Sens EnerGenius DC Manuel utilisateur

SENS EnerGenius® DC Wallbox Technical Manual

SENS Part Number: 101335

Document Revision: A

DCN Number: 107839

Date: May 4, 2020

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.

The SENS name / logo, EnerGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC

Installation & Operation Manual

WALLBOX

Automatic Battery Charger/Power Supply

1840 Industrial Circle

Longmont, CO 80501

Phone: 303.678.7500

800.742.2326

Fax: 303.678.7504

Email: [email protected]

Web: www.sens-usa.com

SENS EnerGenius® DC Wallbox Technical Manual 
 

 
TABLE OF CONTENTS 
 
2MODEL NUMBER BREAKOUT.............................................................................................................................. 6 
3PERFORMANCE SPECIFICATIONS........................................................................................................................ 7 
4SYSTEM OVERVIEW........................................................................................................................................... 10 
1. Physical Overview ....................................................................................................................................10 
2. Functional Overview ................................................................................................................................10 
2.1. Configuration ...........................................................................................................................................10 
5MOUNTING INSTRUCTIONS.............................................................................................................................. 12 
1. Mounting Location...................................................................................................................................12 
2. Mounting Instructions.............................................................................................................................. 12 
6SETUP AND WIRING.......................................................................................................................................... 14 
1. Wire Ratings and Sizes .............................................................................................................................14 
2. Grounding Instructions and Connection..................................................................................................16 
3. DC Connection..........................................................................................................................................16 
4. AC Connection..........................................................................................................................................17 
5. Standard Alarm Connections ...................................................................................................................17 
6. Optional Pilot Relay Connections.............................................................................................................19 
7. CANbus and RS-485 Connections............................................................................................................. 20 
8. Ethernet ...................................................................................................................................................22 
9. SENSbus Connection ................................................................................................................................22 
Figure 10 –SENSbus Connection............................................................................................................................23 
10. Verify Connections...................................................................................................................................23 
7START-UP PROCEDURE ..................................................................................................................................... 24 
1. Connect Battery/Outputs.........................................................................................................................24 
2. Verify Configuration.................................................................................................................................24 
3. Apply AC Input Voltage ............................................................................................................................25 
4. Power Off .................................................................................................................................................25 
8ALARMS, LEDS AND DISPLAY............................................................................................................................ 26 
1. LED Indicators...........................................................................................................................................26 
2. Individual Alarm Relay Contacts...............................................................................................................26 
3. LCD Panel .................................................................................................................................................27 
4. Alarm Definitions .....................................................................................................................................27 
9OPERATION ....................................................................................................................................................... 33 
1. Charging Algorithms................................................................................................................................. 33 
2. Float Mode...............................................................................................................................................34 
3. Dynamic Boost™ Mode............................................................................................................................34 
4. HELIX Mode..............................................................................................................................................35 
5. Charging Low or Zero-volt Batteries ........................................................................................................35 
6. Commissioning Batteries..........................................................................................................................35 
7. Battery Check...........................................................................................................................................35 
8. Shunt Trip AC Breaker - optional..............................................................................................................36 
9. Restore Factory Defaults..........................................................................................................................36 
10. Keypad Operation ....................................................................................................................................36 
11. Configuration with SENS Setup Utility .....................................................................................................41 
12. Temperature Compensation....................................................................................................................41 
13. Load Share Charger Operation.................................................................................................................42 
14. Efficiency..................................................................................................................................................42 
SERVICE AND MAINTENANCE........................................................................................................................... 43 
1. Recommended Annual Maintenance.......................................................................................................43 
2. Power Module Access..............................................................................................................................43 
3. Air Filter....................................................................................................................................................44 
4. Fans.......................................................................................................................................................... 44 
5. Supplemental Surge Protectors ...............................................................................................................44 
MODBUS COMMUNICATIONS.......................................................................................................................... 45 
1. TCP/IP Modbus—Optional .......................................................................................................................45 

SENS EnerGenius® DC Wallbox Technical Manual 
 

 
2. RS-485 Modbus—Optional......................................................................................................................45 
3. Modbus Holding Registers .......................................................................................................................45 
4. Basic Charging Alarms Bit Definition........................................................................................................47 
5. Charging Status Bit Definition.................................................................................................................. 48 
6. Charging Alarms Extended Bit Definition.................................................................................................48 
7. Charging AC Alarms Bit Definition............................................................................................................49 
8. Accessory Channel Alarms Bit Definition .................................................................................................49 
9. Accessory System Alarms Bit Definition...................................................................................................49 
10. Accessory Assigned Channel Alarms Bit Definition..................................................................................50 
11. Writable Control Flags (Coils)...................................................................................................................50 
TROUBLESHOOTING/ERROR CODES................................................................................................................. 51 
1. Configuration Error Codes........................................................................................................................51 
2. Troubleshooting Guide.............................................................................................................................54 
GLOSSARY.......................................................................................................................................................... 60 
 

SENS EnerGenius® DC Wallbox Technical Manual

1IMPORTANT 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.

1.3. Do not expose charger to rain or snow.

1.4. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of

fire, electric shock, or injury to persons.

1.5. This charger is intended for commercial and industrial use. ONLY TRAINED AND QUALIFIED PERSONNEL

MAY INSTALL AND SERVICE THIS UNIT.

1.6. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way;

shut off power at the branch circuit protectors and have the unit serviced or replaced by qualified

personnel.

1.7. To reduce risk of electric shock, disconnect the branch circuit feeding the charger before attempting any

maintenance or cleaning. Turning off controls will not reduce this risk.

1.8. Use appropriate lockout / tagout procedures to ensure safety of all personnel installing and servicing this

equipment. The input and output breakers are equipped with provision to lock breakers in the OFF

position.

1.9. WARNING –RISK OF EXPLOSIVE GASES

1.9.1. WORKING IN THE VICINITY OF A LEAD-ACID OR NICKEL-CADMIUM BATTERY IS DANGEROUS.

STORAGE BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR

THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU READ THIS MANUAL AND FOLLOW THE

INSTRUCTIONS EACH TIME YOU USE THE CHARGER.

1.9.2. To reduce the risk of battery explosion, follow these instructions and those published by the battery

manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery.

Review cautionary markings on these products and on the engine.

1.10. PERSONAL PRECAUTIONS

1.10.1. Someone should be within range of your voice or close enough to come to your aid when you work

near a storage battery.

1.10.2. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or

eyes.

1.10.3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a

storage battery.

1.10.4. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte

enters eye, immediately flood the eye with running cold water for at least 10 minutes and get

medical attention immediately.

1.10.5. NEVER smoke or allow a spark or flame in vicinity of battery or engine.

1.10.6. 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.

1.10.7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a

storage battery. A storage battery can produce a short circuit current high enough to weld a ring or

SENS EnerGenius® DC Wallbox Technical Manual

the like to metal, causing a severe burn.

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.

1.10.9. NEVER charge a frozen battery.

1.10.10. Consult national and local ordinances to determine if additional battery fault protection is

necessary in your installation.

1.11. Preparing Battery For Charge

1.11.1. Be sure area around battery is well ventilated while battery is being charged.

1.11.2. Ensure battery terminals are clean and properly tightened. Be careful to keep corrosion from

coming in contact with eyes.

1.11.3. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer.

Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid

batteries, carefully follow manufacturer’s recharging instructions.

1.11.4. Study all battery manufacturer specific precautions such as removing or not removing cell caps

while charging and recommended rate of charge. The recommended charge current range must

include the rated output current of the charger.

1.12. Charger Location

1.12.1. Locate the charger as far away from the battery as DC cables permit.

1.12.2. Never place the charger directly above or below the battery being charged; gases from the battery

will corrode and damage charger.

1.12.3. Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling

battery.

1.12.4. Do not operate charger in a closed-in area or restrict ventilation in any way.

1.12.5. Do not set anything on top of the charger.

SENS EnerGenius® DC Wallbox Technical Manual

2MODEL NUMBER BREAKOUT

120

100

Parameter

Code

Value

Product Family

EnerGenius DC

Enclosure Type

Wallbox

AC Input Voltage

Three Phase - 480VAC

AC Interrupt

Standard Interrupt Rating (25kAIC)

High Interrupt Rating (65kAIC)

DC Output Voltage

120

120 VDC

240

240 VDC

DC Interrupt

Standard Interrupt Rating (10kAIC)

High Interrupt Rating (25kAIC), not available on 240VDC units

Output Current

120 VDC

240 VDC

025

25A

✓

035

35A

✓

050

50A

✓

075

75A

✓

100

100A

✓

Redundancy

No Redundancy

N+1 Redundancy

Communications and

Interface

Standard - (LCD, Keypad, 5 Form-C Relays, Ethernet)

Standard with Breaker Status

Accessory Hardware

None

High Current AC Alarm Relays (2X 120VAC, 5A)

High Current AC/DC Alarm Relays (2X 150VDC 3A / 240VAC 10A)

AC Breaker Shunt Trip

Option B and Option C

Surge Protection

Standard Surge Protection

Supplemental AC/DC Surge Protection

Mounting

Wallmount

Configuration

Standard Configuration

PIP Compliant (requires Accessory Hardware selection to be A, B, or D)

Factory Specified Custom Configuration

SENS EnerGenius® DC Wallbox Technical Manual

3PERFORMANCE 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.

Forced ConductionTM cooling keeps the high efficiency power electronics free of dust and dirt, making EnerGenius

DC well-suited for operation in industrial, utility, power plant, and other harsh environments. Two variable speed,

premium ball-bearing fans cool each rectifier. Rectifiers maintain nearly full output capability even if one fan fails.

A fan failure alarm system with local and remote indication enables service dispatch while the second fan

continues to run. The fan module is easily replaced in the field with common tools.

5 standard Form-C contact alarms are factory set and field reconfigurable, with indication via communication

port, front panel LCD and five assignable alarm relays. Two additional pilot relays to switch external loads or

alarms are optional.

Options include supplemental surge suppression, and data communication including Modbus, DNP3 and IEC

61850. Chargers can be equipped with one or multiple communication protocols. Specifications are detailed in

the table below, see following sections for installation and operation instructions.

Table 1 –Specifications

AC input

Voltage, frequency

Full output power: 358-528 VAC 3-phase line to line

connected, 50% power limit from 188-357 VAC. 47-63 Hz.

Input current

24A maximum at 358VAC for maximum configured unit.

Overcurrent protection

3-pole UL 489 listed circuit breaker

25 kAIC standard, 65 kAIC optional, lockable

Loss of phase

Continues operating with current limit reduced to 50%

AC transient protection

Layered electrical transient defenses. Optional UL1449 Type

1 Listed supplemental surge protection, alarmed and with

field replaceable elements, surge capacity rated 75kA 8/20

µs; visual and remote indications.

Loss of phase

Continues operating with current limit reduced to 50%

Efficiency

Up to 95%, see section 9.14

Power Factor and Total

Harmonic Distortion

>.98 typical at maximum rated load current and boost

charge voltage. Total Harmonic Distortion <3%

DC output

Voltage

120 VDC or 240 VDC nominal: 120 VDC: output adjustable

from 8-160V. 240 VDC: output adjustable from 16-320V.

Current

Output limit: 14kW or 100A for 120VDC models, whichever

is less or 14kW or 50A for 240VDC models, whichever is less

Soft Start

System gradually increases current with a maximum of 5

seconds to full-required output

Charging modes

Multi-stage, including float, boost, HELIX and commissioning

charge modes

Current limit

100% current capability subject to temperature limits and AC

voltage limits; field adjustable from 25% to 100%

Charging characteristic

Constant voltage, current limited; patented Dynamic Boost

and HELIX control

Line & load regulation

±0.5%

SENS EnerGenius® DC Wallbox Technical Manual

Output Ripple

< 30mV with battery, <100mV off-battery for 120VDC,

<200mV off-battery for 240VDC. Delivers fast-responding,

stable, well-filtered DC without battery.

Step response

8ms typical without battery, to recover within 1% of rated

output voltage from load step change of 50% rated output

current

Output protection

Electronic current limit. 2-pole UL 489 listed circuit breaker.

10 kAIC standard, 25 kAIC optional, lockable

DC surge protection

Layered electrical transient defenses. Optional UL1449 Open

Type 2 Listed supplemental surge protection, alarmed and

with field replaceable elements, surge capacity rated 75kA

8/20 µs; visual and remote indications.

Battery types

Flooded lead-acid, AGM, Ni-Cd, VRLA, and lithium

DC power supply operation

Delivers fast-responding, stable, well-filtered DC without

battery

Battery temp.

compensation

Standard. On-board sensor modifies output voltage when

temperature is between 0°C and+40°C. Slope adjustable,

factory set to –0.18% per degree C. Optional remote battery

monitor provides battery temperature probe.

Dead battery charge

Starts into and recharges zero-volt battery

Parallel/load share

operation

Two or more independent chargers actively current share

and synchronize all modes for increased current or fault

tolerance when common RJ-45 network cable is connected

to each charger’s paralleling bus

Output blocking protection

Prevents sparking during battery connection or during hot

swap operation

Adjustment &

Controls

Charge mode control

Fully automatic patented Dynamic Boost system. Manual

boost, timed boost & battery commissioning charging

options are available from front panel control

Front panel control

Change all parameters including voltages, current limits,

alarm parameters, relay assignments, network

configurations, time-outs, and more

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%; DC ammeter to ±5%; AC

Voltmeter to +2%; AC ammeter to +5%; AC frequency meter

to ±1.5%; DC Output Watts; DC Output as a percent of

maximum rated output

Status display

20-character display of status & alarm messages.

Data logging

Data logging to internal nonvolatile memory, based on

events and at fixed times. Logs retrieved using computer

network connection.

Alarms

Alarm Outputs

Factory set, field reconfigurable, latching and non-latching.

Alarms available via communication port, alarm relays, and

on LCD.

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.

Two optional 120VAC, 5A, resistive or 150VDC, 3A / 240VAC,

10A assignable

Optional pilot relay

functions

Form C contacts configurable as pilot relays to switch

external loads based on user-configurable conditions

Networking

Modbus communications

Optional Modbus RS-485 or TCP/IP on RJ-45 port

DNP3

Optional DNP3 RS-485 or TCP/IP on RJ-45 port

IEC 61850

Optional IEC 61850 TCP/IP on RJ-45 port

SENSbus

Proprietary bus for connection of paralleled chargers and

SENS accessories

Environmental

Operating temperature

-40C to +70C; full spec from -40C to +50C. Display may be

unreadable and suffer reduced life above 65°C. Cold starts

down to -40°C.

Ingress protection

IP 20; NEMA 1

Humidity

5% to 95%, non-condensing

Altitude

0-6,500 ft (2,000 meters). Above this altitude, output is

derated 0.012% per additional meter at rated ambient

temperature.

Vibration & shock

resistance

EN60068-2-6, EN 60068-2-64 & EN 60068-2-27

Electrical transient

ANSI/IEEE C62.41, EN 61000-4-12 on power terminals, IEC

61000-6-5 and ANSI/IEEE C37.90

Abuse

protection

Reverse polarity

Charger self-protects without output protective device

clearing. Indication via LED & LCD.

Wrong voltage battery

Charger-battery voltage mismatch shuts down charger after

5 minutes. Indication via LED & LCD.

Overvoltage shutdown

Selective; shutdown only operates the overvoltage

shutdown is caused by the charger itself

Overtemperature

protection

Gradual output power reduction if heatsink temperature

becomes excessive; recovery is automatic.

Regulatory

Compliance

North America

C-UL Listed for US & Canada: CSA 22.2, No. 107.2, UL 1012,

UL 508A

NFPA-70, NEMA PE-5, PIP (optional)

FCC Part 15, Class A commercial use and ICES-003 (Canada)

European Union (CE)

EMC: 2014/30/EU (EN 61000-6-2 & EN 61000-6-4)

LVD: 2014/35/EU (EN 60335-1 & EN 60335-2-29)

RoHS 2: 2017/2102/EU (EN 50581)

Construction

Housing

Wall mount

Housing material

Aluminum with powder coated finish

Weight

85 lbs (38.6kg) maximum

Cable entry

Side entry with one 1-1/2 inch NPT opening for DC and two 1

inch NPT openings for AC and two 1/0 inch NPT for

alarms/comms

SENS EnerGenius® DC Wallbox Technical Manual

Network/Alarm

connections

Modbus: RJ-45 or terminal blocks 28 to 16 AWG. Form C

alarms: 28 to 16 AWG.

Power connections

AC breaker: 14 –1/0AWG

DC breaker: 1AWG –350kcmil

4SYSTEM OVERVIEW

4.1. Physical Overview

Figure 1 –EnerGenius DC Wallbox Overview

4.2. Functional Overview

4.2.1. Configuration

Each EnerGenius DC Wallbox System comes factory configured for its application from the factory.

Configuration details are given on the configuration label (see Figure 2). These values are assigned

according to the profile configuration selected during the customer order. Profiles are available

for various battery types and applications. 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.

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