SENS EnerGenius Technical Manual

Installation & Operation Manual

NRG12-20: 12-Volt, 20-Amp Battery Charger
NRG24-20: 24-Volt, 20-Amp Battery Charger
NRG22-20: 12/24-Volt, 20-Amp Battery Charger

®
SENS Part Number: 101298
N ™
Document Revision:
DCN Number: 106194
1840 Industrial Circle
Date: October 25, 2012
Longmont, CO 80501
Phone: 303.678.7500
Installation or service questions? 800.742.2326
Call SENS at 1.800.742.2326 (303.678.7500) Fax: 303.678.7504
between 8 a.m. and 5 p.m. (Mountain Time) Email: [email protected]
Monday
Service through1.800.742.2326
hotline: Friday, or visit our website. Web: www.sens-usa.com
1.303.678.7500 1
Copyright © Stored Energy Systems LLC 2007
 SENS EnerGenius Technical Manual

IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR

1. SAVE THESE INSTRUCTIONS.

2. DO NOT EXPOSE CHARGER TO RAIN OR SNOW.
3. Use of an attachment not recommended or sold by SENS may result in a risk of fire, electric shock,
or injury to persons.
4. ONLY TRAINED AND QUALIFIED PERSONNEL MAY INSTALL AND SERVICE THIS
UNIT.
5. 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.
6. 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.

WARNING:
RISK OF EXPLOSIVE
GASES.
A. 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 EACH
TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE
INSTRUCTIONS EXACTLY.
B. To reduce the risk 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.

7. PERSONAL PRECAUTIONS

A. Someone should be within range of your voice or close enough to come to your aid when you work near a
storage battery.
B. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or eyes.
C. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a storage
battery.
D. 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.
E. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
F. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short circuit battery
or other electrical part that may cause explosion. Using insulated tools reduces this risk, but will not
eliminate it.
G. 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 the like to metal,
causing a severe burn.
H. Use this charger for charging LEAD-ACID or LIQUID ELECTROLYTE NICKEL-CADMIUM
batteries only. Do not use this battery charger for charging dry cells, alkaline, lithium, nickel-metal-
hydride, or sealed nickel-cadmium batteries that are commonly used with home appliances. These batteries
may burst and cause injuries to persons and damage to property.
I. NEVER charge a frozen battery.

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 SENS EnerGenius Technical Manual

MODEL NUMBER CONFIGURATION

This manual contains important safety, installation and operating instructions for SENS battery charger model
NRG12-20 (configured for 12V,20A only), NRG24-20 (configured for 24V, 20A only) and NRG22-20 (field
configurable for 12V or 24V, 20A).
Model Number Breakout
NRG 22-20-

Model Output Output Input Voltage Alarm System Agency Category

Voltage Current Frequency Code Code Code

12: 12 volts 20: 20 Amps H: 120/208-240V, C: 5 Alarms L: UL, CUL Listed S: Standard
24: 24 volts 50/60 Hz** R: Recognized E: OSHPD labeled***
22: 12/24 volts R: 120/208-240V, Component
60 Hz*

NOTE: Not all configurations are available on all models.

Contact the factory for confirmation.
*UL listed, CSA certified
**UL listed, CSA certified and CE marked
***California Special Seismic Certification Pre-Approval

INSTALLATION INSTRUCTIONS
WARNING:
ONLY TRAINED AND QUALIFIED PERSONNEL
MAY INSTALL AND SERVICE THIS UNIT.

6” (150 mm) minimum

ventilation clearance
top and bottom

Mount to vertical surface of 3/4” (19 mm) plywood or other

2” (50 mm) minimum material of equal strength and durability, using four 1/4” (6
ventilation clearance mm) diameter mounting screws. For mounting in a high
on both sides vibration environment, use of six fasteners is recommended.

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 SENS EnerGenius Technical Manual

1. PREPARING FOR USE:

WARNING:
ONLY TRAINED AND QUALIFIED
PERSONNEL MAY INSTALL AND
SERVICE THIS UNIT.

A. INSTALLATION OF THE UNIT MUST COMPLY WITH LOCAL ELECTRICAL CODES

AND OTHER APPLICABLE INSTALLATION CODES.
B. INSTALLATION MUST BE MADE ACCORDING TO THE INSTALLATION
INSTRUCTIONS AND ALL APPLICABLE SAFETY REGULATIONS.

W = 13.95”
H = 13.06”
D = 6.83”

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 SENS EnerGenius Technical Manual
Neutral +Battery
Temperature sensor
115/230VAC Alarm contacts -Battery

Use wire routing devices to hold

alarm and temperature sensor
Grounding conductors at least 1/4” (6.3 mm)
Conductor away from power conductors

Use conductors rated 90C or higher.

Input conductors must be suitable for 15A circuits.
Battery conductors must be suitable for 40A circuits. See Section 5.
Alarm and temperature sensor may use low power conductors.
C. This unit is permanently connected to the AC circuit and to the battery. An external disconnect device with a minimum of
0.12”(3 mm) pole separation must be located in the AC input to the charger.
 Do not energize the AC supply circuit until ALL wiring is connected, internal controls are properly set, and the cover is
secured. Always shut the AC supply circuit off before installing or removing any wiring or opening the cover for any
reason.
 Always observe proper polarity of the DC output leads.
 Always connect the output leads in this order: ungrounded charger output first, then ungrounded battery terminal, then
grounded charger output, and grounded battery terminal last. If the battery must be disconnected for service, remove the
output wiring in the reverse of the order given above.
D. Be sure battery terminals are clean and properly tightened. Be careful to keep corrosion from coming in contact with eyes.
E. Add distilled water to each cell until the electrolyte reaches the level specified by the battery manufacturer. This helps
purge excess gas from the cells. Do not over fill. For a battery without cell caps, carefully follow the manufacturer’s
recharging instructions.
F. Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while charging and
recommended rates of charge.
 The recommended charge current range must include the rated output current of this charger, which is 20 amperes.
 Set the float voltage jumper to the battery manufacturer’s recommended float charge voltage. Incorrect charge voltage
will accelerate generation of explosive gases, increasing the risk of fire or explosion.
G. Enable the automatic boost charge mode (equalizing charge) only if recommended by the battery manufacturer
H. Determine the voltage of the battery by referring to the engine or battery owner’s manual and make sure that the 12V/24V
select jumper is set to the correct voltage.

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 SENS EnerGenius Technical Manual

2. CHARGER LOCATION
Do not set a battery or any other object on top of the charger. This will obstruct the ventilation openings and cause
excessive heating. Ensure the charger is protected from blowing or dripping water.
3. GROUNDING INSTRUCTIONS
This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment grounding
conductor (earthing conductor) should be run with the circuit conductors and connected to the equipment grounding
terminal in the charger. This terminal is marked with the ground symbol. Connections to the battery charger should
comply with all local codes and ordinances.
4. NEUTRAL CONNECTION
The grounded circuit conductor (neutral) should be connected to the terminal marked “N” on the input terminal block, TB1.
5. WIRE RATINGS
A. All conductors should be rated for use at 90º C or higher.
B. All input and output conductor sizes should be coordinated with the fault protection devices: 15A on AC input (14
AWG, 2.5 mm2 typical), 40A on DC output (8 AWG, 6.0 mm2 typical), 1 A on Alarm terminal block (20 AWG, 0.5
mm2 typical).
C. Before installation, ensure adequate battery to charger wire gauge. Wire gauge that is too small may activate the open
battery detector and the charger will shut down. The maximum allowed resistance seen by the charger is found in
TABLE 1. These figures already include an allowance for charger variations (they are 80% of the typical trip-point)
and are for the complete circuit: total of battery leads, battery's internal resistance, and any external equipment. The
total resistance seen by the charger must not exceed the following values:
TABLE 1
12V 24V
Maximum Resistance 36m 71m

D. To determine the appropriate cable and length, please refer to the following table:
TABLE 2
Wire Size Resistance Maximum Charger to Recommended Charger to
per Foot Battery Distance (Ft.) Battery Distance (Ft.)
AWG mm2 mΩ/Ft. 12V 24V 12V 24V
8 10 0.63 24 48 7 15
6 16 0.40 38 77 12 24
The above lengths consider the resistance of the battery and cables only and do not take into account any
additional interconnects.
The above lengths are for operation at 25C. For high temperature installations (40C) reduce lengths by 10%.
In the case of high resistance in the cables to the battery the charger Battery Fault LED may flash
(approximately once every 60 seconds). Cable runs exceeding the proper length for the cable gauge used most
often cause this problem. The appropriate solution is to change the cable gauge to properly correspond with the
necessary cable length (see TABLE 2). In some cases where the resistance is not too far above maximum, the
charger may recover after some time (approximately 10 minutes) and start charging the batteries. If it is not
possible to decrease the system resistance the Battery Fault feature can be disabled. Please contact SENS at 1-
800-742-2326 for further information.
E. Refer to local electrical codes for additional requirements.
F. See Section 10 for Terminal Block wire ranges.
6. FUSE RATINGS
A. CAUTION: For continued protection against risk of fire, replace only with same type and rating of fuse.
B. DC Output Fuse – SENS part number 304532. Littelfuse 299040, 40A, 32V, Slo-Blo, blade type
C. AC Input Fuse – SENS part number 304468. Bussmann Type BK/ABC-15, or Littelfuse 314015P, 15A,
250VAC, fast acting, ferrule type cylindrical, ¼” X 1-¼”

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 SENS EnerGenius Technical Manual

7. MOUNTING LOCATION
A. See the safety instructions for important information concerning the charger location.
B. The charger should be installed in a sheltered area, protected from rain and snow.
C. The charger should not be located where temperatures are expected to be colder than -20º C, or hotter than +40º C
for operation at rated output current.
WARNING:
NEVER CHARGE STORAGE BATTERIES AT TEMPERATURES ABOVE
OR BELOW THE LIMITS SPECIFIED BY THE BATTERY
MANUFACTURER. NEVER ATTEMPT TO CHARGE A FROZEN BATTERY.
D. Allow sufficient room for routing the fixed wiring to the charger. AC input enters the left side; DC output and
alarms exit on the right.
E. Leave clear space for ventilation all around the unit: at least 6 inches (15 cm) at the top and bottom; at least
2 inches (5 cm) on the sides.
F. Charger should be mounted on a flat vertical surface so that the chassis does not warp when tightened to the wall
G. The charger should be mounted vertically, with the input and output terminal blocks lowermost.
WARNING:
OTHER MOUNTING ORIENTATIONS INTERFERE WITH PROPER
VENTILATION AND MAY CAUSE THE CHARGER TO OVERHEAT.
H. Do not mount the charger over any heat generating equipment.
I. Minimize vibrations that the charger will be subjected to.

8. STATIC DISCHARGE PRECAUTIONS

The printed circuit board contains static sensitive components. Damage can occur even when static levels are too
low to produce a noticeable discharge shock. To avoid static discharge damage:
A. Handle the charger by the chassis only. Remove the cover only when access is essential for installation and
service, and replace it promptly when finished.
B. If possible, wear an approved static protection strap. If one is not available, touch one hand to the chassis before
contacting any other part of the charger.

9. MOUNTING PROCEDURES
WARNING:
THIS CHARGER IS INTENDED FOR COMMERCIAL AND INDUSTRIAL
USE. ONLY TRAINED PERSONNEL WHO ARE QUALIFIED TO
PERFORM ELECTRICAL INSTALLATIONS SHOULD INSTALL OR
SERVICE THIS UNIT.
The charger mounts to a wall or other vertical support. The mounting surface must safely support the charger’s
weight, which is 40 pounds (18 kg), and also the weight of the fixed wiring.
*ATTENTION: FOR MOUNTING IN A HIGH VIBRATION ENVIRONMENT YOU MAY USE 6 FASTENERS
AS SHOWN ON PAGE 4.
Mounting on a concrete surface:
 All mounting hardware is provided by the installer.
 Use optional ¾ in. thick, 18 in. x 24 in. sheet of marine plywood (not provided) to provide a suitable
mounting surface for the charger.
 Drill four holes to secure the plywood to the wall using a minimum of four ¼ in. drive pin type expansion
anchors to secure the plywood to the wall. Secure the plywood to the wall.
 Drill four (or six*) holes using the diagram on pg. 4 for ¼ (or M6) draw nut type expansion anchors through
the plywood into the cement wall.
 Insert the four (or six*) draw nut type expansion anchors through the plywood into the cement wall.
 Mount charger to draw nut type expansion anchors with nuts and flat washers.

7
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 SENS EnerGenius Technical Manual
Mounting on a drywall:
 Use ¾ in. thick plywood to span two vertical support members in the wall. The plywood sheet normally does
not have to be more that 2 ft. by 2 ft. square.
 Place plywood to avoid electrical wiring, plumbing, etc., concealed behind wall.
 Secure the plywood to the vertical support members using ¼ in. by 2 in. lag bolts and flat washers in a
minimum of four places.
 Mark four (or six*) holes on the plywood using the diagram on pg. 4. Drill pilot holes into the plywood to
secure the mounting bolts.
 Mount charger using four (or six*) 1/4 in. by ½ in. (or M6) lag bolts and flat washers.

Mounting on a metal surface:

 Mount charger using four (or six*) ¼-20 by 3/4 in (or M6) hex head bolts, flat washers and split lock
washers to attach the battery charger to a frame, panel or cross member in four (or six*) places. Use the
diagram on pg. 4 to place the pilot holes, if needed.
 Tighten all bolts to recommended torque of 45-50 inch pounds.

9. WIRING
A. All wiring must comply with applicable codes and local ordinances. See Section 5 for recommended gauges.
B. The charger contains a DC output fuse for internal fault protection, but this will not protect the DC
wiring from fault currents available from the battery. CONSULT NATIONAL CODES AND LOCAL
ORDINANCES TO DETERMINE IF ADDITIONAL BATTERY FAULT PROTECTION IS
NECESSARY IN YOUR INSTALLATION.

WARNING:
ENSURE THAT AC POWER IS DISCONNECTED AT THE
CIRCUIT BREAKER OR OTHER SAFETY DISCONNECT
BEFORE WIRING THE CHARGER.
C. Connect the equipment grounding conductor (earthing) to the charger’s grounding terminal. This should
always be the first wire connected and the last wire disconnected.
D. Connect the DC output conductors to TB3. Make the connections in the order shown in Figure 2A (negative
ground) or Figure 2B (positive ground). The terminals accept 14 through 6 AWG (2.5 through 16 mm2)
conductors.
CAUTION:
OBSERVE POLARITY. THE POSITIVE CHARGER OUTPUT
TERMINAL IS LABELED “+” AND THE NEGATIVE
TERMINAL IS LABELED “-”.

WARNING:
BE SURE TO ROUTE DC POWER WIRING AT LEAST ¼ INCH (6.3
MM) AWAY FROM AC WIRING, ALARM WIRING, AND THE
CIRCUIT BOARD.

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 SENS EnerGenius Technical Manual

FIGURE 2A FIGURE 2B

E. Connect the AC line and neutral conductors at TB1. If there is an identified grounded circuit conductor
(neutral), attach it to the terminal marked N. TB1 will accept 14-6 AWG (2.5-16 mm2) conductors.

WARNING:
BE SURE TO ROUTE ALL AC WIRING AT LEAST ¼ INCH
(6 MM) AWAY FROM DC WIRING, ALARM WIRING, AND
THE CIRCUIT BOARD.
F. If the optional alarms are used, connect the alarm wiring to their respective terminals on TB5. Route
alarm wiring through the plastic bushing below TB5, keeping the conductors at least ¼ inch (6 mm)
away from DC wiring, AC wiring, and the circuit board. The terminals accept 24-14 AWG (0.25-1.5
mm2) conductors.
WARNING:
CONNECT ALARM TERMINALS ONLY TO LOW
VOLTAGE, LIMITED ENERGY (“CLASS 2”) CIRCUITS.
ALARM CIRCUITS ARE RATED 2A AT 30 VDC, 0.5A AT 125
VAC, MAXIMUM SWITCHING CAPACITY 62.5VA, 60W.

BATTERY AC CHARGER HIGH LOW

RELAY FAIL FAIL FAIL BATTERY BATTERY
CONTACTS ALARM ALARM ALARM ALARM ALARM
(HI DC) (LO DC)
COMMON TB5-1 TB5-4 TB5-7 TB5-10 TB5-13

OPEN ON TB5-2 TB5-5 TB5-8 TB5-11 TB5-14

ALARM
CLOSE ON TB5-3 TB5-6 TB5-9 TB5-12 TB5-15
ALARM

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 SENS EnerGenius Technical Manual

G. If the optional remote temperature sensor is used:

 Remove the internal sensor at TB4, if it is present.
 Locate the remote sensor where it will accurately detect the battery temperature.
 Connect the remote sensor leads to TB4. The sensor is not polarized, so it does not matter which lead
connects to terminal #1.
 Route sensor wiring through the plastic bushing below TB5, keeping the conductors at least ¼ inch
(6 mm) away from DC wiring, AC wiring, and the circuit board.
H. Verify that all connections are secure and in the proper locations. Tighten all unused screws on the terminal
blocks to secure them against vibration.
I. Ensure all wires are routed so the cover will not pinch them.

10. INTERNAL ADJUSTMENTS

WARNING:
MAKE SURE THE AC POWER TO THE CHARGER IS SHUT
OFF WHILE MAKING THE FOLLOWING ADJUSTMENTS.

Meter Display Jumper

JP800. Choose VOLTS,
AC line voltage switch AMPS, or AUTO for meter
110-120V: Use 115V position display view.
208-240V: Use 230V position

Jumper JP1.
“Jump start” battery Configure battery and
initialization mode output voltage settings.

Automatic boost jumper

Use NORM setting for
fast charge. Use Off
setting for float charge

Float voltage jumper

Set according to
battery supplier’s
specifications

Battery range jumper

(12V or 24V battery)

SAME FOR ALL

MODELS
A. Set the AC voltage select switch (SW100) according to the line voltage. Use the 115V position for nominal
mains voltages between 110V and 120V. Use the 230V position for nominal mains voltages between 208V
and 240V.
B. Set the battery range jumper (JP1A) according to nominal battery voltage. Use the 12V position for 12V
batteries. Use the 24V position for 24V batteries.
C. Set the boost mode jumper (JP1B) according to whether the battery should have automatic boost charging. If
the battery manufacturer recommends boost charging (equalization) use the NORMAL position. If not, use the
OFF position.

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D. Set the float voltage select jumper (JP1C) according to the battery manufacturer’s recommended 25ºC
float voltage. The settings are:
 14.30/28.60 for 10 or 20 cell Nickel Cadmium at 1.43V/cell
 13.62/27.24 for 6 or 12 cell (VRLA) lead-acid at 2.27V/cell, and for 19 cell Nickel Cadmium at 1.43V/cell
 13.50/27.00 for 6 or 12 cell (VRLA or high capacity) lead-acid at 2.25V/cell, and for 19 cell Nickel Cadmium at
1.42V/cell
 13.31/26.62 for 6 or 12 cell (flooded) lead-acid at 2.22V/cell, and for 19 cell Nickel Cadmium at 1.40V/cell
 13.08/26.16 for 6 or 12 cell lead-acid at 2.18V/cell
 12.87/25.74 for 9 or 18 cell Nickel Cadmium at 1.43V/cell
E. Set the Display Selector jumper to one of the 3 available positions on JP800 (see photograph previous page):
 VOLTS – Place the short jumper in the “upper” position next to the word “VOLTS”. The 3-digit LED meter display
will show DC Volts only
 AUTO – Place the short jumper in the center position next to the word “AUTO”. The 3-digit LED meter display
will automatically and continuously alternate between DC Amps and DC Volts. The display shows DC Amps for
approximately 6 seconds and DC Volts for approximately 3 seconds.
 AMPS – Place the short jumper in the “lower” position next to the word “AMPS”. The 3-digit LED meter display
will show DC Amps only.
WARNING:
USE ONE JUMPER ONLY ON THE DISPLAY SELECTOR JP800. USE ONLY THE
“SHORT” JUMPER PROVIDED FOR JP800, TO AVOID INTERFERENCE WHEN
REPLACING THE COVER (“TALL” JUMPERS ARE TO BE USED ONLY ON JP1).
F. The JUMP position allows initial charging of Nickel Cadmium batteries, or new lead acid batteries supplied from the
manufacturer dry and discharged, from a zero charge state. The JUMP feature can also be used when recharging
excessively discharged batteries already in service. To initially charge/commission zero charge batteries, place a
jumper (spare provided with charger) in the JUMP position on JP1. Operate the charger long enough to retain more
than 1.5V/cell for lead acid and 1.0V/cell for nickel cadmium batteries or until the charger returns to FLOAT MODE
(FLOAT MODE LED will be green). See SENS Application Note 10 to finish fully commissioning the batteries, as
using the JUMP feature alone is not sufficient. Once the batteries are fully charged, the jumper may be removed or
left in the JUMP position permanently. The jumper may remain in the JUMP position permanently to ensure that the
charger is able to recharge very low or dead batteries. If battery voltage is below 9V (12V system) or 18V (24V
system) when AC power is restored and the JUMP feature is not activated, the charger will go into Battery Fault
(alarm state that disables charger). In this situation the charger will not charge the batteries. If the JUMP feature is
enabled when AC power is restored, the charger will begin charging. Depending on the battery state of charge, the
charger may go into Battery Fault and remain so for some period of time (generally 12 – 24 hours) while the batteries
are slowly charged. The Battery Fault LED will cycle (approximately once every minute) during this time. Once
Battery Fault stops cycling, the charger will return to FLOAT or BOOST MODE as normally demanded.
WARNING:
USE THE JUMP FEATURE ONLY WITH LIQUID ELECTROLYTE NICKEL-
CADMIUM BATTERIES, OR WITH RECENTLY FILLED NEW LEAD ACID
BATTERIES SUPPLIED FROM THE MANUFACTURER DRY AND DISCHARGED.
WHILE THE JUMP FEATURE MAY BE USED TO CHARGE EXCESSIVELY
DISCHARGED LEAD ACID BATTERIES THAT HAVE ALREADY BEEN IN
SERVICE, CONSULT THE BATTERY MANUFACTURER TO DETERMINE IF
AND HOW THEY CAN SAFELY BE RESTORED TO SERVICE.
WARNING:
LEAVING A JUMPER IN THE JUMP POSITION DISABLES THE BATTERY
VOLTAGE INTERLOCK, WHICH INCREASES THE RISK OF ACCIDENTALLY
OVERCHARGING 12V BATTERIES WITH 24V SETTINGS. INCORRECT
CHARGE VOLTAGE WILL ACCELERATE GENERATION OF EXPLOSIVE
GASES, INCREASING THE RISK OF FIRE OR EXPLOSION.
G. For fully enclosed models, replace the cover by sliding it straight onto the charger. Ensure the cover’s locating
tabs engage the slots in the chassis. Secure the cover with its four mounting screws.

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 SENS EnerGenius Technical Manual
11. CHECK OUT

Green for temperature-corrected charger voltage

Green for normal AC input
Red for internal charger failure
Red for excessive battery voltage
DC Volt/Amp Meter Display

Red for low battery voltage

Red for low or missing AC input
Green for normal voltage (float charge)
Yellow for boost voltage (fast charge)
*Red for open, wrong voltage, reversed battery, or defective battery

See OPERATOR INSTRUCTION section for LED indicator definitions:

A. Verify the status LEDs:
 AC FAIL should be ON. If not, the DC output may be open or reversed, or the battery may be
extremely discharged.
 BATT FAULT should be OFF. If it lights, check for reversed polarity of the DC wiring.
 The DC LOW (Low Battery) LED may be either on or off, depending on the battery’s state of charge.
 All other LEDs and the meter display should be off.
 If the DC HIGH LED is on, check battery voltage jumper setting.
B. Apply AC power by closing the branch circuit breaker and any other disconnect devices.
C. The meter display should light immediately after power on. The green AC /ON LED should be lighted. If a
temperature sensor is present, either internal or remote, the green T-COMP (Temperature Compensation)
LED should be lighted.
D. If the BATT FAULT LED lights when AC is applied, this indicates that the battery voltage does not agree
with the Range jumper setting. The charger is interlocked, and will not operate in this condition.
Disconnect AC power, then correct the jumper setting or battery voltage before proceeding.
E. After a short delay (typically 10 seconds or less), the charger will produce output.
F. If the meter display jumper is selected to read Amps or automatic Volts/Amps:
 Current should be close to 20A if the battery requires recharging. If automatic boost is enabled, the
BOOST MODE LED may light, in which case the battery will be charged until it reaches 106% of the
float voltage. If boost is disabled, the green FLOAT MODE LED should be on and the battery will
charge until it reaches the float voltage setting.
 Output current will be low if the battery is fully charged, possibly too low to read on the meter. This is
normal, provided the correct charging voltage is present. The green FLOAT MODE LED should light
when output current is below approximately 18A.

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 SENS EnerGenius Technical Manual

OPERATOR INSTRUCTIONS
WARNING:
NO OPERATOR SERVICEABLE PARTS INSIDE.
DO NOT OPEN. COVER MUST BE IN PLACE DURING USE.
USE THIS CHARGER FOR CHARGING LEAD-ACID OR
NICKEL-CADMIUM BATTERIES ONLY.
A. ADVANCED DESIGN FEATURES
Battery Friendly:
 Float and boost voltage selectable at install per specific battery vendor recommendations.
 Remote temperature compensation for most accurate float and boost voltage control.
 Able to charge a dead battery.
 Float and Boost voltage electronically controlled with a 4-rate fast charge program. See chart below.
4 -R A T E C H A R G IN G

C h a rg e r in “fa st ch a rg e (b o o st) m o d e ”
B oo st vo lta ge lim it
Vb C h a rg e r in “flo a t m o d e ”
F lo a t vo lta g e lim it
O n ce b o o s t vo lta g e is
Battery voltage

a chieved cu rren t ta p e rs off T ra n sitio n : ch a rg e r sh ifts to

flo a t m o d e w h e n b a tte ry
cu rre n t a c ce p ta n c e d ro p s
Current limit

B a tte ry cu rre n t a c ce p ta n ce

e ge
rg
ge
ge

ha ar
ar
ar

c h
ch

rc
ch

nt
pe
ng
g

e
rr
in

ta
ni
sh

cu
ai

t e
ni

t
nt

an ra
Fi

ai

st h
M

ig
on H
C

Temperature Compensation:
 The battery charger is temperature compensated to match the negative temperature coefficient of the battery.
Thus, the output voltage will increase slightly as the temperature decreases and decrease as temperature in-
creases.
 The output voltage is clamped at 0 and +40 Degrees C to protect against extremely high or low output voltage.
See chart below.

AUTOMATIC TEMPERATURE COMPENSATION

Temperature vs. volts per cell lead acid
2.7
Float volts per cell

2.6 SENS limits here to prevent damaging

high voltages at customer equipment
2.5 SB
2.4 AGM
2.3 Gel
2.2 NRG
2.1
2
-30 0 20 40 60 80
Temperature Degrees C

Fault Tolerant: The charger is protected from the following faults:

 Internal power component failures.
 Over heating (over temperature output power reduction).
 Protected against power line transients and surges.

Battery Fault Protection and Alarm:

 The battery charger automatically checks the battery voltage before power-on startup. If the battery voltage is

Service hotline: 1.800.742.2326

1.303.678.7500 13
13
 SENS EnerGenius Technical Manual

either too high or too low, the charger enters a “lockout” period for approximately 10 seconds before attempting
an automatic restart.
 The “JUMP” feature (described in Section 11-F in this manual) may be used to allow the battery charger to over-
ride the lockout and start charging a low-voltage discharged battery.
 The battery charger will not start if the battery or battery cables have a short circuit, and will start automatically
with a good battery if the short circuit is removed.
 In addition to detecting low battery voltage and short circuits, the battery charger also monitors the peak voltage
at its DC output terminals and will enter lockout if the DC cable resistance is too high or if the battery’s internal
resistance is too high.
 If a battery is connected backwards, this reverse polarity condition will keep the battery charger in lockout and it
will remain in lockout until the battery is disconnected. A reverse polarity condition will not blow a fuse; the
battery charger will start and run normally when a good battery is connected with correct polarity.
 Whenever one of these fault conditions triggers the battery fault protection circuitry as described above, the
“Batt Fault” relay and LED are both activated.
 If polarity is correct, DC cables OK, and the “JUMP” feature attempted, the battery fault alarm most likely indi-
cates a defective battery. Replace with a new battery.
Robust Hardened Construction:
 Shock and Vibration tested to UL 991, 2G.
 Shock and Vibration tested to UL 991, 5G option available.
 Lightning transient immunity to ANSI/IEEE C62.41 Cat. B and EN 50082-2 heavy industrial.
 Wide operating temperature range: -20 to + 40 Degrees C. Charger will operate at reduced output current rating
up to +60 Degrees C.
 Conformal coated printed wiring boards for erosion protection.
Worldwide Agency Approvals:
 UL listed, UL 1236.
 CUL listed to CSA C22.2 107.2- M89.
 CE marked for EMC directive (industrial environment) and EN 60335-2-29.
 Worldwide operating voltage and frequency ranges.

B. FRONT PANEL LED INDICATOR DEFINITIONS AND TROUBLE SHOOTING:

Green for normal AC input Green for temperature-corrected charger voltage

Red for internal charger failure
Red for excessive battery voltage
DC Volt/Amp Meter Display

Red for low battery voltage

Red for low or missing AC input
Green for normal voltage (float charge)
Yellow for boost voltage (fast charge) *Red for open, wrong voltage, reversed battery,
Service hotline: 1.800.742.2326 or defective battery
1.303.678.7500 14
 SENS EnerGenius Technical Manual

ITEM TEXT LED Meaning Troubleshooting

1 CHGR FAIL RED Charger Fail Charger unable to provide charging current
to battery. Replace unit.
AC input voltage is too low to supply prop-
er current when load is applied.
Control board is damaged and should be
replaced.
2 DC HIGH RED Battery DC Voltage High Check that the battery range voltage jumper
setting agrees with battery used.
High battery alarm voltage is 17v for 12v

3 DC LOW RED Battery DC Voltage Low Check that battery range voltage jumper
setting agrees with battery used. Check for
defective battery.
Check DC load.
Low battery alarm voltage is 12v for 12v
System and 24v for 24v system
4 AC FAIL RED Input AC Missing Check AC input voltage to charger. Have
qualified installer check AC line voltage
switch setting. Setting must agree with AC
voltage at site. Check AC fuse.
5 T-COMP GREEN On if Temperature Com- Confirm if temperature compensation is
pensation Working, Off if intended to be used. Only one sensor (Local
Temperature Compensa- or remote) should be connected.

6 AC/ ON GREEN AC input good Should be on in normal use.

If LED is OFF, AC FAIL should be ON.
7 FLOAT GREEN Charger Output in Float If the automatic boost jumper is in the OFF
MODE Mode location, this LED will always be on.
If the automatic boost jumper is in the
“NORM” location, this LED will come on
after the battery is nearly charged up and
will stay on.
8 BOOST AMBER Charger Output in Boost This LED will not be on if the automatic
MODE Mode boost jumper is in the OFF location, or if
the automatic boost jumper is in the
“NORM” location and the battery is nearly
fully charged up.
9 BATT FAULT RED Battery Fault-Charger  Battery reversed.
automatically disabled:  High resistance in charger leads (leads
too small, too long , poorly connected,
open). See Section 5 for information on
wire length and gauge.
 Battery internal open circuit.
 Battery voltage does not match charger
voltage range
 Defective battery, replace with new
battery

Service hotline: 1.800.742.2326

1.303.678.7500 15
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—REPEATED BLOWN AC FUSE

START:
AC FAIL LED red

INPUT
SWITCH FUSE
CONFIGURED FOR Y PROPERLY CONFIGURE N
STILL END
115V BUT SOURCE SELECTION SWITCH BLOWS?
IS 230V?

N Y

AC VOLTS
FUSE
CORRECT N N
CORRECT AC INPUT STILL
(MEASURE WITH END
SUPPLY PROBLEM BLOWS?
MULTIMETER)?

Y Y

FUSE
AC FREQUENCY Y CORRECT AC INPUT N
STILL END
LOW? SUPPLY PROBLEM BLOWS?

N Y

CONTACT CUSTOMER
SERVICE

Service hotline: 1.800.742.2326

1.303.678.7500 16
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—AC FAIL ALARM

START:
AC FAIL LED red

INPUT
SELECTION PROPERLY ALARM
N N
SWITCH PROPERLY CONFIGURE STILL END
CONFIGURED? SELECTION SWITCH PRESENT?

Y Y

AC VOLTS AND ALARM

FREQ CORRECT N CORRECT AC INPUT N
STILL END
(MEASURE WITH SUPPLY PROBLEM PRESENT?
MULTIMETER)?

Y Y

ALARM
AC INPUT FUSE Y REPLACE AC N
STILL END
BLOWN? INPUT FUSE PRESENT?

N Y

ALARM
ALL CONNECTORS N FIX N
STILL END
FIRMLY SEATED? CONNECTIONS
PRESENT?

Y Y

ALARM
N
REPLACE CIRCUIT STILL END
BOARD TRAY PRESENT?

CONTACT CUSTOMER
SERVICE

Service hotline: 1.800.742.2326

1.303.678.7500 17
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—CHARGER FAIL ALARM

START:
CHGR FAIL LED red

AC VOLTS LOW ALARM

(MEASURE WITH Y CORRECT AC INPUT N
STILL END
MULTIMETER)? SUPPLY PROBLEM PRESENT?

N Y

ALL ALARM
N FIX N
CONNECTORS STILL END
FIRMLY SEATED? CONNECTIONS PRESENT?

Y Y

ALARM
REPLACE CIRCUIT N
STILL END
BOARD TRAY PRESENT?

CONTACT CUSTOMER
SERVICE

Service hotline: 1.800.742.2326

1.303.678.7500 18
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—DC HIGH ALARM

START:
DC HIGH LED red

BATTERY RANGE ADJUST JUMPER ALARM

N N
VOLTAGE JUMPER FOR 12V OR 24V STILL END
PROPERLY SET? BATTERY PRESENT?

Y Y

CORRECT BATTERY/
DC VOLTS HIGH LOAD VOLTAGE ALARM
Y N
(MEASURE WITH (CONSIDER SURFACE STILL END
MULTIMETER)? CHARGE, ALTERNATOR, PRESENT?
EQUIPMENT)

N Y

ALARM
N
REPLACE CIRCUIT STILL END
BOARD TRAY PRESENT?

CONTACT CUSTOMER
SERVICE

Service hotline: 1.800.742.2326

1.303.678.7500 19
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—DC LOW ALARM

START:
DC LOW LED red

BATTERY RANGE ALARM

N ADJUST JUMPER N
VOLTAGE JUMPER STILL END
FOR 12V OR 24V
PROPERLY SET? PRESENT?
BATTERY

Y Y

AC VOLTS AND ALARM

FREQ CORRECT N CORRECT AC INPUT N
STILL END
(MEASURE WITH SUPPLY PROBLEM PRESENT?
MULTIMETER)?

Y Y

CHARGER IN
ALARM
CURRENT LIMIT Y DETERMINE CAUSE OF N
CURRENT LIMIT AND STILL END
(MAX CURRENT,
CORRECT PROBLEM PRESENT?
LOW VOLTAGE)?

N Y

ALARM
N
REPLACE CIRCUIT STILL END
BOARD TRAY PRESENT?

CONTACT CUSTOMER
SERVICE

Service hotline: 1.800.742.2326

1.303.678.7500 20
 SENS EnerGenius Technical Manual

TROUBLESHOOTING GUIDE—BATTERY FAULT ALARM

START:
BATT FAULT LED red

FIX LEADS THAT ARE TOO

BATT FAULT LED LONG, TOO SMALL, POOR- ALARM
N HIGH RESISTANCE N
SOLID RED Y LY CONNECTED OR OPEN STILL
IN CHARGER END
(NOT FLASHING)? (SEE MANUAL FOR WIRE PRESENT?
OUTPUT LEADS?
LENGTH/GAUGE RE-
QUIREMENTS)

Y N Y

TO “BATTERY DEFECTIVE”

REPLACE
CIRCUIT
BATTERY RANGE ALARM
N ADJUST JUMPER N BOARD TRAY
VOLTAGE JUMPER FOR 12V OR 24V STILL END
PROPERLY SET? BATTERY PRESENT?

Y Y ALARM
N
STILL END
PRESENT?

Y
ALARM
BATTERY REVERSE Y CORRECT BATTERY N
STILL END CONTACT
POLARIZED? CONNECTION PRESENT? CUSTOMER
SERVICE

N Y

BATTERY
ALARM
FROM NO DEFECTIVE Y N
REPLACE BATTERY STILL END
“HIGH (INTERNAL OPEN
PRESENT?
RESISTANCE” CIRCUIT, SHORT,
ETC.)?

N Y

ALARM
DC OUTPUT FUSE Y REPLACE DC STILL N
END
BLOWN? OUTPUT FUSE PRESENT?

N
Y

Service hotline: 1.800.742.2326

1.303.678.7500 21
 SENS EnerGenius Technical Manual

NORMAL SET UP:

1. Apply AC power by closing the branch circuit breaker and any other disconnect devices.
2. The meter display should light immediately after power on. The green AC/ ON LED should be lighted. If a
temperature sensor is present, either internal or remote, the green T-COMP (Temperature Compensation) LED
should be lighted.
3. After a short delay (typically 10 seconds or less), the charger will produce output. If the meter display jumper is
selected to read Volts or automatic Volts/Amps, the voltmeter reading should increase, indicating the battery is
being charged.
4. If the meter display jumper is selected to read Amps or automatic Volts/Amps:
 Current should be close to 20A if the battery requires recharging. If automatic boost is enabled, the BOOST
MODE LED may light, in which case the battery will be charged until it reaches 106% of the float voltage. If
boost is disabled, the green FLOAT MODE LED should be on and the battery will charge until it reaches the
float voltage setting.
 Output current will be low if the battery is fully charged, possibly too low to read on the meter. This is normal,
provided the correct charging voltage is present. The green FLOAT MODE LED should light up when output
current is below approximately 18A.

C. ALARM DESCRIPTION, FIVE ALARM MODEL:

RELAY BATTERY AC FAIL CHARGER HIGH BATTERY LOW BATTERY

CONTACTS FAULT ALARM FAIL ALARM ALARM
ALARM ALARM (HI DC) (LO DC)
COMMON TB5-1 TB5-4 TB5-7 TB5-10 TB5-13
COM COM COM COM COM
OPEN ON TB5-2 TB5-5 TB5-8 TB5-11 TB5-14
ALARM OK OK OK OK OK

CLOSE ON TB5-3 TB5-6 TB5-9 TB5-12 TB5-15

ALARM FAIL FAIL FAIL FAIL FAIL
Defaults to OK Defaults to Defaults to Defaults to OK Defaults to fail
with no AC Fail with no OK with no with no battery with no battery
input AC input AC input

Service hotline: 1.800.742.2326

1.303.678.7500 22
 ALL ADJUSTMENTS TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY
SEE INSTALLATION MANUAL FOR DETAILS
1 With AC power 2 Confirm AC safety 3 Confirm AC select SW set- 4 Connect AC input
to charger OFF ground is secure. ting matches AC input voltage. wires to TB1.
5 Select LED meter 65 Connect DC output 7 Connect alarm
DISPLAY display: Volts only, wires to TB3. wires to TB5.
SELECTOR automatic Volts/Amps, OBSERVE POLARITY
or Amps only. TB4
VOLTS 8 Connect remote
AUTO USE ONE SHORT
temperature sensor to
AMPS JUMPER ONLY
TB4 if required.

9 Confirm boost select jumper is in Sensor

JUMP BOOST the correct position, see manual and (no polarity)
HIGH JUMPER item 13 below.
NORM LOCATIONS
OFF 10 Confirm Battery Float voltage is set to match your
14.30/28.60 battery type (see manual). If battery is fully charged, 5.00" max
13.62/27.24 the voltage display will agree with this value at 25 C
FLOAT or when one leg of temperature sensor is removed.
13.50/27.00 VOL.
13.31/26.62 SEL. 11 12 Apply AC power to
13.08/26.16
Confirm that the charger. No RED LED
12.87/25.74
RANGE select jumper indicators should be on. See
12V RANGE setting matches the manual for alarm, LED display
24V Battery voltage. Make and jumper functions.
no other adjustments.

Call 1-800-742-2326
13 Charger will not start up if dead battery voltage is less
for HELP / Or visit
than 75% of rated voltage. In this case, temporarily short
www.sens-usa.com JUMP pins using BOOST jumper to start a dead battery.
to download manual Return jumper to original position after battery voltage comes
up.

5.00" max

NOTES:

1. LETTERING TO BE BLACK INK ON SILVER FOIL LABEL, MATERIAL RATED PER R/C (PGDQ2).
LABEL ADHESIVE PROVIDED MUST BE SUITABLE FOR USE ON ALUMINUM & RATED FOR
80 DEG C MINIMUM.

2. PSA MATERIAL IS TO BE PROVIDED

WITH RELEASE LINER.

3. RADIUS CORNERS .125" MAXIMUM.

4. THIS DRAWING NOT TO SCALE. DCN No. 105963

Drawn By: HN Date: 2/7/2011
Approved By: Date:
DWG Name: LABEL, INSIDE COVER, NRG10/20
PN: 808526 DWG REV. E

3/23/2011 2:55 PM 808526_RevE.xls

 STOP!
Verify that all settings shown below are correct before
energizing charger. CAUTION: Correct settings are essential
to ensure proper battery performance and long battery life. FACTORY SETTINGS
Before installation, ensure adequate battery to charger wire
Charger is factory set for the
gauge. Wire gauge that is too small may activate the open following settings. Change the
battery detector and the charger will shut down: setting if needed for your battery
Recommended Charger to Battery or site conditions
Distance (Ft.)
AWG 12V/10A 24V/10A 12V/20A 24V/20A Input: 208-240 VAC
120 VAC
10 10 19 N/A N/A
Jump: DISABLED
8 15 30 7 15
Fast charge: ENABLED / OFF
6 24 48 12 24
For runs exceeding the above values, call SENS at 1-800-742-2326 Float voltage: 14.30 28.60
or (303) 678-7500. 13.62 27.24
13.50 27.00
AC Input 13.31 26.62
Selector 13.08 26.16
Switch 12.87 25.74
Voltage range: 12-volt 24-volt
Enable/disable
automatic fast 12/24 dual
Select meter charge system
display:
Volts only,
Automatic Select position closest to
Volts/Amps, the battery mfgr’s
or Amps only recommended float
Verify that charger voltage. CAUTION:
Adjustments

CAUTION:
AC input switch Use ONE short Failure to use the proper
Output

matches AC jumper only setting will result in poor

supply BEFORE battery performance and
energizing short battery life
charger.
CAUTION: CAUTION:
Applying 208/240 Read manual
volts when before using this If your charger is
charger is in 115- JUMP position. equipped with the
volt position will optional12/24-volt
blow charger select feature, place
input fuse. Thermistor activates local jumper in the voltage
temperature of your system
compensation (TC)
battery
Connect optional remote
sensor here in place of
thermistor. Remove
thermistor if you wish to
disable TC

Form C alarms
terminal block
AC input DC output
terminal terminal
block block

PN: 101294 REV: E Copyright © Stored Energy Systems LLC 2009 Temp comp
terminal block
 SENS Limited Warranty: NRG Series Battery Charger

What is covered?
This warranty covers any defect in material and workmanship on NRG model battery chargers manufactured by Stored
Energy Systems, a Colorado Limited Liability Company (SENS).

What this warranty does not cover:

This warranty does not cover damages, defects or failures of your equipment resulting from shipping damage, accidents,
installation errors, unauthorized adjustment or repair, unauthorized third-party service, failure to follow instructions,
misuse, fire, flood, acts of persons not in our control, and acts of God.

For how long:

Three years from date of shipment, except magnetic parts and power semiconductors, which are covered for 10 years.

What we will do:

If your battery charger is defective within the warranty period, we will repair it or, at our option, replace it at no charge
to you.

If we choose to replace your charger, we may replace it with a new or refurbished one of the same or similar design.
The repair or replacement will be warranted for the remainder of the original warranty period. If we determine that your
charger cannot be repaired or replaced, we will refund its purchase price to you.

What we ask you to do:

Contact SENS service department to obtain warranty service instructions. To obtain warranty service the product must
be returned, freight prepaid, to the factory under a 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.

Limitation:
This warranty is limited to defects in material or workmanship of the product. It does not cover loss of time,
inconvenience, property damage or any consequential damages. Repair, replacement or refund of the purchase price of
the equipment is your exclusive remedy.

Extended Warranty: NRG Series Battery Charger

Extended Warranty Period
At any time during the standard Limited Warranty period, customer may purchase extended warranty to lengthen the warranty
period on the entire product to 5 or 10 years from date of original shipment. All other terms of SENS Limited Warranty (see
above) apply.

Premium Warranty: NRG Series Battery Charger

Premium Warranty Coverage

At the time of original purchase, customer may purchase premium warranty coverage for the standard warranty period or for
extended periods of 5 or 10 years from date of original shipment. With premium warranty coverage, SENS will, if requested
by customer, pay reasonable and customary labor and mileage charges for replacement or repair of the charger, limited to
100% of the company’s original net product invoice amount, in the form of a credit toward future purchases of product from
SENS. Premium warranty service is available only to the original customer who purchased the product from SENS; it does
not pass through to other distributors, dealers or users. All other terms of SENS Limited Warranty (see above) apply.

Form 258 Rev C