Sens PowerCab 2 Manuale utente

SENS PowerCab2 Technical Manual

SENS Part Number: 101343

Document Revision: A

DCN Number: 108523

Date: February 27, 2024

PATENTED US 9,270,140; 9,385,556; 9,413,186; 9,509,164;

9,466,995; 9,948,125; 10,575,433

Installation or service questions?

Call SENS between 8 a.m. and 5 p.m. (Mountain Time),

Monday through Friday, or visit our website.

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

Installation & Operation Manual

PowerCab®2

Factory-packaged Non-stop DC Power Systems

1840 Industrial Circle

Longmont, CO 80501

Phone: 303.678.7500

800.742.2326

Fax: 303.678.7504

Email: service@sens-usa.com

Web: www.sens-usa.com

SENS PowerCab2 Technical Manual 
 

 
TABLE OF CONTENTS 
 
1IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR ............................................................ 4 
2PERFORMANCE SPECIFICATIONS........................................................................................................................ 6 
3MOUNTING INSTRUCTIONS.............................................................................................................................. 10 
1. Mounting Location...................................................................................................................................10 
2. Mounting Instructions.............................................................................................................................. 10 
4SETUP AND WIRING .......................................................................................................................................... 11 
1. Wire Ratings and Sizes .............................................................................................................................11 
2. Grounding Instructions and Connection ..................................................................................................11 
3. DC Distribution Connection...................................................................................................................... 11 
4. AC Connection..........................................................................................................................................12 
5. Standard Alarm Connections ................................................................................................................... 12 
6. High Current Relay Connections—Optional............................................................................................. 13 
7. CANbus Connections................................................................................................................................15 
8. RS-485 Connections .................................................................................................................................15 
9. Ethernet ................................................................................................................................................... 16 
10. Service Connection................................................................................................................................... 17 
11. Verify Connections ................................................................................................................................... 17 
12. Verify Covers ............................................................................................................................................17 
5START-UP PROCEDURE ..................................................................................................................................... 18 
1. Connect Battery ....................................................................................................................................... 18 
2. Verify Configuration.................................................................................................................................18 
3. Apply AC Input Voltage ............................................................................................................................ 18 
4. Connect DC Distribution Outputs.............................................................................................................18 
5. Power Off ................................................................................................................................................. 18 
6ALARMS, LEDS AND DISPLAY ............................................................................................................................ 19 
1. LED Indicators...........................................................................................................................................19 
2. Individual Alarm Relay Contacts...............................................................................................................20 
3. LCD Panel .................................................................................................................................................20 
4. Latched Alarms.........................................................................................................................................20 
5. Alarm Definitions .....................................................................................................................................20 
7OPERATION ....................................................................................................................................................... 26 
1. Charging Algorithms................................................................................................................................. 26 
2. Float Mode............................................................................................................................................... 26 
3. Dynamic Boost™Mode ............................................................................................................................ 26 
4. HELIX Mode..............................................................................................................................................26 
5. Charging Low or Zero-volt Batteries ........................................................................................................27 
6. Commissioning Batteries.......................................................................................................................... 27 
7. Battery Check ........................................................................................................................................... 27 
8. Shunt Trip AC Breaker—Optional............................................................................................................. 27 
9. Restore Factory Defaults.......................................................................................................................... 28 
10. Keypad Operation ....................................................................................................................................28 
10.3. Menu Options ..........................................................................................................................................29 
11. Configuration with SENS Setup Utility ..................................................................................................... 35 
12. Protocol Communications Circuit Board..................................................................................................35 
13. Temperature Compensation....................................................................................................................36 
14. Efficiency ..................................................................................................................................................37 
8SERVICE AND MAINTENANCE ........................................................................................................................... 38 
1. Recommended Annual Maintenance....................................................................................................... 38 
2. Power Module Access ..............................................................................................................................38 
3. Air Filter.................................................................................................................................................... 38 
4. Fans ..........................................................................................................................................................38 
5. Supplemental Surge Protectors ...............................................................................................................38 
9MODBUS COMMUNICATIONS .......................................................................................................................... 39 
1. TCP/IP Modbus.........................................................................................................................................39 

SENS PowerCab2 Technical Manual 
 

 
2. Modbus RS-485 ........................................................................................................................................ 39 
3. Modbus Holding Registers ....................................................................................................................... 40 
4. Basic Charging Alarms Bit Definition........................................................................................................ 41 
5. Charging Status Bit Definition ..................................................................................................................42 
6. Charging Alarms Extended Bit Definition.................................................................................................43 
7. Charging AC Alarms Bit Definition............................................................................................................43 
8. Accessory Channel Alarms Bit Definition .................................................................................................43 
9. Accessory System Alarms Bit Definition................................................................................................... 44 
10. Accessory Assigned Channel Alarms Bit Definition..................................................................................44 
11. Writable Control Flags (Coils) - Single coil writes: 0xFF00 for ON, 0x0000 for OFF .................................44 
DNP3 COMMUNICATIONS—Optional .............................................................................................................. 45 
1. TCP/IP DNP3.............................................................................................................................................45 
2. RS-485 DNP3 ............................................................................................................................................45 
3. SENS DNP3 Config Tool ............................................................................................................................ 45 
4. Implementation Table.............................................................................................................................. 46 
5. Binary Inputs ............................................................................................................................................47 
6. Binary Outputs .........................................................................................................................................49 
7. Analog Inputs ...........................................................................................................................................50 
8. Analog Outputs ........................................................................................................................................51 
NACL SALT BATTERY OPERATION—Optional ................................................................................................... 52 
1. LED Indication .......................................................................................................................................... 52 
2. Modbus TCP/IP......................................................................................................................................... 53 
TROUBLESHOOTING/ERROR CODES................................................................................................................. 58 
1. Reset Button............................................................................................................................................. 58 
2. Configuration Error Codes........................................................................................................................ 58 
3. Troubleshooting Guide............................................................................................................................. 59 
GLOSSARY.......................................................................................................................................................... 66 
 

SENS PowerCab2 Technical Manual

1IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR

1.1. SAVE THESE INSTRUCTIONS –This manual contains important safety and operating instructions for

PowerCab2 DC backup systems.

1.2. Before using system, read all instructions and cautionary markings on battery charger, battery, and product

using battery.

1.3. Use of an attachment not recommended or sold by the backup system manufacturer may result in a risk of

fire, electric shock, or injury to persons.

1.4. This backup system is intended for commercial and industrial use. ONLY TRAINED AND QUALIFIED

PERSONNEL MAY INSTALL AND SERVICE THIS UNIT.

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

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

personnel.

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

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

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

equipment. The AC, BATTERY and CHARGER breakers are equipped with provision to lock breakers in the

OFF position.

1.8. WARNING –RISK OF EXPLOSIVE GASES

1.8.1. WORKING IN THE VICINITY OF A BATTERY IS DANGEROUS. STORAGE BATTERIES MAY GENERATE

EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST

IMPORTANCE THAT YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EACH TIME YOU

USE THE CHARGER.

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

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

Review cautionary markings on these products and on the engine.

1.9. PERSONAL PRECAUTIONS

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

near a storage battery.

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

eyes.

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

storage battery.

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

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

medical attention immediately.

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

1.9.6. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short

circuit the battery or another electrical part that may cause explosion. Using insulated tools reduces

this risk but will not eliminate it.

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

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

the like to metal, causing a severe burn.

SENS PowerCab2 Technical Manual

1.9.8. When charging batteries, charge LEAD-ACID, LIQUID ELECTROLYTE NICKEL-CADMIUM, NICKEL-

ZINC or SODIUM-CHLORIDE batteries only. Consult SENS before using with any other type of

battery or changing battery type from originally supplied with system - other batteries may burst

and cause injuries to persons and damage to property. NEVER charge a frozen battery.

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

in your installation.

1.10. Preparing Battery For Charge

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

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

coming in contact with eyes.

SENS PowerCab2 Technical Manual

2PERFORMANCE SPECIFICATIONS

PowerCab2 factory-packaged non-stop DC power systems, specially hardened for use in harsh industrial

environments. Advanced technology switch mode power conversion is significantly smaller & lighter than

conventional line frequency (e.g. SCR) power conversion and, even without a battery connected, delivers lower

output ripple and much faster dynamic response.

Forced ConductionTM cooling keeps the high efficiency power electronics free of dust and dirt, making PowerCab2

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

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

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

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

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

front panel LCD and five assignable alarm relays. Four additional high current alarm relays are optional.

Options include various cabinet size/configurations, NEMA 3R ingress protection, fans, heaters, batteries, DC

distribution breakers, supplemental surge suppression, and DNP3 data communications. Modbus data

communications comes standard with each system. Systems can be equipped with multiple communication

protocols. Specifications are detailed in the table below, see following sections for installation and operation

instructions. Multiple systems can be housed in a single cabinet, allowing for full redundancy or dual AC feed

systems.

Specifications

AC input

Voltage, frequency

Full output power: 358-528 VAC 3-phase line to line connected, 50% power

limit from 188-357 VAC. 47-63 Hz.

Input current

96A maximum at 358VAC (for maximum configured unit), see section 4.4

Overcurrent

protection

3-pole UL 489 listed circuit breaker

25 kAIC standard, 65 kAIC optional, lockable. Two breakers optional for dual

AC feed.

Optional breaker status provides indication and alarm when the AC breaker

is in open or tripped position

Optional breaker shunt trip provides input overvoltage damage protection

by turning off breaker when the input voltage exceeds an adjustable level

AC transient

protection

Layered electrical transient defenses. Optional UL1449 Type 1 Listed

supplemental surge protection, alarmed and with field replaceable

elements, surge capacity rated 75kA 8/20 µs; visual and remote indications.

Loss of phase

Continues operating with current limit reduced to 50%

Efficiency

Up to 95%, see section 7.14

Power Factory & Total

Harmonic Distortion

To 0.98 typical at maximum rated load current and boost charge voltage.

Total Harmonic Distortion <3%

DC output

Voltage

120 VDC or 240VDC nominal. 120VDC: output adjustable from 8-160V. 240

VDC: output adjustable from 16-320V. If AC voltage is not applied, charger

powers down below 60VDC.

Current

120VDC output limit: 56kW or 400A, whichever is less.

240VDC output limit: 56kW or 200A, whichever is less.

Soft Start

System gradually increases current with a maximum of 5 seconds to full-

required output

Charging modes

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

Current limit

100% current capability subject to temperature limits and AC voltage limits;

field adjustable to max rated current.

SENS PowerCab2 Technical Manual

Charging

characteristic

Constant voltage, current limited; patented Dynamic Boost and HELIX

control

Line & load regulation

±0.5%

Output ripple

<30mV with battery, <100mV off-battery for 120VDC, <200mV off-battery

for 240VDC. Delivers fast-responding, stable, well-filtered DC without

battery.

Step response

8ms typical, to recover within 1% of rated output voltage from load step

change of 50% rated output current

Output protection

Electronic current limit. 2-pole UL 489 listed charger feed and battery main

circuit breakers.

Output ≤200A: 10 kAIC standard, 25 kAIC optional. Output >200A: 50 kAIC

standard, 100 kAIC optional. Lockable.

Optional breaker status provides indication and alarm when the Charger

breaker is in open or tripped position

DC distribution

Internal panel, 2-pole UL 489 circuit breakers, 22 or 34 positions

DC surge protection

Layered electrical transient defenses. Optional UL1449 Open Type 2 Listed

supplemental surge protection, alarmed and with field replaceable

elements, surge capacity rated 75kA 8/20 µs; visual and remote indications.

Includes replaceable fuses, refer to separately provided diagrams.

Batteries

Optional, type lead-acid, NiZn or NaCl (salt), 40-200Ah (varies based on

battery type). Optional battery monitoring.

DC power supply

operation

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

Battery temp.

compensation

Standard. On-board sensor modifies output voltage when temperature is

between 0°C and+40°C. Slope adjustable, factory set to –0.18% per degree

C. Optional remote battery monitor provides battery temperature probe.

Dead battery charge

Starts into and recharges zero-volt battery

Redundancy

Optional N+1 or N+2 redundancy provides more power modules than are

required to meet the rated output. All modules will actively share the load

up to the rated current of the system. Should a power module fail, each

remaining module will equally share the connected system load and battery

recharge demand.

Output blocking

protection

Prevents sparking during battery connection or during hot swap operation

Output Derating

Input Voltage/#

Phases

% Output

Power

Available

Max. Available Output

Current Per Module*

140VDC

60VDC

30VDC

400-480VAC/3-ph

Full Rating

(7kW)

50A

400-480VAC/1-ph

50% (3.5kW)

25A

50A

208-240VAC/3-ph

50% (3.5kW)

25A

50A

208-277VAC/1-ph

25% (1.75kW)

12.5A

29A

50A

*120V-50A shown, divide current values in half for 240V-25A modules

Auxiliary DC power

supply

Optional, 12-48VDC, 300W, consumes one distribution breaker position

Auxiliary AC inverter

Optional, 120VAC 60Hz or 230VAC 50Hz, 600/1000/1100/2000/3000W

options, consumes one distribution breaker position

SENS PowerCab2 Technical Manual

Adjustment &

Controls

Charge mode control

Fully automatic patented Dynamic Boost system. Manual boost, timed

boost & & battery commissioning charging options are available from front

panel control.

Front panel control

Change all parameters including voltages, current limits, alarm parameters,

network configurations, time-outs, and more

Computer adjustment

Change all parameters, troubleshoot, create/save configuration files for

quick download to chargers using network connection and SENS Setup

Utility software available at www.sens-usa.com

Status

reporting

LEDs

Two multi-color front panel status LEDs

Metering

AC/DC Voltmeter accurate to ±1%; AC/DC ammeter to ±1%; AC frequency

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

rated output

Status display

20-character display of status & alarm messages.

Alarms

Alarm Outputs

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

via communication port, alarm relays, and on LCD.

Alarm Inputs

Two optional input contacts (via optional battery monitor) to monitor status

of, and modify charger operation based on, external devices such as battery

room fan or hydrogen monitor.

Alarm Form C

contacts

Nine Form C contacts, rated 30V, 2A resistive, assignable. Up to four

optional 120V, 5A resistive or 150VDC, 3A / 240VAC, 10A assignable.

Pilot relay functions

Form C contacts configurable as pilot relays to switch external loads based

on user-configurable conditions.

Networking

Modbus

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

DNP3

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

SENSbus

Proprietary bus for connection of paralleled chargers and SENS accessories

Environmental

Operating

temperature

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

and suffer reduced life above 65°C. Cold starts down to -40°C.

Ingress protection

NEMA1/IP20 or NEMA3R/IP34

System fan

Optional cabinet door fan, thermostat controlled, turns on at +40°C,

includes replaceable fuses, refer to separately provided diagrams

Heater

Optional cabinet heaters, keeps batteries above freezing

Humidity

5% to 95%, non-condensing

Altitude

0-6,500 ft (2,000 meters). Above this altitude, output is derated 0.012% per

additional meter at rated ambient temperature.

Vibration & shock

resistance

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

Electrical transient

ANSI/IEEE C62.41, EN 61000-4-12 on power terminals, IEC 61000-6-5 and

ANSI/IEEE C37.90 (withstands 4kV line‐to‐line/line‐to‐earth without optional

AC surge protection, 6kV or greater with optional AC surge protection)

Abuse

protection

Reverse polarity

Charger self-protects without output protective device clearing. Indication

via LED & LCD.

Wrong voltage

battery

Charger-battery voltage mismatch shuts down charger after 5 minutes.

Indication via LED and LCD.

Overvoltage

shutdown

Selective; shutdown only operates if charger causes the overvoltage

condition

Overtemperature

protection

Gradual output power reduction if heatsink temperature becomes

excessive; recovery is automatic.

SENS PowerCab2 Technical Manual

Regulatory

Compliance

North America

C-UL Listed for US & Canada: UL 508A

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

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

Construction

Housing

Floor mount; integrated key lock

Housing material

Aluminum with powder coated finish or stainless steel

Weight

Refer to separately provided system diagrams for weight information

Cable entry

Rear, bottom or side access, refer to separately provided system diagrams

Network/Alarm

connections

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

AWG.

Power connections

AC breaker: 14 –1/0AWG

DC Distribution breakers: ≤20A: 14 –10AWG. >20A: 10 –1/0AWG.

SENS PowerCab2 Technical Manual

3MOUNTING INSTRUCTIONS

INSTALLATION OF THE UNIT MUST COMPLY WITH LOCAL ELECTRICAL CODES AND OTHER APPLICABLE

INSTALLATION CODES AND BE MADE ACCORDING TO THE INSTALLATION INSTRUCTIONS AND ALL

APPLICABLE SAFETY REGULATIONS.

Printed circuit boards contain static sensitive components. Damage can occur even when static levels are too

low to produce a noticeable discharge shock. To avoid static discharge damage, handle circuit boards by the

panel they are installed on only. Remove covers only when access is essential for installation and service and

replace promptly when finished.

3.1. Mounting Location

See separately provided system diagrams for dimensions and mounting information.

3.1.1. System is rated NEMA1/IP20 or NEMA3R/IP34.

3.1.2. Charger will operate at full specification when located where temperatures are within -40°C

(-40°F) to +50°C (122°F). Output power is gradually reduced at higher temperatures.

3.1.3. Leave clear space around all system ventilation openings.

3.1.4. The cabinet is intended to be floor mounted. The mounting surface must safely support the

weight of the system and the fixed wiring.

3.1.5. Allow sufficient room for routing the fixed wiring to the system. All field connections wires enter

the system from the rear, top or bottom.

3.1.6. Do not mount the system above any heat generating equipment or where it could get wet.

3.2. Mounting Instructions

3.2.1. Drill floor mounting holes and mount system using dimensions on separately provided system

diagrams. Mounting hardware is not included with the system and must be provided by the

installer.

3.2.2. Mount the system before connecting AC, DC, communications and alarm wiring to ensure

unobstructed access to mounting holes.

3.2.3. Inspect the connections, busbars, and wiring for any loose debris or damage from installation.

3.2.4. Use all mounting points provided on the separately provided system diagrams.

3.2.5. Ensure all ventilation openings are clear and unobstructed.

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