Sens MicroGenius 2 Installation & Operation Manual
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Sens MicroGenius 2 Installation & Operation Manual

Genset, marine & stationary battery charger
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Genset, Marine & Stationary Battery
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;
PATENTS PENDING
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 2017
The SENS name / logo, MicroGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC
180W: 12V, 10A; 24V, 6A
300W: 12V, 12A; 24V, 10A
450W: 12/24V, 15A
101324
J
107448
March 22, 2018
Charger
1
SENS MicroGenius 2 Technical Manual
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 2017 The SENS name / logo, MicroGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC...

  • Page 2: Table Of Contents

    SENS MicroGenius 2 Technical Manual TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR ................3 MODEL NUMBER BREAKOUT ..............................4 PERFORMANCE SPECIFICATIONS ............................5 SYSTEM OVERVIEW ................................10 MOUNTING INSTRUCTIONS ..............................11 5.1. Mounting Location ................................11 5.2.

  • Page 3: Important Safety Instructions For Installer And Operator

    SENS MicroGenius 2 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 2 battery chargers. 1.2. Do not expose open-frame charger to rain or snow.

  • Page 4: Model Number Breakout

    SENS MicroGenius 2 Technical Manual charger to supply power to an extra-low voltage electrical system or to charge any type of non- rechargeable, dry cell, alkaline, lithium, nickel-metal-hydride, or sealed nickel-cadmium batteries that are commonly used with home appliances. These batteries may burst and cause injuries to persons and damage to property.

  • Page 5: Performance Specifications

    SENS MicroGenius 2 Technical Manual PERFORMANCE SPECIFICATIONS ® MicroGenius 2 is a switchmode, regulated, filtered, microprocessor-controlled, current limited battery charger designed for heavy-duty industrial service. Chargers may be configured for three primary applications: 1) quick recharge and long life maintenance of engine start batteries, 2) DC power supply and battery charging for marine environments, and 3) DC power and standby battery charging for industrial control and safety systems.
  • Page 6 SENS MicroGenius 2 Technical Manual DC output Voltage 12/24V nominal; field selectable; adjustable from 0-34V using computer to charger cable and SENS Setup Utility Kit (SENS p/n 209254 plus SENS software available at www.sens-usa.com) Current 180W: 10A at 12V nominal and 6A at 24V nominal, 180W maximum...
  • Page 7 Flooded lead-acid, AGM or Ni-Cd for engine starting; VRLA for reserve power; ultracapacitor Computer adjustment Change or customize settings from computer using computer to charger cable and SENS Setup Utility Kit (SENS p/n 209254 plus SENS software available at www.sens-usa.com) Keypad adjustment...
  • Page 8 SENS MicroGenius 2 Technical Manual Environ- Operating temperature 180W, enclosed: -40°C to +70°C; meets full specification from mental -40°C to +55°C 180W, open-frame: -40°C to +70°C; meets full specification from - 40°C to +60°C 300W: -40°C to +70°C; meets full specification from -40°C to +50°C 450W: -40°C to +70°C;...
  • Page 9 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 10: System Overview

    SENS MicroGenius 2 Technical Manual SYSTEM OVERVIEW Fully enclosed model with optional alarm/communications circuit board shown. Refer to the nameplate label or the label on the inside lower cover for factory configured output and alarm relay assignments. MOUNTING FASTENERS: MOUNTING: Mount enclosed chassis Use four ¼...

  • Page 11: Mounting Instructions

    SENS MicroGenius 2 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 12: Mounting Instructions

    SENS MicroGenius 2 Technical Manual charger is operating at full current load and maximum ambient temperature. 5.1.2.3. The charger will operate at full specification when located where temperatures are within the following ranges. Output power is gradually reduced at higher temperatures.

  • Page 13: Charger Setup

    (see Figure 3). If the system voltage or battery type is different than the factory configuration, or if other custom settings are required, the charger may be reconfigured using the jumpers, the optional front panel keypad, or by software programming using the SENS Setup Utility. Figure 1 – Jumper Settings...

  • Page 14: Standard Jumper Configuration

    SENS MicroGenius 2 Technical Manual Figure 3 – Configuration Label (on inside lower cover) View output voltage, battery type and configuration code set at the factory View alarm relay assignments set at the factory 6.1.1. Changing Voltage Range Using Factory Jumpers Mode...
  • Page 15 SENS MicroGenius 2 Technical Manual Figure 5 – Standard Jumper Configuration 6.2.1. Battery Type Jumper Set the BATTERY TYPE jumper appropriate for the battery type used. Table 2 – Charging Algorithms by Battery Type Charging Algorithm Battery Type Float Dynamic...

  • Page 16: Keypad Configuration-Optional

    SENS MicroGenius 2 Technical Manual 6.2.1.5. Ultracapacitors Place one jumper each in the AGM and NICD battery type positions and leave one jumper in the RANGE position if charging ultracapacitors rather than batteries (see section 10.5). 6.2.2. Float Voltage Jumpers When the charger is in Float mode the output voltage is maintained at the float voltage setting.

  • Page 17: Program Mode

    Removing all jumpers from the BATTERY TYPE, FLOAT and RANGE positions enables Program Mode. In Program Mode the charger output is determined by values programmed in the charger using the SENS Setup Utility (see section 10.10). If the charger has not been specially programmed, removing all jumpers will result in an error state and the charger will not produce output.

  • Page 18: Modbus Communications Setup

    Modbus Organization (http://www.modbus.org/specs.php). Modbus communications settings must be configured using the optional keypad or SENS Setup Utility prior to initiating. See section 10.15 further information on Modbus operation and configuration.

  • Page 19: Wiring

    SENS MicroGenius 2 Technical Manual Figure 10 – Modbus Termination LT = Line Termination 120-ohm resistor WIRING All wiring must comply with applicable codes and local ordinances. WARNING: ENSURE THAT AC POWER IS DISCONNECTED AT A CIRCUIT BREAKER OR OTHER SAFETY DISCONNECT BEFORE WIRING THE CHARGER Figure 11 –...

  • Page 20: Wire Ratings And Sizes

    7.1.3. For best performance and recharge time, refer to the following table to determine the appropriate output conductor gauge and length. Use of a remote temperature sensor (SENS p/n 209481, see section 7.6) is highly recommended for best charging performance.

  • Page 21: Grounding Instructions And Connection

    SENS MicroGenius 2 Technical Manual 7.2. Grounding Instructions and Connection 7.2.1. Charger must be grounded to reduce risk of electric shock. The charger must be connected to a grounded, metal, permanent wiring system, or an equipment-grounding conductor (earthing conductor) must be run with the circuit conductors and connected to equipment-grounding terminal on charger.
  • Page 22 SENS MicroGenius 2 Technical Manual Figure 12– Pluggable Terminal Block (TB2 pins 1-9 shown) PULL TO REMOVE FROM HEADER THREE POSITIONS PER RELAY: COM, OK, FAIL Table 4 – Alarm Relay Contact Wiring for Genset Configuration Wire from COM to OK for alarm present on open circuit or from COM to FAIL for present on closed circuit.

  • Page 23: Remote Temperature Sensor Connection-Optional

    24 hours without causing damage to the battery. Temperature compensation is disabled by connecting a short across the remote temperature sensor terminal block on the main circuit board, using the optional keypad or by setting the temperature compensation slope to zero using the SENS Setup Utility. See section 10.11...

  • Page 24: Load Share Connection-Optional

    SENS MicroGenius 2 Technical Manual Table 7 for connector pinout. 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/n208026). Communications are non-isolated and referenced to negative battery terminal.

  • Page 25: Verify Connections

    SENS MicroGenius 2 Technical Manual 7.10. Verify Connections 7.10.1. Verify that all connections are secure and in the proper locations. Tighten all unused screws on the terminal blocks to secure them against vibration. 7.10.2. Ensure all wires are routed in a way that the cover or other objects will not pinch or damage them.

  • Page 26: Individual Alarm Relay Contacts-Optional

    SENS MicroGenius 2 Technical Manual good, system DC output good, some individual charger(s) in alarm state AC good, low incompatible battery error (charger *SOLID GREEN FLASHING YELLOW disabled) *SOLID GREEN FLASHING GREEN/YELLOW AC good, output limited by high temperature *SOLID GREEN...
  • Page 27 SENS MicroGenius 2 Technical Manual 9.4.2. High DC Voltage Indicates DC output voltage is above factory alarm setpoint (see Table 9), standard jumper configuration setpoint (see Table 10), or the programmed level if the charger is in Program Mode. Activates solid yellow DC LED. Optional alarm/communications circuit board HIGH DC relay contacts change to Fail state after delay when alarm is assigned to relay contacts.
  • Page 28 SENS MicroGenius 2 Technical Manual 9.4.3. Battery Discharging Indicates battery is beginning to discharge and DC output voltage is below factory alarm setpoint (see Table 13), standard jumper configuration setpoint (see Table 14), or the programmed level if the charger is in Program Mode. Alarm setpoint must be set higher than LOW DC alarm. Activates solid yellow DC LED.
  • Page 29 SENS MicroGenius 2 Technical Manual 9.4.4. Low DC Voltage Indicates battery has discharged and DC output voltage is below factory alarm setpoint (see Table 11), standard jumper configuration setpoint (see Table 12), or the programmed level if the charger is in Program Mode. Activates solid yellow DC LED. Optional alarm/communications circuit board LOW DC relay contacts change to Fail state after delay when alarm is assigned to relay contacts.
  • Page 30 SENS MicroGenius 2 Technical Manual 9.4.5. Battery End of Discharge Indicates DC output voltage is below factory alarm setpoint (see Table 15), standard jumper configuration setpoint (see Table 16), or the programmed level if the charger is in Program Mode.
  • Page 31 SENS MicroGenius 2 Technical Manual 9.4.7. Overvoltage Shutdown Indicates that the charger has executed a high voltage shutdown and DC output voltage is above factory alarm setpoint (see Table 17), standard jumper configuration setpoint (see Table 18), or the programmed level if the charger is in Program Mode. The charger disables itself whenever excessive output voltage occurs while the charger is delivering current.
  • Page 32 SENS MicroGenius 2 Technical Manual 9.4.9. Low Cranking Voltage Indicates the battery voltage is likely to be inadequate to provide engine-cranking capability. Indicates that DC output voltage during a prior cranking event dropped below 6V for a 12V system and below 12V for a 24V system. This alarm is latching, and must be manually reset by disconnecting both AC and DC power or using optional keypad.
  • Page 33 SENS MicroGenius 2 Technical Manual 9.4.16. No Battery Temperature Sensor Indicates disabled or failed remote temperature sensor. Optional alarm/communications circuit board NO BATT TEMP SENSOR relay contacts change to Fail state after delay when alarm is assigned to relay contacts.

  • Page 34: Operation

    SENS MicroGenius 2 Technical Manual Only applicable to multi-charger systems with an optional remote alarm/communications panel accessory. Indicates one or more individual charger(s) are in an alarm state. Activates flashing green/red DC LED. Optional alarm/communications circuit board INDIVIDUAL CHARGER relay contacts change to Fail state after delay when alarm is assigned to relay contacts.

  • Page 35: Dynamic Boost™ Mode

    SENS Setup Utility. Use of the optional remote temperature compensation probe is highly recommended to maximize charging performance and optimize battery life.

  • Page 36: Helix Mode

    SENS MicroGenius 2 Technical Manual 15.20 30.40 VRLA Disabled Disabled 13.80 27.60 15.20 30.40 Disabled Disabled *Configuration Code displayed on charger label. Table 23 – Standard Jumper Configuration Boost Voltage Settings Boost Battery Float Jumper Battery Type Voltage Range 14.18 14.00...

  • Page 37: Ultracapacitor Mode

    SENS MicroGenius 2 Technical Manual automatically and no configuration is required by the operator. HELIX mode can be disabled using the optional keypad, the SENS Setup Utility, or by selecting a different battery type using the charger jumpers. HELIX mode adds two DC output voltage settings to the traditional Boost and Float voltages. These are called Eco-Float and Refresh.

  • Page 38: Keypad Operation

    Change the security code to a unique value by scrolling to the “Service Tools” menu and then the “Change Security Code” option. Contact SENS Customer Service if a custom password is lost or forgotten (800-742-2326 or www.sens-usa.com).
  • Page 39 SENS MicroGenius 2 Technical Manual Battery Temp. Temperature at battery if a remote temperature sensor is connected Internal Temp. Temperature inside charger Boost Settings Auto Boost Delay Adjust amount of time from 0 to 5 minutes to delay before entering Boost mode after power is cycled or battery type is changed.
  • Page 40 SENS MicroGenius 2 Technical Manual units. Select DC Output (multiple output Select output to adjust specific settings models only) Low Crank Alarm Adjust setpoint to trigger Low Crank alarm from 6V to 98% of Float, must be at least 2%...
  • Page 41 SENS MicroGenius 2 Technical Manual output models DC Output #B Enable or disable output B for multiple output models DC Output #C Enable or disable output C for multiple output models DC Output #D Enable or disable output D for multiple...

  • Page 42: Program Mode

    (see Figure 11 for location in charger and Figure 13 for detail). The ports are in parallel and either port may be used for the SENSbus Adapter connection. See the SENS Setup Utility user manual for information on configuring the charger.

  • Page 43: Load Share Charger Operation

    SENS MicroGenius 2 Technical Manual setting the temperature compensation slope to zero using the SENS Setup Utility. If the optional LCD is included, the temperature present at a sensor (local or remote) is displayed. Actual battery temperature is only displayed if the optional remote temperature sensor is connected to the charger and placed at the batteries.

  • Page 44: 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 45: Modbus Communications

    SENS MicroGenius 2 Technical Manual 12 MODBUS COMMUNICATIONS Modbus communications settings must be configured using the SENS Setup Utility prior to executing communications. Modbus is provided over RS-485 using RTU or ASCII mode. 12.1. Modbus Holding Registers Address High Address Low...
  • Page 46 SENS MicroGenius 2 Technical Manual Address High Address Low Name Description Units Scale Default Output AC Line 0x056 0x057 AC Line Frequency Frequency Default Output AC Line 0x058 0x059 AC Line 1 Voltage 32768 Voltage 1 Default Output AC Line...

  • Page 47: Status Definition

    SENS MicroGenius 2 Technical Manual Address High Address Low Name Description Units Scale Default Output Program Boost time limit (used for Program 0x0A0 0x0A1 3600 Boost Time Limit Mode setting) Default Output Current Current Limit setpoint in % of output...

  • Page 48: Alarm Bit Definition

    SENS MicroGenius 2 Technical Manual Value Name Description Decimal 0x0F HELIX Refresh HELIX Refresh Charge Mode 0x10 Periodic Boost Scheduled or Forced Time controlled Boost 0x11 Battery Check Scheduled or Forced Battery Check Routine 0x12 Commission Charge Timed Commission Charge 12.3.

  • Page 49: Extended Status Bit Definition

    SENS MicroGenius 2 Technical Manual 12.4. Extended Status Bit Definition Bit Address Name Description Decimal 0x00 Output Idle Charger output is disabled Charger operating in slave mode (should not occur on 0x01 Slave Mode system displays) 0x02 Helix Float Charge...

  • Page 50: Troubleshooting/Error Codes

    SENS MicroGenius 2 Technical Manual Address Description Details Decimal 0x011 Reset periodic boost charge schedule ON to reset schedule, OFF is no-op 0x012 Start/stop battery check, Channel A ON to start, OFF to stop 0x013 Reset periodic battery check schedule...
  • Page 51 SENS MicroGenius 2 Technical Manual Error Scope Description Corrective Action controlled by its jumper settings. Output can be Level" setting in the "Service Tools" menu to "Monitor either keypad controlled or jumper-selected, but Only." For factory default settings install jumpers on not both simultaneously.

  • Page 52: Troubleshooting

    SENS MicroGenius 2 Technical Manual Error Scope Description Corrective Action cables. - Check for miswired, disconnected, or damaged input and output connections. - To use this output, enable it using the keypad “DC Output #" selection in the "Other Settings" menu or the setup utility.
  • Page 53 1 of J901 and that J1939 Data Low goes to pin 2 of J901. 4. If step 3 didn’t resolve the issue, verify that requested command is supported by SENS charger per J1939 table in charger manual. 5. If the steps above didn’t resolve the issue, check...
  • Page 54 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 55 SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions equipment). 1. Alarm setpoint incorrect for 1. Check that charger battery settings and alarms are application set appropriately for the application and battery *SOLID SOLID AC good, low battery 2.
  • Page 56 SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions 3. Alarm setpoint incorrect for voltage as required. application 2. If step 1 doesn’t resolve RED AC light, remove both 4. Battery discharged or defective AC and DC power for 1 minute, then reapply power.
  • Page 57 SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions 3. If in program mode, ensure that charger has been programmed to desired settings (program mode is set from the factory to have no output). 1. Missing or invalid code (boot 1.

  • Page 58: Glossary

    In Program Mode, charger output is determined by values programmed in the charger using computer to charger cable (SENSbus adapter) and SENS Setup Utility Kit (SENS p/n 209254 plus SENS software available at www.sens-usa.com). Removing all jumpers from the BATTERY TYPE, FLOAT and RANGE positions enables Program Mode.
  • Page 64 ABS Steel Vessel Rules 4-8-2/7.7.1. Notes / Documentation: Drawing No. COMPLIANCE SPEC, MicroGenius 2, Pages: 7 Drawing No. 2DCAD-MG2-STD-ENC, Charger drawing, Revision: B, Pages: 2 Drawing No. Alarm list, ABS alarm reqs mapped to MG2 charger, Pages: 1 Drawing No.
  • Page 65 MG2_ABS_Recharge_2016-09-09, MG2_ABS_Recharge_2016-09-09, Pages: 71 Drawing No. MicroGenius_2_Model_Designation, Pages: 1 Drawing No. SENS IP 22 Test, SENS IP 22 Test Report, Pages: 10 Drawing No. UL File E109740 Project 4787560097, UL_Reverse_Polarity_Test, Pages: 1 Drawing No. UL Project 4787560097, SENS UL NofA-4787560097-Sep-20-2016, Pages: 1 Drawing No.
  • Page 66 1840 Industrial Circle Longmont, CO 80501 U.S.A. Product Type: MicroGenius 2 Battery Charger Model Numbers: MX-YY-YYYY-YY, where X = 1, 3, 4, F, G, H; Y = any digit; Conformance to Directive 2014/30/EU of the European Parliament and of the Council...
  • Page 67 At any time during the standard Limited Warranty period, customer may purchase extended warranty to lengthen the warranty period on the entire product to 5 or 10 years from date of original shipment. All other terms of SENS Limited Warranty (see above) apply.

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