user manual
Contents
1. gt Powering the device from an unsuitable energy source as a general rule mains supply voltage that is too high gt Accidental original mains supply surge or lightning strike generally causing irreversible damage to the equipment Replacement of fuses with fuses with different characteristics that could cause irreversible damage to the equipment gt Obvious connection errors causing irreversible damage to the equipment NOT DOLPROREYA 03 gt Water 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 distribu tor or entrusted to a specialist electronic equip ment recycling company EC compliance This device complies with the applicable Euro pean standards and has an EC mark Its certificate of compliance is available on request For further information or assistance please contact REYA SAS 2599 Route de la F nerie 06580 P gomas Tel 33 0 493 904 700 Fax 33 0 493 474 257 e mail reya reya com www reya com2. 4 9 x 13 4 x 14 2 inches 7 5x13 4x 14 2 Weight 6 Kg 11 5kg EMC EN55014 1 SAFETY EN60335 2 29 Front LED display Display Optional remote touch screen display Mains 3 point cage terminal for cables with a connector cross section of 10mm2 max M8 pins connectors Battery sensor 2 point cage terminal for cables with a connector cross section of 1 5mm2 max Alarm relay 2 point cage terminal for cables with a connector cross section of 1 5mm2 max External CAN bus 2 RJ11 connectors CAN bus connectors WARRANTY WARRANTY NOT DOLPROREYA 03 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 gt This device is not protected against battery polarity reversals Risk of irreversible damage to the equipment gt 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 gt Modifications to the housing additional holes in particular could result in the scattering of swarf or metal filings onto the circuit board and consequently in malfunctions or irreversible damage to the equipment gt Interference with or modifications to the circuit board could result in operating modes not originally anticipated and consequently in malfunctions or irreversible damage to the equipment
3. 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 flow 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 CONNECTIONS CONNECTIONS NOT DOLPROREYA 03 NOT DOLPROREYA 03 Ventilation direction DETAILS OF CONNECTIONS S rey MINE N 5294 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 SE e Fuses sea temp Mains cable gland Li N PE SENSOR DC 001 0C2 003 EXT COM1 COM CONNECTIONS CONNECTIONS NOT DOLPROREYA 03 NOT DOLPROREYA 03 Example of connection on the basis of 3 distinct sets of batteries Marking Functionalities AC mains phase 10mm2 max wire colour code brown or bl
4. 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 SEN SOR connector on the charger board in no par ticular 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 Reference voltage 25 15 30 14 525 14 28 EA Charging voltage 13 25 12 525 13 34 ji 30 20 10 10 20 30 40 50 60 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 NOT DOLPROREYA 03 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
5. 20V AC 60Hz capacity Length lt 5m 16 Length lt 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 AWGIT mm2 AWG9 The AC mains power line must feature a cut off device with differential protection to specifically 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 Mains power 220 Mains power 100 Charger 240V 50Hz 120V 60Hz capacity 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 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 irrever sible nature of this fault the fuse is not accessible for maintenance of any kind NOT DOLPROREYA 03 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
6. A 32V rapid 24V 100A mini automotive fuse 150A 32V rapid CHARGE CURVE SELECTION The up to date digital electro nics based on an RSC microcontroller monitor the charging process by optimi sing the voltage current and recharging time parameters on the basis of the initial char ge level of the batteries using the exclusive scanning charge function NOT DOLPROREYA 03 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 flat head screwdriver A 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 recommen ded 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
7. Length between 3 kangin lt Ann ei l nei am 0o Ii 12V 60A 25mm2 AWG3 35mm2 AWG2 12V 90A 35mm2 AWG2 50mm2 AWGO 1 24V 40A 1 6mm2 AWG5 20mm2 AWG4 24V 60A 25mm2 AWG3 35mm2 AWG2 24V 100A 35mm2 AWG2 50mm2 AWGO 1 These chargers are equipped with airtight grommets with automatic opening Simply pressing the central section of the membrane is sufficient to allow the cable to pass through the grommet CONNECTIONS CONNECTIONS NOT DOLPROREYA 03 AC CABLES AND CIRCUIT BREAKER DC fuses When maintaining the charger s internal fuses these must be replaced by fuses with strictly iden tical 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 out put on the battery a fuse to protect connections specifically 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 External battery fuse BAT supply for each battery Internal charger fuse DC supply Charger capacity 3 x 25A 32V rapid 12V 60A mini automotive fuse 80A 52V rapid 12V 90A 4 x 30A 32V rapid 100A 32V rapid mini automotive fuse 32V rapid 60A 32V rapid mini automotive fuse 3 x 25A 32V rapid 24V 60A mini automotive fuse 80A 32V rapid 5 x 30
8. OPERATING AND USERS MANUAL DOLPHIN PRO Battery charger 24V40A REYA Code 399160 24V60A REYA Code 399170 24V100A REYA Code 399180 12V60A REYA Code 399140 12V90A REYA Code 399150 Feya SAFETY PRECAUTIONS SAFETY PRECAUTIONS NOT DOLPROREYA 03 TO PREVENT ANY RISK OF ELECTRIC SHOCK OR FIRE READ THIS MANUAL CAREFULLY BEFORE INSTALLING THE EQUIPMENT In the event of any problems or misunderstan dings please contact REYA This equipment is not designed for use by people including children with diminished physical sen sorial or mental capacities or people without ex perience 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 per son Ensure that children are supervised in order to prevent them playing with the device This equipment contains components that may cause eleciric arcs or sparks when connecting cables for example To prevent any risk of fire or explosion do not install this equipment close to flammable materials liquids or gases A Installation precautions To prevent any risk of irreversible damage to the equipment ensure that you comply scrupulously with the following recommendations gt This device must not be installed close to a heat source gt It must not be installed in an airtight or badly ventilated compartm
9. System within the actual battery In this case refer to the battery manufacturer s recommendations for the choice of charging cycle SETTINGS SETTINGS NOT DOLPROREYA 03 PROGRAMME PHASE VAY 24V 0 Open V BOOST 14 4V 28 8V lead V FLOAT 13 2V 26 4V 1 Airtight V BOOST 14 2V 28 4V lead V FLOAT 13 6V 27 2V 2 Lead V BOOST 14 8V 29 6V calcium V FLOAT 13 8V 27 6V 3 Delphi V BOOST 15 4V 30 8V type V FLOAT 13 8V 27 6V BOOST w FLOAT Charge curve T2 Ti 3 95 te man b Op V BOOST 14 8V 29 6V 4 tima V MAX 15 5V 31 0V type V FLOAT 13 8V 27 6V Charge curve Winte lead ring V BOOST Open V FLOAT 28 8V 26 4V Charge curve NOT DOLPROREYA 03 Winte 6 ring V BOOST 14 2V 28 4V Airtight V FLOAT 13 6V 27 2V lead Charge curve 7 GEL amp V BOOST 14 4V 28 8V AGM V FLOAT 13 8V 27 6V VW BOOST Y FLOAT Charge curve T2 Ti x 3 95 alba T Power V FLOAT 13 6V 27 2V supply Charge curve LiFeSo4 g MS 14 4V 28 8V grated BMS W BOOST Charge Ti thr max ai Tz i curve TieTix0 5 OPERATION OPERATION NOT DOLPROREYA 03 BATTERY TEMPERATURE SENSOR The temperature sensor allows the charging voltage to be adjusted depending on the battery temperature It therefore allows the
10. ack AC mains neutral 10mm2 max wire colour code blue white or red PE AC mains earth 10mm2 max wire colour code green amp yellow or green battery negative common pin M8 wire colour code black 061 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 Charge curve and battery char SELECT ging mode selector 10 positions from 0 to 9 BATTERY FUSES Battery protection fuses on the DC supply EXT COMI 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 Ay Important of the main battery REPLAY Dry alarm contact Check the quality of connections and proper tightening of connections CONNECTIONS CONNECTIONS NOT DOLPROREYA 03 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 Charger 220 240V AC 50Hz 100 1
11. at the following recommendations are scrupulously observed before performing any maintenance on the device gt All maintenance operations must only be carried out by a suitably qualified technician gt In the event of damage to the mains leads and or batteries these may only be replaced by a qualified person to avoid any danger gt The mains power supply must be disconnected cable or switch gt The DC or BAT supply on the battery must also be disconnected to prevent any transfer of power gt To allow the high voltage capacitors to discharge on the circuit board wait for 5 minutes before carrying out any work inside the housing gt The fuses must be replaced by fuses with strictly identical characteristics and performance levels NOT DOLPROREYA 03 RECEIPT OF THE PRODUCT Contents of the packaging gt The charger gt Its User manual gt Its mains cable gland accompanied by its mounting nut to be installed on the housing prior to connection gt Its battery temperature sensor 24V100A version only Checking Check the product s identifi 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 screws not supplied to a robust mounting or wall Ideally the product should be in a vertical position with
12. e mains ca ble gland in the packaging must be assembled and correctly attached to the housing using the nut provided in the hole designed for this purpo se gt For safety reasons the device s EARTH terminal PE Protective Earth terminal must be connec ted to the system s physical earth yellow amp green wire of the mains cable Refer to the wiring dia gram for more information gt To prevent parasite heating ensure that the ca ble 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 A Activation precautions To prevent any risk of electric shock on ac tivation 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 specifications section When in operation take particular care that this device is not subjected to conducted or ra diated interference at levels higher than the legal limits otherwise malfunctions may occur e g de vice too close to a powerful transmitter NOT DOLPROREYA 03 In other respects this device transmits conducted and radiated interference at l
13. ent gt The ventilation inlets must not be obstructed gt Clearance of at least 10 cm must be allowed around the housing to guarantee adequate convection NOT DOLPROREYA 03 gt This device must not be exposed to running wa ter water spray and dust of any kind gt We recommend securing the device in a ver tical position with the cable outlet pointing downwards gt You are formally prohibited from making mechanical alterations to the housing including making additional holes for example gt Under no circumstances should this device be seen as a toy It should therefore quite clearly not be left in the hands of a child A Connection precautions To prevent any risk of electric shock or irreversible damage to the equipment you should comply strictly with the following recommendations gt The installation to which this device is connected must comply with the applicable regulations gt This 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 gt The 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 SAFETY PRECAUTIONS SAFETY PRECAUTIONS NOT DOLPROREYA 03 gt Prior to Commencing connection th
14. evels that comply with the applicable regulations Ensure that other sensitive equipment used in the vicinity is compa tible 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 first number indicating the year of manufacture e g 12 for 2012 a letter indicating the month of manufac ture e g C for the month of March as well as a 5 figure 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 GENERAL CHARACTERISTICS CONTENTS of the BOX NOT DOLPROREYA 03 Maintenance precautions To prevent any risk of electric shock during maintenance operations ensure th
15. fault has disappeared Type V FLOAT 13 8V V FLOAT 27 6V Excessive output Shutdown type with automatic restart 7 To voltage once the fault has disappeared Op V BOOST 14 8V V BOOST 29 6V then 31 0V tima then15 5V V FLOAT 27 6V Battery Type V FLOAT 13 8V 5 polarity Output fuse Winte reversal eset y re io ioe a Shutdown type with automatic restart p 7 aa Rs once the fault has disappeared lead temperature TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UK NOT DOLPROREYA 03 12V 60A 12V 90A 24V 40A 24V 60A 24V 100A NOT DOLPROREYA 03 Dimensions A C 12V 602 12V 902 24V 402 24V 602 24V 100A Height A 360 mm 14 2 inch Width B 340 mm 13 4 inch Depth C 125 mm 4 9 inch ede HS Shutdown type with automatic restart temperature E once the fault has disappeared sensor General mains supply Mains fuse fault General battery supply Output fuses on DC supply fault Climatic Climatic Tropicalised specially coated circuit board Operating 10 C to 55 C temperature storage 20 C to 70 C temperature Humidity 10 to 90 without condensation Convection Forced by thermostat controlled fan Wall mounted housing in painted g aluminium Protection IP20 rating Mounting Using 4 x 4mm screws P 125 x 340 x 360 mm 190x340x 360 Width x Height
16. 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 OPERATION OPERATION NOT DOLPROREYA 03 Modes and display scenarios MEANING 300 FLASHING LED INITIALIZATION Charger powered on and or Chan ge of charging cycle All LEDs for 3 seconds ABSORPTION PHASE Batteries in re charging phase charge from 0 to 80 POWER ON BOOST EQUALIZA TION PHASE Batteries in re charging phase charge from 80 to 100 POWER ON ABS End of the equali sation 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 auto matic 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 NOT DOLPROREYA 03 BATTERY TEMPERATURE FAULT MEANING Exce
17. ower z V FLOAT 13 6V V FLOAT 27 2V lt 30A limited by soft start lt 604 supply current b LifeSo4 tion 12A 5A 16A 7A 14A 6A 15A 9A 15A M V FLOAT 14 4V V FLOAT 28 8V Active 1200VA 1500VA 1350VA 2000VA 3500VA BMS powe Tempe 25mV C 70 of rature oP te SC by an external 9 by an external y Sma Derating Withouderatia Pnom F compen sensor sensor 115V rated sation power Voltage Meins TI A T20A T20A T20A 2xT20A tole 2 tuse 6 3x32 6 3x32 6 3x32 6 3x32 6 3x32 rance mm mm mim Ripple lt 1 BW lt 20MHz BATTERY CHARGING CHARACTERISTICS Maxi mU 60A 90A 40A 60A 100A of 3 independent supplies curent 1 52 4 5 9 5 57 outputs 3xF30A 4x F30A 5 x 30A Number lt minia minia 3 x F25A minia of 19 Shagna es setting Supply ture ture miniature automo ture cycles y fuse DC automo automo tive automo tive tive fuse tive Charge sitet In general 3 statuses type I U Uo fuse fuse fuse Open V BOOST 14 4V V BOOST 28 8V lead V FLOAT 13 2V V FLOAT 26 4V Airtight V BOOST 14 2V V BOOST 28 4V PROTEGIEN lead V FLOAT 13 6V V FLOAT 27 2V Output surde Current limited type Lead V BOOST 14 8V V BOOST 29 6V 2 calcium V FLOAT 13 8V V FLOAT 27 6V Output Shutdown type with automatic restart hort circuit i Delphi V BOOST 15 4V V BOOST 30 8V short circui once the
18. ssive battery temperature fault Automatic restart after a min delay of 30 seconds subject to disappearance of the fault 300 D FLASHING LED TEMP BATTERY SENSOR FAULT External tempera ture 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 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS UK NOT DOLPROREYA 03 NOT DOLPROREYA 03 Technical specifications 12V 60A 12V 90A 24V 402 24V 60A 24V 100A 12V 60A 12V 90A 24V 40A 24V 60A 24V 100A MAINS POWER CHARACTERISTICS Winte Mains 100V 120V 60Hz and or 220 240V 50Hz 220 240V ting BOOTE es voltage 1 5 1 5 airtight V FLOAT 13 6V V FLOAT 27 2V lead Power P typically 0 9 Gel amp V BOOST 14 4V V BOOST 28 8V AGM V FLOAT 13 8V V FLOAT 27 6V Output typically 83 typically 87 P
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