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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; 10,575,433
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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
WALLBOX
Automatic Battery Charger/Power Supply
101335
A
107839
May 4, 2020
SENS EnerGenius® DC Wallbox 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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Table of Contents
Troubleshooting
Related Manuals for Sens EnerGenius DC
Summary of Contents for Sens EnerGenius DC
- 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 2020 The SENS name / logo, EnerGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC...
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Page 2: Table Of Contents
Shunt Trip AC Breaker - optional ......................36 9.9. Restore Factory Defaults .......................... 36 9.10. Keypad Operation ............................ 36 9.11. Configuration with SENS Setup Utility ..................... 41 9.12. Temperature Compensation ........................41 9.13. Load Share Charger Operation ......................... 42 9.14. - Page 3 SENS EnerGenius® DC Wallbox Technical Manual 11.2. RS-485 Modbus—Optional ........................45 11.3. Modbus Holding Registers ........................45 11.4. Basic Charging Alarms Bit Definition ......................47 11.5. Charging Status Bit Definition ........................48 11.6. Charging Alarms Extended Bit Definition ....................48 11.7.
- Page 4 SENS EnerGenius® DC Wallbox Technical Manual IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR 1.1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for EnerGenius® DC Wallbox battery chargers. 1.2. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and product using battery.
- Page 5 1.10.8. When charging batteries, charge LEAD-ACID or LIQUID ELECTROLYTE NICKEL-CADMIUM batteries only. Consult SENS before using with any other type of battery - other batteries may burst and cause injuries to persons and damage to property.
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Page 6: Model Number Breakout
SENS EnerGenius® DC Wallbox Technical Manual MODEL NUMBER BREAKOUT Parameter Code Value Product Family EnerGenius DC Enclosure Type Wallbox AC Input Voltage Three Phase - 480VAC Standard Interrupt Rating (25kAIC) AC Interrupt High Interrupt Rating (65kAIC) 120 VDC DC Output Voltage... -
Page 7: Performance Specifications
SENS EnerGenius® DC Wallbox Technical Manual PERFORMANCE SPECIFICATIONS EnerGenius DC high power industrial/utility class 3-phase battery charger/power supply, specially hardened for use in harsh industrial environments. Advanced technology switch mode power conversion is significantly smaller & lighter than conventional line frequency (e.g. SCR) power conversion and, even without a battery connected, delivers lower output ripple and much faster dynamic response. - Page 8 Local computer Change all parameters, troubleshoot, create/save configuration files for quick download to chargers using network connection and SENS Setup Utility software available at www.sens-usa.com Status reporting LEDs Two multi-color front panel status LEDs Metering DC Voltmeter accurate to ±2%;...
- Page 9 SENS EnerGenius® DC Wallbox Technical Manual Alarm Inputs Two optional input contacts (via optional battery monitor) to monitor status of, and modify charger operation based on, external devices such as battery room fan or hydrogen monitor. Alarm Form C contacts Five Form C contacts, rated 30V, 2A resistive, assignable.
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Page 10: System Overview
Some of the available configuration options may not be applicable to a given installation. Adjustments to settings can be made via the front panel keypad or the SENS Setup Utility software via ethernet connection of the EnerGenius DC Wallbox unit to a computer. - Page 11 Optional communication protocols include Modbus (TCP/IP and RS-485), DNP3 (TCP/IP and RS-485) and IEC 601850 4.2.3.7. Module Redundancy The EnerGenius DC Wallbox can be factory ordered with N+1 redundancy. This provides an additional power module than is required to meet the rated output. The modules will actively...
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Page 12: Mounting Instructions
Multiple units can be assigned to a common load or units can be allocated to separate outputs for multiple unique loads. All of the channelized EnerGenius DC Wallbox units on a common communication bus can be controlled / monitored from a single point. Each unique load should be assigned to a unique channel. - Page 13 SENS EnerGenius® DC Wallbox Technical Manual 5.2.2. Drill four wall mounting holes using dimensions provided on diagrams at back of manual. WARNING: PROTECT UNIT FROM ALL DRILL SHAVINGS AND DEBRIS! IF INSTALLING UNIT WITHOUT POWER MODULES INSERTED, USE A FLASHLIGHT TO VISUALLY INSPECT AND REMOVE CONSTRUCTION DEBRIS CONTAMINATION FROM POWER MODULE CONNECTORS PRIOR TO INSERTION OF POWER MODULES.
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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 SENS EnerGenius® DC Wallbox Technical Manual Table 2 – DC Output Cable Size Charger Maximum Charger Rated Resistance Wire Size to Battery Output per Foot Distance (Ft.) Current (mΩ/Ft.) (Amps) 120V 240V 2.50 1.60 1.00 0.63 13.3 0.40 2.50 NEC - not allowed 1.60...
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Page 16: Grounding Instructions And Connection
SENS EnerGenius® DC Wallbox Technical Manual 6.2. Grounding Instructions and Connection 6.2.1. 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 17: Ac Connection
See charger inside cover label for original factory alarm relay assignments (see Figure 2). Alarm relay assignments are custom configurable using the SENS Setup Utility. Connect alarm wiring to the respective terminals on the pluggable terminal block in the charger (see Figure 4 for detail). To make wiring easier, the terminal block unplugs from the header. - Page 18 SENS EnerGenius® DC Wallbox Technical Manual Figure 4 – Standard Alarm Connections (TB1 - pins 1-15 shown) PULL TO REMOVE FROM HEADER 5 RELAYS, 3 POSITIONS PER RELAY: COM, OK, FAIL Table 8 – Alarm Relay Contact Wiring for Stationary Power Configuration Wire from COM to OK for alarm present on open circuit or from COM to FAIL for present on closed circuit.
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Page 19: Optional Pilot Relay Connections
Optional pilot relay relay assignments are custom configurable using the front panel keypad (based on application) or the SENS Setup Utility. Connect optional alarm wiring to the respective terminals on the pluggable terminal block in the charger (see Figure 5 for detail). To make wiring easier, the terminal block unplugs from the header. -
Page 20: Canbus And Rs-485 Connections
SENS EnerGenius® DC Wallbox Technical Manual 6.7. CANbus and RS-485 Connections Every charger includes CANbus and RS-485 communications via two RJ-45 jacks. 6.7.1. CANbus The unit is equipped with CANbus communications support via the RJ45 ports. This interface is intended for communication with customer devices including battery monitoring systems, user interfaces, and customer-specific CAN protocol communications. - Page 21 Modbus +D1 (A) No connect pass-through Power* Common (isolated) *Main circuit PCA only, used for interconnect between SENS devices Figure 7 – RJ-45 to Terminal Block Adapter — Optional Pin 1 6.7.4. Termination For proper operation, a 120-ohm terminator is required at the ends of the CAN and/or RS-485 bus.
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Page 22: Ethernet
The unit is equipped with an ethernet RJ45 port (see Figure 9). Connect Cat5 or better ethernet cable. This provides a 10/100 ethernet connection. Ethernet communication includes ethernet connectivity to the charger for monitoring and configuration via the SENS Setup Utility, Modbus TCP/IP (optional) and DNP3 (optional). -
Page 23: Verify Connections
Connect a network cable from one charger to another using the SENSbus RJ-45 port on each charger to automatically initiate load sharing (see Figure 10). The only optional hardware required is a Cat5 or better RJ-45 network cable available either from SENS or local computer supply. -
Page 24: Start-Up Procedure
Refer to the label on the inside lower cover for factory configured output voltage, battery type and configuration code (see Figure 2). 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 additional details on keypad navigation. -
Page 25: Apply Ac Input Voltage
SENS EnerGenius® DC Wallbox Technical Manual This configuration code is intended for standard power supply applications where a storage battery is not connected. 7.3. Apply AC Input Voltage Verify the AC input is the correct value (188-528 VAC, 47-63 Hz) and apply AC to charger. -
Page 26: Alarms, Leds And Display
See Table 8 for typical alarm relay assignments. The relays can be configured to be latching or non-latching with adjustable delays using the SENS Setup Utility. The relays can be configured to be latching or non-latching with adjustable delays using the SENS Setup Utility. -
Page 27: Lcd Panel
Voltage 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. Alarm setpoint must be set higher than LOW DC and END OF DISCHARGE alarms. - Page 28 Indicates battery has discharged and DC output voltage is below Low DC Voltage factory 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 DISCHARGE alarms.
- Page 29 Indicates DC output voltage is below Battery End Discharge 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 30 SENS EnerGenius® DC Wallbox Technical Manual VRLA 2.530 2.568 2.833 VRLA 2.530 2.568 2.833 2.200 *Configuration Code displayed on charger label. 8.4.8. Reverse Polarity Indicates battery is connected backwards. Charger output is disabled until the condition is corrected. Activates flashing red/yellow DC LED. When this alarm is assigned to a relay contact REVERSE POLARITY will cause the assigned relay to change to the Failed state after the time delay.
- Page 31 Indicates battery voltage is below the Startup Voltage setpoint or the configured level if setpoint is adjusted using keypad or SENS Setup Utility. When this alarm is assigned to a relay contact DC BELOW STARTUP VOLTAGE will cause the assigned relay to change to the Failed state after the time delay.
- Page 32 SENS EnerGenius® DC Wallbox Technical Manual 8.4.23. Check Filter Indicates charger has experienced a thermal roll back which might be caused by a clogged input air filter. Check module input air filter and clean if needed. When this alarm is assigned to a relay contact CHECK FILTER will cause the assigned relay to change to the Failed state after the time delay.
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Page 33: Operation
SENS EnerGenius® DC Wallbox Technical Manual 8.4.33. AC Voltage High Indicates AC Voltage is above the AC Max Voltage alarm setpoint. 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. -
Page 34: Float Mode
Dynamic Boost can be enabled or disabled by the user at any time. 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 optimize battery life. -
Page 35: Helix Mode
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/commission a zero-volt or fully discharged battery. To initiate the defeat system, navigate to the BATTERY SET UP menu to set the desired minimum startup voltage level. -
Page 36: Shunt Trip Ac Breaker - Optional
Ground Fault Trip Point 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 EnerGenius® DC Wallbox Technical Manual Table 20 – Menu Navigation or for main fields Step 1 or for details within each main field Step 2 or to adjust values Step 3 to return to main fields Step 4 ...
- Page 38 SENS EnerGenius® DC Wallbox Technical Manual Output Settings Float Voltage Adjust output Float voltage, must be greater than 60% of Boost setting Boost Voltage Adjust output Boost voltage from, must be same or greater than Float setting, must not be greater than 166% of Float...
- Page 39 SENS EnerGenius® DC Wallbox Technical Manual Battery Set-up Battery Select (type) Select type of battery to be charged - flooded lead-acid, AGM, nickel-cadmium VRLA, power supply. Battery Select (cells) Adjust number of series cells in battery string Batt Commission (voltage)
- Page 40 SENS EnerGenius® DC Wallbox Technical Manual Display Test Press UP arrow to set all LCD segments black and DOWN arrow to clear all LCD segments UI Access Control Select allowed user interface access. Access options include read-only viewing, normal access or full access adjustments for advanced users.
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Page 41: Configuration With Sens Setup Utility
Temperature compensation is disabled by using the keypad or by setting the temperature compensation slope to zero using the SENS Setup Utility. The temperature present at a sensor (local or remote) is displayed on the front panel LCD. Actual battery temperature is only displayed if the optional remote temperature sensor is connected to the charger and placed at the batteries. -
Page 42: Load Share Charger Operation
SENS EnerGenius® DC Wallbox Technical Manual 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 43: Service And Maintenance
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 access cover on the top of the unit (see Figure 13). To remove a module first unlock the module by moving the cam latch to the unlock position. -
Page 44: Air Filter
An alarm will indicate if a fan needs to be serviced or replaced. See Figure 15 for fan servicing details. Contact SENS for replacement components and detailed service instructions. -
Page 45: Modbus Communications
11.2. RS-485 Modbus—Optional Serial 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. Modbus is provided over RS-485 using RTU or ASCII mode. - Page 46 SENS EnerGenius® DC Wallbox Technical Manual 0x00C 0x00D Model Num 1_4 Model number character 0x00E 0x00F Model Num 5_8 Model number character 0x010 0x011 Model Num 9_12 Model number character 0x012 0x013 Model Num 13_16 Model number character 0x014 0x015...
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Page 47: Basic Charging Alarms Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual 0x0EE 0x0EF Unit Line Current 2 AC Line 2 Current 32768 0x0F0 0x0F1 Unit Line Voltage 3 AC Line 3 Voltage 32768 0x0F2 0x0F3 Unit Line Current 3 AC Line 3 Current 32768 Timer for elapsed time with a given... -
Page 48: Charging Status Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual Battery On Battery is beginning to discharge and DC output voltage is below Batt 0x13 Discharge Discharge Voltage alarm setpoint. Battery End 0x14 DC output voltage is below Batt End Discharge Voltage alarm setpoint. -
Page 49: Charging Ac Alarms Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual Battery temperature is above the High Battery 0x02 High Battery Temperature Temperature alarm setpoint. Battery temperature is high enough that the unit has High Battery Temperature shut off for safety precautions. Only available when a... -
Page 50: Accessory Assigned Channel Alarms Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual The AC breaker is OPEN or has tripped. Only available with Breaker 0x02 AC1 Breaker Status option. 0x03 Unused Unused 0x04 Unused Unused The DC supplementary surge protector has expired and needs 0x05 DC SPD replacement. -
Page 51: Troubleshooting/Error Codes
SENS EnerGenius® DC Wallbox Technical Manual 12 TROUBLESHOOTING/ERROR CODES 12.1. Configuration Error Codes Error codes are displayed on front panel LCD. Error Scope Description Corrective Action Charger Invalid output channel. Chargers must - If necessary, enable the channel using the... - Page 52 SENS EnerGenius® DC Wallbox Technical Manual Channel Too few chargers operating. The - Use the "Set DC Output" setting in the combined output rating of all chargers "Other Settings" menu or the setup utility to operating on this channel is less than the verify all chargers' output channel settings.
- Page 53 SENS EnerGenius® DC Wallbox Technical Manual to select the Battery Type, Float Voltage, and Range for your battery. Unit (or Missing chargers. A charger that should - Check for a charger that has failed System) be present is missing, has failed, or (indicated by its LED status).
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Page 54: Troubleshooting Guide
SENS EnerGenius® DC Wallbox Technical Manual 12.2. Troubleshooting Guide AC LED DC LED Fan / Symptom Possible Causes Recommended Actions Filter Status Display AC and 1. Proper AC or DC 1. Using a voltmeter, check that DC LEDs and voltages not applied... - Page 55 SENS EnerGenius® DC Wallbox Technical Manual *SOLID SOLID AC good, 1. Charger has 1. Remove both AC and DC power GREEN charger fail or experienced an for 1 minute, then reapply power. overvoltage unexpected fault 2. If fault remains, check shutdown 2.
- Page 56 SENS EnerGenius® DC Wallbox Technical Manual covers installed. 3. Reduce operating environment temperature. Charger will automatically increase power as temperature is lowered. *SOLID DOUBLE AC good, load 1. Charger output 1. Check that individual charger GREEN FLASH share fail settings do not settings are identical.
- Page 57 SENS EnerGenius® DC Wallbox Technical Manual RED AC light, a charger module failure is the likely cause. Replace module. DC LED 1. Check that charger battery settings and alarms are set appropriately for the application and battery under charge. 2. If settings and alarms are...
- Page 58 SENS EnerGenius® DC Wallbox Technical Manual SOLID SOLID AC fail, charger 1. Charger is in a fault AC LED fail or state 1. Using a voltmeter, check that overvoltage 2. Charger module AC input voltage and frequency at shutdown failure AC input terminal block/breaker are in the range 188VAC –...
- Page 59 SENS EnerGenius® DC Wallbox Technical Manual failure is the likely cause. Replace module. DC LED 1.Check that charger voltage is set correctly for the battery. After making any correction to the setting, remove both AC and DC power for 1 minute, then reapply power.
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Page 60: 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 EnerGenius DC chargers use the term “Boost” for the higher output voltage mode (see section 9.3) - Page 61 FOR 1-1/2 INCH NPT CONDUIT 12.00 4X MOUNTING LOCATIONS FOR 3/8IN HARDWARE NAME DATE DESCRIPTION UNLESS OTHERWISE SPECIFIED: DRAWN 12/9/2019 DIAGRAM,ENERGENIUS DC,WALLBOX,INSTALL DIMENSIONS ARE IN INCHES 1840 INDUSTRIAL CIRCLE DEFAULT TOLERANCES: CHECKED LONGMONT, CO 80501 303-678-7500 ANGLES THIRD ANGLE PROJECTION SIZE DOCUMENT NUMBER WWW.SENS-USA.COM...
- Page 62 SCALE 1 : 1 ALARM RELAYS RS-485 / CAN SENSBUS ETHERNET NAME DATE DESCRIPTION UNLESS OTHERWISE SPECIFIED: DRAWN 12/9/2019 DIAGRAM,ENERGENIUS DC,WALLBOX,INSTALL DIMENSIONS ARE IN INCHES 1840 INDUSTRIAL CIRCLE DEFAULT TOLERANCES: CHECKED LONGMONT, CO 80501 303-678-7500 ANGLES THIRD ANGLE PROJECTION SIZE DOCUMENT NUMBER WWW.SENS-USA.COM...
- Page 64 Manufacture Address: 1840 Industrial Circle Longmont, CO 80501 U.S.A. Product Type: EnerGenius DC Battery Charger and Accessories Models DK-*, DS-*, DW-* DM-*, DU-* DR-*, and RM-* where “*” = any Model Numbers: series of digits and dashes Conformance to Directive 2014/30/EU of the European Parliament and of the Council...
- Page 65 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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