Dolphin Pro hd+ 24v40a User manual

TECHNICAL MANUAL

24V40A

REYA Code: 399.165

24V60A

REYA Code: 399.175

24V100A

REYA Code: 399.185

Battery charger

NOT-DOLPROHD-00

SAFETY PRECAUTIONS

TO PREVENT ANY RISK OF ELECTRIC

SHOCK OR FIRE, READ THIS MANUAL

CAREFULLY BEFORE INSTALLING THE

EQUIPMENT.

In the event of a problem or if you do not

understand, 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 instructions 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 to avoid

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 inammable

materials, liquids or gases.

Installation precautions.

In order to prevent any risk of permanent

damage to the charger, the following

recommendations should be strictly

observed.

4The device must not be installed close

to a heat source.

4It must not be installed in an airtight or

badly-ventilated compartment.

4The cooling vents must not be

obstructed.

4Leave a free space of at least 10 cm

all around the case, to allow proper

convection.

4This device must not be exposed to

running water, water spray or dust of any

nature.

4It is recommended that the charger be

mounted vertically, with the cable exit

facing downwards.

4The case must not be mechanically

modied, for example by drilling additional

holes.

4In no sense is this device a toy. It should

therefore not be left in the hands of a

child.

Connection precautions.

To prevent any risk of electric shock or

irreversible damage to the equipment,

ensure you scrupulously respect the

recommendations below.

4The installation to which the device

is connected must be compliant with

applicable standards.

4The charger is designed to operate on

single phase mains power supplies 230V

50Hz or 115V 60Hz. 115V / 230V selection

is automatic. (230V only for the 24V100A

model)

4The mains power supply must have

a main power on/off switch, with

differential protection, to protect persons,

notably in cases of electric shock. Refer

to the charger electrical consumption

characteristics for the rating and selection

of the protection circuit breaker.

4Before connecting the charger, the

mains power cable grommet supplied in

the package carton must be assembled

and properly mounted on the case (using

the mounting nut), in the specic hole

provided.

4For safety, the charger EARTH terminal

(marked PE “Protective Earth”) must be

connected to the main site earth circuit

SAFETY PRECAUTIONS

NOT-DOLPROHD-00

SAFETY PRECAUTIONS EN

(green/yellow wire in the mains power

cable). Refer to the wiring diagram for

more information.

4To prevent overheating, check that

cables are the specied section and that

connections are tight.

IMPORTANT: The charger is not protected

against batteries being connected with

reverse polarity. A wrong connection on

the battery side automatically destroys

the battery fuses and causes permanent

damage to the electronics board.

Startup precautions.

4In order to prevent any risk of electric

shock when switching on or during

operation, the protection cover must be

installed and properly screwed to the

mount.

4The charger complies with applicable

regulations concerning emitted

interference and immunity to external

interference (see EMC paragraph in the

Technical Specications section).

4When operating the charger, ensure

that it is not subjected to conducted or

radiated interference at levels above

the legal limits (e.g. charger too close to

a powerful transmitter), as such exposure

may cause malfunctions.

4Also, the charger emits conducted

and radiated interference at levels

compliant with applicable regulations.

Ensure that other equipment, used close

to the charger, is electro-magnetically

compatible, otherwise malfunctions may

be caused.

Charger serial number

The serial number is shown on the grey

or white label, bonded on one of the

sides of the charger. The serial number is

vertical. The rst two digits indicate the

year of manufacture (e.g. 15 for 2015),

followed by a letter indicating the month

of manufacture (e.g. C for the month

of March), followed by a 5-digit number

which is the charger number within the

series.

Important

Note on the choice of charge curve

Usingachargingcyclethatisincompatible

with the battery technology may seriously

damage the battery.

This is particularly true for cycles with

charge voltages that exceed the battery

manufacturer’s recommended charge

voltage.

Example: Considerable risk of battery

overheating and release of gases that

represent a health hazard.

Curve No. 9 is compatible with a LiFeSo4

battery, on condition that the battery

has a BMS (Battery Management System)

protection function.

You should refer to the battery

manufacturer’s recommendations when

selecting the charge cycle.

SAFETY PRECAUTIONS

NOT-DOLPROHD-00

INSTALLATION EN

Maintenance precautions

In order to prevent any risk of electric

shock during maintenance work, the

following recommendations should be

strictly observed before carrying out any

work:

4Maintenance work should only be

carried out by an appropriately qualied

technician.

4To avoid danger, damaged mains

power and/or battery cables should only

be replaced by a qualied person.

4Mains power must be disconnected

(cable or on/off switch).

4The -DC or -BAT battery side connection

must also be disconnected to avoid any

energy transfer.

4Wait 5 minutes for the high voltage

capacitors to discharge (on the

electronics board), before working inside

the case.

4Fuses should be replaced by fuses of

identical rating and performance.

WHEN YOU RECEIVE THE CHARGER

Package contents

4Charger.

4Installation manual.

4Mains power cable grommet with

its mounting nut (to be installed on

the case before connecting the

cables).

4Battery temperature sensor.

Preliminary checks

Check the charger identication

label, bonded on one of the case

sides, to ensure that the technical

data specied corresponds to your

requirement (mains power voltage,

charger rating, etc.).

Installation conditions

The charger is mounted using 4 screws, dia.

4mm (not supplied), on a support or wall that is

sufciently strong.

Check that the mounting screws used are

compatible with the type of mounting wall (resin,

wood, metal, etc.).

The charger should be positioned against the wall

and mounted rmly. Ideally, the charger should

be mounted vertically, with the cable exit facing

downwards. Leave a free space of at least 10 cm

all around the case, to allow optimum convection,

particularly on the cooling air inlet/outlet sides.

Inside the charger, the cooling air ows from right

to left when viewed from the front (see photo

below).

SAFETY PRECAUTIONS

NOT-DOLPROHD-00

CONNECTIONS

INSTALLATION

CONNECTIONS

The charger connections are accessible by

removing the hatch in the front panel. To open

the hatch, remove the mounting screw. Then

rotate the hatch to remove it.

Before connecting the cables, the mains power

cable grommet must be installed and properly

mounted on the case, in its specic hole (hole on

left when viewed from the front of the charger).

The cable grommet is mounted on the case

using the plastic nut supplied. The nut is installed

inside the case. Ensure that the nut is properly

tightened.

CONNECTION DETAILS

Cooling air ow

Mains power

cable grommet

worm

cold

NOT-DOLPROHD-00

CONNECTIONS

Identication Functions

L AC mains power phase, max.

10mm² (wire colour code: brown or

black)

N AC mains power neutral, max.

10mm² (wire colour code: blue,

white or red)

AC mains power earth, max.

10mm² (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 2 battery positive, pin M8

(wire colour code: red)

+DC3 Auxiliary 3 battery positive, pin M8

(wire colour code: red)

CHARGE

SELECT

Curve and battery charge mode

selector, 10 positions (0 to 9)

BATTERY FUSES Battery protection fuses (on the

–DC supply)

EXT TOUCH CAN bus for TOUCH screen con-

nection

EXT COM1

& COM2

CAN bus for network operation

ID SELECT Conguration charger ID (network

operation)

TEMP SENSOR Battery temperature sensor

(2 wires no polarity, no direction)

RELAY Alarm dry contact

CONNECTIONS

AC CABLES AND CIRCUIT BREAKER

AC wiring

Check that cables are properly connected and

that the connections are tight.

For the mains power supply, it is preferable to use

an industrial cable, type HO7RNF. Observe the

recommendations below.

AC circuit breaker

The AC mains power line must have an on/

off switch with integral differential protection,

to protect persons, notably in cases of electric

shock.

Circuit breaker sensitivity must be 30mA. The

circuit breaker current rating must correspond to

the charger consumption. For this, observe the

recommendations below.

Nota : The charger has an internal protection fuse

on access L, which notably protects against a

general fault on the electronics board. As the fault

concerned is permanent, this fuse is not accessible for

maintenance.

Charger rating 230VAC 50Hz

Length < 5m (16ft)

115VAC 60Hz

Length < 5m (16ft)

24V 40A 2.5mm² / AWG13 4mm² / AWG11

24V 60A 2.5mm² / AWG13 4mm² / AWG11

24V 100A 4mm² / AWG11 6mm² / AWG9

Charger rating Mains power 230V

50Hz

Mains power 115V

60Hz

24V 40A 8A – 30mA 16A – 30mA

24V 60A 10A – 30mA 20A – 20mA

24V 100A 20A – 30mA -

NOT-DOLPROHD-00

CONNECTIONS EN

DC CABLES AND FUSES

DC wiring

Check that cables are properly connected and

that connections are tight.

Battery cables should be as direct and short as

possible.

Each battery output can deliver the full power of

the charger and all cables should therefore be of

identical section. Recommended cable sections

are specied below.

The chargers are equipped with waterproof

grommets with an “automatic” opening

function.

Press the centre of the membrane to thread the

cable through the grommet.

Charger rating Length < 2m (6ft) Length from 3 to

5m (10 to 16ft)

24V 40A 16mm² / AWG5 20mm² / AWG4

24V 60A 25mm² / AWG3 35mm² / AWG2

24V 100A 35mm² / AWG2 50mm² / AWG0-1

CONNECTIONS

AC CABLES AND CIRCUIT BREAKER

DC fuses

If fuses inside the charger have to be replaced,

they should be replaced by fuses with identical

characteristics and performance. Risk of

permanent damage to the charger.

It is necessary and strongly recommended that

a connections protection fuse be installed as

close as possible to each positive output from the

battery. This notably provides protection against

a short circuit and/or battery cable overheating,

for example due to cable sheath damage.

CHARGE CURVE SELECTION

The voltage, current and charge time parameters

are monitored, as a function of the initial battery

status, by up-to-date digital electronics, using a

RISC micro-controller, which

also monitors and optimises the

charging process, through the

exclusive “scanning charge”

function.

Charger rating

Charger internal

fuse

(–DC supply)

Battery external

fuse

(+BAT supply of

each battery)

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

NOT-DOLPROHD-00

CONNECTIONS EN

Battery performance and life cycle are thus

enhanced.

The fully automatic charge cycles protect the

battery against overloads, and the charger can

thus be left permanently connected.

The charge programme is selected using the

“CHARGE SELECT” rotary selector on the charger

board. The selected programme number is

indicated by the arrow (programme No. 1 on the

photo above). The programme is selected using

a small at-head screwdriver.

CAUTION

Using a charging cycle that is incompatible with

the battery technology may seriously damage

the battery.

This is particularly true for cycles with charge

voltages that exceed the battery manufacturer’s

recommended charge voltage.

Considerable risk of battery overheating and

release of gases that represent a health hazard.

Curve No. 9 is compatible with a LiFeSo4 battery,

on condition that the battery has a BMS (Battery

Management System) protection function.

You should refer to the battery manufacturer’s

recommendations when selecting the charge

cycle. Toggle switch Thumb-wheel

Charger

Master

1: Master / 2 3 4: Network ID

Charge cycle according

to battery technology (10

positions)

Charger

Slave

No. 1

1: Slave / 2 3 4: Network ID ID Slave No. 1 (e.g. position 1)

Charger

Slave

No. 2

1: Slave / 2 3 4: Network ID ID Slave No. 2 (e.g. position 2)

Toggle switch Position 2: Determines whether the

charger is Master or Slave. Only ONE

Master per battery ID.

Position 2, 3, 4: Determine a battery ID,

i.e. a group of chargers operating on

one battery. Slave chargers attached to

a Master must have the same battery ID.

Thumb-wheel On Master charger: Determines the

charge curve for the Master and Slaves

operating on one battery.

On Slave charger: Determines the

charger ID (or the Slave No., from 0 to 9)

operating on one battery.

NETWORK MODE

NOT-DOLPROHD-00

SETTINGS SETTINGS EN

PROGRAMME PHASE VOLTAGE

Open

lead-

acid

V. BOOST

V. FLOAT

28.8V

26.4V

Sealed

lead-

acid

V. BOOST

V. FLOAT

28.4V

27.2V

2Lead-

calcium

V. BOOST

V. FLOAT

29.6V

27.6V

3“Delphi”

type

V. BOOST

V. FLOAT

30.8V

27.6V

Charge curve

Winter

storage

open

lead-

acid

V. BOOST

V. FLOAT

28.8V

26.4V

Charge curve

7GEL &

AGM

V. BOOST

V. FLOAT

28.8V

27.6V

Charge curve

8Power

supply V. FLOAT 27.2V

Charge curve

LiFeSo4

+ inte-

gral BMS

V. FLOAT 28.8V

Charge curve

Winter

storage

sealed

lead-

acid

V. BOOST

V. FLOAT

28.4V

27.2V

Charge curve

Type

“Op-

tima”

V. BOOST

V. MAX

V. FLOAT

29.6V

31.0V

27.6V

Charge curve

NOT-DOLPROHD-00

OPERATION OPERATION EN

BATTERY TEMPERATURE SENSOR

The temperature sensor allows the charge voltage

to be corrected as a function of the battery

temperature.

This results in a longer battery life cycle, mainly

in cases where the ambient temperature in the

battery room is high.

The sensor is screwed onto the main battery

positive terminal (generally ancillary). The 2 wires

are connected to the “TEMP SENSOR” connector

on the charger board (there is no polarity).

The compensation is around +/-25mV per °C for a

24V battery (see curves below).

TOUCH DISPLAY

This HD+ charger is equipped with an interactive

colour TOUCH screen. Screen functions are

described below.

NOT-DOLPROHD-00

OPERATION OPERATION EN

NOT-DOLPROHD-00

TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS EN

Technical specications

24V 40A 24V 60A 24V 100A

MAINS POWER CHARACTERISTICS

Mains power voltage 115V 60Hz and/or

230V 50Hz (+/-15%)

230V

(+/-15%)

Power factor 0.9 typ.

Efciency 87 typ.

Inrush current < 30A, limited by

soft start < 60A

Consumption 14A/6A 15A/9A 15A

Active power 1350VA 2000VA 3500VA

Derating @ 115V Without

derating

70%

Pnom -

Mains power fuse

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 charge cycles (0 to 9), se-

lectable by rotary selector

Charge curves In general 3 statuses, type

I.U.Uo

Open lead-acid V.BOOST = 28.8V

V.FLOAT = 26.4V

Sealed lead-acid V.BOOST = 28.4V

V.FLOAT = 27.2V

Lead-calcium V.BOOST = 29.6V

V.FLOAT = 27.6V

“Delphi” type V.BOOST = 30.8V

V.FLOAT = 27.6V

“Optima”

type

V.BOOST = 29.6V then 31.0V

V.FLOAT = 27.6V

Winter storage open lead-

acid

V.BOOST = 28.8V

V.FLOAT = 26.4V

Winter storage sealed

lead-acid V.BOOST = 28.4V

V.FLOAT = 27.2V

24V 40A 24V 60A 24V 100A

Gel & AGM V.BOOST = 28.8V

V.FLOAT = 27.6V

Power supply V.FLOAT = 27.2V

LiFeSo4 + integral BMS V.FLOAT = 28.8V

Temperature

compensation

+/-25mV / °C

(by an external sensor)

Voltage tolerance +/-2%

Ripple < 1 % (BW < 20 MHz)

Maximum current 40A

(+/-5%)

60A

(+/-5%)

100A

(+/-5%)

-DC supply fuse

3 x F25A

(miniature automo-

tive fuse)

5 x 30A

(miniature

automo-

tive fuse)

PROTECTION

Overload in output “Current limited” type

Short circuit in output “Shutdown” type with automatic