1. Manuals
  2. Brands
  3. Sens Manuals
  4. Power Supply
  5. PowerCab 2
  6. Installation & operation manual

Sens PowerCab 2 Installation & Operation Manual

Factory-packaged non-stop dc power systems
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PowerCab
Factory-packaged Non-stop DC Power Systems
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 2024
The SENS name / logo, PowerCab, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC
101343
A
108523
February 27, 2024
1
SENS PowerCab2 Technical Manual
2
®
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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PowerCab 2 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Sens PowerCab 2

Summary of Contents for Sens PowerCab 2

  • 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 2024 The SENS name / logo, PowerCab, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC...

  • Page 2: Table Of Contents

    7.9. Restore Factory Defaults .......................... 28 7.10. Keypad Operation ............................ 28 7.10.3. Menu Options ............................29 7.11. Configuration with SENS Setup Utility ..................... 35 7.12. Protocol Communications Circuit Board ....................35 7.13. Temperature Compensation ........................36 7.14. Efficiency ..............................37 SERVICE AND MAINTENANCE ...........................
  • Page 3 Writable Control Flags (Coils) - Single coil writes: 0xFF00 for ON, 0x0000 for OFF ......... 44 DNP3 COMMUNICATIONS—Optional ......................45 10.1. TCP/IP DNP3 ............................. 45 10.2. RS-485 DNP3 ............................45 10.3. SENS DNP3 Config Tool ..........................45 10.4. Implementation Table ..........................46 10.5. Binary Inputs ............................47 10.6. Binary Outputs ............................49 10.7.

  • Page 4: Important Safety Instructions For Installer And Operator

    SENS PowerCab2 Technical Manual IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR 1.1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for PowerCab2 DC backup systems. 1.2. Before using system, read all instructions and cautionary markings on battery charger, battery, and product using battery.
  • Page 5 SENS PowerCab2 Technical Manual 1.9.8. When charging batteries, charge LEAD-ACID, LIQUID ELECTROLYTE NICKEL-CADMIUM, NICKEL- ZINC or SODIUM-CHLORIDE batteries only. Consult SENS before using with any other type of battery or changing battery type from originally supplied with system - other batteries may burst and cause injuries to persons and damage to property.

  • Page 6: Performance Specifications

    SENS PowerCab2 Technical Manual PERFORMANCE SPECIFICATIONS PowerCab2 factory-packaged non-stop DC power systems, 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 7 SENS PowerCab2 Technical Manual Charging Constant voltage, current limited; patented Dynamic Boost and HELIX characteristic control Line & load regulation ±0.5% Output ripple <30mV with battery, <100mV off-battery for 120VDC, <200mV off-battery for 240VDC. Delivers fast-responding, stable, well-filtered DC without battery.
  • Page 8 Change all parameters including voltages, current limits, alarm parameters, network configurations, time-outs, and more Computer adjustment 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...
  • Page 9 SENS PowerCab2 Technical Manual Regulatory North America C-UL Listed for US & Canada: UL 508A Compliance NFPA-70, NEMA PE-5, PIP (optional) FCC Part 15, Class A commercial use and ICES-003 (Canada) Construction Housing Floor mount; integrated key lock Housing material...

  • Page 10: Mounting Instructions

    SENS PowerCab2 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 11: Setup And Wiring

    Refer to the label on the inside front door for factory configured output and alarm relay assignments. The system may be reconfigured using the front panel keypad or by software programming using the SENS Setup Utility. All wiring must comply with applicable codes and local ordinances. See separately provided system diagrams for access covers and conduit entry holes.

  • Page 12: Ac Connection

    See label on inside of system door for original factory alarm relay assignments. 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. To make wiring easier, the terminal block unplugs from its header.

  • Page 13: High Current Relay Connections-Optional

    SENS Setup Utility. 4.6. High Current Relay Connections—Optional Optional high current relay assignments are custom configurable using the SENS Setup Utility. There are two high current alarm relay options available from the factory. The first variant of alarm circuits (2) is rated 5A at 120VAC.
  • Page 14 SENS PowerCab2 Technical Manual Optional High Current Relay Connections 2 RELAYS, 3 POSITIONS PER PULL TO REMOVE RELAY: FROM HEADER COM, OK, FAIL 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.

  • Page 15: Canbus Connections

    No connect pass-through Power* Common (isolated) *Main circuit PCA only, used for interconnect between SENS devices 4.8. RS-485 Connections Every system includes RS-485 connections via a 4-pin pluggable terminal block. This interface is intended for monitoring and communicating with the system. Available protocols include Modbus (standard on all systems) and DNP3 (optional).

  • Page 16: Ethernet

    This provides a 10/100 ethernet connection. P-clamps provided with system (see envelope inside cabinet) to install and route alarm wiring as desired. Ethernet communications includes ethernet connectivity to the system for monitoring and configuration via the SENS Setup Utility, Modbus TCP/IP (standard on all systems) and DNP3 (optional).

  • Page 17: Service Connection

    The unit is equipped with a Service RJ45 port. This SENSbus connection is used for internal devices and SENS accessory connections. Do not connect multiple PowerCab2 systems together using this connection unless directed to on the separately provided system diagrams.

  • Page 18: Start-Up Procedure

    The Config Code indicates charging algorithm and alarm setpoints configured at the factory. Review and adjust charger configuration using the front panel keypad or the SENS Setup Utility if factory configured settings require modification. See section 7.10 for additional details on keypad navigation.

  • Page 19: Alarms, Leds And Display

    SENS PowerCab2 Technical Manual ALARMS, LEDS AND DISPLAY 6.1. LED Indicators The system is equipped with two LEDs on the main display, one for AC status and one for DC status. See further alarm definitions in section 6.5. See section for optional NaCl (salt) battery LED indicators.

  • Page 20: Individual Alarm Relay Contacts

    All alarm messages displayed on the front panel LCD are latching. Alarm relay configurations created using the SENS Setup Utility may be configured as latching if desired. Once an alarm condition no longer exists, the alarm message will no longer display in the main/home screen but will remain under the “Latched Alarms”...
  • Page 21 Indicates DC output voltage is below Battery End Discharge factory alarm setpoint 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 22 SENS PowerCab2 Technical Manual normal the charger will continue charging. If DC voltage behavior is abnormal, as is typical with a battery voltage mismatch, the charger will shut down and lock off after approximately five minutes. Activates flashing yellow DC LED. When this alarm is assigned to a relay contact INCOMPATIBLE BATTERY will cause the assigned relay to change to the Failed state after the time delay.
  • Page 23 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 24 SENS PowerCab2 Technical Manual 6.5.26. High Battery Temperature Indicates battery temperature is above the High Battery Temperature setpoint. This alarm is only available when a remote battery temperature sensor is installed with the optional remote battery monitor. When this alarm is assigned to a relay contact HIGH BATTERY TEMPERATURE will cause the assigned relay to change to the Failed state after the time delay.
  • Page 25 SENS PowerCab2 Technical Manual 6.5.36. DC SPD Indicates supplementary DC surge protective device has degraded from repeated electrical transients and needs to be replaced. Only active with optional supplementary surge protector options. When this alarm is assigned to a relay contact DC SPD will cause the assigned relay to change to the Failed state after the time delay.

  • Page 26: Operation

    The boost time limit is set to 24 hours by default. 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 27: Charging Low Or Zero-Volt 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 28: Restore Factory Defaults

    SENS PowerCab2 Technical Manual 7.9. Restore Factory Defaults Restore factory defaults using the front panel keypad or the SENS Setup Utility. The following values will revert to original factory settings: Battery type Temperature Compensation Slope Cell count Auto Boost Time Limit...

  • Page 29: Menu Options

    SENS PowerCab2 Technical Manual 7.10.3. Menu Options Input, output, temperature and alarm status are displayed on the front panel LCD by default. Press the UP or DOWN arrow to access additional menus as described below. Absolute maximum voltage limits apply to all output and alarm settings. A message is displayed indicating an adjustment is limited due to settings conflict.
  • Page 30 SENS PowerCab2 Technical Manual Adjust amount of time from 0 to 5 minutes to delay before entering Boost mode after power is Auto Boost Delay cycled or battery type is changed. Delay affects all outputs for multiple output models. Auto-Boost...
  • Page 31 SENS PowerCab2 Technical Manual Adjust setpoint to trigger Low DC voltage alarm, Low DC Voltage must be greater than End Discharge setting and less than Battery Discharging setting Adjust setpoint to trigger Battery Discharging alarm, must be between Low DC setting and 98%...
  • Page 32 SENS PowerCab2 Technical Manual Set to 1 for single-phase or 3 for three-phase Number of Phases input voltage Basic Set nominal input voltage for charger model. Settings Nominal Volts AC Must match hardware jumper/terminal block on inside of charger when jumper exists.
  • Page 33 SENS PowerCab2 Technical Manual Press UP arrow to set all alarm relays and DOWN Relay Test arrow to clear all relays Press UP arrow to turn vent fan on and DOWN Check Vent Fan arrow to turn vent fan off Alarm Test Simulate/set alarms for testing purposes.
  • Page 34 Adjust DNP3 baud rate, 230.4 Kbps maximum Set to factory default DNP3 configuration or select one of two custom configurations. Use Conf File SENS DNP3 Config Tool to generate custom configuration file. DNP3 Configuration Enable or disable DNP3 TCP-IP Port...

  • Page 35: Configuration With Sens Setup Utility

    Cat5 minimum RJ45 cable between the ethernet port on the charger and the ethernet port on the computer (see section 4.9). Connect using the “SENSnet” option in the SENS Setup Utility. See the SENS Setup Utility user manual for information on connecting to and communicating with the charger.

  • Page 36: Temperature Compensation

    Update Firmware Using Webpage Use this method to update firmware only on the protocol communications board. Update firmware for all other charger devices using the SENS Setup Utility (see section 7.11). 7.12.3.1. Download new protocol communications board firmware bundle from the SENS website (sens-usa.com/support/download-center/).

  • Page 37: Efficiency

    SENS PowerCab2 Technical Manual Example Temperature Compensation Curves 7.14. Efficiency The figure below shows the efficiency of the system at a given input voltage for a 120VDC 50A unit with 150VDC output voltage. Efficiency Efficiency - 150VDC Output 97.0% 96.0% 95.0%...

  • Page 38: Service And Maintenance

    If the system was ordered with the optional supplemental surge protection, these devices may need to be replaced if operated under extensive surge conditions. Should the device need to be replaced, indication will be provided on the LEDs, display, and alarms. Contact SENS for replacement components and detailed service instructions.

  • Page 39: 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 40: Modbus Holding Registers

    SENS PowerCab2 Technical Manual 9.3. Modbus Holding Registers PowerCab2products provide an extensive array of Modbus registers. The following are common registers that are applicable to most applications. Contact SENS for further information if necessary. See section 11.2 for NaCl (salt) battery Modbus registers.

  • Page 41: Basic Charging Alarms Bit Definition

    SENS PowerCab2 Technical Manual 0x0E2 0x0E3 Unit Boost Timer Boost timer Unit Periodic Boost 0x0E4 0x0E5 Time until next Boost Countdown 0x0E6 0x0E7 Unit Line Frequency AC Line Frequency 0x0E8 0x0E9 Unit Line Voltage 1 AC Line 1 Voltage 32768...

  • Page 42: Charging Status Bit Definition

    SENS PowerCab2 Technical Manual Boost mode time limit has expired and charger has returned to Float AutoBoost 0x10 mode. Boost mode is disabled until the time limit is reset. The Boost Lockout Active time limit is reset when power is cycled.

  • Page 43: Charging Alarms Extended Bit Definition

    SENS PowerCab2 Technical Manual 9.6. Charging Alarms Extended Bit Definition Bit Address Name Description Decimal Module has experienced a thermal roll back which can 0x00 Check Filter be caused by a clogged input air filter. Module has faulted because it over-heated and thermal...

  • Page 44: Accessory System Alarms Bit Definition

    SENS PowerCab2 Technical Manual 9.9. Accessory System Alarms Bit Definition Bit Address Name Description Decimal Invalid System Configuration of system is conflicted. Charger will continue to operate 0x00 Config but may not be fully functional until the issue is resolved.

  • Page 45: Dnp3 Communications-Optional

    None 10.3. SENS DNP3 Config Tool The SENS DNP3 Config Tool is a worksheet that allows user configuration of all DNP3 data points. PowerCab2products ship with a default DNP3 configuration. Use the SENS DNP3 Config Tool to create a customized DNP3 configuration file. The SENS DNP3 Config Tool is available from the communications protocol circuit board webpage (see sections and 7.12).

  • Page 46: Implementation Table

    SENS PowerCab2 Technical Manual 10.4. Implementation Table Object Variation Number Description Binary Input (default) 1 (default) Binary Input Binary Input With Status Binary Input Change (default) Binary Input Change without Time Binary Input Change with Time 3 (default) Binary Input Change With Relative Time...

  • Page 47: Binary Inputs

    SENS PowerCab2 Technical Manual 10.5. Binary Inputs Default Point Name Description Class Summary High DC High DC detected at output terminals of unit Output voltage is below the Low DC Voltage Summary Low DC Threshold Unit has failed or cannot produce output. Reset charger to clear alarm.
  • Page 48 SENS PowerCab2 Technical Manual Charger components are over maximum temperature; so, the power output has been Summary Thermal Fold Back lowered. Summary Current Limiting Charger is outputting maximum current. Output Current is under the low current alarm Summary Low Current threshold.

  • Page 49: Binary Outputs

    SENS PowerCab2 Technical Manual Charger has detected that the output is not Summary DC Output Open connected to anything Summary Charger Low Charger is currently below its rated temperature, Temperature output may be derated Summary Battery Low Battery is below adjustable temperature limit...

  • Page 50: Analog Inputs

    SENS PowerCab2 Technical Manual 10.7. Analog Inputs Default Default Point Name Description Units Class Deadband Program Revision Revision of application code DNP Revision Revision of DNP Error Code defined in manual Setup Error Code (0=No Error) Unit Serial Unit Serial Number of Device...

  • Page 51: Analog Outputs

    SENS PowerCab2 Technical Manual 10.8. Analog Outputs Point Name Units DC Alarm Delay AC Alarm Delay DC ChannelA End Discharge VPC mV/cell DC ChannelA Low DC VPC mV/cell DC ChannelA Battery Discharge VPC mV/cell DC ChannelA Battery Check VPC mV/cell...

  • Page 52: Nacl Salt Battery Operation-Optional

    SENS PowerCab2 Technical Manual 11 NACL SALT BATTERY OPERATION—Optional The PowerCab2 system may optionally include NaCl (salt) batteries. NaCl batteries include an internal battery management system to optimally charge the batteries. The batteries must be warm before delivering energy; the internal battery management system automatically begins the warm-up process as soon as power is applied.

  • Page 53: Modbus Tcp/Ip

    SENS PowerCab2 Technical Manual 11.2. Modbus TCP/IP NaCl batteries Modbus TCP/IP communications are factory configured as indicated in the table below. NaCl Batteries TCP/IP Modbus Default Settings Setting Value IP Address 0.0.0.0 DHCP/AUTO Subnet Mask Gateway Port Number Modbus Slave...
  • Page 54 SENS PowerCab2 Technical Manual 11.2.2. Reconfigure Modbus Slave Address If the default battery Modbus slave address is not preferred, reconfigure using the Tera Term software provided at https://teratermproject.github.io/index-en.html. 11.2.2.1. Connect computer with Tera Term software to battery using provided USB-A to USB-A cable.
  • Page 55 SENS PowerCab2 Technical Manual 11.2.3. Modbus Holding Registers The following table includes the Modbus Holding Registers for the NaCl batteries only. See section for remaining system Holding Registers. Adjust polled value by the offset first, then multiply by the scale factor.
  • Page 56 SENS PowerCab2 Technical Manual 11.2.4. Modbus Bitmap ALARM BITMAP WARNING BITMAP LED BITMAP IO BITMAP register 15 INDEX registers 11-14 register 7-10 register 6 GREEN_0 MAIN_SWITCH_CLOSED TaM1 GREEN_1 ALARM_OUT_ACTIVE TaM2 AMBER_0 AMBER_1 VOLT_MEASUREMENT_ALLOWED TbM1 BLUE_0 VOLTAGE STRING RELAY TbM2 BLUE_1...
  • Page 57 SENS PowerCab2 Technical Manual SOCL I2TW I2TA ULAL 55-63 NOT USED NOT USED 11.2.5. LED Status LED status is encoded in two bits. GREEN_1 GREEN_0 BLUE_1 BLUE_0 LED STATUS AMBER_1 AMBER_0 RED_1 RED_0 BLINK SLOW BLINK FAST...

  • Page 58: Troubleshooting/Error Codes

    SENS PowerCab2 Technical Manual 12 TROUBLESHOOTING/ERROR CODES 12.1. Reset Button Press the RST button to reset the charger control and display circuitry. The system will take approximately 30 seconds to reset. Output voltage is not affected during reset. 12.2. Configuration Error Codes Error codes are displayed on front panel LCD.

  • Page 59: Troubleshooting Guide

    SENS PowerCab2 Technical Manual meet the required output rating (plus the additional chargers needed for "N+1" or "N+2" redundant operation). - Verify that each channel is assigned enough chargers to meet the required DC output rating (plus any extra chargers needed to provide "N+1"...
  • Page 60 SENS PowerCab2 Technical Manual color). If main control board LEDs are on, check that the main control board to display board cable is correctly installed between SERVICE Port on main control board and display accessory display board J1, and that both ends of the cable are fully inserted.
  • Page 61 SENS PowerCab2 Technical Manual Modbus +D1 (A) goes to pin 5 of J2 and that Modbus –D0 (B) goes to pin 4 of J2. 4. If cable wiring is correct, verify that charger and application MODBUS settings are as required.
  • Page 62 SENS PowerCab2 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 ventilation openings...
  • Page 63 SENS PowerCab2 Technical Manual 3. If steps 1 and 2 don’t resolve 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.
  • Page 64 SENS PowerCab2 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 shutdown failure AC input terminal block/breaker are in the range 188VAC –...
  • Page 65 3. If steps 1 and 2 don’t resolve issue, a charger module failure is the likely cause. Contact SENS or replace charger module. ALTERNATING No output 1. Missing or invalid 1.

  • Page 66: 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.

Table of Contents