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EnerGenius® DC

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EnerGenius® DC is SENS’ new generation of industrial and utility chargers based on modular, ruggedized switchmode technology.  Ruggedized switchmode power conversion offers huge advantages in size, weight, serviceability, efficiency, and DC power quality to industry.  Switchmode reliability is well proven through decades of use in the aerospace industry and military applications — where reliability is critical.  Designed and built in the USA, EnerGenius® DC builds from the highly successful power conversion and software architectures proven in our MicroGenius® 2 family.  

More Power. Less Space. Environmentally Hardened.

  • Hardened powertrain: Small, energy efficient and rugged
  • Fast responding, pure DC: Delivers ripple-free output even without battery
  • Small size & light weight: Saves floor space and money
  • Dirt and dust protected: Electronics stay cool and clean even in dirty environments
  • Industrial electrical ratings: 480 VAC 3-phase input; transient & surge protected
  • Remote communications: Optional Modbus and DNP3
  • PIP specification compliant: Includes optional high current alarm relays

EnerGenius® DC

  • Get Started
  • Benefits
  • Easy, Efficient, Flexible

EnerGenius DC
EnerGenius DC_Logo_Horizontal_Black and Red

EnerGenius® DC is purpose-designed for industrial and power utility applications. It is the first, best and only DC power system to combine three dimensions of performance industrial users require:

  • Proven reliability & high level of protection against environmental attack;
  • The performance, efficiency, size, weight and servicing advantages inherent to modular switchmode technology; and
  • Standards compliance and data interfaces unique to industrial and utility end users.

Three packaging styles are available, all utilizing native 480 volt AC, 3-wire input: compact unit, wall box, and floor-mounted cabinet systems.

Smaller & lighter than legacy chargers

EnerGenius® DC chargers are much smaller and lighter than legacy technology chargers. Their small size and light weight — in many cases less than one-fifth the size and weight of competing chargers — provides for easier fit and installation in both new construction and replacement applications.

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Rugged design backed by 5-year warranty

EnerGenius® DC features layered defenses against electrical transients and other environmental threats found in industrial environments.  To protect the charger from dust and contaminants, EnerGenius® DC’s patented forced conduction cooling system uses redundant fans to remove heat with airflow never touching sealed electronics. SENS industry-best 5-year limited warranty backs up all models.

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Hot-swap power modules

Lightweight 7kW hot-swap power modules can be installed or removed while the charger is operating, yielding huge benefits for reliability, service, and expansion.  By installing one module more than required for the application (N+1 redundancy), reliability is greatly enhanced; if a power module fails, the charger continues to deliver full power without interruption.  Users can also increase power on the fly by adding a module.  The system automatically updates all relevant settings with no interruption to the charger’s operation.

Cabinet models even offer the option of complete redundancy – independent AC inputs, DC output, rectifiers, circuit breakers, and control panels – in a single package.

 

Easy installation & service

Compact and wallbox models are small and light enough to be installed by a single person without the need for mechanical assistance. Once in service, power modules can be easily and safely swapped-out while the charger is live without the need for highly trained service personnel. If a power module were to fail, chargers with two or more modules will continue to operate at reduced capacity, providing more flexibility in scheduling service.

Clean, efficient power

Switchmode rectifiers convert power at high frequency, inherently producing very low ripple DC output.  EnerGenius® DC operates as a DC power supply delivering clean, fast-responding DC even without a connected battery.   There is no need to purchase “eliminator” or “super filtering” options to achieve power quality sufficient to support electronic controls.  And, with near unity power factor, EnerGenius® DC consumes up to 45% less current than competing products, helping organizations meet energy conservation goals.

Superb flexibility

EnerGenius® DC chargers will charge virtually any type of stationary battery including all types of lead-acid, NiCd and lithium. Users can select the alarms they require and map them to either standard or high current and relays.  Communications options include Modbus, DNP3 and IEC 61850 protocols.  Chargers are UL-listed and comply with the NEMA PE-5 / IEEE 2405 standard, with PIP standard compliance optional.  Chargers are optimized for three-phase AC input from 400-480 volts but will operate on any single or three-phase supply of 208 volts or higher.

Detailed Specs

1. INTRODUCTION

General Product Description and Overview
Industrial/utility class battery charger/power supply, specially hardened for use in harsh industrial environments.

2. AGENCY STANDARDS AND CERTIFICATIONS
  • Safety Agency Standards
    • UL Listed for the United States (UL US) and Canada ( CUL) to UL 1012 and CSA 22.2 No.107.2
    • CE-Marked
    • NEMA PE-5
    • NFPA 70
  • FCC Standards Emissions
    • 47-CFR-15 (FCC Part 15) Class A
  • Electrical Transient
    • ANSI/IEEE C62.41, EN 61000-4-12 on power terminals, IEC 61000-6-5 and ANSI/IEEE C37.90
  • Vibration and Shock
    • EN60068-2-6, EN-60068-2-64 and EN-60068-2-27
  • PIP Compliance shall be available
3. AC MAINS SUPPLY
  • The AC input voltage range shall be 400-480VAC.
  • The AC input shall be three phase line to line connected.
  • The AC input frequency range shall be 47-63Hz.
  • Charger shall operate at 50% power limit from 188-357VAC.
  • The AC input voltage tolerance shall be +10%.
4. EFFICIENCY AND POWER FACTOR
  • Charging system efficiency shall be up to 95%.
  • The charger shall provide active power factor correction. The power factor shall be 0.98 or greater at maximum rated load current and boost voltage.
  • The total harmonic distortion shall be less than 3%.
5. OUTPUT
  • Output Voltage and Adjustment Range
    • For 120VDC nominal output models the adjustment range shall be 8-150V.
    • For 240VDC nominal output models the adjustment range shall be 16-315V.
  • Output Current
    • The output current of the charging system shall be up to 400A for each 120VDC system and up to 200A for each 240VDC system.
    • Redundancy options shall be optional for all current levels other than the maximum 400A at 120VDC and 200A at 240VDC.
    • Dual System configurations shall be available. A Dual System provides two independent, isolated charging systems with distinct AC input breakers, DC output breakers and controls in a single cabinet.
    • Dual AC configurations shall be available. A Dual AC system allows for two independent, isolated AC inputs to be connected converting power to the DC bus.
  • The charger shall support connection in parallel with two or more systems.
  • The charger shall support the following battery types:
    • Flooded Lead Acid
    • AGM (Absorbed glass mat)
    • Nicad (nickel-cadmium)
    • VRLA (valve regulated lead acid)
  • Battery Temperature Compensation
    • Battery temperature compensation shall be standard using the charger internal ambient sensor. The nominal voltage-temperature (V-T) curve changes output voltage when the temperature of the sensor is between 0°C and +40°C at the rate of – 0.18% per degree C.
    • The slope for user-programmed battery settings shall be programmable from 0.00% per degree C to -0.30% per degree C.
    • The factory voltage setting shall correspond with +25°C.
    • A remote battery temperature sensor shall be optional for placement at the battery location.
  • Line and load voltage regulation shall be better than ±0.5% of the set value at 25°C.
  • Output Ripple.
    • The output ripple shall be less than 30mV on-battery, less than 100mV off-battery for 120VDC systems.
    • The output ripple shall be less than 30mV on-battery, less than 200mV off-battery for 240VDC systems.
  • The step response shall be 8ms typical, to recover within 1% of rated output voltage from load step change of 50% of the rated output current.
  • The charging system shall operate in a stable fashion with or without a battery connected.
  • The system shall charge a fully discharged battery from zero volts.
6. ENVIRONMENTAL
  • The charger shall operate from -40°C to 70°C, full specification from -40°C to 50°C.
  • The charger shall be able to be stored in temperatures from -40°C to 80°C.
  • The charger shall be capable of cold starts down to -40°C.
  • Ingress Protection
    • The ingress protection shall be IP 20, NEMA 1 minimum
    • Charger shall have internal ingress protection such that no falling foreign objects in ventilation openings can cause electrical safety hazards or equipment damage.
  • The charger shall operate in humidity levels ranging from 5% to 95%, non-condensing.
  • The charger shall operate at full specification from 0 to 6,500 ft, or 0 to 2000m above sea level. Above this altitude, the output shall be derated 0.012% per additional meter at rated ambient temperature.
  • Cooling
    • Charger thermal components shall be conduction cooled.
    • The cooling method shall keep the high efficiency rectifiers free of dust and dirt, making the charger well-suited for operation in industrial, utility, power plant, and other harsh environments.
    • Two variable speed, premium ball-bearing fans shall cool each rectifier.
    • Rectifiers shall maintain nearly full output capability even if one fan fails.
    • A fan failure alarm system with local and remote indication shall enable service dispatch while the second fan continues to run.
    • The fan module shall be able to be easily replaced in the field with common tools.
7. PROTECTION
  • The AC input to the system shall be protected by a UL489 3-pole AC input breaker with a minimum interrupt rating of 10KAIC.
  • Charging System Protection.
    • Soft start shall gradually increase current with a maximum of 5 seconds to full-required output.
    • Reverse Polarity Protection
      • Charging system shall not start into a reverse connected battery.
      • The charging system shall recover automatically after removal of a fault condition.
    • Charger-battery voltage mismatch shall shut down the charger after 5 minutes. Indication via LED and LCD.
    • Output Blocking Protection
      • The charger shall prevent sparking during battery connection or during hot-swap.
      • Charger shall have an “ORing” function to isolate a non-functioning charging system from others in a redundant charging system configuration.
  • The output of the charging system shall be protected by a UL489 listed 2-pole DC output breaker with a minimum interrupt rating of 10KAIC.
8. OPTIONAL SYSTEM ITEMS
  • High interrupt AC breakers shall be available with interrupt ratings up to 65KAIC.
  • High interrupt DC breakers shall be available with interrupt ratings up to 100KAIC.
  • Supplemental Surge Protection
    • Supplemental surge protection provides additional surge protection for the system from damage due to lightning, transients, and power surges.
    • The AC protective device shall be UL 1449 Listed, the maximum discharge current shall be 75kA 8/20 μs and the protection level shall be 1500V.
    • The DC protective device shall be UL 1449 Listed, the maximum discharge current shall be 75kA 8/20 μs and the protection level shall be 620V.
  • Up to (2) 120VAC, 5A relays shall be optional.
  • Up to (4) 150VDC, 3A or 240VAC, 10A relays shall be optional.
  • AC Breaker shall be available with shunt trip on certain models. This feature will automatically turn off the AC power to the charger when the AC voltage exceeds 550VAC for greater than 3 seconds. This will prevent any internal damage to the charger should any overvoltage condition occur.
9. USER INTERFACE
  • The user interface shall include a backlit LCD displaying plain language text, a multicolor LED panel showing system status, and a user control panel.
  • Remote Interface
    • System status and limited control shall be available via optional Modbus RS-485 and TCP/IP communications
    • System status and limited control shall be available via optional DNP3 communications.
    • Connection to the charger shall be available via ethernet connection. A software utility shall be available that provides status, control, and configuration options for remote status and control of the charger.
  • System shall be equipped with a 1% accuracy meter for indicating AC input and DC output voltage and 1% accuracy meter for indicating AC input and DC output current.
  • Security levels shall be selectable via the User Interface Mode menu using the front panel keypad.
    • This prevents an unauthorized user from changing settings that would affect charger operation, while still allowing full configurability for the authorized users.
    • Control software prevents conflicts between operating voltage setpoints, temperature compensation system and alarm setpoints.
  • Battery Check
    • A battery check feature shall be provided.
    • The user shall be able to initiate a test of the battery system from the charger and remotel.y
    • Battery checks shall be able to be scheduled at regular automatic intervals.
    • Battery check result shall be displayed via communications and alarms.
10. INDICATIONS AND ALARMS
  • Any alarm indication shall cause plain language text to appear on the LCD and change appropriate LEDs. Normal LED indication shall be green. Alarm LEDs shall be red. Warning LEDs shall be amber. Multiple alarms result in the relevant LEDs changing color and multiple alarm message screens on the LCD. Alarm status shall also be available via communication interfaces.
  • Nine alarm Form C relays shall be provided: Alarm assignment may be changed with the control software. The following alarms shall be provided, and shall be made assignable to any relay:
    • AC Line Failure
    • High DC Voltage
    • Battery on Discharge
    • Low DC Voltage
    • Battery End of Discharge
    • Module Failure
    • Over Voltage Shutdown
    • Reverse Polarity
    • Incompatible Battery
    • Invalid Settings
    • Fan Fail
    • Thermal Foldback
    • Temperature Probe Fault
    • Current Limiting
    • Ground Fault Positive
    • Ground Fault Negative
    • Low Current
    • Load Share FaiL
    • DC Below Startup Voltage
    • Battery Check
    • Check Filter
    • Thermal Fault
    • High Battery Temperature
    • High Battery Temperature Shutdown
    • AC Phase Missing
    • AC Voltage Over Maximum
    • AC Voltage Low
    • AC Frequency Out of Range
    • AC Voltage High
    • AC Surge Protector Fault with optional hardware
    • DC Surge Protector Fault with optional hardware
    • AC Breaker OFF with optional hardware
    • DC Breaker OFF with optional hardware
11. COMMUNICATIONS
  • Configuration and Firmware Updates
    • A Setup Utility shall be available providing a custom configuration and diagnostics software utility that runs on a Windows PC via an ethernet port.
12. MECHANICAL
  • Enclosure Material and Finish
    • Cabinet construction shall be 1/8” 5052 aluminum.
    • Cabinet finish shall be powder-coated ANSI 61 gray.
  • Intended for permanent installation using hard-wired electrical conduit.
  • Charger enclosure shall accommodate top, bottom, or side cable conductor entry.
  • Accommodation shall be provided for routing field conductors in a safe and orderly manner.
  • Unit weight shall not exceed 500lbs (227kg).
13. CHANGES TO SPECIFICATION
  • In order to meet evolving customer requirements, changes to the product and to this specification may be made without notice from time to time.

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