COMMS GENIUS USER MANUAL DRAFT
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1. pesca op 7 2 4 1 Battery Installation Wiring Steps 2 4 4 1 1 1 0 000 00 102 01 0 0 3 8 6 2 5 11 83 15 a ty aioe atta ales acid 11 3 2 11 9 95 2 11 MAINTENANCE AND REPAIR 22 2 2 2 4 0 2 2 0 0 00000004400000000000000000041 11 4 1 Battery 11 4 2 Charger Maintenance 5 11 SENS R19 Technical Manual 1 DESCRIPTION AND SPECIFICATIONS The configurable R19 product is a rack system consisting of various combinations of a charger batteries distribution breakers and an inverter Charger distribution breakers and inverter are ordered separately but are factory installed in the system by SENS Batteries are also ordered separately and shipped with the system but field installation in the rack is required Table 1 Specifications Feature Rack 19 inches wide 6ft or 7ft height models available EIA 310 spacing Input See charger manual for AC inp2. 4X 16 0 2X 11 0 2X 17 0 875 MOUNTING HOLES DETAIL A BOTTOM VIEW SCALE 1 4 1 340 5 DCN 106857 REV DESCRIPTION INITIAL RELEASE DATE 8 17 2015 APPROVED ERS uv SENS STORED ENERGY SYSTEMS 1840 INDUSTRI WWW SENS U PROPRIETARY AND CO THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF STORED ENERGY SYS REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF STORED ENERGY SYSTEMS LLC IS PROHIBITED CIRCLE 5 NFIDENTIAL TEMS LLC ANY RACK HEIGHT MAY VARY SEE SPECIFIC SYSTEM DETAILS UNLESS OTHERWI SE SPECIFIED 5 DIMENSIONS ARE IN INCHES DEFAULT TOLERANCES ANGLES 1 TWO PLACE DECIMAL 02 THREE PLACE DECIMAL 005 DO NOT SCALE DRAWING DRAWN ERS CHECKED DESCRIPTION DIAGRAM R19 MOUNTING THIRD ANGLE PROJECTION SIZE D DOCUMENT NUMBER DIA 00633 REV A SHEET 1 OF 1
3. BUILDING CODES AND BE MADE ACCORDING TO THE INSTALLATION INSTRUCTIONS AND APPLICABLE SAFETY REGULATIONS ONLY TRAINED AND QUALIFIED PERSONNEL MAY INSTALL AND SERVICE THIS UNIT 2 1 Installation Location and Handling The R19 rack system is shipped on a wood pallet Ship and store the rack system in an upright position on the pallet Do not remove the rack system or any other equipment from pallet until the rack is transported to the installation location Refer to DIA 00633 at back of manual for dimensional access and clearance information Locate the rack system in a controlled environment within the specified operating temperature range given in table 1 The rack system is designed to be floor mounted Four mounting holes are provided at the bottom of the rack to accommodate 34 inch anchoring bolts studs A clearance of 6 inches is 2 2 2 3 recommended all sides and the top of the rack Refer to DIA 00633 at back of manual for mounting details WARNING THE RACK SYSTEM IS DESIGNED FOR INSTALLATION IN CONTROLLED ENVIRONENTS WITH CONTROLLED ACCESS BY AUTHORIZONED PERSONEL ONLY HAZARDOUS ENERGY IS PRESENT CUSTOMER IS RESPONSIBLE TO ENSURE THAT BACK OF RACK SYSTEM IS NOT ACCESSIBLE PLEASE CONSULT LOCAL AUTHORITY AND APPLICABLE BUILDING CODES FOR ALL INSTALLATION DETAILS OF THIS SYSTEM Electric Load Guidelines If battery string disconnect breakers are not present the maximum simultaneous sum of all loads connected to
4. CING 3 1 Charger See charger manual for charger operating instructions 3 2 Inverter See inverter manual for inverter operating instructions 3 3 Distribution Operate breaker handles as required for given installation Ensure electric load requirements are met as described in Section 2 3 4 MAINTENANCE AND REPAIR 4 1 Battery Maintenance Follow the battery manufacturer s guidelines on maintenance service and replacement of batteries 4 2 Charger Maintenance a Annually Check all field wiring connections for electrical and mechanical integrity verifying no corrosion or loose hardware is present b Annually Verify that convection cooling vents are not blocked or clogged c Every 10 years If the charger is typically operated at ambient temperatures above 30 C 86 F replace the filter capacitors Regardless of ambient temperatures replace the filter capacitors if high charger output ripple is not desired 11 2 NOTES 1 THE INSTALLATION OF THIS EQUIPMENT SHALL COMPLY WITH ALL LOCAL AUTHORITY AND APPLICABLE BUILDING CODES 2 THE RACK SYSTEM IS DESIGNED FOR INSTALLATION IN CONTROLLED ENVIRONENTS WITH CONTROLLED ACCESS BY AUTHORIZONED PERSONEL ONLY HAZARDOUS ENERGY IS PRESENT CUSTOMER IS RESPONSIBLE TO ENSURE THAT BACK OF RACK SYSTEM IS NOT ACCESSIBLE 3 PROVIDE A MINIMUM OF 6IN OF CLEARANCE SPACE ON SIDES AND TOP OF RACK SYSTEM 4 HEIGHT AND WEIGHT OF RACK SYSTEM MAY VARY SEE SPECIFIC SYSTEM DETAILS
5. ING BATTERY POWER SYSTEMS PROVIDE ELECTRICAL VOLTAGE AND AMPERAGE LEVELS THAT ARE CONSIDERED ELECTRICAL HAZARDS ONLY QUALIFIED PERSONNEL SHOULD INSTALL OPERATE AND SERVICE THIS EQUIPMENT USE APPROPRIATE INSTALLATION METHODS INCLUDING USING ONLY INSULATED TOOLS REMOVE ALL JEWELRY AND WATCHES BEFORE INSTALLATION ENSURE THAT ALL BATTERY CABLE TERMINALS ARE INSULATED FROM THE RACK ASSEMBLY PRIOR TO POWERING CHARGER OR CONNECTING BATTERIES Due to shipping requirements batteries are shipped on the pallet base of the R19 systems The batteries must be installed in the field Before unpacking the battery blocks note the system voltage from the rack system label Each battery shelf is intended to contain a single unique battery string Each string has the same voltage as the system voltage When multiple shelves are present each battery string one per shelf is factory connected in parallel at the distribution panel bus bars The battery string cables connecting the distribution panel to batteries are factory installed and are to be terminated to the batteries in the field The interconnect cables required to connect the batteries in a battery string are included on the rack pallet when required SWITCH ALL BREAKERS CHARGER DISTRIBUTION AND BATTERY STRING TO OFF BEFORE INSTALLING BATTERIES 2 4 1 1 2 9 Battery Installation and Wiring Steps See Figures 6 and 7 for example battery installations See Figure 8 for ba
6. SENS R19 Technical Manual R19 RACK SYSTEMS Installation amp Operation Manual SENS Manual P N 101323 Gi SEN lt Document Revision DCN Number 106877 STORED ENERGY SYSTEMS Date 10 19 2015 1840 Industrial Circle Longmont CO 80501 Phone 303 678 7500 MADE IN U S A 800 742 2326 Installation or service questions Fax 303 678 7504 Call SENS between 8 a m and 5 p m Mountain Time Email service sens usa com Monday through Friday or visit our website Web www sens usa com Copyright Stored Energy Systems LLC 2015 1 The SENS name logo are trademarks of Stored Energy Systems LLC TABLE CONTENTS 1 2 DESCRIPTION AND SPECIFICATIONS 3 INSTALLATION 65 222 22 2440 00 40 0 90 0 3 2 1 Installation Location and 3 2 2 Electric Load 21 27 1 4 2 3 Field Wiring InStrUCtionS 5 4 2 3 2 1 Return Bus Bar Wiring 42 002 12 0 001000008 00000000050000050000 5 2 3 2 2 Distribution Breaker Wiring 5 2 3 2 3 Distribution Auxiliary WV NING 6 24 i Battery
7. er Figure 8 Ensure all battery terminals are protected with factory supplied covers 10 Torque all battery cables and connections as specified on the battery label SENS R19 Technical Manual Figure 6 Battery Wiring Example Top Terminal 2 TERMINAL BATTERIES 4 TOP TERMINAL BATTERIES 4 FRONT TERMINAL BATTERIES 10 Figure 8 Battery Layout Wiring 12V STRING 24V STRING 48V STRING foo OH 1 3 ac H 1 4 I SENS R19 Technical Manual 3 OPERATING INSTRUCTIONS WARNING COMPONENTS WITHIN THIS SYSTEM MAY BE ENERGIZED AT HIGH VOLTAGE POTENTIALS DO NOT TOUCH EXPOSED LIVE METAL SURFACES WHILE POWER IS APPLIED THE RACK SYSTEM SHOULD ONLY BE ACCESSED OPERATED AND SERVICED BY TRAINED AND QUALIFIED PERSONNEL DANGER TURN OFF CHARGER BEFORE DISCONNECTING BATTERY CABLES DISCONNECT ALL BATTERIES BEFORE SERVICING USE APPROPRIATE METHODS INCLUDING USING ONLY INSULATED TOOLS REMOVE ALL JEWELRY AND WATCHES BEFORE SERVI
8. er access to wiring terminals the front cover can be removed from the distribution panel by removing the eight screws shown in Figure 1 on the front of the cover SENS R19 Technical Manual Figure 1 Distribution Panel without Cover Front View J ar 68 d 4 2 2 2 a 3 i 22 297 ce ce 5 2 3 2 1 Return Bus Bar Wiring Grounded The return grounded bus bar is located at the top of the panel It is the bus bar without breakers The return bus bar is provided with 0 250 inch clearance holes on 0 625 inch centers intended for installation with double hole 90 crimp lugs Panduit type LCDXZ 14AF recommended where Z gauge The bus bar accepts wire sizes of 8 2 AWG Nuts and bolts are factory installed Torque return bus bar connections 1 4 20 hardware to 45 in lbs Figure 2 Return grounded Connections 2 3 2 2 Distribution Breaker Wiring Ungrounded Each distribution breaker is provided with a 1 4 20 stud for field termination Attachment hardware is factory provided This connection is intended for installation with single hole 90 crimp lugs Panduit type LCAXZ 14F recommended where Z gauge The distribution breaker accepts wire sizes of 8 2 AWG Torque breaker stud connection 1 4 20 hardware to 45 in lbs Figure 3 Distribution ungrounded Connection 2 3 2 3 Distribution Auxiliary Wiring 2 3 3 2 3 4 Each distribution breake
9. r is provided with contacts for auxiliary connections Each auxiliary switch is S P D T 1 NC 1 NO and is rated for 3A at 50VDC Each contact is a 0 110 quick connect terminal Use appropriate wiring and terminals Ensure terminals are insulated to ensure spacing requirements are met Ensure proper spacing to bus bars to ensure no shorts occur Figure 4 Distribution Auxiliary Contacts Inverter Wiring If an inverter is present see inverter manual for inverter output wiring Inverter DC input and ground wiring is factory installed Ground Lug Wiring Connect the system grounding conductor to the ground lug located at the top inner surface of the right upright The lug accepts Class B and C wire size 14 2 0 AWG and Class G K wire size 14 1 0 AWG Tighten connections as described in Table 3 SENS R19 Technical Manual Figure 5 Ground Lug Connection Table 3 Ground Lug Tightening Torque Wire Size Class B amp C Wire Size Class G K Tightening Torque 1 1 0 75in lbs 8 5 Nm 4 1 55in lbs 6 2 Nm 3 2 0 8 4 50 155 5 6 Nm 6 4 10 8 45in lbs 5 1 Nm 8 14 10 40in lbs 4 5 Nm 14 10 N A 35in lbs 4 0 Nm 2 3 5 Additional Breakers Additional locations are available to add breakers in the field if desired Contact SENS to order additional breakers Separately ordered breakers from SENS include hardware and insulators 2 4 Battery Installation WARN
10. the distribution panel may not exceed 100A If battery string disconnect breakers are present the maximum simultaneous sum of all loads connected to the distribution panel may not exceed 80A 80 of 100A rated breaker per battery string See table 2 Table 2 Electric Load Limitations Battery String Configuration Maximum Simultaneous System Load No string disconnect breakers 100A 1 battery string with string disconnect breakers 80A 2 battery strings with string disconnect breakers 160A 3 battery strings with string disconnect breakers 240A Field Wiring Instructions Field wiring connections are made to the charger distribution panel inverter and ground lug All wiring and wiring terminals are to be installed in accordance with the applicable electrical code All cables must be protected from mechanical strain Ensure wiring terminals are installed with 1 2 inch minimum spacing to conductive surfaces Do not remove installed insulators of the distribution panel SWITCH ALL BREAKERS CHARGER DISTRIBUTION AND BATTERY STRING TO OFF BEFORE INSTALLING FIELD WIRING 2 3 1 Input Wiring Connect input wiring to charger input breaker terminals See charger manual for input wiring specifications 2 3 2 Distribution Wiring Distribution wiring is terminated directly to the return bus bar and the distribution breakers Size the distribution wiring according to the size of the load and distribution breaker For bett
11. ttery layout configurations Place batteries on shelve s ensuring proper placement to achieve system voltage each battery shelf contains a unique battery string and multiple shelves are connected in parallel The battery shelves are provided with slots for use with customer supplied battery securing straps Secure batteries as needed depending on installation parameters Verify that all terminals of the battery cables are insulated Ensure continued proper insulation of all terminals during battery installation Connect the hot ungrounded supply wire to the hot ungrounded terminal of the first battery Note that the ground reference depends on the system configuration The lower bus bar of the distribution panel is the hot ungrounded bus If the system has multiple battery strings connect the other hot ungrounded supply wires Connect the return ground wires to the return ground terminal of the last battery Note that the ground reference depends on the system configuration The upper bus bar of the distribution panel is the return ground bus If the system has multiple battery strings connect the other return ground wires CAUTION IF MULTIPLE BATTERY STRINGS ARE PRESENT AND THERE ARE NO STRING DISCONNECTS ALL THE OPEN RETURN GROUND WIRES ARE LIVE ENSURE PROPER INSULATION OF ALL CABLE TERMINALS Connect batteries together using the interconnect cables supplied Verify all battery connections for proper order and terminal polarity p
12. ut specifications Output 12VDC negative grounded 24VDC negative grounded or 48VDC positive grounded models available nominal values given Charger optional 12 48VDC EnerGenius charger See charger manual for detailed output specifications Distribution breakers optional allows for up to 10 single pole DC breakers Breaker current ratings range from 15 100A Inverter requires one distribution breaker slot if present Auxiliary Switches Each distribution breaker supplied with contacts for auxiliary signals Auxiliary switches S P D T rated for at 50VDC and include 0 110 male quick connect terminals Batteries optional 12V batteries 0 3 battery trays with or without string disconnects select top or front battery terminals Inverter optional 600W optional on 12V 24V amp 48V systems configurable output for 100VAC 6 6 0A 117VAC 6 5 1A or 230VAC 6 2 7A 1100W optional on 24V amp 48V systems configurable output for 100VAC 6 11 0A 117VAC 6 9 5A or 230VAC 6 4 8A Operating 20 C to 50 4 F to 122 F normal operating range Temperature With optional Inverter 20 C to 30 C full power operating range de rated 20 per 10 C above 30 C 50 C maximum See battery manufacturer s ratings for additional temperature restrictions 2 INSTALLATION INSTRUCTIONS INSTALLATION MUST COMPLY WITH ALL APPLICABLE LOCAL ELECTRICAL AND
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