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Sens MicroGenius S2 Installation & Operation Manual

Automatic battery charger/power supply
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Automatic Battery Charger/Power Supply
Installation & Operation Manual
SENS Part Number:
Document Revision:
DCN Number:
Date:
PATENTED US 9,270,140; 9,385,556; 9,413,186; 9,509,164;
9,466,995; 9,948,125
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 2018
The SENS name / logo, MicroGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC
101330
F
107594
February 22, 2019
SENS MicroGenius S2/S4 Technical Manual
1
1840 Industrial Circle
Longmont, CO 80501
Phone: 303.678.7500
800.742.2326
Fax:
303.678.7504
Email:
service@sens-usa.com
Web:
www.sens-usa.com

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  • Page 1 Call SENS between 8 a.m. and 5 p.m. (Mountain Time), Web: www.sens-usa.com Monday through Friday, or visit our website. Copyright © Stored Energy Systems LLC 2018 The SENS name / logo, MicroGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC...

  • Page 2: Table Of Contents

    Battery Check ................................35 9.9. Restore Factory Defaults ............................35 9.10. Keypad Operation ..............................36 9.11. Configuration with SENS Setup Utility ........................40 9.12. Temperature Compensation ............................40 9.13. Load Share Charger Operation ........................... 41 9.14. Remote Alarm/Communications Panel Accessory ..................... 42 J1939 COMMUNICATIONS ..............................

  • Page 3: Important Safety Instructions For Installer And Operator

    SENS MicroGenius S2/S4 Technical Manual 1 IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR 1.1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for ® MicroGenius S2 and S4 battery chargers. 1.2. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and product using battery.
  • Page 4 SENS MicroGenius S2/S4 Technical Manual NICKEL-CADMIUM batteries only, with rated capacity of 30 to 1100 Ampere hours. Charger certified for fire pump and emergency generator applications. For a 24 hour recharge time do not exceed 220 Ampere hours of capacity per 12A charger output current. Do not use this battery...

  • Page 5: Model Number Breakout

    SENS MicroGenius S2/S4 Technical Manual MODEL NUMBER BREAKOUT Field Parameter Code Value Product Family MicroGenius S S2 chassis Enclosure S4 chassis Single output, no breakers Single output, AC and DC breakers (S4 only) Single output, AC/DC breakers with supplemental surge (S4 only)

  • Page 6: Performance Specifications

    DC output Voltage 12/24V nominal; multiple output assignments (optional); adjustable from 0-34V using front panel keypad or computer to charger cable/native USB (optional) and SENS Setup Utility Kit (SENS p/n 209254 plus SENS software available at www.sens-usa.com) Current 15-60 Amps, see section 2. Output power reduced by approximately 20% for output voltages greater than 24 VDC when input voltage is less than 170 VAC.
  • Page 7 -20 ° Humidity 5% to 95%, non-condensing Water ingress IP20; IP 22/NEMA 3R with optional drip shield (SENS p/n 209291 for S2 and 209287 for S4) Vibration Swept Sine (EN60068-2-6): 4G, 18-500 Hz, 3 primary axes Random: 20-500Hz, .01G...
  • Page 8 EN 50581 WEEE: 2012/19/EU This charger is considered electrical and electronic equipment (EEE) for non-household use and should be recycled accordingly. Do not dispose as unsorted municipal waste. See SENS website (www.sens- usa.com) for information on how to properly recycle. Construction...
  • Page 9 SENS MicroGenius S2/S4 Technical Manual openings S4 case size: rack mount brackets for 19 and 23 inch racks (optional) Dimensions See drawings and dimensions at back of manual Weight S2 case size: 13 lbs (5.9 kg) maximum S4 case size: 32 lbs (14.5 kg) maximum...

  • Page 10: System Overview

    SENS MicroGenius S2/S4 Technical Manual SYSTEM OVERVIEW Diagrams follow to demonstrate multiple configurations. Figure 1 – S2 Model KEYPAD AND LCD AC STATUS LED Adjustments, status and alarms CONNECT RS-485 DC STATUS LED MODBUS OR J1939 TO RJ-45 REMOVE PLUGGABLE ALARM...
  • Page 11 SENS MicroGenius S2/S4 Technical Manual Figure 2 – S4 Single Output with Breakers KEYPAD AND LCD AC STATUS LED Adjustments, status and alarms CONNECT RS-485 DC STATUS LED MODBUS OR J1939 TO RJ-45 REMOVE PLUGGABLE ALARM TERMINAL BLOCKS TO INSTALL ALARM WIRES 28–16 AWG (0.08–1.5 mm...
  • Page 12 SENS MicroGenius S2/S4 Technical Manual Figure 3 – S4 Single/Multiple Output without Breakers KEYPAD AND LCD AC STATUS LED Adjustments, status and alarms CONNECT RS-485 DC STATUS LED MODBUS OR J1939 TO RJ-45 REMOVE PLUGGABLE ALARM TERMINAL BLOCKS TO INSTALL ALARM WIRES 28–16 AWG (0.08–1.5 mm...

  • Page 13: Mounting Instructions

    SENS MicroGenius S2/S4 Technical Manual MOUNTING INSTRUCTIONS INSTALLATION OF THE UNIT MUST COMPLY WITH LOCAL ELECTRICAL CODES AND OTHER APPLICABLE INSTALLATION CODES AND BE MADE ACCORDING TO THE INSTALLATION INSTRUCTIONS AND ALL APPLICABLE SAFETY REGULATIONS. Printed circuit boards contain static sensitive components. Damage can occur even when static levels are too low to produce a noticeable discharge shock.

  • Page 14: Setup And Wiring

    IMPORTANT! The charger is configured at the factory and typically requires no adjustments before operating. Refer to the label on the inside lower cover for factory configured output and alarm relay assignments. The charger may be reconfigured using the front panel keypad or by software programming using the SENS Setup Utility.

  • Page 15: Grounding Instructions And Connection

    SENS MicroGenius S2/S4 Technical Manual 0.63 0.25 0.16 0.63 0.25 0.16 0.63 0.25 0.16 0.63 0.25 0.16 The above lengths consider the resistance of the battery and cables only and do not take into account any additional interconnects. The above lengths are for operation at 25°C/77°F. For high temperature installations (40°C/104°F) increase wire gauge by 10%.
  • Page 16 SENS MicroGenius S2/S4 Technical Manual Figure 4 – Multiple Output Connection Table 3 – DC Allowed Wire Gauge and Torque Requirements Charger Allowed Wire Gauge Required Torque Tool Connection Type Model ≤#4: 22 In-Lb (2.5 Nm) 20-2 AWG (0.5-35 mm...

  • Page 17: Ac Connection

    See charger inside cover label for original factory alarm relay assignments (see Figure 5). Alarm relay assignments are custom configurable using the front panel keypad (based on application) or the SENS Setup Utility. Connect alarm wiring to the respective terminals on the pluggable terminal block in the charger (see Figures 1-3 for location in charger and Figure 6 for detail).
  • Page 18 SENS MicroGenius S2/S4 Technical Manual Figure 5 – Configuration Label (on inside lower cover) View alarm relay assignments set at the factory View output voltage, battery type and configuration code set at the factory Figure 6 – Pluggable Terminal Block...

  • Page 19: Remote Temperature Sensor Connection-Optional

    SENS MicroGenius S2/S4 Technical Manual Table 8 – Alarm Relay Contact Wiring for Marine Configuration Wire from COM to OK for alarm present on open circuit or from COM to FAIL for present on closed circuit. RELAY 1 RELAY 2...

  • Page 20: Sae J1939 Communications Setup (Canbus)

    For multiple output chargers, J1939 address 1 (main charger) is assigned to charger output A and address 2 (auxiliary charger) is assigned to output B by default. Use the keypad or the SENS Setup Utility to configure J1939 addresses to any desired charger output.

  • Page 21: Modbus Communications Setup

    An adapter from RJ-45 to an 8-position terminal block may be connected to the RJ-45 connector and is available to order separately (SENS p/n 208026). Modbus communications settings may be configured using the keypad or SENS Setup Utility prior to initiating.

  • Page 22: Load Share Connection-Optional

    SENS MicroGenius S2/S4 Technical Manual 6.8.2. Modbus TCP/IP—Optional Connect TCP/IP Modbus communications using a twisted pair cable at the RJ-45 connector on the optional TCP/IP circuit board located on the inside front cover and separate from the alarm/communications circuit board (see Figures 1-3 for location in charger). TCP/IP Modbus communications settings must be configured using the DeviceInstaller Software provided by Lantronix Inc.

  • Page 23: Remote Alarm/Communications Panel Accessory Connection-Optional

    Refer to the label on the inside lower cover for factory configured output voltage, battery type and configuration code (see Figure 5). Values for each output are displayed separately for multiple output chargers. Review and adjust charger configuration using the front panel keypad or the SENS Setup Utility if factory configured settings require modification. See section 9.10...

  • Page 24: Apply Ac Input Voltage

    SENS MicroGenius S2/S4 Technical Manual 7.2.2.1. FLA This setting is ideal for flooded lead-acid batteries used in engine starting applications. The charging algorithm for flooded lead-acid batteries includes Float mode (see section 9.2), Dynamic Boost™ mode (see section 9.3) and HELIX mode (see section 9.4).

  • Page 25: Individual Alarm Relay Contacts

    LCD will indicate which output is in an alarm state. Alarm setpoints are configured separately for each output using the keypad. By default, the relay contacts change state 30 seconds after the onset of a fault. The relay delay is configurable using the front panel keypad (see section 9.10) or the SENS Setup Utility. See section...

  • Page 26: Lcd Panel

    Indicates DC output voltage is above factory alarm setpoint (see Table 12) or the configured level if setpoint is adjusted using keypad or SENS Setup Utility. Activates solid yellow DC LED. Alarm/communications circuit board HIGH DC relay contacts change to Fail state after delay when alarm is assigned to relay contacts.
  • Page 27 Indicates battery is beginning to discharge and DC output voltage is below factory alarm setpoint (see Table 13) or the configured level if setpoint is adjusted using keypad or SENS Setup Utility. The BATTERY DISCHARGING alarm is the first to trigger of three low output voltage alarms and is followed by LOW DC and then END OF DISCHARGE.
  • Page 28 Indicates DC output voltage is below factory alarm setpoint (see Table 15) or the configured level if setpoint is adjusted using keypad or SENS Setup Utility. This alarm is intended only for longer discharge rates (i.e. not engine starting applications) and indicates the normal end-of-discharge voltage for a lead-acid battery.
  • Page 29 SENS MicroGenius S2/S4 Technical Manual Table 16 – Factory Overvoltage Shutdown Setpoints Overvoltage Shutdown Setpoint Configuration Battery Type Code* 17.00 34.01 17.00 34.01 17.00 34.00 17.00 34.01 Ultracapacitor 17.60 29.20 VRLA 15.18 30.36 15.41 30.82 17.00 34.00 VRLA 15.18 30.36 15.41...
  • Page 30 SENS MicroGenius S2/S4 Technical Manual J1939 INACTIVE relay contacts change to Fail state after delay when alarm is assigned to relay contacts. 8.4.13. Modbus Inactive Indicates the charger cannot access the Modbus network and is not receiving messages when configured to use Modbus communications. Alarm/communications circuit board MODBUS INACTIVE relay contacts change to Fail state after delay when alarm is assigned to relay contacts.
  • Page 31 SENS MicroGenius S2/S4 Technical Manual Figure 13 – S2 Ground Fault Jumper Figure 14 – S4 Ground Fault Jumper 8.4.19. Low Current Indicates current drawn from the charger is below factory alarm setpoint. Chargers intended for genset applications are shipped with the low current alarm disabled. Chargers intended for marine and standby power applications are shipped with the low current alarm set to 2% of the charger’s rated output current.

  • Page 32: Operation

    SENS MicroGenius S2/S4 Technical Manual 8.4.20. Load Share Fail Indicates that chargers connected for load sharing are not sharing the current load. Activates double flashing yellow DC LED. Alarm/communications circuit board LOAD SHARE FAIL relay contacts change to Fail state after delay when alarm is assigned to relay contacts.

  • Page 33: Float Mode

    NFPA-20 fire pump or NFPA-110 emergency power system installations. Order chargers from the factory configured for fire pump/emergency power system installations or configure the charger appropriately using the keypad or SENS Setup Utility. Use of the optional remote temperature compensation probe is highly recommended to maximize charging performance and...

  • Page 34: Helix Mode

    HELIX mode can be enabled/disabled using the keypad, the SENS Setup Utility, or by selecting a different battery type. HELIX mode adds two DC output voltage settings to the traditional Boost and Float voltages. These are called Eco-Float and Refresh.

  • Page 35: Commissioning Batteries

    Activate a Battery Check using the keypad or SENS Setup Utility. Using the keypad, navigate to the “Battery Check” menu to enable a Battery Check and configure battery check minimum voltage and duration. Select the appropriate output for chargers with multiple outputs.

  • Page 36: Keypad Operation

    SENS MicroGenius S2/S4 Technical Manual 9.10. Keypad Operation The front panel keypad provides the ability to adjust charger settings without the SENS Setup Utility. 9.10.1. Security Code Protection Chargers may be security code protected to ensure only authorized personnel may adjust charger settings.
  • Page 37 SENS MicroGenius S2/S4 Technical Manual to delay before entering Boost mode after power is cycled or battery type is changed. Delay affects all outputs for multiple output models. Select DC Output (multiple output Select output to adjust specific settings models only)
  • Page 38 SENS MicroGenius S2/S4 Technical Manual from 6V to 98% of Float, must be at least 2% less than Float setting End Discharge Adjust setpoint to trigger Battery End-of- Discharge alarm, must be less than Low DC setting Low DC Voltage...
  • Page 39 SENS MicroGenius S2/S4 Technical Manual output models DC Output #D Enable or disable output D for multiple output models Set Output Assign charger modules to each S2/S4 output for multiple output models Select DC Output (multiple output Battery Check Select output to adjust specific settings...

  • Page 40: Configuration With Sens Setup Utility

    MicroGenius copyright year 9.11. Configuration with SENS Setup Utility Use the SENS Setup Utility to program the charger with custom settings rather than using the keypad. Custom configuration is typically completed by OEMs, qualified dealers/distributors, and packagers. The setup utility allows configuration of all charger settings including alarm relay assignments.

  • Page 41: Load Share Charger Operation

    SENS MicroGenius S2/S4 Technical Manual Figure 16 – Example Temperature Compensation Curves 9.13. Load Share Charger Operation Multiple chargers may be connected in parallel to provide charger redundancy and increased charging current. Load sharing chargers are fault tolerant; one charger failure will not cause failures in paralleled chargers.

  • Page 42: Remote Alarm/Communications Panel Accessory

    In most cases, charger default J1939 settings are sufficient to automatically begin using J1939 communications after connecting the charger to the network. Use the SENS Setup Utility to adjust J1939 settings (e.g. baud rate, vehicle system instance, etc.) if required.

  • Page 43: Modbus Communications

    SENS MicroGenius S2/S4 Technical Manual 11 MODBUS COMMUNICATIONS Modbus communications settings may be configured using the keypad or SENS Setup Utility prior to executing communications. Modbus is provided over RS-485 using RTU or ASCII mode or over TCP/IP as an option.

  • Page 44: Modbus Holding Registers

    SENS MicroGenius S2/S4 Technical Manual Use the DeviceInstaller software to change the IP Address of the TCP/IP module by using the Assign IP command in the menu toolbar. The software will request the Device Identification (hardware address) of the module. This address is identified as “MAC” and is displayed on the charger label located on the outside of the charger enclosure.
  • Page 45 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Default Output Periodic Interval between periodic boost 0x054 0x055 Boost Period events (0 = disabled) Default Output AC Line 0x056 0x057 AC Line Frequency Frequency Default Output AC Line...
  • Page 46 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Discharge Program (used for Program Mode setting) Default Output Batt End Alarm setpoint for End Discharge 0x09E 0x09F V/Cell 32768 Discharge Program (used for Program Mode setting)
  • Page 47 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Output A Periodic Boost Interval between periodic boost 0x0E4 0x0E5 Period events (0 = disabled) Output A AC Line 0x0E6 0x0E7 AC Line Frequency Frequency 0x0E8 0x0E9 Output A AC Line Voltage 1...
  • Page 48 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Time Limit Mode setting) Output A Current Limit Current Limit setpoint in % of output % Rated 0x132 0x133 32768 Setting current as a 10 bit value...
  • Page 49 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale 0x178 0x179 Output B AC Line Voltage 1 AC Line 1 Voltage 32768 0x17A 0x17B Output B AC Line Current 1 AC Line 1 Current 32768 AC Line 2 Voltage (Not applicable to...
  • Page 50 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Helix Refresh Time Output B Default Output 0x1C8 0x1C9 Helix Eco Time 3600 Helix Eco Time Output B Default Output Interval between scheduled Periodic 0x1CA 0x1CB Days...
  • Page 51 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale AC Line 3 Voltage (Not applicable to 0x210 0x211 Output C AC Line Voltage 3 32768 single phase chargers) AC Line 3 Current (Not applicable to 0x212...
  • Page 52 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Voltage Setting Output C Battery Check Interval between scheduled 0x25E 0x25F Days 86400 Interval automatic battery checks Output C Battery Check 0x260 0x261 Duration of battery check...
  • Page 53 SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Output D Battery Check Interval between scheduled 0x2A6 0x2A7 Interval automatic battery checks Output D Number of Number of chargers detected on 0x2A8 0x2A9 Chargers SENSbus, 0 - 30...

  • Page 54: Status Definition

    SENS MicroGenius S2/S4 Technical Manual Address High Address Low Name Description Units Scale Duration Output D Default Output 0x2F2 0x2F3 Commissioning VPC V/Cell 32768 Commissioning VPC Output D Default Output 0x2F4 0x2F5 Commissioning Duration 3600 Commissioning Duration Output D Default Output...

  • Page 55: Extended Status Bit Definition

    SENS MicroGenius S2/S4 Technical Manual Bit Address Name Description 0x08 Alarm Invalid Settings Charger disabled because jumper setting is not correct J1939 enabled, but no bus access (did not obtain an 0x09 Alarm J1939 Inactive address) 0x0A Alarm Thermal Foldback...

  • Page 56: Writable Control Flags (Coils)

    SENS MicroGenius S2/S4 Technical Manual Bit Address Name Description Decimal 0x11 Three Phase Input Charger has three phase input 0x12 Battery Temperature Valid Have valid remote temperature sensor reading 0x13 Scheduled Equalize Enabled Scheduled boost charge cycles enabled Scheduled Battery Check...

  • Page 57: Troubleshooting/Error Codes

    SENS MicroGenius S2/S4 Technical Manual Address Description Details Decimal 0x042 Start/stop battery check, Channel D ON to start, OFF to stop 0x043 Reset periodic battery check schedule ON to reset schedule, OFF is no-op 0x044 Clear battery check failure, Channel D...
  • Page 58 SENS MicroGenius S2/S4 Technical Manual Error Scope Description Corrective Action Duplication is allowed for modules in different the replacement charger for the same position as the units, i.e. with different "Unit Serial Numbers". module being removed. Modules using the “default” output do not use - To prevent confusion, the position jumper settings charger positions.

  • Page 59: Troubleshooting

    SENS MicroGenius S2/S4 Technical Manual 12.2. Troubleshooting AC LED DC LED Symptom Possible Causes Recommended Actions 1. Proper AC or DC voltages not 1. Using a voltmeter, check that AC input voltage and applied frequency at AC input terminal block/breaker are 2.
  • Page 60 High goes to pin 1 of J2 and that J1939 Data Low goes to pin 2 of J2. 5. If cable wiring is correct, verify that requested command is supported by SENS charger per J1939 table in charger manual. 6. Check for address conflicts on the network Basic J1939 1.
  • Page 61 SENS MicroGenius S2/S4 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions LLOW temperatures temperature is lowered. DOUBLE 1. Charger output settings do not 1. Check that individual charger settings are identical. *SOLID FLASH AC good, load share fail match between chargers Adjust as required.
  • Page 62 SENS MicroGenius S2/S4 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions are in the range 80VAC – 264VAC / 47Hz – 63Hz or that > 8VDC is present at DC output terminal block/breaker and that the DC polarity is correct.

  • Page 63: Glossary

    “Boost” is employed most frequently in the context of accelerating the recharge of a fully or partially discharged battery that is periodically discharged. The MicroGenius S2/S4 chargers use the term “Boost” for the higher output voltage mode (see section 9.3)
  • Page 66 Asbestos in this product. - End user must use output cables that have sufficient current carrying capacity as per ABS Steel Vessel Rules 4-8-2/7.7.1. Notes / Documentation: Drawing No. COMPLIANCE SPEC MicroGenius S2 and S4, Pages:4 Drawing No. 2DCAD-S2-STD, 2DCAD, S2, STANDARD, Revision: A, pages:1 Drawing No. 03/21/2018 12:59:27 PM Copyright 2001 American Bureau of Shipping.
  • Page 67 No. S4_ABS_Disharge_310Ahr_2017_10_03, S4_ABS_Disharge_310Ahr Drawing No. S4_ABS_Recharge_310Ahr_2017_10_04, S4_ABS_Recharge_310Ahr Drawing No. MicroGenius_S2_and_S4_Model_Series_Designation, pages:2 Drawing No. SENS S2 IP22 Test, MICROGENIUS S2 IP22 DRIP AND SOLD INTRUSION TEST, pages:15 Drawing No. SENS S4 IP22 Test, MICROGENIUS S4 IP22 DRIP AND SOLD INTRUSION TEST, pages:13 Drawing No.
  • Page 68 Certificate Number: 18-HS1717491-PDA Approval. The approvals of Drawings and Products remain valid as long as the ABS Rule, to which they were assessed, remains valid. ABS cautions manufacturers to review and maintain compliance with all other specifications to which the product may have been assessed. Further, unless it is specifically indicated in the description of the product;...
  • Page 69 Manufacture Address: 1840 Industrial Circle Longmont, CO 80501 U.S.A. Product Type: MicroGenius S2/S4 Battery Charger Model Numbers: SX-YYY-YYYYYYYY, where X = 2 or 4; Y = any digit; Conformance to Directive 2014/30/EU of the European Parliament and of the Council...
  • Page 70 Return Material Authorization (RMA) number provided by SENS. If, in SENS’ opinion, the problem can be rectified in the field, SENS may elect to ship replacement parts for customer installation instead of having the product returned to the factory.

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