Sens TD Series Operating manual

TD Series
BATTERY CHARGER
OPERATION & MAINTENANCE
GUIDE
Model:
Rated Output:
Volts Amps
SENS part no.: 101148
Document revision: F
DCN No. 106651
Date Issued 9/19/2014
1840 Industrial Circle
Longmont, CO 80501
Fax: [phone]
Tel: [phone]
Email: [e-mail]
Web: www.sens-usa.com
Installation or Service problems? Call SENS at [phone] between 8
a.m. and 5 p.m. Mountain time Monday through Friday, or visit our website.
Copyright©Stored Energy Systems LLC 2006 - 2014

101148 Rev F Page 2of 6
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety and operating instructions for Stored Energy Systems (SENS) TD
series charger.
Before using the battery charger, read all instructions and cautionary markings on the battery charger, battery
and equipment connected to the battery system.
WARNING:
Please read these
safety warnings and
heed them. Failure
to do so could
result in either
severe personal
injury or equipment
damage.
This equipment uses and generates lethal voltages. The equipment should only be installed and
maintained by trained persons. Do not attempt to install or operate this equipment unless you are certain
you are adequately trained.
WARNING: This charger is intended for incorporation inside of OEM cabinets. For protection against
personal injury and fire, the charger must be installed inside of a suitable and safe enclosure.
To reduce the risk of injury, charge only properly sized lead-acid or nickel cadmium batteries. Other types
of batteries or under-sized batteries may burst causing personal injury and damage.
• Do not install or operate charger if it has been dropped or otherwise damaged. Return it to the factory for
repair.
• Install the charger in accordance with all local codes.
• Do not expose charger to rain or snow.
• Do not disassemble charger; return to factory when service or repair is required. Incorrect assembly may
result in a risk of electric shock or fire.
• To reduce risk of electric shock, de-energize and disconnect the AC input and the battery from the
charger before attempting maintenance or cleaning.
• Use of an accessory not recommended or sold by SENS may result in a risk of fire, electric shock or
personal injury.
• During normal operation, batteries may produce explosive hydrogen gas. Never smoke, use an open
flame, or create sparks near the battery or charger.
• Remove jewelry, watches, rings, etc. before installing battery or charger.
1
READ THIS
FIRST
The installation and use instructions are vital to t
he satisfactory operation of the charger. If you have any
questions, contact SENS service department.
WARNING:
Follow exactly the simple procedures outlined in this manual for electrical connection and
start
-up. Failure to follow prescribed procedures could lead to personal injury and/or equipment damage.
Changing factory
-set potentiometers voids the warranty. Contact the factory if you believe that the settings
on your charger are incorrect.
Before determining that the charger is not working correctly, check the
following:
1. Is AC power available to the charger?

101148 Rev F Page 3of 6
2. Are any fuses blown?
3. Is the charger connected to a battery of the correct voltage?
4. Was the charger damaged in transit or installation?
5. If you determine that the charger is not working because it is not putting out any current, check the battery’s
state of charge. If the battery is fully charged and there are no other loads it is normal for the charger to
indicate zero current flow.
6. If the battery is being over
- or undercharg
ed, check whether the output voltage settings have been tampered
with. The pots should be locked, with a hard red varnish applied.
7. Are the remote temperature compensation (RTS) connections tight?
1.1
Description and Application
NOTE:
This manual covers several charger models with different output voltage and current ratings. The
power circuits are similar, and theory of operation is identical.
The TD is a fully automatic battery charger and DC current source offering the following features:
•
Field selectable 120/208/240 VAC input, 60 Hz
• Constant voltage output
• Electronic current limiting
• High voltage shutdown
• AC and DC fuses
• Temperature compensation with remote sensing
• Charger “OK” auxiliary circuit
The charger is designed to mai
ntain and recharge VRLA style batteries.
1.2
Upon Delivery
Inspect the charger for damage caused during transit, and report damage to the carrier immediately. Then
contact SENS to determine how best to repair/replace the damaged unit.
WARNING:
Pay particular attention to wires at the DC output terminal. If the DC output leads or the surge
suppressor leads or bodies are bent or otherwise damaged from shipping, contact SENS immediately to
remedy the problem. If any of these leads is bent a battery s
hort-circuit could occur.
2
Installation
2.1
Mechanical Installation
Refer to the attached chassis
diagram MEC\990104, which shows overall dimensions and hole centers.
Attach the charger to cabinet, bulkhead or other robust surface using 1/4” bolts
as follows:
• Vertical mount
Transformer at top
• Horizontal mount
Any orientation
• Inverted
Any orientation
2.2
Electrical Installation
The attached diagram
SCH\00210shows location of AC input and DC output connections, as well as
120/208/240 VAC input selection.
CAUTIO
N Ensure that no loose hardware or metal shavings fall into the charger. Operation with such
debris in critical areas could cause charger malfunction
..
AC Input Connection
Refer to the attached schematic diagram SCH\00210

101148 Rev F Page 4of 6
Before connecting the AC leads, change the input voltage selection jumpers (if necessary) to the desired
voltage. The factory setting is for 240 VAC.
Connect your AC service to the terminal block.
Input Fusing
The charger is shipped with the
correct fusing for 120 volt input. If configuring for 208 or 240 VAC input,
the fuse must be changed to a voltage rating of 250 VAC, and to the correct current rating.
Refer to Table 2.2
AC Service Required
Table 2.2 below shows the approximate input VA
and amperes required by each unit in the series, along with
recommended input fuse values.
WARNING:
The user is responsible for ensuring that a fuse of the correct voltage and current rating is used
in this charger. 125 volt rated fuses are satisfactory for 120 volt input. 250 volt fuses must be used when the
input selection is 208 or 240 VAC.
TABLE 2.2
Input Power Consumption
Output I/P 120 V 208 V 240 V
Voltage
Current Fuse VA Curr. Fuse Curr. Fuse Curr Fuse
36/48 3 amps 6A 300 2.4 3A 1.6 2A 1.6 2A
36/48 5 amps 10A 499 4.0 5A 2.4 3A 2.4 3A
36/48 7 amps 15A 699 4.8 6A 3.2 4A 2.4 3A
60/72 3 amps 6A 434 4.0 5A 2.4 3A 2.4 3A
60/72 5 amps 10A 723 5.6 7A 4.0 5A 3.2 4A
60/72 7 amps 15A 1013 9.6 12A 4.8 6A 4.8 6A
84/120 3 amps 6A 707 8.0 10A 4.0 5A 4.0 5A
84/120 5 amps 10A 1179 9.6 12A 5.6 7A 4.8 6A
84/120 7 amps 15A 1650 12.0 15A 7.2 9A 6.4 8A
132/168 3 amps 6A 1044 9.6 12A 5.6 7A 4.8 6A
132/168 5 amps 10A 1739 16.0 20A 8.0 10A 7.2 9A
132/168 7 amps 15A 2435 20.0 25A 12.0 15A 9.6 12A
180/240 3 amps 6A 1369 12.0 15A 7.2 9A 6.4 8A
180/240 5 amps 10A 2282 20.0 25A 12.0 15A 9.6 12A
180/240 7 amps 15A 3194 26.0 30A 16.0 20A 16.0 20A
252 6 amps 15A 3328 N/A N/A 16.0 20A 16.0 20A
Battery Connection
Before making DC connections, correctly identify the positive an negative leads;
DO NOT CONNECT BATTERY BACKWARDS.
2.3 Alarm Connections
An auxiliary 120 VAC output is provided to drive an external “charger OK” indicator. The output is
rated at one amp. Make connections to TB7 pins 9 and 10 of the control as shown on drawing
SCH\00210.
2.4 Remote Temperature Sensor
The charger is equipped with a remote temperature sensor. THIS SENSOR IS AN INTEGRAL PART
OF THE CHARGER’S CONTROL CIRCUIT, AND MUST BE CONNECTED TO THE CHARGER IN
ORDER FOR IT TO OPERATE. When installing the charger fix the sensor in a place that is most
representative of the normal ambient temperature of the system battery. The sensor is non-polarized.

101148 Rev F Page 5of 6
3
Operation
3.1 Before Energizing Charger
Before starting the charger, ensure that the battery polarity is correct, and that the input voltage
selection is correct.
3.2 Normal Operation
Normal operation is indicated when the charger supplies current to the battery and when the auxiliary
contact provides 120 VAC.
3.3 High Voltage Shutdown
The charger will automatically shut itself down when the DC voltage is more than about 3% higher
than the output voltage setting. When the output voltage setting is changed, the high voltage shutdown
point automatically adjusts along with the float setting.
3.4 Charger Failure
Any of the following conditions will cause an indication of charger failure (removal of 120 VAC from
the auxiliary “charger OK” circuit).
• AC fuse blown
• DC fuse blown
• High voltage shutdown
• Disconnection or damage to the remote temperature sensor
• In rare occasions when the DC amps drop to less than 0.5 amps
Note that the charger will not operate without the remote temperature sensor attached.
4
Adjustments
4.1
Read This First
The only adjustment that
can be made in the field is the output voltage adjustment. Do not attempt to
change any other settings, as these are factory final test adjustments only.
4.2
Output Voltage Adjustment
The charger’s output voltage can be adjusted in the field by acting on the potentiometer labeled “V ADJ”.

101148 Rev F Page 6of 6
5
Troubleshooting
Symptom
Possible Cause
Test
Corrective Action
No output /
Charge Fail alarm
Control board
failure
Replace with known good
board
Replace board, send bad
board to SENS for repair
AC failure
Measure AC line voltage
Tighten connections and
verify AC jumper
positions
Fuse blown
Check fuse for continuity
Replace if open
High DC Shutdown
Check LED D7 on control
board
If lit, see "High output
voltage" under Symptom
Remote
Temperature Sensor
disconnected
Check remote connections
Tighten connections or
replace if necessary
Power rectifier
circuit failure
Test all power diodes with
meter; perform SCR test
on all SCRs
Replace all shorted, open
or bad parts
Charger producing
less than 0.5 amps
with fully charged
batteries
Apply a load
System okay if charger
produces current when
load applied. If not, see
failure options above.
AC or DC fuse
blows
Power diode, SCR,
or freewheeling
diode short
Check all devices for
shorts
Replace shorted device(s)
AC or DC fuse
blows
Control board
failure
Replace with known good
board
Replace board, send bad
board to SENS for repair
Low output
voltage
Control board
failure
Replace with known good
board
Replace board, send bad
board to SENS for repair
Misadjusted
Voltage pot (R7) on
control board
Adjust pot and see if
output voltage is affected
Adjust R7 to correct
output voltage
Overload
Disconnect load and check
output voltage
Check load for problems
Check for AC line voltage
over charger's specified
operating range
Contact utility company
Line voltage less
that charger's
specified operating
range
Measure AC line voltage
and check AC jumper
positions
Use larger gauge AC
wires or contact utility
company
High DC voltage
shutdown
Control board
failure
Replace with known good
board
Replace board, send bad
board to SENS for repair
Alternate/secondary
charging source
connected in
parallel with a float
voltage 6% higher
than the TD
Disconnect alternate
charging source
Replace/repair alternate
charging source
Excessive output
voltage
Misadjusted
Voltage pot (R7) on
control board
Adjust pot and see if
output voltage is affected
Adjust R7 to correct
output voltage
Improperly
functioning
alarms or
indicators
Control board
failure
Replace with a known
good board
Replace board, send bad
board to SENS for repair

SENS Limited Warranty Policy
What is covered:
This warranty covers any defect in material and workmanship on battery chargers manufactured
by Stored Energy Systems, a Colorado Limited
Liability Company (SENS).
What this warranty does not cover:
This warranty does not cover damages, defects or failures of your equipment resulting from
shipping damage, accidents, installation errors, unauthorized adjustment or repair, unauthorized
third-party service, failure to follow instructions, misuse, fire, flood, acts of persons not in our
control, and acts of God.
For how long:
Two years from date of shipment.
What we will do:
If your battery charger is defective within two years of date of shipment, we will repair it or, at
our option, replace it at no charge to you.
If we choose to replace your charger, we may replace it with a new or refurbished one of the
same or similar design. The repair or replacement will be warranted for the remainder of the
original two-year warranty period. If we determine that your charger cannot be repaired or
replaced, we will refund its purchase price to you.
What we ask you to do:
First contact SENS service department to obtain warranty service instructions. To obtain
warranty service the product must be returned, freight prepaid, to the factory under a Return
Merchandise Authorization (RMA) number provided by SENS. If, in SENS’ opinion, the
problem can be rectified in the field, SENS may elect to ship replacement parts for customer
installation instead of having the product returned to the factory.
Limitation:
This warranty is limited to defects in material or workmanship of the product. It does not cover
loss of time, inconvenience, property damage or any consequential damages. Repair,
replacement or refund of the purchase price of the equipment is your exclusive remedy.
Form.135-1