NRG10A Manual

SENS EnerGenius NRG Technical Manual
Installation & Operation Manual

NRG12-10: 12-Volt, 10-Amp Battery Charger
NRG24-10: 24-Volt, 10-Amp Battery Charger
NRG22-10: 12/24-Volt, 10-Amp Battery Charger
®
Part Number: 101295
X ™
Document Revision:
DCN Number: 106910
1840 Industrial Circle
Date: December 16, 2015
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: service@sens-usa.com
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 2006
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 the manufacturer 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.
Service hotline: 1.800.742.2326

1.303.678.7500 2
MODEL NUMBER CONFIGURATION

This manual contains important safety, installation and operating instructions for battery charger model NRG12-10
(configured for 12V,10A only), NRG24-10 (configured for 24V, 10A only) and NRG22-10 (field configurable for
12V or 24V, 10A).
Model Number Breakout
NRG 22-10-
Model Output Output Input Voltage Alarm System Option Code Optional Supplier
Voltage Current Frequency Code (may not be present) Code (may not be present)
12: 12 volts 10: 10 Amps H: 120/208-240V, C: 5 Alarms E: OSHPD labeled***

24: 24 volts 50/60 Hz**
22: 12/24 volts R: 120/208-240V,
60 Hz*
NOTE: Not all configurations are available on all models. Contact the factory for confirmation.
All NRG models are C-UL Listed to UL 1236.
*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
2” (50 mm) minimum

ventilation clearance
on each side
Mount to vertical surface of 3/4” (19 mm) plywood

or other material of equal strength and durability,
using four mounting screws 1/4” (6 mm) diameter.

1.303.678.7500 3
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.
Charger Dimensions:
W: 7.66 Inches (195 mm).

H: 12.50 Inches (318 mm).
D: 6.48 Inches (165 mm).

1.303.678.7500 4
Use conductors rated 90°C/194°F or higher.

Input conductors must be suitable for 10A circuits.
Battery conductors must be suitable for 30A 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 10 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.
1.303.678.7500 5
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 input terminal block TB1.
5. WIRE RATINGS
A. All conductors should be rated for use at 90ºC/194°F or higher.
B. All input and output conductor sizes should be coordinated with the fault protection devices: 10A on AC input (14
AWG, 2.5 mm2 typical), 30A on DC output (10 AWG, 6.0 mm2 typical). 1 A on Alarm terminal block (20 AWG,
0.5 mm2 typical). AC input current is 6A at 120VAC and 3A at 208-240VAC.
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 58m 116m
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
10 6.0 1.00 25 50 10 19
8 10 0.63 40 79 15 30
6 16 0.40 63 126 24 48
The above lengths consider the resistance of the battery and cables only and do not take into account any additional inter-
connects. The above lengths are for operation at 25°C/77°F. For high temperature installations (40°C/104°F) 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.
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 – Bussman Type BK/ATC-30, or Littelfuse 287030 [ATOF30], 30A, 32V, fast acting, blade type
automotive
C. AC Input Fuse – Bussman Type BK/AGC-10-R, 10A, 250VAC, fast acting, ferrule type cylindrical, ¼” X 1-¼”

1.303.678.7500 6
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 -20ºC/-4°F, or hotter than
+40ºC/104°F 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 25 pounds (11.3 kg), and also the weight of the fixed wiring.
Mounting on a concrete surface:
 All mounting hardware is provided by the installer.
 Use optional ¾ inch 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 holes using the mounting diagram on pg. 4 for ¼ in. (or M6) draw nut type expansion anchors
through the plywood into the cement wall.
 Insert the four 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.

1.303.678.7500 7
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 holes on the plywood using the mounting diagram on pg. 4. Drill pilot holes into the plywood to
secure the mounting bolts.
 Mount charger using four ¼ in. by 1/2 in. or M6 lag bolts and flat washers.
Mounting on a metal surface:

 Mount charger using four ¼ -20 by 3/4 in. hex head bolts, flat washers and split lock washers or M6
fastening hardware suitable to attach the battery charger to a frame, panel or cross member in four places.
Use the mounting diagram on pg. 4 to place the pilot holes, if needed.
 Tighten all bolts to recommended torque of 45-50 inch pounds.
10. 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. Tighten connections to 10.5 Lb-In (1.2 Nm).
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.

1.303.678.7500 8
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. Tighten connections to
10.5 Lb-In (1.2 Nm).
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 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 28-16 AWG (0.20-1.0 mm2) conductors. Tighten
connections to 2.0 Lb-In (0.22 Nm).
WARNING:
CONNECT ALARM TERMINALS ONLY TO LOW VOLTAGE, LIMITED
ENERGY (“CLASS 2”) CIRCUITS. ALARM CIRCUITS ARE RATED 2A AT
30 VDC/VAC, MAXIMUM SWITCHING CAPACITY 62.5VA, 60W.
RELAY BATTERY AC FAIL CHARGER FAIL HIGH BATTERY LOW BATTERY
CONTACTS FAULT ALARM ALARM ALARM ALARM (HI DC) ALARM (LO DC)
COMMON TB5-1 TB5-4 TB5-7 TB5-10 TB5-13
COM COM COM COM COM
NORMALLY TB5-2 TB5-5 TB5-8 TB5-11 TB5-14
CLOSED (NC) OK OK OK OK OK
Defaults to OK Defaults to OK Defaults to OK
OPEN ON with no AC and with no AC and with no AC and
ALARM DC power DC power DC power
OPEN (NO) FAIL FAIL FAIL FAIL FAIL
Defaults to Fail Defaults to Fail
CLOSE ON with no AC and with no AC and DC
ALARM DC power power
For Normally Closed (NC) contacts wire from COM to OK. For Normally Open (NO) contacts wire from COM to FAIL.

1.303.678.7500 9
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.
11. INTERNAL ADJUSTMENTS

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

AC line voltage switch JP800. Choose VOLTS,
110-120V: Use 115V position AMPS, or AUTO for meter
208-240V: Use 230V position display view.
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)
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.
D. Set the float voltage select jumper (JP1C) according to the battery manufacturer’s recommended 25ºC/º77F
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
1.303.678.7500 10
 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 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. 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.
1.303.678.7500 11
12. 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 10A 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 9 A (5A for single alarm).

1.303.678.7500 12
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 voltag e lim it
Vb C h a rg e r in “flo a t m o d e ”
F loa t voltage lim it
O n ce bo os t volta ge is
Battery voltage
a ch ieved cu rre nt ta p ers o ff T ran sition : ch arge r shifts to

floa t m od e w he n b attery
c urren t a cc ep tan ce drop s
Current limit
B a tte ry cu rre n t a c c e p ta n c e
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Temperature Compensation:
 The battery charger is temperature compensated to match the negative temperature coefficient of the bat-
tery. Thus, the output voltage will increase slightly as the temperature decreases and decrease as tempera-
ture increases.
 The output voltage is clamped at 0°C/32°F and +40°C/104°F to protect against extremely high or low
output voltage. See chart below.
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 volt-
1.303.678.7500 13
13
age is 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°C/-4°F to +40°C/104°F. Charger will operate at reduced output current
rating up to +60°C/140°F.
 Conformal coated printed wiring boards for erosion protection.
W o r l d w i d e A g e n c y A p p r o v a ls :
 UL listed, UL 1012, 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 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

1.303.678.7500 14
ITEM TEXT LED Meaning Troubleshooting
1 CHGR FAIL RED Charger Fail Charger unable to provide charging current to bat-
tery. Replace unit.
AC input voltage is too low to supply proper cur-
rent 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 system
and 34v for 24v system.
3 RED Battery DC Voltage Low Check that battery range voltage jumper setting
DC LOW agrees with battery used. Check for defective bat-
tery.
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. Set-
ting must agree with AC voltage at site. Check AC
fuse.
5 T-COMP GREEN On if Temperature Com- Confirm if temperature compensation is intended to
pensation Working, Off if be used. Only one sensor (Local or remote) should
Temperature Compensa- be connected.
tion Option not used.
6 AC/ ON GREEN 1 alarm model: Charger Should be on in normal use.

operating normally
1 alarm model: If LED is OFF, AC FAIL, CHGR
5 alarm model: AC input FAIL or BATT FAULT LED should be ON.
good
5 alarm model: If LED is OFF, AC FAIL should be
ON.
7 FLOAT MODE GREEN Charger Output in Float If the automatic boost jumper is in the OFF loca-
Mode tion, 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 boost
MODE Mode 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

1.303.678.7500 15
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

1.303.678.7500 16
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

1.303.678.7500 17
TROUBLESHOOTING GUIDE—CHARGER FAIL ALARM
START:
CHGR FAIL LED red
AC VOLTS LOW ALARM

Y CORRECT AC INPUT N
(MEASURE WITH STILL END
SUPPLY PROBLEM PRESENT?
MULTIMETER)?
N Y
ALL ALARM
CONNECTORS N FIX N
STILL END
FIRMLY SEATED? CONNECTIONS PRESENT?
Y Y
ALARM
REPLACE CIRCUIT N
STILL END
BOARD TRAY PRESENT?
CONTACT CUSTOMER
SERVICE

1.303.678.7500 18
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
BOARD TRAY PRESENT?
CONTACT CUSTOMER
SERVICE

1.303.678.7500 19
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
BOARD TRAY PRESENT?
CONTACT CUSTOMER
SERVICE

1.303.678.7500 20
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

1.303.678.7500 21
C. 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 10A 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 9.0 A (5A for single alarm).
D. ALARM DESCRIPTION:
RELAY BATTERY AC FAIL CHARGER FAIL HIGH BATTERY LOW BATTERY
CONTACTS FAULT ALARM ALARM ALARM ALARM (HI DC) ALARM (LO DC)
COMMON TB5-1 TB5-4 TB5-7 TB5-10 TB5-13
COM COM COM COM COM
CLOSED (NC) OK OK OK OK OK
Defaults to OK Defaults to OK Defaults to OK
OPEN ON with no AC and with no AC and with no AC and
ALARM DC power DC power DC power
OPEN (NO) FAIL FAIL FAIL FAIL FAIL
Defaults to Fail Defaults to Fail
CLOSE ON with no AC and with no AC and DC
ALARM DC power power
For Normally Closed (NC) contacts wire from COM to OK. For Normally Open (NO) contacts wire from COM to FAIL.

1.303.678.7500 22
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
or site conditions
Recommended Charger to Battery
Distance (Ft.) Input: 208-240 VAC
120 VAC
AWG 12V/10A 24V/10A 12V/20A 24V/20A
Jump: DISABLED
10 10 19 N/A N/A Fast charge: ENABLED / OFF
8 15 30 7 15
6 24 48 12 24 Float voltage: 14.30 28.60
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
Temp comp
PN: 101294 REV:G Copyright © Stored Energy Systems LLC 2009 terminal block
Powering Critical Infrastructure
EC Declaration of Conformity
In accordance with EN ISO 17050-1:2010
Manufacturer: Stored Energy Systems
Manufacture Address: 1840 Industrial Circle

Longmont, CO 80501
U.S.A.
Product Type: Battery Charger
Model Numbers: NRGAA-BB-HCYYYY, where AA = 12, 22, 24; BB = 10; Y = any

digit/blank space
Conformance to Directive 2014/30/EU of the European Parliament and of the Council

Directives: of 26 February 2014 on the harmonisation of the laws of the Member
States relating to electromagnetic compatibility (recast)
Directive 2014/35/EU of the European Parliament and of the Council of

26 February 2014 on the harmonisation of the laws of the Member
States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits (recast)
Directive 2011/65/EU of the European Parliament and of the Council of

8 June 2011 on the restriction of the use of certain hazardous
substances in electrical and electronic equipment (recast)
Harmonized and/or Directive 2014/30/EU (EMC)

technical specifications EN 61000-6-2:2005/AC:2005
applied in full: EN 61000-6-4:2007/A1:2011
Directive 2014/35/EU (LVD)

EN 60335-1:2012/A11:2014
EN 60335-2-29:2004/A2:2010
Directive 2011/65/EU (RoHS (recast))

EN 50581:2012
Place and date of first Longmont, CO USA on May 13, 2004

issue:
Under the sole responsibility of Stored Energy Systems, the undersigned hereby declares that the
equipment specified above conforms to the essential requirements of the above Directives(s) and
Standard(s).
________________________________________ 11/20/2017
______________________
Sam Coleman Date
Compliance Manager
Stored Energy Systems, LLC
STORED ENERGY SYSTEMS, LLC 1840 INDUSTRIAL CIRCLE, LONGMONT, COLORADO 80501 FAX 303.678.7504 303.678.7500
www.sens-usa.com email: info@sens-usa.com
FORM-226 REV E DATE ISSUED: 11/20/2017

SENS Limited Warranty: NRG and MicroGenius Battery Chargers
What is covered?
This warranty covers any defect in material and workmanship on NRG or MicroGenius 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 and MicroGenius Battery Chargers

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 and MicroGenius Battery Chargers
Premium Warranty Coverage

At the time of original purchase, customer may purchase premium warranty coverage for the standard warranty period. 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 E Date Issued: 10/26/2015

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SENS EnerGenius NRG Technical Manual

Installation & Operation Manual

IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR

1. SAVE THESE INSTRUCTIONS.

Service hotline: 1.800.742.2326

MODEL NUMBER CONFIGURATION

12: 12 volts 10: 10 Amps H: 120/208-240V, C: 5 Alarms E: OSHPD labeled***

6” (150 mm) minimum

2” (50 mm) minimum

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

Service hotline: 1.800.742.2326

1. PREPARING FOR USE:

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

W: 7.66 Inches (195 mm).

Service hotline: 1.800.742.2326

Use conductors rated 90°C/194°F or higher.

Service hotline: 1.800.742.2326

8. STATIC DISCHARGE PRECAUTIONS

Service hotline: 1.800.742.2326

Mounting on a metal surface:

Service hotline: 1.800.742.2326

Service hotline: 1.800.742.2326

G. If the optional remote temperature sensor is used:

11. INTERNAL ADJUSTMENTS

Meter Display Jumper

Automatic boost jumper

Float voltage jumper

Battery range jumper

Red for low battery voltage

See OPERATOR INSTRUCTION section for LED indicator definitions:

Service hotline: 1.800.742.2326

a ch ieved cu rre nt ta p ers o ff T ran sition : ch arge r shifts to

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

Battery Fault Protection and Alarm:

B. FRONT PANEL LED INDICATOR DEFINITIONS AND TROUBLE SHOOTING:

Red for low battery voltage

Service hotline: 1.800.742.2326

6 AC/ ON GREEN 1 alarm model: Charger Should be on in normal use.

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—REPEATED BLOWN AC FUSE

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—AC FAIL ALARM

AC VOLTS AND ALARM

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—CHARGER FAIL ALARM

AC VOLTS LOW ALARM

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—DC HIGH ALARM

BATTERY RANGE ADJUST JUMPER ALARM

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—DC LOW ALARM

BATTERY RANGE ALARM

AC VOLTS AND ALARM

Service hotline: 1.800.742.2326

TROUBLESHOOTING GUIDE—BATTERY FAULT ALARM

FIX LEADS THAT ARE TOO

Service hotline: 1.800.742.2326

4. If the meter display jumper is selected to read Amps or automatic Volts/Amps:

Service hotline: 1.800.742.2326