Sens EnerGenius NRG24-10

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The SENS EnerGenius NRG is a battery charger designed for commercial and industrial use, specifically for charging lead-acid or liquid electrolyte nickel-cadmium batteries. It is available in various models: NRG12-10 (12-Volt, 10-Amp), NRG24-10 (24-Volt, 10-Amp), and NRG22-10 (field configurable for 12V or 24V, 10-Amp). The device is built with robust, hardened construction and includes advanced design features for battery-friendly operation and fault tolerance.

Function Description:

The EnerGenius NRG battery charger provides a controlled charging current to maintain and recharge batteries. It features a 4-rate fast charge program with selectable float and boost voltage settings, allowing for precise charging tailored to specific battery vendor recommendations. The charger can handle initial charging of new, dry, and discharged lead-acid batteries or nickel-cadmium batteries from a zero-charge state, as well as recharging excessively discharged batteries already in service. It incorporates automatic temperature compensation to adjust the output voltage based on ambient temperature, ensuring optimal charging and battery longevity. The charger also includes a "JUMP" feature to override lockout conditions and initiate charging for low-voltage discharged batteries.

Important Technical Specifications:

Models: NRG12-10 (12V, 10A), NRG24-10 (24V, 10A), NRG22-10 (12V/24V, 10A).
Input Voltage/Frequency:
- H: 120/208-240V, 50/60 Hz (UL listed, CSA certified, CE marked).
- R: 120/208-240V, 60 Hz (UL listed, CSA certified).
Output Current: 10 Amps.
Alarm System Code: C: 5 Alarms.
Optional Supplier Code: E: OSHPD labeled (California Special Seismic Certification Pre-Approval).
Dimensions: W: 7.66 Inches (195 mm), H: 12.50 Inches (318 mm), D: 6.48 Inches (165 mm).
Weight: 25 pounds (11.3 kg).
Conductor Ratings: All conductors rated for 90°C/194°F or higher.
- AC Input: 10A (14 AWG, 2.5 mm² typical).
- DC Output: 30A (10 AWG, 6.0 mm² typical).
- Alarm Terminal Block: 1A (20 AWG, 0.5 mm² typical).
AC Input Current: 6A at 120VAC, 3A at 208-240VAC.
Maximum Allowed Resistance (Battery to Charger): 58mΩ for 12V, 116mΩ for 24V.
Fuse Ratings:
- DC Output Fuse: Bussman Type BK/ATC-30 or Littelfuse 287030 [ATOF30], 30A, 32V, fast acting, blade type automotive.
- AC Input Fuse: Bussman Type BK/AGC-10-R, 10A, 250VAC, fast acting, ferrule type cylindrical, ¼" X 1-¼".
Operating Temperature Range: -20°C/-4°F to +40°C/104°F (operates at reduced output current up to +60°C/140°F).
Environmental Protection: Conformal coated printed wiring boards for erosion protection.
Agency Approvals: UL listed (UL 1012, UL 1236), CUL listed (CSA C22.2 107.2- M89), CE marked (EMC directive EN 61000-6-2:2005/AC:2005, EN 61000-6-4:2007/A1:2011, LVD EN 60335-1:2012/A11:2014, EN 60335-2-29:2004/A2:2010, RoHS EN 63000:2018).
Shock and Vibration Tested: UL 991, 2G (5G option available).
Lightning Transient Immunity: ANSI/IEEE C62.41 Cat. B and EN 50082-2 heavy industrial.

Usage Features:

Model Configuration: Field configurable for 12V or 24V operation (NRG22-10).
Installation: Designed for vertical mounting on a flat surface (3/4" (19 mm) plywood or equivalent) with specific ventilation clearances: 6" (150 mm) minimum top and bottom, 2" (50 mm) minimum on each side. Input and output terminal blocks should be lowermost.
AC Voltage Select Switch (SW100): Allows selection between 115V (for 110-120V mains) and 230V (for 208-240V mains).
Battery Range Jumper (JP1A): Configures the charger for 12V or 24V batteries.
Boost Mode Jumper (JP1B): Enables or disables automatic boost charging (equalization) based on battery manufacturer recommendations. "NORMAL" for boost, "OFF" for float charge only.
Float Voltage Select Jumper (JP1C): Sets the float voltage according to battery manufacturer's recommended 25°C/77F float voltage. Settings include:
- 14.30/28.60 for 10 or 20 cell Nickel Cadmium at 1.43V/cell.
- 13.62/27.24 for 6 or 12 cell (VRLA) lead-acid at 2.27V/cell, and for 19 cell Nickel Cadmium at 1.43V/cell.
- 13.50/27.00 for 6 or 12 cell (VRLA or high capacity) lead-acid at 2.25V/cell, and for 19 cell Nickel Cadmium at 1.42V/cell.
- 13.31/26.62 for 6 or 12 cell (flooded) lead-acid at 2.22V/cell, and for 19 cell Nickel Cadmium at 1.40V/cell.
- 13.08/26.16 for 6 or 12 cell lead-acid at 2.18V/cell.
- 12.87/25.74 for 9 or 18 cell Nickel Cadmium at 1.43V/cell.
Meter Display Jumper (JP800): Selects the display mode for the 3-digit LED meter:
- "VOLTS": Displays DC Volts only.
- "AUTO": Alternates between DC Amps (6 seconds) and DC Volts (3 seconds).
- "AMPS": Displays DC Amps only.
"JUMP" Feature: Allows initial charging of deeply discharged batteries (Nickel Cadmium or new, dry lead-acid) by overriding the battery voltage interlock. This feature should be used with caution as it disables the battery voltage interlock, increasing the risk of overcharging if settings are incorrect.
LED Indicators: Provide visual status of the charger's operation and fault conditions:
- Green T-COMP ACTIVE: Temperature-corrected charger voltage.
- Green AC/ON: Normal AC input.
- Red CHGR FAIL: Internal charger failure.
- Red DC HIGH: Excessive battery voltage.
- Red DC LOW: Low battery voltage.
- Green FLOAT MODE: Normal voltage (float charge).
- Yellow BOOST MODE: Boost voltage (fast charge).
- Red BATT FAULT: Open, wrong voltage, reversed battery, or defective battery.
Alarm Outputs (TB5): Provides relay contacts for various alarm conditions: Battery Fault, AC Fail, Charger Fail, High DC Voltage, and Low DC Voltage. These are low voltage, limited energy ("Class 2") circuits, rated 2A at 30 VDC/VAC, maximum switching capacity 62.5VA, 60W.

Maintenance Features:

Troubleshooting Guides: Comprehensive flowcharts are provided for diagnosing common issues such as repeated blown AC fuse, AC Fail alarm, Charger Fail alarm, DC High alarm, DC Low alarm, and Battery Fault alarm.
Internal Access: The cover can be removed for internal adjustments and wiring, but only by trained and qualified personnel. Static discharge precautions are emphasized when accessing internal components.
Fuse Replacement: Instructions for replacing DC output and AC input fuses are provided.
Wiring Connections: Detailed instructions for connecting AC input, DC output, grounding, and alarm wiring, including recommended wire gauges and tightening torques.
Battery Terminal Care: Emphasizes keeping battery terminals clean and properly tightened, and adding distilled water to cells as specified by the battery manufacturer.
Fault Tolerance: The charger is protected against internal power component failures, overheating (with output power reduction), and power line transients and surges.
Battery Fault Protection: Automatically checks battery voltage before startup, detects short circuits, high DC cable resistance, and reverse polarity. Activates "Batt Fault" relay and LED upon fault detection.
Service Hotline: Contact information for SENS service department for installation or service questions, available Monday through Friday, 8 a.m. to 5 p.m. (Mountain Time).
Warranty:
- Standard Limited Warranty: Three (3) years from shipment date for NRG and MicroGenius 2, S2 chargers (magnetic parts and power semiconductors covered for 10 years). Five (5) years for MicroGenius S4. Covers defects in material and workmanship. Repair, replacement, or refund of purchase price is the exclusive remedy.
- Extended Warranty: Available for purchase to lengthen the warranty period to 5 or 10 years from original shipment.
- Premium Warranty: Available at original purchase, covers reasonable and customary labor and mileage charges for replacement or repair, limited to 100% of the original net product invoice amount, in the form of a credit toward future purchases. This is available only to the original customer.