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SENS EnerGenius® DC Wallbox Technical Manual 

 

 

 

 

1 

 

 

 

 
 
 
 
 
 
 
 
 
 

 

 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

SENS Part Number: 

101335 

Document Revision: 

A 

DCN Number:   

107839 

Date:   

 

May 4, 2020 

PATENTED US 9,270,140; 9,385,556; 9,413,186; 9,509,164; 
9,466,995; 9,948,125; 10,575,433 

Installation or service questions?  
Call SENS between 8 a.m. and 5 p.m. (Mountain Time),  
Monday through Friday, or visit our website. 

Copyright © Stored Energy Systems LLC 2020 
The SENS name / logo, EnerGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC 

 

Installation & Operation Manual 

WALLBOX 

Automatic Battery Charger/Power Supply

 

1840 Industrial Circle  
Longmont, CO 80501 
Phone:   303.678.7500 
 

800.742.2326 

Fax: 

303.678.7504   

Email:  [email protected] 
Web: 

www.sens-usa.com 

Summary of Contents for EnerGenius 101335

Page 1: ...ll SENS between 8 a m and 5 p m Mountain Time Monday through Friday or visit our website Copyright Stored Energy Systems LLC 2020 The SENS name logo EnerGenius HELIX and Dynamic Boost are trademarks o...

Page 2: ...t Battery Outputs 24 7 2 Verify Configuration 24 7 3 Apply AC Input Voltage 25 7 4 Power Off 25 8 ALARMS LEDS AND DISPLAY 26 8 1 LED Indicators 26 8 2 Individual Alarm Relay Contacts 26 8 3 LCD Panel...

Page 3: ...11 6 Charging Alarms Extended Bit Definition 48 11 7 Charging AC Alarms Bit Definition 49 11 8 Accessory Channel Alarms Bit Definition 49 11 9 Accessory System Alarms Bit Definition 49 11 10 Accessory...

Page 4: ...IS DANGEROUS STORAGE BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION FOR THIS REASON IT IS OF UTMOST IMPORTANCE THAT YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EACH TIME YOU...

Page 5: ...ater in each cell until battery acid reaches level specified by battery manufacturer Do not overfill For a battery without removable cell caps such as valve regulated lead acid batteries carefully fol...

Page 6: ...DC units G Output Current 120 VDC 240 VDC 025 25A 035 35A 050 50A 075 75A 100 100A J Redundancy 0 No Redundancy 1 N 1 Redundancy K Communications and Interface A Standard LCD Keypad 5 Form C Relays Et...

Page 7: ...detailed in the table below see following sections for installation and operation instructions Table 1 Specifications AC input Voltage frequency Full output power 358 528 VAC 3 phase line to line con...

Page 8: ...rs actively current share and synchronize all modes for increased current or fault tolerance when common RJ 45 network cable is connected to each charger s paralleling bus Output blocking protection P...

Page 9: ...is derated 0 012 per additional meter at rated ambient temperature Vibration shock resistance EN60068 2 6 EN 60068 2 64 EN 60068 2 27 Electrical transient ANSI IEEE C62 41 EN 61000 4 12 on power term...

Page 10: ...tem comes factory configured for its application from the factory Configuration details are given on the configuration label see Figure 2 These values are assigned according to the profile configurati...

Page 11: ...Pilot Relays are available for connection of external loads and alarms Two pilot relays are provided The first relay is factory assigned as a summary alarm These are configurable using the SENS Setup...

Page 12: ...nting Location See diagrams at back of manual for dimensions and mounting information 5 1 1 Charger is rated IP20 5 1 2 Charger will operate at full specification when located where temperatures are w...

Page 13: ...ccess to mounting holes 5 2 4 Mount the charger using four 3 8 inch M10 screws with standard flat washers Mounting hardware is not included with the charger and must be provided by the installer 5 2 5...

Page 14: ...Use conduit entry holes as shown in Figure 3 Figure 3 EnerGenius DC Wallbox Conduit Openings WARNING ENSURE THAT AC POWER IS DISCONNECTED AT THE MAINS CIRCUIT BREAKER OR OTHER SAFETY DISCONNECT BEFORE...

Page 15: ...8 4 0 63 76 152 6 13 3 0 40 120 240 4 21 2 0 25 192 384 2 33 6 0 16 300 600 75 10 5 3 1 00 NEC not allowed 8 8 4 0 63 NEC not allowed 6 13 3 0 40 80 160 4 21 2 0 25 128 256 2 33 6 0 16 200 400 1 0 53...

Page 16: ...isconnected from DC bus Connect the DC output conductors to the DC output terminal block breaker in the charger see Figures 1 3 Always observe proper polarity of the DC output leads Always connect the...

Page 17: ...ng KAIC AC Breaker Interrupt Optional Rating KAIC 120 50 21 6 30 25 65 120 75 21 6 30 25 65 120 100 21 6 30 25 65 240 25 21 6 30 25 65 240 35 21 6 30 25 65 240 50 21 6 30 25 65 6 5 Standard Alarm Conn...

Page 18: ...pen on alarm normally closed OK TB1 2 OK TB1 5 OK TB1 8 OK TB1 11 Defaults to OK with no AC and DC power OK TB1 14 Close on alarm normally open FAIL TB1 3 Defaults to FAIL with no AC input FAIL TB1 6...

Page 19: ...circuit See Table 9 There are two type of alarm relay options available from the factory The first variant of alarm circuits 2 are rated 5A at 120VAC The second variant of alarm circuits 2 are rated 3...

Page 20: ...ial RS 485 communications support via the RJ45 ports This interface is intended for monitoring and communicating with the charger Available protocols include Modbus and DNP3 See manual sections on spe...

Page 21: ...oper operation a 120 ohm terminator is required at the ends of the CAN and or RS 485 bus If multiple devices are on the bus only the devices on the ends of the network bus need termination resistors F...

Page 22: ...equipped with a SENSbus RJ45 port see Figure 10 This connection is used to interconnect SENS specific devices WARNING DO NOT PLUG ETHERNET INTO THIS CONNECTION Connect remote accessories to the charg...

Page 23: ...determine which charger is designated as the master unit 6 9 2 Remote Battery Monitor Optional The optional remote battery monitor accessory provides the ability to monitor battery temperature ambien...

Page 24: ...fers to AGM absorbed glass mat type batteries that are employed in engine starting applications This charging mode should not be used with switchgear or other industrial type batteries For AGM type ba...

Page 25: ...Eventually as the battery is charged the charging current demand will taper to a value below the current limit setpoint of the charger and the charger will revert to constant voltage output Chargers c...

Page 26: ...some individual charger module s in alarm state SOLID GREEN FLASHING YELLOW AC good Incompatible Battery error charger disabled SOLID GREEN FLASHING GREEN YELLOW AC good output limited by high temper...

Page 27: ...a relay contact AC LINE FAIL will cause the assigned relay to change to the Failed state after the time delay 8 4 2 High DC Voltage Indicates DC output voltage is above the High DC Voltage factory al...

Page 28: ...alarm setpoint see Table 14 or the configured level if setpoint is adjusted using keypad or SENS Setup Utility Alarm setpoint must be set lower than BATTERY DISCHARGING and higher than END OF DISCHARG...

Page 29: ...ttery and or load or is providing more current than the charger s control system is commanding This alarm is typically caused by a module internal component failure This alarm does not occur during AC...

Page 30: ...lternating flashing yellow AC and DC LEDs When this alarm is assigned to a relay contact INVALID SETTINGS will cause the assigned relay to change to the Failed state after the time delay 8 4 11 Fan Fa...

Page 31: ...to a relay contact GROUND FAULT NEGATIVE will cause the assigned relay to change to the Failed state after the time delay 8 4 18 Low Current Indicates current from the charger is below the Low Curren...

Page 32: ...he Failed state after the time delay 8 4 27 Charger Low Temperature Indicates charger is currently below its rated temperature Output may be derated When this alarm is assigned to a relay contact CHAR...

Page 33: ...d Only active with Breaker Status option Alarm communications circuit board DC BREAKER relay contacts change to Fail state after delay when alarm is assigned to relay contacts 9 OPERATION 9 1 Charging...

Page 34: ...ual or automatic boost timers or earlier generation automatic boost control systems Dynamic Boost is automatically used by the charger depending on battery type selected See the inside cover label for...

Page 35: ...a mismatched condition cycle AC and DC power to reset the charger and resume charging This safety feature can be temporarily defeated from the keypad or the SENS Setup Utility in order to charge comm...

Page 36: ...g the front panel keypad by scrolling to the Battery Set up menu and selecting Restore Factory Default Settings Values that will revert to original factory settings include Battery type Temperature Co...

Page 37: ...ear Failure Clear status of all latched alarms Meters AC Input AC input voltage and frequency DC Output voltage DC output voltage and current DC Output power DC output watts and of rated output being...

Page 38: ...just amount of time to delay activation of alarms after alarm event takes place from 5 to 60 seconds Alarm comms circuit board alarm relay contacts and alarms on communications ports are delayed LED a...

Page 39: ...the DC Startup Voltage Restore Factory Default Settings Restore settings to factory configuration Other Settings Relay Assignment Selection alarm relay assignments based on application see Table 8 LCD...

Page 40: ...tion Select RTU or set to OFF to disable Modbus communications Modbus Configuration Address Adjust Modbus slave address from 1 to 255 RS 485 Set to OFF to disable Modbus communications Modbus Configur...

Page 41: ...he battery A SENS remote battery monitor is required for this functionality When temperature compensation is active the output voltage will increase slightly as temperature decreases decrease as tempe...

Page 42: ...ad share operation a 120 ohm terminator is required at the ends of the SENSbus Chargers intended for load sharing must be configured with the same output settings in order to load share properly The L...

Page 43: ...lean and free from debris see section 10 2 10 2 Power Module Access The EnerGenius DC Wallbox is powered by up to two EnerGenius DC power modules These modules can be accessed by removing the module a...

Page 44: ...to operate though output power may be reduced depending on continuous loads and ambient temperature An alarm will indicate if a fan needs to be serviced or replaced See Figure 15 for fan servicing det...

Page 45: ...rial Modbus communications over RS 485 using RTU or ASCII mode are optional Modbus communications settings may be configured using the keypad or SENS Setup Utility prior to executing communications Mo...

Page 46: ...s see section 11 7 Bitfield 1 50 0x032 51 0x033 Accessory Channel Alarms Accessory Channel Alarm status bits see section 11 8 Bitfield 1 52 0x034 53 0x035 Accessory System Alarms Accessory System Alar...

Page 47: ...voltage is caused by the charger 5 0x05 Reverse Polarity Battery is connected backwards Output is disabled until the condition is corrected 6 0x06 Unused Unused 7 0x07 Incompatible Battery Unit is con...

Page 48: ...e system has faulted 27 0x1B Battery Check Battery has failed the most recent battery check 11 5 Charging Status Bit Definition Bit Address Name Description Decimal Hex 0 0x00 Output Idle Charging sta...

Page 49: ...ng An AC phase is missing or out of range Only available in a 3 phase capable device 2 0x02 AC Voltage Over Maximum AC Voltage has gone above max AC voltage allowed by the charger on any phase NOTE Th...

Page 50: ...Unused Unused 17 0x11 Unused Unused 18 0x12 No Power Board Data No module power boards are found on SENSBus 11 10 Accessory Assigned Channel Alarms Bit Definition Bit Address Name Description Decimal...

Page 51: ...ts use the keypad Enable Disable DC Output Ch selection in the Other Settings menu or the setup utility to disable all output channels for the display board Then use the Set DC Output setting in the O...

Page 52: ...ndant operation Verify that each channel is assigned enough chargers to meet the required DC output rating plus any extra chargers needed to provide N 1 or N 2 redundant operation Check for disconnect...

Page 53: ...lity to verify the System Charger Count setting For N 1 or N 2 redundant operation this should be the number of charger modules connected to the SENSbus network Non redundant systems normally use a 0...

Page 54: ...eed to be replaced Contact SENS SOLID GREEN FLASH or SOLID GREEN Unable to Communicate using MODBUS 1 No communication bus termination installed 2 Communication cable is plugged into the wrong charger...

Page 55: ...consider battery surface charge and any other connected equipment SOLID GREEN SOLID YELLOW AC good low battery voltage 1 Alarm setpoint incorrect for application 2 Battery discharged or defective 1 Ch...

Page 56: ...n control board is likely contact SENS SOLID RED SOLID GREEN AC fail battery voltage good 1 Proper AC voltages or frequency not applied 2 Charger module failure 1 Using a voltmeter check that AC input...

Page 57: ...meter check that AC input voltage and frequency at AC input terminal block breaker are in the range 188VAC 428VAC 47Hz 63Hz or that 60VDC is present at DC output terminal block breaker and that the DC...

Page 58: ...power Ensure AC voltage and or DC voltage is within specified operating limits of the charge 2 If fault remains check overvoltage shutdown settings and again remove both AC and DC power for 1 minute...

Page 59: ...using setup utility 2 If steps 1 doesn t resolve issue or setup utility is not available replace charger ALTERNATING FLASHING GREEN Starting up 1 Charger is still powering on 2 Failed display board 1...

Page 60: ...higher output voltage mode see section 9 3 Equalize Voltage A higher output voltage used to quickly recharge batteries and ensure that all battery cells in a battery string are charged to the same lev...

Page 61: ...INSTALLATION FOR EASY OF ASSEMBLY 5 IMPORTANT WHEN INSTALLTING UNIT ENSURE THAT NO DEBRIS OR PARTICLES FALL INTO UNIT 6 REVISIONS DCN REV DESCRIPTION DATE APPROVED 107772 A INITIAL RELEASE 12 9 2019...

Page 62: ...COMMUNICATION CONNECTIONS DETAIL C SCALE 1 1 RS 485 CAN SENSBUS ETHERNET ALARM RELAYS NOTES WIRE RANGES REFER TO THE PHYSICAL CAPACITY OF THE TERMINALS IN ADDITION 1 TO PHYSICAL LIMITATIONS CONDUCTOR...

Page 63: ...WIRING AC LINE 2 B AC LINE 3 C STATUS A REVISIONS REV DESCRIPTION DCN DATE APPROVED A INITIAL RELEASE 107772 12 19 2019 ERS 1 B C D 2 3 4 5 6 7 8 4 3 2 1 8 7 6 5 A B C D XX X FINISH MATERIAL ANGLES X...

Page 64: ...the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits recast Directive EU 2017 2102 o...

Page 65: ...choose to replace your charger we may replace it with a new or refurbished one of the same or similar design The repair or replacement will be warranted for the remainder of the original five year wa...

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