Sens EnerGenius IQ2 User manual

SENS EnerGenius IQ2 Technical Manual
1
SENS Part Number: 101340-1
Document Revision: A
DCN Number: 108031
Date: May 18, 2021
MADE IN U.S.A
PATENTED US 9,270,140; 9,385,556; 9,413,186; 9,509,164;
9,466,995; 9,948,125
Installation or service questions?
Call SENS between 8 a.m. and 5 p.m. (Mountain Time),
Monday through Friday or visit our website.
Copyright © Stored Energy Systems LLC 2021
The SENS name / logo, EnerGenius, HELIX, and Dynamic Boost are trademarks of Stored Energy Systems LLC
Installation & Operation Manual
Automatic Battery Charger & DC Supply
12 to 240 Volts Nominal, 6 to 150 Amps
1840 Industrial Circle
Longmont, CO 80501
Phone: [phone]
800.742.2326
Fax: [phone]
Email: [e-mail]
Web: www.sens-usa.com

SENS EnerGenius IQ2 Technical Manual
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TABLE OF CONTENTS
1IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR ..........................................................4
2QUICK INSTALLATION GUIDE ........................................................................................................................6
3PERFORMANCE SPECIFICATIONS...................................................................................................................7
4MODEL NUMBER BREAKOUT ........................................................................................................................8
5MECHANICAL INSTALLATION ........................................................................................................................9
5.1. Lifting...................................................................................................................................................9
5.2. Charger Mounting Options ...................................................................................................................9
5.3. Ventilation ...........................................................................................................................................9
5.4. Environmental Considerations..............................................................................................................9
6ELECTRICAL INSTALLATION ...........................................................................................................................9
6.1. AC Input Connections...........................................................................................................................9
6.2. DC Output Connections......................................................................................................................11
6.3. Alarm Wiring......................................................................................................................................12
6.4. Operating Chargers in Parallel.............................................................................................................14
6.5. CANbus and RS-485 Connections—Optional .......................................................................................14
6.6. Ethernet—Optional ............................................................................................................................16
6.7. SENSbus Connection—Optional..........................................................................................................17
6.8. Remote Temperature Sensor Connection—Optional...........................................................................19
7POWER ON/POWER OFF PROCEDURES....................................................................................................... 20
7.1. Verify Input AC Supply........................................................................................................................20
7.2. Verify Configuration ...........................................................................................................................20
7.3. Verify Charger Output.........................................................................................................................21
7.4. Begin Charging ...................................................................................................................................21
7.5. Power Off...........................................................................................................................................21
8ALARMS, LEDS AND DISPLAY....................................................................................................................... 22
8.1. Front Panel User Interface..................................................................................................................22
8.2. LCD Panel...........................................................................................................................................22
8.3. AC and DC LED Indicators ...................................................................................................................22
8.4. Mimic Panel LEDs...............................................................................................................................23
8.5. Individual Alarm Relay Contacts..........................................................................................................24
8.6. Latched Alarms...................................................................................................................................24
8.7. Alarm Definitions ...............................................................................................................................24
9OPERATION................................................................................................................................................. 31
9.1. Charging Algorithms...........................................................................................................................31
9.2. Float Mode.........................................................................................................................................31
9.3. Dynamic Boost™ Mode.......................................................................................................................31
9.4. HELIX Mode........................................................................................................................................32
9.5. Charging Low or Zero-volt Batteries....................................................................................................32
9.6. Commissioning Batteries ....................................................................................................................33
9.7. Battery Check.....................................................................................................................................33
9.8. Restore Factory Defaults ....................................................................................................................33
9.9. Keypad Operation ..............................................................................................................................33
9.9.3. Menu Options ....................................................................................................................................34
9.10. Configuration with SENS Setup Utility.................................................................................................39
9.11. Temperature Compensation...............................................................................................................39
9.12. Load Share Charger Operation............................................................................................................40
10 MODBUS COMMUNICATIONS..................................................................................................................... 40
10.1. TCP/IP Modbus—Optional..................................................................................................................40
10.2. RS-485 Modbus—Optional .................................................................................................................40
10.3. Modbus Holding Registers..................................................................................................................41
10.4. Basic Charging Alarms Bit Definition ...................................................................................................42
10.5. Charging Status Bit Definition .............................................................................................................43
10.6. Charging Alarms Extended Bit Definition.............................................................................................44
10.7. Charging AC Alarms Bit Definition.......................................................................................................44
10.8. Accessory Channel Alarms Bit Definition.............................................................................................44

SENS EnerGenius IQ2 Technical Manual
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10.9. Accessory System Alarms Bit Definition ..............................................................................................45
10.10. Accessory Assigned Channel Alarms Bit Definition ..............................................................................45
10.11. Writable Control Flags (Coils)..............................................................................................................45
10.12. Legacy IQ Modbus..............................................................................................................................46
11 MAINTENANCE AND TROUBLESHOOTING................................................................................................... 52
12 GLOSSARY................................................................................................................................................... 61

SENS EnerGenius IQ2 Technical Manual
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1IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR
1.1. SAVE THESE INSTRUCTIONS –This manual contains important safety and operating instructions for
EnerGenius® IQ2 battery chargers.
1.2. Before using battery charger, read all instructions and cautionary markings on battery charger, battery, and
product using battery.
1.3. Do not expose charger to rain or snow.
1.4. Use of an attachment not recommended or sold by the battery charger manufacturer may result in a risk of
fire, electric shock, or injury to persons.
1.5. This charger is intended for commercial and industrial use. ONLY TRAINED AND QUALIFIED PERSONNEL
MAY INSTALL AND SERVICE THIS UNIT.
1.6. GROUNDING INSTRUCTIONS - This battery charger must be connected to a grounded metal permanent
wiring system or an equipment-grounding conductor run with circuit conductors and connected to
equipment-grounding terminal on battery charger. Connections to the battery charger must comply with all
local codes and ordinances.
1.7. 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.
1.8. 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.
1.9. WARNING –HEATSINKS AND OTHER METALLIC SURFACES WITHIN THE CHARGER MAY BE ENERGIZED AT
HIGH VOLTAGE POTENTIALS, WHICH CAN BE LETHAL. DO NOT TOUCH EXPOSED METAL SURFACES WITHIN
THE CHARGER WHILE EITHER INPUT POWER OR BATTERY IS APPLIED.
1.10. WARNING –RISK OF EXPLOSIVE GASES
1.10.1. 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 YOU READ THIS MANUAL AND FOLLOW THE
INSTRUCTIONS EACH TIME YOU USE THE CHARGER.
1.10.2. 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.
1.11. PERSONAL PRECAUTIONS
1.11.1. Someone should be within range of your voice or close enough to come to your aid when you work
near a storage battery.
1.11.2. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or
eyes.
1.11.3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a
storage battery.
1.11.4. 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.
1.11.5. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
1.11.6. Be extra cautious to reduce risk of dropping a metal tool onto the battery. It might spark or short

SENS EnerGenius IQ2 Technical Manual
5
circuit the battery or another electrical part that may cause explosion. Using insulated tools reduces
this risk but will not eliminate it.
1.11.7. 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.
1.11.8. When charging batteries, charge LEAD-ACID or LIQUID ELECTROLYTE NICKEL-CADMIUM batteries
only. Consult SENS before using with any other type of battery - other batteries may burst and cause
injuries to persons and damage to property.
1.11.9. NEVER charge a frozen battery.
1.11.10. 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 and local ordinances to
determine if additional battery fault protection is necessary in your installation.
1.12. Preparing Battery for Charge
1.12.1. Be sure area around battery is well ventilated while battery is being charged.
1.12.2. Ensure battery terminals are clean and properly tightened. Be careful to keep corrosion from
coming in contact with eyes.
1.12.3. Add distilled water in each cell until battery acid reaches level specified by battery manufacturer.
Do not overfill. For a battery without removable cell caps, such as valve regulated lead acid
batteries, carefully follow manufacturer’s recharging instructions.
1.12.4. Study all battery manufacturer specific precautions such as removing or not removing cell caps
while charging and recommended rate of charge. The recommended charge current range must
include the rated output current of the charger.
1.13. Charger Location
1.13.1. Locate the charger as far away from the battery as DC cables permit.
1.13.2. Never place the charger directly above or below the battery being charged; gases from the battery
will corrode and damage charger.
1.13.3. Never allow battery acid to drip on charger when reading electrolyte specific gravity or filling
battery.
1.13.4. Do not operate charger in a closed-in area or restrict ventilation in any way.
1.13.5. Do not set anything on top of the charger.
1.14. Notice to users in the European Union: Declaration of Conformity limits the use of chargers to non-public
power grids.

SENS EnerGenius IQ2 Technical Manual
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2QUICK INSTALLATION GUIDE
A. Read all cautionary warnings in section 1.
B. Remove the charger from the packaging and inspect for damage. See section 5.1 for information on moving
and lifting the charger. Notify SENS immediately (1-800-742-2326) if damage from shipping is evident.
C. See section 5.2 for mounting options.
D. Adjust input voltage jumper or wiring if necessary.
NOTICE:
WHEN THE INPUT JUMPER OR WIRING IS MOVED, THE “NOMINAL VOLTS AC” SETTING MUST BE
ADJUSTED USING THE FRONT PANEL KEYPAD. UNDER THE MAIN “AC” MENU, NAVIGATE TO THE
“BASIC SETTINGS” MENU AND THEN THE “NOMINAL VOLTS AC” MENU TO SELECT THE
NOMINAL AC INPUT VOLTAGE THAT WILL BE CONNECTED TO THE CHARGER.
All 120/208/240V (input codes P and T) models include a 3-way AC input voltage selection jumper. Ensure the
AC voltage selection jumpers are in the correct position for your AC supply as shown below:
All 208/240V 60Hz (input code Z) models include a dual AC input voltage selection terminal block. Ensure the
AC voltage wire is in the correct position for your AC supply as shown below:
E. Connect AC wires—Ensure that the AC input supply is de-energized and the charger AC input circuit breaker
is opened. Wire the AC input circuit to the empty lugs of the AC input breaker. Connect the earthed
conductor of the AC input circuit to the grounding lug inside the charger. See Table 2 for AC input breaker
208V
240V
Jump 5 to 6 and 1 to 2
Jump 3 to 4 (both jumpers)
Jump 4 to 5 (both jumpers)

SENS EnerGenius IQ2 Technical Manual
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wire size. See diagrams at back of manual for wiring and breaker location.
F. Connect DC wires—Ensure that any battery disconnect device in the system, if used, is opened (batteries
disconnected from DC bus), and that the DC output breaker in the charger is opened. Connect the DC output
wires to the load side of the DC output breaker, observing the correct polarity as labeled on the charger.
Make sure the small signal leads also attached to the breaker remain connected. See Table 3 for DC output
breaker wire sizes. See diagrams at back of manual for wiring and breaker location.
G. Connect optional alarm wires—Alarm wiring enters the charger on the upper left side of the enclosure. Knock
out the conduit opening and connect alarm wiring, taking care to route the wiring through appropriate cable
guides provided within the charger. See diagrams at back of manual for alarm wiring. See Table 4 for alarm
wiring connection locations.
H. Energize the AC input supply at supply panel—With the charger input AC and output DC breakers still
opened, energize the AC input supply, and check the voltage at the line (left) side of the input AC breaker,
making sure it is the correct value for the charger.
I. Verify battery voltage—With the charger input AC and output DC breakers still opened, close any system
battery disconnect, if used, and measure the battery voltage at the battery (left) side of the charger DC
output circuit breaker, making sure it is near the nominal DC voltage rating of the charger.
J. Verify battery polarity—With the DC output circuit breaker still opened, close charger AC breaker to start
charger. The charger status display will come on and the charger will execute its initialization routines. The
charger output should ramp up to within 5% of battery voltage. It will not ramp up to the float voltage setting
until the DC circuit breaker is closed.
NOTE:
If a reverse polarity alarm is present on the front panel LCD, the polarity of the battery
connection to the charger is incorrect. Turn off the AC power source and correct the
reverse polarity problem.
K. Close the DC output breaker—Depending on the state of charge of the batteries and the load on the DC bus,
the charger may go into current limit at this time, in which case the output voltage as displayed on the LCD
will be reduced as the charger operates in constant current mode. Eventually as the battery is charged, the
charging current demand should taper to a value below the current limit set point of the charger, and the
charger should revert to constant voltage output.
L. See section 9.6 to initially charge/commission zero charge batteries.
M. If automatic boost charging is desired, configure boost mode using the front panel (see section 9.9.3).
N. It is highly recommended that for proper operation of two chargers connected in parallel to the same battery
that one charger is connected to the second charger with a digital load-sharing cable. The digital load sharing
cable should never be connected when two chargers are each connected to different batteries.
3PERFORMANCE SPECIFICATIONS
See IQ2 Product Data Sheet and Product Specification on SENS website (www.sens-usa.com) for detailed
performance specifications.

SENS EnerGenius IQ2 Technical Manual
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4MODEL NUMBER BREAKOUT
Q
024
050
T
L
5
1
4
A
R
A
B
C
D
E
F
G
H
I
J
Field
Parameter
Code
Value
A
Product Family
Q
EnerGenius IQ
B
Output Voltage
012
12 volts
024
24 volts
048
48 volts
120
120 volts
240
240 volts
C
Output Current
006
6 amps
012
12 amps
016
16 amps
025
25 amps
035
35 amps
050
50 amps
075
75 amps
100
100 amps
150
150 amps
D
Input Voltage
T
115-120/208/230-240V 60Hz
P
115-120/208/230-240V 50/60Hz
Z
208/240V 60Hz
8
480V 60Hz
V
400V 50/60Hz
4
230-240V 50/60Hz
E
Agency Approval
L
60Hz, UL 1012, C-UL
H
60Hz, UL 1236, C-UL
G
50/60Hz, UL 1012, C-UL and CE mark (includes inrush limiting)
J
50/60Hz, UL 1236, C-UL and CE mark (includes inrush limiting,
available on 12V and 24V modules only)
S
Special
F
Compliance Option
5
Standard
6
PIP compliance (requires 7+1 or 12+1 alarm relay option)
G
Input Breaker Interrupt Option
1
Standard interrupt breaker (inrush limiter with 50/60Hz only)
3
Medium interrupt (18-25 KAIC) breaker & inrush limiter
7
High interrupt (65 KAIC) breaker & inrush limiter
H
Output Filter/Blocking Diode
Configuration
1
Standard filter, no diodes
2
Low ripple filter, no diodes
3
Standard filter, blocking and reverse diodes
4
Low ripple filter, blocking and reverse diodes
I
Alarm Relay/Communications
Option
A
Summary alarm only
C
7 relays (30V/2A) + 1 relay (120VAC/5A)
L
Remote Temp Sense + Load-sharing network cable
K
Options C and L
M
5 Relays (30V/2A) + Modbus 10/100Base-T and RS-485
N
Options C and M
J
Special Options
E
OSHPD labeled
H
10kA min interrupt DC output breaker
R
Rack Mount

SENS EnerGenius IQ2 Technical Manual
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5MECHANICAL INSTALLATION
5.1. Lifting
The Q1 case size (19 inch) charger is designed to be lifted from the bottom by pallet jack or lift truck.
The Q2 case size (23 inch) charger is designed to be lifted either from the bottom by pallet jack or lift
truck or from the top via a strap and hook arrangement attached to four 3/8-inch eyebolts (not provided)
installed in the top of the unit. See drawings at back of manual for eyebolt installation locations.
5.2. Charger Mounting Options
The Q1 case size charger is designed to mount on a wall using wall mount flanges on the sides of the
chassis. Rack mounting is orderable as a factory option.
The Q2 case size charger is designed to accommodate either wall or floor mounting. The charger has
integral wall mounting flanges on the sides of the chassis. Rack mounting is orderable as a factory option.
Floor pieces are orderable as optional kits.
See drawings at back of manual for details on mounting configurations. Do not mount the charger in
locations subject to high vibration. Do not mount the charger directly to the frame of an engine or
generator set.
5.3. Ventilation
The charger is designed to be convection cooled. Required clearances around the unit for proper cooling
are 6 inches on the top and 4 inches on the bottom.
5.4. Environmental Considerations
The charger should be installed in a sheltered area, protected from rain and snow. The suggested
operating temperature range is –20°C/-4°F to +50°C/122°F, but the charger will operate safely outside of
this range. The charger is rated for –40°C/-40°F for black/cold start, and once it self-heats to –20°C/-4°F is
guaranteed to meet all published specifications. The charger thermal limiter reduces output current to
prevent over-heating when ambient temperature is too high.
6ELECTRICAL INSTALLATION
WARNING:
BEFORE ELECTRICAL INSTALLATION, ENSURE THE FOLLOWING:
A. AC MAINS SUPPLY CIRCUIT IS DE-ENERGIZED
B. AC INPUT BREAKER ON THE CHARGER IS OPENED
C. DC OUTPUT BREAKER ON THE CHARGER IS OPENED
D. BATTERY DISCONNECT, IF USED, IS OPENED (BATTERY REMOVED FROM DC BUS)
IMPORTANT! The charger is configured at the factory and typically requires no adjustments before operating.
Refer to the label on the inside of the door for factory configured output and alarm relay assignments. The
charger may be reconfigured using the front panel keypad or by software programming using the SENS Setup
Utility. See drawings at back of manual for quick reference installation information. Diagrams reflect charger
setup for a typical installation only. For applications not covered in the diagram, please consult charger
supplier.
6.1. AC Input Connections
The battery charger is designed to be permanently connected to an appropriately rated single
phase, grounded AC mains circuit. Wiring used must be sized appropriately for the charger input
current and must be selected to meet any applicable local codes (see Table 1 for charger circuit
breaker ratings and Table 2 for recommended wire gauges). Connect to the line side of the
input circuit breaker and ground lug via conduit knockout openings on the lower left side of the
charger enclosure (see diagrams at back of manual). The earthed conductor of the AC mains

SENS EnerGenius IQ2 Technical Manual
10
circuit must be connected to the charger-grounding terminal. Input (AC line) wiring must be
kept at least 1/4" (6.3 mm) away from all output, alarm, data interface wiring, and from other
uninsulated electrical parts not connected to the input conductor.
AC input tolerance is –12%, +6% for 60Hz models based on standard North American line voltages of
120V, 208V, 240V, and 480V and ±10% for 50/60Hz models based on standard European line voltages of
230V and 400V. Rated input frequency for all units is ±5%.
Table 1: AC Input Current and AC/DC Circuit Breaker Current Ratings
Charger
Model
Rated AC Input Current
*AC Input Branch Circuit Breaker Ratings
Charger Input Breaker Current
Ratings
Charger
Output
Breaker
Current
Ratings
208V
60Hz
(3),
208/
240V
60Hz
(Z)
230/
240V
50/60
Hz (4),
60Hz
(S)
480V
60Hz
(8)
120/208/
240V 50/60
Hz (P), 60Hz
(T)
400V
50/60
Hz (V)
208V
60Hz
(3),
208/
240V
60Hz
(Z)
230/
240V
50/60
Hz (4),
60Hz
(S)
480V
60Hz
(8)
120V
50/60
Hz (P),
60Hz
(T)
208V
50/60
Hz (P),
60Hz
(T)
240V
50/60
Hz (P),
60Hz
(T)
400V
50/60
Hz (V)
208V
60Hz
(3),
208/
240V
60Hz
(Z)
230/
240V
50/60
Hz
(4),
60Hz
(S)
480V
60Hz
(8)
120/
208/
240V
50/60
Hz (P),
60Hz (T)
400V
50/60
Hz (V)
Q012-012
0.8
3.2/1.8/1.6
1.0
15
10, 15
10, 15
10, 15
15
15
10, 15
15
15
Q012-016
1.0
4.2/2.4/2.1
1.2
15
10, 15
10, 15
10, 15
15
15
10, 15
15
20
Q012-025
1.6
6.3/3.6/3.1
1.9
15
10, 15
10, 15
10, 15
15
15
10, 15
15
35
Q012-035
2.1
8.5/4.9/4.3
2.6
15
15
10, 15
10, 15
15
15
15
15
45
Q012-050
3.1
13/7.2/6.3
3.8
15
20
10, 15
10, 15
15
15
20
15
70
Q012-075
N/A
N/A
4.6
18/11/9.1
5.5
N/A
N/A
15
25
15
15
15
N/A
N/A
15
25
15
100
Q012-100
N/A
N/A
6.1
24/14/12
7.3
N/A
N/A
15
30
20
15
15
N/A
N/A
15
30
15
125
Q012-150
N/A
N/A
9.0
36/21/18
11
N/A
N/A
15
45
30
25
15
N/A
N/A
15
45
15
200
Q024-006
0.7
2.9/1.7/1.5
0.9
15
10, 15
10, 15
10, 15
15
15
10, 15
15
10
Q024-012
1.4
5.6/3.2/2.8
1.7
15
10, 15
10, 15
10, 15
15
15
10, 15
15
15
Q024-016
1.8
7.4/4.3/3.7
2.2
15
10, 15
10, 15
10, 15
15
15
10, 15
15
20
Q024-025
2.9
12/6.7/5.8
3.5
15
15
10, 15
10, 15
15
15
15
15
35
Q024-035
4.0
16/9.1/7.9
4.7
15
20
15
10, 15
15
15
20
15
45
Q024-050
5.6
23/13/11
6.8
15
30
20
15
15
15
30
15
70
Q024-075
N/A
N/A
8.3
33/19/17
9.9
N/A
N/A
15
45
25
25
15
N/A
N/A
15
45
15
100
Q024-100
N/A
N/A
11
44/25/22
13
N/A
N/A
15
60
35
30
20
N/A
N/A
15
60
20
125
Q024-150
37
32
16
N/A
19
50
40
20
N/A
N/A
N/A
25
50
40
20
N/A
25
200
Q048-006
1.3
5.2/3.0/2.6
1.6
15
10, 15
10, 15
10, 15
15
15
10, 15
15
10
Q048-012
2.6
10/5.9/5.1
3.1
15
15
10, 15
10, 15
15
15
15
15
15
Q048-016
3.3
13/7.7/6.7
4.0
15
20
10, 15
10, 15
15
15
20
15
20
Q048-025
5.2
21/12/10
6.2
15
30
15
15
15
15
30
15
35
Q048-035
7.1
29/17/14
8.6
15
40
25
20
15
15
40
15
45
Q048-050
10
40/23/20
12
15
50
30
25
15
15
50
15
70
Q048-075
34.1
30
15
N/A
18
45
40
20
N/A
N/A
N/A
25
45
40
20
N/A
25
100
Q048-100
45
39
20
N/A
24
60
50
25
N/A
N/A
N/A
30
60
50
25
N/A
30
125
Q120-006
3.1
12/7.0/6.1
3.7
15
15
10, 15
10, 15
15
15
15
15
15
Q120-012
5.9
24/14/12
7.0
15
30
20
15
15
15
30
15
15
Q120-016
7.8
31/18/16
9.4
15
40
25
20
15
15
40
15
20
Q120-025
12
47/27/24
14
15
60
35
30
20
15
60
20
35
Q120-035
38
33
17
N/A
20
50
45
25
N/A
N/A
N/A
25
50
45
25
N/A
25
45
Q120-050
54
46
23
N/A
28
70
60
30
N/A
N/A
N/A
40
70
60
30
N/A
35
70
Q240-006
5.9
24/14/12
7.0
15
30
20
15
15
15
30
15
15
Q240-012
11
44/26/23
14
15
60
35
30
20
15
60
20
15
Q240-016
35
30
15
N/A
18
50
40
20
N/A
N/A
N/A
25
45
40
20
N/A
25
20
Q240-025
54
46
23
N/A
28
70
60
30
N/A
N/A
N/A
40
70
60
30
N/A
35
35
*User must incorporate a branch circuit breaker external to the charger to provide a mode of disconnection from the supply
mains.

SENS EnerGenius IQ2 Technical Manual
11
FLOATING OR
NOTE:
Breakers designated as “10, 15” indicate a 10 Amp breaker for input code
T and a 15 Amp breaker for input code P.
Table 2: AC Input Wire Gauge Ratings
Rated Charger Input
Wire Gauge
Min
Max
≤240 VAC, ≤24A
# 14 Cu or Al
#2 Cu or Al
≤240 VAC, 60 Hz, > 24A
# 14 Cu or Al
#2 Cu or Al
≤240 VAC, 50/60 Hz, > 24A
# 14 Cu, #12 Al
# 1/0 Cu or Al
> 240 VAC (all)
# 14 Cu, #12 Al
#2 Cu, #4 Al
All 65 KAIC Breakers (Special Order)
# 14 Cu, #12 Al
# 1/0 Cu or Al
NOTE:
Table 2 represents only the physical capabilities of the terminals. In addition to
the physical limitations, conductors must be electrically adequate per local
electrical safety regulations (such as the National Electrical Code®).
6.2. DC Output Connections
WARNING:
OBSERVE PROPER POLARITY WHEN CONNECTING THE BATTERY CIRCUIT TO THE
CHARGER. FAILURE TO DO SO COULD RESULT IN EXPLOSIONAND DAMAGE TO THE
BATTERY CHARGER. SHOULD THE BATTERY CONNECTIONS BE REVERSED, AN ALARM
WILL BE PRESENT ON THE FRONT PANEL LCD WHEN AC POWER IS APPLIED. IF PRESENT,
RECHECK BATTERY AND SENSE LEAD CONNECTIONS TO OUTPUT BREAKER FOR PROPER
POLARITY BEFORE CLOSING THE DC CIRCUIT BREAKER OR OPERATING THE CHARGER.
The battery charger is designed for permanent connection to the battery and DC load circuit. Wiring used
must be sized appropriately for the charger output current and must be selected to meet any applicable
local codes (see Table 1 for circuit breaker ratings and Table 3 for wire gauges). Connection is made to the
load side of the output circuit breaker via conduit knockout openings on the lower left side of the charger
enclosure. Proper polarity for connection to the circuit breaker is labeled on the inside of the charger near
the output circuit breaker. Output (DC battery) wiring must be kept at least 1/4" (6.3mm) away from all
alarm and data interface wiring, and from other uninsulated electrical parts not connected to the output
conductor.
240VDC battery chargers typically use 3-pole output circuit breakers and are configured for
floating or negative DC grounded systems. Move breaker connections for positive grounded
systems as shown below.
The battery may be disconnected (for test or replacement purposes) while leaving the charger
powered on without interrupting the load. With battery disconnected, on charger with 2-stage
filter, the maximum transient voltage deviation is 5% of initial voltage when subjected to load
current changes between 20% to 100% and 100% to 20% of full rated load current. Recovery to

SENS EnerGenius IQ2 Technical Manual
12
within 1% of steady state voltage is within 200 milliseconds. Transient response in units with
battery eliminator output filter is slower.
CAUTION:
Small sense leads are connected to the load (output) side of the DC output circuit
breaker. These must remain connected with the proper polarity after installation of
the output power DC wiring or the charger will not function properly.
NOTE:
If required for your installation, either the positive or the negative charger
output may be connected to earth ground. If this is done, the ground fault
alarm must be disabled to prevent a false alarm (see section 9.9.3 to configure
ground fault alarm).
Table 3: DC Output Wire Gauge Ratings
Rated Charger Output
Wire Gauge
Volts
Current
Min
Max
12V - 48V
≤ 50A
# 14 Cu or Al
# 2 Cu or Al
75 & 100A
# 4 Cu or Al
# 2/0 Cu or Al
150A
#4 Cu Only
# 4/0 Cu Only
120V & 240V
≤ 16A
# 14 Cu, #12 Al
# 4 Cu or Al
≥25A
# 14 Cu, #12 Al
# 1/0 Cu or Al
CAUTION:
Output terminals on 150A models are approved for use with copper conductors only. Do not use
aluminum output conductors for 150A models.
NOTE:
Table 3 represents only the physical capabilities of the terminals. In addition to
the physical limitations, conductors must be electrically adequate per local
electrical safety regulations (such as the National Electrical Code®).
6.3. Alarm Wiring
Each charger comes standard with one summary alarm on the control circuit board that allows the
user to monitor several alarms at once with one set of dry contacts. Additional alarm relay
package options are available. The optional alarm relay circuit board includes seven discrete Form
C contacts rated 2A at 30V AC or DC plus one additional relay rated 5A at 120VAC. The 120VAC/5A
relay is configured at the factory as a pilot relay that automatically closes when the charger enters
BOOST mode and opens when the charger reverts to FLOAT mode. The optional communications
protocol circuit board includes five discrete Form C contacts rated 2A at 30V AC or DC.
See Figure 1 and drawings at back of manual for relay details and location in charger. See the charger
front door label for original factory alarm relay assignment code (see Figure 2). See Table 4 for
assignment details. Alarm relay assignments are custom configurable using the SENS Setup Utility.
Conduit knockouts are provided for alarm wires. Connect alarm wiring to alarm terminal blocks (see
drawings at back of manual). See Table 4 for typical alarm pin designations. The alarm wires should be
connected from COM, through user supervisory system, then to either FAIL or OK. Wire from FAIL or OK
to COM depending on whether the alarm should be present on an open or closed circuit (see Table 4).
The optional alarm relay circuit board terminals accept 24-14 AWG (0.25-2.5 mm2) conductors. The
optional communications protocol circuit board terminals accept 28-16 AWG (0.08-1.5 mm2) conductors.
Alarm and data interface wiring must be kept at least 1/4" (6.3mm) away from input conductors, output
conductors, and from other uninsulated electrical parts not connected to the alarm or data conductor.

SENS EnerGenius IQ2 Technical Manual
13
Figure 1 –Alarm Relays
(case size Q2 with optional alarm relay and communications protocol circuit boards shown)
Figure 2 –Factory Configuration Information on Label
View output voltage,
battery type and
configuration code
set at the factory
View alarm relay
assignment code.
See Table 4 for
details.
Control circuit
board summary
alarm relay
Optional
alarm relay
circuit board
Optional
communications
protocol circuit
board relays

SENS EnerGenius IQ2 Technical Manual
14
Table 4 –Alarm Relay Contact Wiring for Stationary Power Configuration (code NGN-IQ)
Wire from COM to OK for alarm present on open circuit or from COM to FAIL for present on closed circuit.
RELAY 1
Non-
latching Coil
RELAY 2
Non-
latching Coil
RELAY 3
Latching Coil
RELAY 4
Latching Coil
RELAY 5
Latching Coil
RELAY 6
Latching Coil
RELAY 7
Latching Coil
RELAY 8
Non-
latching Coil
Relay
Contacts
AC Fail
Charger Fail
Ground
Fault
High DC
Low DC
End-of-
Discharge
Battery
Check
Failure
Boost Mode
Active
Common
COM
(TB1-1)
COM
(TB2-1)
COM
(TB3-1)
COM
(TB4-1)
COM
(TB5-1)
COM
(TB6-1)
COM
(TB7-1)
COM
(TB8-1)
Open on
alarm
OK
(TB1-2)
OK
(TB2-2)
OK
(TB3-2)
OK
(TB4-2)
OK
(TB5-2)
OK
(TB6-2)
OK
(TB7-2)
OK
(TB8-2)
Close on
alarm
FAIL (TB1-3)
Defaults to
FAIL with no
AC and DC
power
(normally
closed)
FAIL (TB2-3)
Defaults to
FAIL with no
AC and DC
power
(normally
closed)
FAIL (TB3-3)
FAIL (TB4-3)
FAIL (TB5-3)
FAIL (TB6-3)
FAIL (TB7-3)
FAIL (TB8-3)
Defaults to
FAIL with no
AC and DC
power
(normally
closed)
•A Summary alarm is located on the control circuit board and includes all alarms assigned to above relays.
•Chargers configured at the factory for genset applications (code GEN) include relay 1-5 assignments:
Summary, AC Fail + Charger Fail, Low Crank, High DC, Low DC. Relays 6-8 assignable using SENS Setup Utility.
•Chargers configured at the factory for marine applications (code MAR) include relay 1-5 assignments:
Summary, AC Fail + Charger Fail, Ground Fault, High DC, Low DC. Relays 6-8 assignable using SENS Setup
Utility.
6.4. Operating Chargers in Parallel
It is highly recommended that for proper operation of two chargers connected in parallel to the same
battery that one charger is connected to the second charger with a digital load sharing cable (see
section 6.7for further information). The digital load sharing cable should never be connected when
two chargers are each connected to different batteries.
6.5. CANbus and RS-485 Connections—Optional
The unit is equipped with CANbus and RS-485 communications via two RJ-45 jacks when the optional
communications protocol circuit board is included (see Figure 3).
6.5.1. CANbus
The unit is equipped with CANbus communications support via the RJ45 ports. This interface is
intended for communication with customer devices including battery monitoring systems, user
interfaces, and customer-specific CAN protocol communications. Consult the factory for
configuration and setup.
6.5.2. RS-485
The unit is equipped with serial RS-485 communications support via the RJ45 ports. This interface
is intended for monitoring and communicating with the charger using protocols such as Modbus
(optional) and DNP3 (optional). See manual sections on specific protocols for more information.
6.5.3. Connection
Connect communications using a twisted pair cable at the RJ-45 connector on the
communications protocol circuit board (see Figure 3 and drawings at back of manual). Two RJ-45
ports are provided. The ports are in parallel and either port may be used. See Table 5 for
connector pinout. Communications are isolated. An adapter from RJ-45 to an 8-position terminal

SENS EnerGenius IQ2 Technical Manual
15
TWO PORTS:
Connect CANbus and/or
Modbus to one or both
ports
Pin 1
Pin 1
block may be connected to the RJ-45 connector and is available to order separately (SENS p/n
208026, see Figure 4).
Figure 3 –CANbus and RS-485 RJ-45 Connections
(case size Q2 with optional alarm relay and communications protocol circuit boards shown)
Table 5 –Connector Pinout
Pin #
Purpose
1
CANbus
2
CANbus
3
No connect pass-through
4
Modbus –D0 (B)
5
Modbus +D1 (A)
6
No connect pass-through
7
Power*
8
Common (isolated)
*Main circuit PCA only, used for interconnect between SENS devices

SENS EnerGenius IQ2 Technical Manual
16
Pin 1
Figure 4 –RJ-45 to Terminal Block Adapter —Optional
6.5.4. Termination
For proper operation, a 120-ohm terminator is required at the ends of the CAN and/or RS-485
bus. If multiple devices are on the bus, only the devices on the ends of the network bus need
termination resistors. Figure 5 shows an example of how to terminate the network. Termination
may be provided as part of the network cabling or 120-ohm termination plugs for the RJ-45
communications connector on the charger are available to order separately (SENS p/n 803707).
SENS chargers are slave devices. Pull-up and pull-down resistors are optional per Modbus
specifications.
Figure 5 –Typical RS-485 Termination
LT = Line Termination 120-ohm resistor
6.6. Ethernet—Optional
The unit is equipped with an ethernet RJ45 port when the optional communications protocol circuit
board is included (see Figure 6 and drawings at back of manual). Connect Cat5 or better ethernet cable.
This provides a 10/100 ethernet connection. Ethernet communication includes ethernet connectivity to
the charger for monitoring and configuration via the SENS Setup Utility and/or communications protocols
such as Modbus TCP/IP (optional) and DNP3 (optional).

SENS EnerGenius IQ2 Technical Manual
17
Figure 6 –Ethernet Connection
(case size Q2 with optional alarm relay and communications protocol circuit boards shown)
6.6.1. Configure TCP/IP Address
Configure TCP/IP settings using the SENS Setup Utility or the keypad. To adjust settings using the
keypad, ensure the access level is set to allow adjustments. Set the IP address as desired. It may
take up to 10 seconds for the network setting changes to apply. A TCP/IP address of 0.0.0.0
implies DHCP (Dynamic) addressing. Adjust the Gateway and Subnet Mask values as required. The
displayed Hardware Address is the MAC address corresponding to the Ethernet interface. This
value is not adjustable.
6.7. SENSbus Connection—Optional
The unit is equipped with SENSbus RJ45 ports to interconnect SENS specific devices. SENSbus ports are
available on the control circuit board and the optional communications protocol circuit board (see Figure
7 and drawings at back of manual).
WARNING:
DO NOT PLUG ETHERNET INTO THIS CONNECTION
A remote accessory may be connected to multiple chargers. In this case, the remote accessory, chargers
or other equipment may be located at the ends of the communications bus. Ensure a terminator is
located at both ends of the communications bus.

SENS EnerGenius IQ2 Technical Manual
18
Figure 7 –SENSbus Connection
(case size Q2 with optional alarm relay and communications protocol circuit boards shown)
6.7.1. Load Share Connection—Optional
Multiple chargers may be connected in parallel to provide charger redundancy and increased
charging current. Connect a network cable from one charger to another using the SENSbus RJ-45
port on each charger to automatically initiate load sharing (see Figure 7). Use either the SENSbus
port on the control circuit board or on the optional communications protocol circuit board, either
connection is acceptable. Leave a factory installed 120-ohm terminator in a SENSbus port on each
charger to ensure a terminator is located at both ends of the communications bus. The only
optional hardware required is a Cat5 or better RJ-45 network cable available either from SENS or
local computer supply.
Use of this sharing cable is essential to synchronizing operation of the Dynamic Boost and HELIX
modes and helps ensure that current is shared within +10% between chargers. Chargers intended
for load sharing must be configured with the same output settings in order to load share. No
additional user setup is required to enable active current sharing. Two or more chargers
automatically negotiate with each other to determine which charger is designated as the master
unit.
6.7.2. Remote Battery Monitor—Optional
The optional remote battery monitor accessory provides the ability to monitor battery
temperature and ambient temperature. Future options include battery voltage, battery current,
battery float current, 5V logic inputs and other parameters
Connect the remote battery monitor to the charger using a network cable connected to the
SENSbus RJ-45 port. Remove a factory installed 120-ohm terminator from the SENSbus RJ-45 port
to connect the network cable from the remote battery monitor. Ensure a terminator remains in
another SENSbus RJ-45 port on the charger. Place a 120-ohm terminator in the open RJ-45
SENSbus port on the remote battery monitor to ensure a terminator is located at both ends of the
communications bus.
6.7.3. Remote Alarm/Communications Panel Accessory Connection—Optional
The optional remote alarm/communications panel accessory provides the ability to adjust and
communicate with multiple chargers using one external device. The remote panel accessory may
be configured with different alarm relay assignments than the alarm relays native to the charger.

SENS EnerGenius IQ2 Technical Manual
19
Remove a factory installed 120-ohm terminator from the SENSbus RJ-45 port on the charger to
connect the network cable from the remote panel. Ensure a terminator remains in another
SENSbus RJ-45 port on the charger. Connect a straight-thru splitter to the RJ-45 SENSbus port on
the remote panel. Place a 120-ohm terminator in one of the positions on the remote panel
splitter to ensure a terminator is located at both ends of the communications bus. Connect the
remote panel to the charger using a network cable from the SENSbus RJ-45 port on the charger to
the remote panel splitter.
6.8. Remote Temperature Sensor Connection—Optional
The charger includes local temperature compensation using an internal sensor. Alternately, the charger
will use remote temperature compensation based on the temperature of the batteries when an optional
external sensor is located at the batteries and connected to the control circuit board remote
temperature sensor terminal block (see Figure 8). Remote temperature compensation is highly
recommended in all applications. It is most critical in applications where battery and charger are located
in different ambient conditions. Temperature compensation is disabled by setting the temperature
compensation slope to zero using the keypad or SENS Setup Utility. See section 9.11 for further
information regarding temperature compensation. A 50-foot remote temperature sensor is available to
order separately (SENS p/n 209481).
The remote temperature sensor is not polarized; it does not matter which lead connects to each
terminal. Route sensor wiring at least ¼ inch (6 mm) away from DC wiring, AC wiring, and the circuit
board. Locate the remote sensor where it will accurately detect the battery temperature by connecting it
to a grounded battery terminal or the battery case. When securing to the battery case, use an
adhesive/glue properly rated for the application material and temperature, such as Super Glue®.
Figure 8 –Remote Temp Sense Connection
(case size Q2 with optional alarm relay and communications protocol circuit boards shown)

SENS EnerGenius IQ2 Technical Manual
20
7POWER ON/POWER OFF PROCEDURES
7.1. Verify Input AC Supply
With the input AC and output DC breakers open, connect a portable voltmeter to the line side of the input
AC breaker on the charger. Energize the AC supply at main electrical panel and verify it is within
acceptable range.
7.1.1. Verify Nominal AC
For dual and triple input models (input codes, P, T and Z), verify the correct nominal AC input
voltage is set in the “Nominal Volts AC” front panel menu and on the selection jumper/terminal
block inside the charger. See section 2 for details.
7.2. Verify Configuration
Refer to the label on the charger front door for factory configured output voltage, battery type and
configuration code (see Figure 2). Review and adjust charger configuration using the front panel keypad
or the SENS Setup Utility if factory configured settings require modification. See section 9.9.3 for
additional details on keypad navigation.
7.2.1. Output/Battery Voltage
With the input AC and output DC breakers open, connect a portable voltmeter to the load side of
the DC breaker and verify that battery voltage (for applications with batteries) matches charger
output voltage. Charger output voltage is displayed on the front door label (see Figure 2).
7.2.2. Battery Types
Adjusting battery types using the front panel keypad requires advanced security access. Navigate
to the “User Access” menu area to ensure the keypad access level is set to allow adjustments.
7.2.2.1. FLA
This setting is ideal for flooded lead-acid batteries. The charging algorithm options for
flooded lead-acid batteries includes Float mode (see section 9.2), Dynamic Boost™ mode
(see section 9.3) and HELIX mode (for genset applications only, see section 9.4).
7.2.2.2. AGM
The term, “AGM” in this manual and for the charger refers to AGM (absorbed glass mat) type
batteries that are employed in engine starting applications. This charging mode should not
be used with switchgear or other industrial type batteries. For AGM type batteries employed
in switchgear or other industrial applications please see the “VRLA” battery type below.
7.2.2.3. NICD
This setting is appropriate when using nickel-cadmium batteries. The charging algorithm for
nickel-cadmium batteries includes Float mode (see section 9.2) and Dynamic Boost™ mode
(see section 9.3). Nickel-cadmium batteries are used in all applications.
7.2.2.4. VRLA
The “VRLA” battery profile includes all valve regulated batteries, including AGM types, which
are employed in switchgear and other industrial applications. The charging algorithm for
valve-regulated lead-acid batteries includes Float mode only (see section 9.2).
7.2.3. Configuration Code
The Configuration Code indicates charging algorithm and alarm setpoints configured at the
factory. See sections 8 and 9 for further information. Configuration types include:
7.2.3.1. Industrial / Utility (NGN)
This configuration code is intended for standard industrial and utility applications and is the
typical factory-supplied configuration code for EnerGenius IQ.
7.2.3.2. GENSET (GEN)
This configuration code is intended for standard engine start applications.