SENS MicroGenius 2 Technical Manual 1 IMPORTANT SAFETY INSTRUCTIONS/INSTRUCTIONS IMPORTANTES CONCERNANT LA SÉCURITÉ 1.1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions for ® MicroGenius 2 battery chargers. Conserver ces instructions. Ce manuel contient des instructions importantes concernant la sécurité et le fonctionnement.
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SENS MicroGenius 2 Technical Manual 1.11.6. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short circuit the battery or another electrical part that may cause explosion. Using insulated tools reduces this risk but will not eliminate it.
SENS MicroGenius 2 Technical Manual MODEL NUMBER BREAKOUT Model Alarms/Communications* Output Current Power Output Voltage A: base model; includes J-1939 & Modbus RS-485 1006: 10/6A @ 12/24V 1: 180W, enclosed 22: 12/24 Volts D: base model + LCD + 5 Form C alarm relays...
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On-board sensor controls changes in output voltage when compensation temperature is between 0°C and +40°C at a default rate of – 0.18% per degree C; optional remote battery temperature probe (SENS p/n 209481) Output protection Current limit, supplementary overcurrent protection fuse (non-...
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Change or customize settings from computer using SENS Setup Utility and on-board USB connection. Connect legacy units (on-board USB not included) using computer to charger cable provided in SENS Setup Utility kit, SENS p/n 209254. SENS Setup Utility software available at www.sens-usa.com.
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SENS MicroGenius 2 Technical Manual Water ingress Enclosed Models: NEMA2/IP22; NEMA3R/IP34; UL Rainproof Vibration Swept Sine (EN60068-2-6): 4G, 18-500 Hz, 3 primary axes Random: 20-500Hz, .01G Shock EN 60068-2-27 (15G) Electrical transient ANSI/IEEE C62.41 and EN 61000-4-12 on power terminals...
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EN 63000 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...
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...
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.
SENS MicroGenius 2 Technical Manual 5.1.2.5. The mounting surface must safely support the weight of the charger and the fixed wiring. The weight of the open-frame charger is 3.2 pounds (1.5 kg) for 12/24V at ≤15A and 4 pounds (1.8 kg) for remaining models.
12-48VDC models without the optional keypad. Jumpers are not present on 120VDC models; use the optional keypad or SENS Setup Utility (connect using USB if alarms/coms circuit board is included or the SENSbus Adapter if not) to configure instead. Jumpers in the three FLOAT positions indicate the charger is operating using settings configured at the factory per customer order.
Replacing the jumpers in the three FLOAT positions will return the charger to the original factory configuration. Jumpers are not present on 120VDC models; use the SENS Setup Utility to configure instead.
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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...
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). Ultracapacitor charging is available only on 12V and 24V models.
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.
When the optional alarm/communications circuit board is included, the J1939 address should be configured using the SENS Setup Utility or via the optional keypad. For legacy units, the J1939 address may also be configured using the address jumper on the board (see Figure 7) For all other models, configure the address jumper on the main circuit board (see Figure 8).
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SENS MicroGenius 2 Technical Manual 120-ohm termination plugs for the RJ-45 communications connector on the charger are available to order separately (SENS 803707). Figure 10 – Modbus Termination LT = Line Termination 120-ohm resistor...
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.
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SENS MicroGenius 2 Technical Manual Table 3 – DC Output Cable Size Charger Rated Wire Size Resistance Maximum Charger to Battery Distance (Ft.) Output Current per Foot AWG mm 120V (Amps) (mΩ/Ft.) 2.50 49.5 1.60 1.00 124.5 0.63 0.40 1040 2.50...
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.
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SENS MicroGenius 2 Technical Manual 2”) circuits. Alarm circuits are rated 2A at 30V AC or DC. The terminals accept 28-16 AWG (0.08-1.5 mm conductors. Tighten connections to 2.0 Lb-In (0.22 Nm) using a small slotted driver. Route alarm wiring at least ¼...
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...
Multiple chargers may be connected in parallel to provide charger redundancy and increased charging current using a load sharing accessory, available to order separately (SENS p/n 209069). Connect the load sharing accessory from one charger to another using the RJ-45 ports on each charger to automatically initiate load sharing.
SENS MicroGenius 2 Technical Manual end of the network cables to the SENSbus RJ-45 port on each charger. Leave a factory installed 120-ohm terminator in a SENSbus port on the main circuit board on each charger to ensure a terminator is located at both ends of the communications bus.
SENS MicroGenius 2 Technical Manual ALARMS, LEDS AND DISPLAY 9.1. LED Indicators The charger is equipped with two LEDs, one for AC status and one for DC status. See further alarm definitions in section 9.5. Table 8 – LED Definitions...
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”...
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SENS MicroGenius 2 Technical Manual 9.5.2. 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.
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SENS MicroGenius 2 Technical Manual 9.5.3. 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.
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SENS MicroGenius 2 Technical Manual 9.5.4. 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.
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SENS MicroGenius 2 Technical Manual 9.5.5. 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.
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SENS MicroGenius 2 Technical Manual board OVERVOLTAGE SHUTDOWN relay contacts change to Fail state after delay when alarm is assigned to relay contacts. Reset the charger by removing and replacing any jumper on the circuit board to clear the alarm.
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SENS MicroGenius 2 Technical Manual 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 red/yellow DC LED. Optional alarm/communications circuit board INCOMPATIBLE BATTERY relay contacts change to Fail state after delay when alarm is assigned to relay contacts.
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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.
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SENS MicroGenius 2 Technical Manual 9.5.4. 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. 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.
SENS MicroGenius 2 Technical Manual 10 OPERATION 10.1. 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 19. See following sections for descriptions of each charging mode.
SENS Setup Utility. Use of the optional remote temperature compensation probe is highly recommended to maximize charging performance and optimize battery life.
Standard Jumper Configuration (see section 6.2). HELIX operates 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.
Program Mode. When using the keypad, navigate to the “Battery Set-up” menu to enable commissioning and configure commissioning voltage, current and duration. When using Program Mode and the SENS Setup Utility (because the charger is not equipped with the optional keypad), see section 10.10 and the SENS Setup Utility user manual.
SENS MicroGenius 2 Technical Manual 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). 10.9.2. Menu Navigation Use the keypad to scroll through settings to view and adjust. The keypad provides X-Y navigation with main fields up and down, and details within each field left and right (see Figure 14).
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SENS MicroGenius 2 Technical Manual Select type of battery to be charged - flooded Battery Select Type lead-acid, AGM, nickel-cadmium VRLA, power supply. Battery Select Number of Adjust number of series cells in battery string Cells Adjust output Float voltage, must be greater...
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SENS MicroGenius 2 Technical Manual Adjust minimum voltage allowed during Battery Check test, must be greater than End- Batt Check Vmin of-Discharge voltage and less than 98% Float voltage Adjust amount of time between scheduled Sched Batt Check Battery Check tests from 1 to 90 days...
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SENS MicroGenius 2 Technical Manual Adjust DC Startup Voltage. Set to zero to start DC Start Volts into zero-volt battery automatically. Startup Enables charger to attempt to charge a battery Voltage Force Startup with a voltage below the DC Startup Voltage.
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SENS MicroGenius 2 Technical Manual AC Input #A Enable for S2/S4 units AC Input #B Disable for S2/S4 units Select allowed user interface access. Access UI Access Control options include read-only/monitor viewing or full access adjustments for advanced users. Change security code to desired 6 digits. The default security code is 000000 (disabled).
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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 TCP DNP3 Configuration Enable or disable DNP3 TCP-IP...
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Dest Addr Set DNP3 destination address 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. J1939 Configuration BCH1 Assign charger output for J1939 battery Output...
SENS MicroGenius 2 Technical Manual 10.10. SENS Setup Utility and Program Mode Use the SENS Setup Utility to program the charger with custom settings. Remove all jumpers (on models including jumpers) to enable Program Mode. If the charger has not been specially programmed, removing all jumpers will result in an INVALID SETTINGS error state and the charger will not produce output.
SENS MicroGenius 2 Technical Manual Figure 15 – Example Temperature Compensation Curves 10.12. Load Share Charger Operation Multiple chargers may be connected in parallel to provide charger redundancy and increased charging current. Up to 30 chargers may be connected in parallel for load sharing. Load sharing chargers are fault tolerant;...
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.
Slave Address 12.2. Modbus TCP/IP—Optional Modbus communications over TCP/IP is optional and requires configuration using the SENS Setup Utility or the keypad (see section 10.9.3). Adjust IP address as desired. It may take up to 10 seconds for the network setting changes to apply. A TCP/IP address of 0.0.0.0 implies DHCP (Dynamic) addressing.
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SENS MicroGenius 2 Technical Manual Address High Address Low Name Description Units Scale Factor 0x01A 0x01B Model Num 29_32 Model number character Number of times the crank logger has 0x024 0x025 Number of Cranks Detected been tripped. Available on charger only.
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SENS MicroGenius 2 Technical Manual Address High Address Low Name Description Units Scale Factor Default Output Maximum 0x080 0x081 Maximum rated power V/Cell 32768 Power Default Output Maximum 0x082 0x083 Maximum rated voltage in x.xx V V/Cell 32768 Voltage Default Output Maximum...
SENS MicroGenius 2 Technical Manual 12.7. Charging AC Alarms Bit Definition Bit Address Name Description Decimal 0x00 Unused Unused An AC phase is missing or out of range. Only available 0x01 AC Phase Missing in a 3-phase capable device. AC Voltage has gone above max AC voltage allowed...
SENS MicroGenius 2 Technical Manual 13 TROUBLESHOOTING/ERROR CODES 13.1. Configuration Error Codes Error codes are displayed on front panel LCD. Error Scope Description Corrective Action - When a charger contains multiple charger modules, each module in that unit must be set to a different Invalid charger position jumper setting for a position number.
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SENS MicroGenius 2 Technical Manual Error Scope Description Corrective Action presumed that a module has failed, has lost cables. SENSbus data communication, or has an incorrect - If the output is not to be used, disable it by using the output setting.
SENS MicroGenius 2 Technical Manual 13.2. Troubleshooting AC LED DC LED Symptom Possible Causes Recommended Actions 1. Proper AC or DC voltages not 1. Using a voltmeter, check that AC input voltage and applied frequency at AC input terminal block (J100) are in 2.
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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.
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SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions GREEN SOLID using MODBUS on models termination installed accessory display board J2. If terminator is missing, GREEN with accessory display 2. Communication cable is plugged install missing terminator. (Note that a terminator...
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SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions 2. If step 1 doesn’t resolve issue, a main power board failure is the likely cause. Replace charger. 1. Proper AC voltages or frequency AC LED not applied 1.
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SENS MicroGenius 2 Technical Manual AC LED DC LED Symptom Possible Causes Recommended Actions failure is the likely cause. Replace charger. Proper AC voltages or AC LED frequency not applied 1. Using a voltmeter, check that AC input voltage and...
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.
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SENS MicroGenius 2 Technical Manual 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.
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NOTE - MG2 CHARGER MUST HAVE TERMINATOR INSTALLED. TERMINATOR IS INCLUDED WITH REMOTE PANEL. 7.00 6.38 6.38 6.00 NOTES: THIS PRODUCT IS INTENDED FOR USE WITH SENS MICROGENIUS AND ENERGENIUS PRODUCTS INCLUDING MG2, S2, S4, AND ENERGENIUS DC. 6.38 6.00 NAME DATE DESCRIPTION...
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Intended Service Charging batteries and providing DC power in Marine and Offshore Applications Description MicroGenius 2: Switchmode, regulated, filtered, microprocessor-controlled, current limited battery charger designed for heavy-duty industrial service. Primary application: quick recharge and long-life maintenance of engine start batteries and ultracapacitors.
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Certificate Number: 21-2165921-PDA Unit Certification is not required for this product (ratings less than 25 kW). If the manufacturer or purchaser requests an ABS Certificate for compliance with a specification or standard, the specification or standard, including inspection standards and tolerances, must be clearly defined.
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Certificate Number: 21-2165921-PDA This Certificate is valid for installation of the listed product on ABS units which exist or are under contract for construction on or previous to the effective date of the ABS Rules and standards applied at the time of PDA issuance.
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Certificate Number: 21-2165921-PDA This Certificate is valid for installation of the listed product on ABS units which exist or are under contract for construction on or prior to the effective date of the ABS Rules and standards applied at the time of PDA issuance. ABS makes no representations regarding Type Approval of the Product for use on vessels, MODUs or facilities built after the date of the ABS Rules used for this evaluation.
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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, 5, 6, 7, F, G, H, or L; Y = any digit; Conformance to Directive 2014/30/EU of the European Parliament and of the Council...
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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, 5, 6, 7, F, G, H, or L; Y = any digit; Conformance to Electromagnetic Compatibility Regulations 2016...
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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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