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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
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
WALLBOX
Automatic Battery Charger/Power Supply
101335
B
107947
April 27, 2021
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 Wallbox
Summary of Contents for Sens EnerGenius DC Wallbox
- 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 ......................37 9.9. Restore Factory Defaults ........................37 9.10. Keypad Operation ..........................38 9.11. Configuration with SENS Setup Utility ....................42 9.12. Temperature Compensation ....................... 42 9.13. Load Share Charger Operation ......................43 9.14. - Page 3 SENS EnerGenius® DC Wallbox Technical Manual 11.1. TCP/IP Modbus—Optional ........................47 11.2. RS-485 Modbus—Optional ......................... 47 11.3. Modbus Holding Registers ........................47 11.4. Basic Charging Alarms Bit Definition ....................49 11.5. Charging Status Bit Definition ......................50 11.6. Charging Alarms Extended Bit Definition ..................... 50 11.7.
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Page 4: Important Safety Instructions For Installer And Operator
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 AC/DC Voltmeter accurate to ±1%;...
- Page 9 SENS EnerGenius® DC Wallbox Technical Manual external devices such as battery room fan or hydrogen monitor. Alarm Form C contacts Five Form C contacts, rated 30V, 2A resistive, assignable. Two optional 120VAC, 5A, resistive or 150VDC, 3A / 240VAC, 10A 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 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 share the load up to the rated current of the unit. Should a power module fail, the remaining...
- Page 12 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...
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Page 13: Mounting Instructions
SENS EnerGenius® DC Wallbox 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 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: Standard Alarm Connections
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. Alarm circuits are rated 2A at 30V AC or DC. Connect alarm wiring to the respective terminals on the pluggable terminal block in the charger (see Figure 4 for detail). - Page 18 *Summary alarm includes AC Fail, Charger Fail, Battery Discharging, High DC and Low DC alarms. Functions and operation assigned to each relay are typical. Different functions and assignments are available both from the factory and by reassignment using the SENS Setup Utility.
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Page 19: Optional High Current Relay Connections
6.6. Optional High Current Relay Connections Optional high current relay assignments are custom configurable using the SENS Setup Utility. There are two options of high current alarm relays available from the factory. The first variant of alarm circuits (2) is rated 5A at 120VAC. -
Page 20: Canbus And Rs-485 Connections
SENS EnerGenius® DC Wallbox Technical Manual Table 9 – Optional High Current Relay Connections 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 Non-latching Coil... - Page 21 Figure 8 shows an example of how to terminate the network. Termination may be provided as part of the network cabling or 120-ohm termination plugs for the RJ-45 communications connector on the charger are available to order separately (SENS p/n 803707).
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Page 22: Ethernet
Figure 9 – Ethernet Connection 6.8.1. Configure TCP/IP Address Configure TCP/IP settings using the SENS Setup Utility or the keypad. To adjust settings using the keypad, ensure the access level is set to allow adjustments. Set the IP address as desired. It may take up to 10 seconds for the network setting changes to apply. - Page 23 The only optional hardware required is a Cat5 or better RJ-45 network cable available either from SENS or local computer supply. Use of this sharing cable is essential to synchronizing operation of the Dynamic Boost and HELIX modes and helps ensure that current is shared within +10% between chargers.
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Page 24: Verify Connections
SENS EnerGenius® DC Wallbox Technical Manual 6.9.3. Remote Alarm/Communications Panel Accessory Connection—Optional The optional remote alarm/communications panel accessory provides the ability to adjust and communicate with multiple chargers using one external device. The remote panel accessory may be configured with different alarm relay assignments than the alarm relays native to the charger. -
Page 25: 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 26: Apply Ac Input Voltage
SENS EnerGenius® DC Wallbox Technical Manual 7.2.3.4. Power Supply (PSP) 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 by closing the charger AC circuit breaker. -
Page 27: Alarms, Leds And Display
SENS EnerGenius® DC Wallbox Technical Manual ALARMS, LEDS AND DISPLAY 8.1. LED Indicators The charger is equipped with two LEDs, one for AC status and one for DC status. See further alarm definitions in section 8.4. LEDs and the front panel LCD will indicate the alarm(s). -
Page 28: 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 29 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 30 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 31 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 32 Indicates battery voltage is below the factory 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 33 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.
- Page 34 SENS EnerGenius® DC Wallbox Technical Manual LED. When this alarm is assigned to a relay contact AC VOLTAGE LOW will cause the assigned relay to change to the Failed state after the time delay. 8.4.33. AC Frequency Out of Range Indicates AC Frequency is outside of the AC High Frequency and AC Low Frequency alarm setpoints.
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Page 35: Operation
SENS EnerGenius® DC Wallbox Technical Manual OPERATION 9.1. Charging Algorithms The charger uses charging algorithms appropriate for different battery types. The charging algorithm for each battery type includes various combinations of Float mode, Dynamic Boost™ mode, and HELIX mode, as described in Table 17. See following sections for descriptions of each charging mode. -
Page 36: Helix 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 37: Commissioning Batteries
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. Use the keypad or SENS Setup Utility to set the desired minimum startup voltage level and initiate a forced startup. -
Page 38: Keypad Operation
The default security code is 000000 meaning security code is not enabled. Change the security code to a unique value using the front panel keypad. Contact SENS Customer Service if a custom password is lost or forgotten (800-742-2326 or www.sens-usa.com). - Page 39 SENS EnerGenius® DC Wallbox Technical Manual type is changed. Delay affects all outputs for multiple output models. Auto-Boost Enable or disable Dynamic Boost mode Auto Boost Limit Adjust the maximum amount of time charger will be in Dynamic Boost mode from 1 to 100 hours.
- Page 40 SENS EnerGenius® DC Wallbox Technical Manual End Discharge Adjust setpoint to trigger Battery End-of- Discharge alarm, must be less than Low DC setting Low DC Voltage Adjust setpoint to trigger Low DC voltage alarm, must be greater than End Discharge setting and less than Battery...
- Page 41 SENS EnerGenius® DC Wallbox Technical Manual SENSbus is less than the minimum charger count. Disabled by default, meaning no alarm. See Error Code 301 for further details. Battery Check Battery Check Start or stop a manual Battery Check. Batt Check Time...
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Page 42: Configuration With Sens Setup Utility
Communication between a computer and the charger using the SENS Setup Utility requires connection of a Cat5 minimum RJ45 cable between the ethernet port on the charger and the ethernet port on the computer (see section 6.8). Connect using the “SENSnet”... -
Page 43: Load Share Charger Operation
SENS EnerGenius® DC Wallbox Technical Manual Figure 11 – 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 44: Efficiency
SENS EnerGenius® DC Wallbox Technical Manual 9.15. Efficiency Figure 12 shows the efficiency of the charger at a given input voltage for a single 120VDC 50A module at 150VDC output voltage. Figure 12 – Efficiency Efficiency - 150VDC Output 97.0% 96.0%... -
Page 45: 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 46: 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 47: Modbus Communications
Serial Modbus communications over RS-485 using RTU mode is optional. Modbus communications settings may be configured using the keypad or SENS Setup Utility prior to executing communications. Configure Modbus slave address, baud rate, parity and enable/disable Modbus write access as desired. - Page 48 SENS EnerGenius® DC Wallbox Technical Manual 0x006 0x007 Type Device type Enum 0x008 0x009 Serial Serial Number of the Device 0x00A 0x00B Build Date Year (16bit), month(8bit), day(8bit) 0x00C 0x00D Model Num 1_4 Model number character 0x00E 0x00F Model Num 5_8...
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Page 49: Basic Charging Alarms Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual 0x0EC 0x0ED Unit Line Voltage 2 AC Line 2 Voltage 32768 0x0EE 0x0EF Unit Line Current 2 AC Line 2 Current 32768 0x0F0 0x0F1 Unit Line Voltage 3 AC Line 3 Voltage 32768 0x0F2... -
Page 50: Charging Status Bit Definition
SENS EnerGenius® DC Wallbox Technical Manual SENS Bus 0x12 Device is not communicating on SENSbus. Inactive 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 51: 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 52: 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 53: 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 54 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 55 Unit (or Channel Charger assignments used but -To correct this, the SENS Setup Utility must System) not all chargers are set for the DC be used to assign Charger Ids to a channel.
- Page 56 SENS EnerGenius® DC Wallbox Technical Manual happen when adding a module from another system. Hardware Optional Hardware Error. Hardware that This could be a bad configuration. Compare may be optional is not working properly. Option Select Bits with Hardware Status Bits...
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Page 57: Troubleshooting Guide
SENS EnerGenius® DC Wallbox Technical Manual 12.2. Troubleshooting Guide AC LED DC LED Fan / Symptom Possible Causes Recommended Actions Filter Display AC and 1. Proper AC or DC 1. Using a voltmeter, check that DC LEDs and voltages not applied... - Page 58 SENS EnerGenius® DC Wallbox Technical Manual Adjust settings using setup utility as required. SOLID SOLID RED - AC good, 1. Charger has 1. Remove both AC and DC power GREEN charger fail or experienced an for 1 minute, then reapply power.
- Page 59 SENS EnerGenius® DC Wallbox Technical Manual (charger remove both AC and DC power disabled) for 1 minute, then reapply power. SOLID FLASHING AC good, output 1. Charger power is 1. Check for obstructions on GREEN GREEN/ power limited reduced to protect...
- Page 60 SENS EnerGenius® DC Wallbox Technical Manual 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 correct, check and correct battery / load voltage (consider battery surface charge, alternator, and any connected equipment).
- Page 61 SENS EnerGenius® DC Wallbox Technical Manual SOLID SOLID RED - 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...
- Page 62 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 63: Glossary
Equalize charging is employed to improve the performance and life of an already charged battery that is primarily charged using Float voltage. SENS’ convention is to employ the term “Boost” to mean both this cell equalization function and the fast battery recharge function. - Page 64 CHECKED LONGMONT, CO 80501 303-678-7500 ANGLES THIRD ANGLE PROJECTION SIZE DOCUMENT NUMBER WWW.SENS-USA.COM TWO PLACE DECIMAL PROPRIETARY AND CONFIDENTIAL THREE PLACE DECIMAL .005 DIA\00646 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF STORED ENERGY SYSTEMS, LLC. ANY...
- Page 65 CHECKED LONGMONT, CO 80501 303-678-7500 ANGLES THIRD ANGLE PROJECTION SIZE DOCUMENT NUMBER WWW.SENS-USA.COM TWO PLACE DECIMAL PROPRIETARY AND CONFIDENTIAL THREE PLACE DECIMAL .005 DIA\00646 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF STORED ENERGY SYSTEMS, LLC. ANY...
- Page 67 Directives(s) and Standard(s). ________________________________________ _April 28, 2020_______ Sam Coleman Date Compliance Manager Stored Energy Systems, LLC STORED ENERGY SYSTEMS, LLC 1840 INDUSTRIAL CIRCLE, LONGMONT, COLORADO 80501 FAX 303.678.7504 303.678.7500 www.sens-usa.com email: info@sens-usa.com FORM-319 REV A DATE ISSUED: 4/28/2020...
- Page 68 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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