level of charge approaching 100%. This phase is limited to a period of between 30 minutes and 4 hours, depending on the battery’s initial charge level.
FLOAT phase : the voltage and the amperage are reduced to maintain the battery. During the Floating phase the charger only delivers what the battery strictly needs.
In other respects, the key faults (temperature, fuse, voltage, etc.) are also taken into account and shown by the LED display.
Screen
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Battery temperature in °C
The resistor connected initially simulates a temperature of 25°C. The action of the battery temperature sensor allows the charge to be adjusted, upwards or downwards, depending on the battery temperature, i.e.: +/- 15 mV per °C at 12 V +/- 30 mV per °C at 24 V
Charging voltage
Reference voltage
OPERATION OPERATION
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MODE MEANING SOLID LED
FLASHING LED
INITIALIZATION
Charger powered on and/or Chan­ge of charging cycle
All LEDs for 3 seconds
-
ABSORPTION PHASE
Batteries in re­charging phase (charge from 0 to 80%)
POWER ON
BOOST
-
EQUALIZA­TION PHASE
Batteries in re­charging phase (charge from 80% to 100%)
POWER ON
ABS
-
End of the equali­sation cycle within a period of 30 minutes
POWER ON ABS
FLOATING PHASE
Charging cycle completed (charge at 100%)
POWER ON
FLOAT
-
MAINS VOLTAGE FAULT
Mains voltage fault, excessively high or abnormally low
Immediate auto­matic restart, subject to disappearance of the fault
-
POWER ON
CHARGER TEMPERATURE FAULT
Excessive charger temperature fault
Automatic restart after a min delay of 30 seconds, subject to disappearance of the fault
TEMP -
BATTERY TEMPERATURE FAULT
Excessive battery temperature fault
Automatic restart after a min delay of 30 seconds, subject to disappearance of the fault
- TEMP
BATTERY SENSOR FAULT
External tempera­ture sensor fault
Automatic restart after a min delay of 30 seconds, subject to disappearance of the fault
-
TEMP
BAT
OUTPUT VOLTAGE FAULT
Charging voltage fault, excessively high or abnormally low
Automatic restart after a min delay of 60 seconds, subject to disappearance of the fault
BAT -
OUTPUT FUSES FAULT
Output fuse fault
Restart following a mains reset, subject to disappearance of the fault
FUSE -
CAN FAULT
CAN fault secure load
-
TEMP BAT FUSE
Modes and display scenarios
MODE MEANING SOLID LED
FLASHING LED
TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS
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Technical specications
12V 60A 12V 90A 24V 40A 24V 60A 24V 100A
MAINS POWER CHARACTERISTICS
Mains
voltage
100V-120V 60Hz and/or 220-240V 50Hz
(+/-15%)
220-240V
(+/-15%)
Power factor
typically 0.9
Output typically 83% typically 87%
Inrush
current
< 60A < 30A, limited by soft start < 60A
Consump-
tion
12A/5A 16A/7A 14A/6A 15A/9A 15A
Active power
1200VA 1500VA 1350VA 2000VA 3500VA
Derating
@ 115V
Without derating
70% of
Pnom (rated power
-
Mains
fuse
T16A
(6,3x32
mm)
T20A
(6.3x32
mm)
T20A
(6.3x32
mm)
T20A
(6.3x32
mm)
2xT20A (6,3x32
mm)
BATTERY CHARGING CHARACTERISTICS
Number
of
outputs
3 independent supplies
Number
of
cycles
10 charging cycles (from 0 to 9), setting
by means of a dial
Charge
curves
In general 3 statuses, type I.U.Uo
Open
lead
V.BOOST = 14.4V
V.FLOAT = 13.2V
V.BOOST = 28.8V
V.FLOAT = 26.4V
Airtight
lead
V.BOOST = 14.2V
V.FLOAT = 13.6V
V.BOOST = 28.4V
V.FLOAT = 27.2V
Lead
calcium
V.BOOST = 14.8V
V.FLOAT = 13.8V
V.BOOST = 29.6V
V.FLOAT = 27.6V
«Delphi»
Type
V.BOOST = 15.4V
V.FLOAT = 13.8V
V.BOOST = 30.8V
V.FLOAT = 27.6V
«Op-
tima»
Type
V.BOOST = 14.8V
then15.5V
V.FLOAT = 13.8V
V.BOOST = 29.6V then 31.0V
V.FLOAT = 27.6V
Winte-
ring
open
lead
V.BOOST = 14.4V
V.FLOAT = 13.2V
V.BOOST = 28.8V
V.FLOAT = 26.4V
12V 60A 12V 90A 24V 40A 24V 60A 24V 100A
Winte-
ring
airtight
lead
V.BOOST = 14.2V
V.FLOAT = 13.6V
V.BOOST = 28.4V
V.FLOAT = 27.2V
Gel & AGM
V.BOOST = 14.4V
V.FLOAT = 13.8V
V.BOOST = 28.8V
V.FLOAT = 27.6V
Power supply
V.FLOAT = 13.6V V.FLOAT = 27.2V
LifeSo4 +
integra-
ted
BMS
V.FLOAT = 14.4V V.FLOAT = 28.8V
Tempe-
rature
compen-
sation
+/-12mV / °C
(by an external
sensor)
+/-25mV / °C
(by an external
sensor)
Voltage
tole-
rance
+/-2%
Ripple < 1% (BW < 20MHz)
Maxi-
mum
current
60A
(+/-5%)
90A
(+/-5%)
40A
(+/-5%)
60A
(+/-5%)
100A
(+/-5%)
Supply
fuse -DC
3 x F30A
(minia-
ture
automo-
tive
fuse)
4 x F30A
(minia-
ture
automo-
tive
fuse)
3 x F25A
(miniature automo-
tive
fuse)
5 x 30A (minia-
ture
automo-
tive
fuse)
PROTECTION
Output
surge
“Current limited” type
Output
short circuit
“Shutdown” type with automatic restart
once the fault has disappeared
Excessive output
voltage
“Shutdown” type with automatic restart
once the fault has disappeared
Battery polarity reversal
Output fuse
Excessive
internal
temperature
“Shutdown” type with automatic restart
once the fault has disappeared
TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS
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Dimensions
GENERALITES
HS
temperature
sensor
“Shutdown” type with automatic restart
once the fault has disappeared
General
mains supply
fault
Mains fuse
General
battery supply
fault
Output fuses on –DC supply
Climatic
Climatic Tropicalised (specially coated)
circuit board
Operating
temperature
-10°C to +55°C
Storage
temperature
-20°C to +70°C
Humidity 10% to 90% (without condensation)
Convection Forced by thermostat-controlled fan
Housing
Wall-mounted housing in painted
aluminium
Protection
rating
IP20
Mounting Using 4 x 4mm Ø screws
Overall dimen-
sions (Depth x
Width x Height)
125 x 340 x 360 mm
4.9 x 13.4 x 14.2 inches
190x340x 360
7,5x13,4x 14,2
Weight 6 Kg 11,5 kg
EMC EN55014-1
SAFETY EN60335-2-29
Display
Front LED display
Optional remote touch screen
display
Mains
connector
3-point cage terminal for cables with a
cross-section of 10mm2 max
Battery
connectors
M8 pins
Battery sensor
connector
2-point cage terminal for cables with a
cross-section of 1.5mm2 max
Alarm relay
connector
2-point cage terminal for cables with a
cross-section of 1.5mm2 max
External
CAN bus
connectors
2 x RJ11 connectors (CAN bus)
12V 60A 12V 90A 24V 40A 24V 60A 24V 100A
Height A 360 mm (14.2 inch)
Width B 340 mm (13.4 inch)
Depth C 125 mm (4.9 inch)
190 mm
(7.5 inch)
12V 60A - 12V 90A 24V 40A - 24V 60A
24V 100A
WARRANTY WARRANTY
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Warranty
TO PREVENT ANY RISK OF INCORRECT USE OF THE DEVICE, CAREFULLY READ THE LIST OF POTENTIAL EVENTS OR FAULTS NOT COVERED BY THE PRODUCT WARRANTY
4This device is not protected against battery polarity reversals. Risk of irreversible damage to the equipment.
4 Should the device be dropped or fall this could cause irreversible distortion of the housing as well as a “crash” of internal fans and certain electronic components.
4Modications to the housing (additional holes
in particular) could result in the scattering of
swarf or metal lings onto the circuit board and,
consequently, in malfunctions or irreversible damage to the equipment.
4Interference with or modications to the circuit
board could result in operating modes not originally anticipated, and consequently, in malfunctions or irreversible damage to the
equipment.
4Powering the device from an unsuitable energy source (as a general rule, mains supply voltage that is too high).
4Accidental original mains supply surge or lightning strike generally causing irreversible damage to the equipment
. 4Replacement of fuses with fuses with different characteristics that could cause
irreversible damage to the equipment.
4Obvious connection errors causing irreversible damage to the equipment.
4Water spray or running water inside the device that could result in irreversible electronic malfunctions.
Precautions for scrapping
This device contains electronic components and materials that must be recycled at the end of the product’s usable life, for environmental reasons.
At the end of their usable lives all devices must therefore be returned either to the local distribu­tor or entrusted to a specialist electronic equip­ment recycling company.
EC compliance
This device complies with the applicable Euro­pean standards and has an EC mark. Its
certicate of compliance is available on request.
For further information or assistance,
please contact:
REYA SAS
2599 Route de la Fènerie
06580 Pégomas
Tel : (33) 0 493 904 700
Fax : (33) 0 493 474 257
e-mail : reya@reya.com
www.reya.com
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