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SENS EnerGenius® DC Compact Technical Manual

SENS Part Number:

101334

Document Revision:

DCN Number:

107947

Date:

April 27, 2021

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

COMPACT

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

Содержание EnerGenius 101334

Страница 1: ...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...

Страница 2: ...Verify Configuration 23 7 3 Apply AC Input Voltage 24 7 4 Power Off 24 8 ALARMS LEDS AND DISPLAY 25 8 1 LED Indicators 25 8 2 Individual Alarm Relay Contacts 25 8 3 LCD Panel 26 8 4 Alarm Definitions...

Страница 3: ...Bit Definition 46 11 7 Charging AC Alarms Bit Definition 47 11 8 Accessory Channel Alarms Bit Definition 47 11 9 Accessory System Alarms Bit Definition 47 11 10 Accessory Assigned Channel Alarms Bit...

Страница 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...

Страница 5: ...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 follow...

Страница 6: ...40 VDC G Output Current 120 VDC 240VDC 006 6A 012 12A 025 25A 035 35A 050 50A K Comm and Display A Standard LCD Keypad 5 Form C Relays Ethernet L Accessory Hardware 0 None A High Current AC Alarm Rela...

Страница 7: ...ble 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 50 power limit from 18...

Страница 8: ...odes for increased current or fault tolerance when a common RJ 45 network cable is connected to each charger s paralleling bus Output blocking protection Prevents sparking during battery connection se...

Страница 9: ...tput 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...

Страница 10: ...ning for DC and three 1 2 inch openings for AC and alarms comms Network Alarm connections Modbus RJ 45 or terminal blocks 28 to 16 AWG Form C alarms 28 to 16 AWG Power connections AC DC terminal block...

Страница 11: ...4 2 2 Standard Items 4 2 2 1 AC Input Breaker UL 489 listed The breaker is lockable in the OFF position 4 2 2 2 DC Output Breaker UL 489 listed breaker The breaker is lockable in the OFF position 4 2...

Страница 12: ...or ventilation all around the charger at least 6 inches 15 cm at the top at least 4 inches 10 16 cm at the bottom at least 0 5 inches 1 27 cm on each side Operating temperature ranges stated above ass...

Страница 13: ...ips 2 screws Use conduit entry holes as shown in Figure 3 Figure 3 EnerGenius DC Compact Conduit Openings WARNING ENSURE THAT AC POWER IS DISCONNECTED AT THE MAINS CIRCUIT BREAKER OR OTHER SAFETY DISC...

Страница 14: ...63 152 304 6 16 0 4 240 480 35 14 2 5 2 5 NEC not allowed 12 4 1 6 NEC not allowed 10 6 1 69 138 8 10 0 63 109 218 6 16 0 4 171 342 4 25 0 25 274 548 2 35 0 16 429 858 50 14 2 5 2 5 NEC not allowed 1...

Страница 15: ...o grounded battery terminal If the battery must be disconnected for service remove the output wiring in the reverse order Tighten connections to torque specified in Table 4 Route DC wiring at least in...

Страница 16: ...rminals on the pluggable terminal block in the charger see Figure 4 To make wiring easier the terminal block unplugs from its header Pull terminal block straight out from header to remove Connect wire...

Страница 17: ...nctions and assignments are available both from the factory and by reassignment using the SENS Setup Utility 6 6 Optional High Current Relay Connections Optional high current relay assignments are cus...

Страница 18: ...rfaces and customer specific CAN protocol communications Consult the factory for configuration and setup 6 7 2 RS 485 The unit is equipped with serial RS 485 communications support via the RJ45 ports...

Страница 19: ...Common isolated Main circuit PCA only used for interconnect between SENS devices Figure 7 RJ 45 to Terminal Block Adapter Optional 6 7 4 Termination For proper operation a 120 ohm terminator is requi...

Страница 20: ...ludes ethernet connectivity to the charger for monitoring and configuration via the SENS Setup Utility Modbus TCP IP optional and DNP3 optional Figure 9 Ethernet Connection 6 8 1 Configure TCP IP Addr...

Страница 21: ...ons bus Connect a network cable from one charger to another using another position on each splitter to automatically initiate load sharing see Figure 10 Use of this sharing cable is essential to synch...

Страница 22: ...ignments than the alarm relays native to the charger Connect a straight thru splitter to the SENSbus RJ 45 port on each the charger and the remote panel Place a factory installed 120 ohm terminator in...

Страница 23: ...for the charger refers 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 batteri...

Страница 24: ...erates in constant current mode 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 co...

Страница 25: ...C voltage above below alarm setpoint SOLID GREEN FLASHING GREEN RED AC good system DC output good some individual charger module s in alarm state SOLID GREEN FLASHING YELLOW AC good Incompatible Batte...

Страница 26: ...cover as temperature increases LCD life is reduced with sustained operation above 65 C 8 4 Alarm Definitions See Table 11 for a description of LED indicator activity Unless noted otherwise the followi...

Страница 27: ...e Battery Discharging Setpoint V Cell GEN AGM 2 083 FLA 2 083 NCD 2 083 HCB 2 083 MAR VRLA 2 000 AGM 2 000 NCD 2 000 NGN VRLA 2 000 AGM 2 000 NCD 2 000 PSP N A 1 700 Configuration Code displayed on ch...

Страница 28: ...battery 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...

Страница 29: ...is disabled until the condition is corrected Activates alternating flashing yellow AC and DC LEDs When this alarm is assigned to a relay contact INVALID SETTINGS will cause the assigned relay to chan...

Страница 30: ...he charger capability When this alarm is assigned 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...

Страница 31: ...ailed state after the time delay 8 4 27 High Battery Room Temperature Indicates battery room temperature is above the High Battery Room Temperature setpoint This alarm is only available with the optio...

Страница 32: ...setpoint Activates solid yellow AC LED When this alarm is assigned to a relay contact AC VOLTAGE HIGH will cause the assigned relay to change to the Failed state after the time delay 8 4 35 AC SPD Ind...

Страница 33: ...ime limit set to 24 hours by default After operating in boost mode the charger switches to Float mode see section 9 2 If HELIX mode is enabled the charger will enter HELIX mode after operating in Floa...

Страница 34: ...eXtending mode is a type of intermittent charging that can increase the life of some types of batteries HELIX mode can be enabled disabled using the keypad the SENS Setup Utility or by selecting a dif...

Страница 35: ...by the user it can be run either manually or scheduled to run periodically Manually activate a Battery Check schedule a Battery Check to run automatically and configure minimum voltage and duration us...

Страница 36: ...ep 5 to return to Home screen 9 9 3 Menu Options Input output temperature and alarm status are displayed on the front panel LCD by default Press the UP or DOWN arrow to access additional menus as desc...

Страница 37: ...metimes necessary to limit maximum charging current to the battery This parameter allows the total power from the system to be adjusted to less than the full current capability of the system Temp comp...

Страница 38: ...enable Start or stop commissioning cycle Charger will deliver commissioning voltage and current until commissioning hours expire DC Start Volts Adjust DC Startup Voltage Set to zero to start into zero...

Страница 39: ...ode and relock access I O Bus Settings TCP IP Settings TCP IP Address Set TCP IP Address TCP IP Gateway Set TCP IP Gateway TCP IP Subnet Mask Set TCP IP Subnet Mask Hardware Mask Reads Hardware Addres...

Страница 40: ...itor is required for this functionality When temperature compensation is active the output voltage will increase slightly as temperature decreases decrease as temperature increases and is clamped at 0...

Страница 41: ...harger in a multi charger load sharing system fails or is disconnected the remaining chargers will still load share and ignore the faulted charger Each load sharing charger will alarm independently us...

Страница 42: ...charger is equipped with two fans on the top side of the unit The fans act in parallel so that if a fan failure occurs the unit can continue to operate though output power may be reduced depending on...

Страница 43: ...connection information Table 21 TCP IP Modbus Default Settings Setting Value IP Address 0 0 0 0 DHCP AUTO Subnet Mask N A Gateway N A Port Number 502 Modbus Slave Address 10 11 2 Modbus RS 485 Optiona...

Страница 44: ...s Extended Charging Alarm Extended status bits see section 11 6 Bitfield 1 48 0x030 49 0x031 Charging AC Alarms Charging AC Alarm status bits see section 11 7 Bitfield 1 50 0x032 51 0x033 Accessory Ch...

Страница 45: ...e Over Voltage Shutdown setpoint and unit has executed a high voltage shutdown This only occurs when the overvoltage is caused by the charger 5 0x05 Reverse Polarity Battery is connected backwards Out...

Страница 46: ...5 Charging Status Bit Definition Bit Address Name Description Decimal Hex 0 0x00 Output Idle Charging status Output Idle 1 0x01 Slave Mode Charging status Slave Mode 2 0x02 Helix Float Charge Chargin...

Страница 47: ...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...

Страница 48: ...ed 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 Hex...

Страница 49: ...loat settings plus one Range jumper For other standard settings install three jumpers on the charger to select the Battery Type Float Voltage and Range for your battery 102 Charger Module Simultaneous...

Страница 50: ...e Float Voltage and Range for your battery 105 Charger Module Duplicate charger location settings within a unit with channelized outputs Every charger in a unit configured for channelized outputs must...

Страница 51: ...utility to verify the channel DC output current and power ratings For N 1 or N 2 redundant operation use the required output rating i e the total for the minimum number of chargers N that will provid...

Страница 52: ...should be the number of charger modules connected to the SENSbus network Non redundant systems normally use a 0 setting which disables this error check but may be set if error checking is desired 302...

Страница 53: ...at DC output terminal block breaker and that the DC polarity is correct Correct charger AC input and DC output voltage as required 2 If step 1 doesn t resolve issue remove both AC and DC power for 1 m...

Страница 54: ...output terminal block breaker SOLID GREEN SOLID YELLOW AC good high battery voltage 1 Alarm setpoint incorrect for application 2 DC voltage is high due to an external source 1 Check that charger batte...

Страница 55: ...ry voltage good 1 Proper AC voltages or frequency not applied 2 Charger failure 1 Using a voltmeter check that AC input voltage and frequency at AC input terminal block breaker are in the range 188VAC...

Страница 56: ...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 polarity is correct Correct charger AC input and DC output voltage a...

Страница 57: ...oltage 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 then reapply power...

Страница 58: ...lure is the likely cause Contact SENS or replace charger ALTERNATING FLASHING RED No output 1 Missing or invalid code boot load required 1 Update charger firmware using setup utility 2 If step 1 doesn...

Страница 59: ...e definition of Equalize Voltage Equalize Voltage Equalize describes an elevated voltage typically employed to reset the series connected cells of a battery such that cell voltages and capacities more...

Страница 60: ...FALL INTO UNIT 5 REVISIONS DCN REV DESCRIPTION DATE APPROVED 107772 A INITIAL RELEASE 12 9 2019 ERS 107839 B GENERAL UPDATE 4 16 2020 ERS 108042 C CORRECT TYPO 4 27 2021 ERS D C B A A B C D 1 2 3 4 5...

Страница 61: ...OF THE TERMINALS IN ADDITION 1 TO PHYSICAL LIMITATIONS CONDUCTORS MUST BE ELECTRICALLY ADEQUATE PER ALL APPLICABLE ELECTRICAL SAFTEY REGULATIONS SUCH AS THE NATIONAL ELECTRICAL CODE REVISIONS DCN REV...

Страница 62: ...RIPTION 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 XXX SCALE D SIZE TITLE THE INFORMATION CONTAINED IN THIS DRA...

Страница 63: ...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...

Страница 64: ...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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