STORED ENERGY SYSTEMS SuperTorque 8Z Genset Starting System User Guide
- June 13, 2024
- STORED ENERGY SYSTEMS
Table of Contents
STORED ENERGY SYSTEMS SuperTorque 8Z Genset Starting System
Product Information:
The SuperTorqueTM 8Z Genset Starting System is a patented product (US 9,270,140; 9,385,556; 9,413,186; 9,509,164; 9,466,995) designed for commercial and industrial use. It is a reliable and efficient system that provides power to start the engine and charge the internal battery of the genset. The system comes with various connection options and features to ensure proper functionality and safety.
Product Usage Instructions
To properly use the SuperTorqueTM 8Z Genset Starting System, follow these instructions:
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Mounting:
- Install the system using 3/8 inch fasteners.
- Ensure proper orientation by following the “THIS SIDE UP” indication.
- For permanent installation, utilize the 1/2 inch conduit knockouts.
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Battery Shelf or Battery Box:
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Make sure to connect DC wires using a ring lug and M8 fastener.
Use a 13mm socket wrench to tighten it to 60lb-in. -
If necessary, connect SAE battery terminal posts (optional).
However, be cautious as there is always voltage present on the battery terminals. -
To prevent battery discharge when AC power is not connected, press the SLEEP button to turn off display and communications. Press the WAKE UP button to turn them back on.
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Charge the system for a minimum of 8 hours prior to placing it into service or connecting it in parallel.
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For storage, recharge the system every 6 months or when the open circuit battery voltage drops below 13.5VDC (12V nominal systems) or 27.0VDC (24V nominal systems).
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Connections:
- Note: Remove the optional field cover to access connections.
- Connect the SENS SETUP UTILITY using a USB-C cable.
- If an optional display PCA is included, connect the J1939 network cable to the RJ-45 connector. Ensure proper pin connections: pin 1 – Data High, pin 2 – Data Low, pin 8 – COM.
- If an optional comms PCA is included, connect the MODBUS TCP/IP network cable to the RJ-45 connector.
- For load sharing units or remote accessories, connect using the SENSBUS connection. Do not connect Ethernet, J1939, TCP/IP, or RS-485 cables here.
- For AC power input (100-240VAC, 50/60Hz), use the IEC 320 power cord to connect it. Alternatively, you can wire AC to the screw terminal adapter provided with the field termination kit (18-14AWG).
- For load sharing units or SENS-approved external devices, use the AC PASS-THROUGH connection (750W max).
- To connect ALARM RELAY Form C contact wires, remove the pluggable terminal block and tighten the wires (28-16AWG) to 2lb-in.
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Operation:
- Connect the DC wires from the 8Z system to the engine starter or DC bus.
- Connect AC power to the 8Z system to start charging the internal battery.
- If desired, connect optional communications wiring and use the keypad to configure communications settings.
- The output settings are factory programmed, so no adjustments should be attempted.
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AC SOURCE:
- The system supports AC input of 100-240VAC and 50/60Hz.
- Ensure that AC power is not left disconnected to avoid battery damage.
- Do not drain the battery below 10.5VDC (12V nominal systems) or 21.0VDC (24V nominal systems) to prevent damage.
IMPORTANT SAFETY INSTRUCTIONS:
- Use only attachments recommended or sold by the manufacturer to avoid risks of fire, electric shock, or injury to persons.
- Installation and servicing of this genset starting system should only be performed by trained and qualified personnel.
If you need further assistance, please refer to the user manual or contact SENS customer service:
- Phone: 800-742-2326 / 303-678-7500
- Email: service@sens-usa.com
You can also use your smartphone QR code reader to access the user manual.
Mounting
Battery Shelf or Battery Box
Rigid Floor Mount
Connections
Note – remove optional field cover to access connections
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Connect SENS SETUP UTILITY using USB-C
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Remove pluggable terminal block to connect MODBUS RS-485 wires when optional display/comms PCA included (28-16AWG, tighten to 2lb-in, pin 1: +D1 (A), pin 2: –D0 (B), pin 3: COM, pin 4: Shield)
M/N: 8Z-XX-X-XX-B-X-X-XX
M/N: 8Z-XX-X-XX-C-X-X-XX -
To prevent battery discharge when AC power is not connected, press ”SLEEP” button to turn off display and communications
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Connect J1939 network cable to RJ-45 connector when optional display PCA included (pin 1: Data High, pin 2: Data
Low pin 8: COM)
M/N: 8Z-XX-X-XX-B-X-X-XX -
Connect MODBUS TCP/IP network cable to RJ-45 connector when optional comms PCA included
M/N: 8Z-XX-X-XX-C-X-X-XX -
SENSBUS – connect load sharing units or remote accessories (DO NOT connect Ethernet, J1939,TCP/IP OR RS-485 here)
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Connect DC wires using ring lug and M8 fastener (13mm socket wrench, tighten to 60lb-in) Optional – SAE battery terminal posts
CAUTION: voltage always present on battery terminals! -
Press ”WAKE UP” button to turn display and communications on when AC power is not connected
WARNING: this will cause battery discharge, connect ac power as soon as possible -
Connect AC INPUT
(100-240VAC, 50/60Hz) using IEC 320 power cord
Optional – wire AC to screw terminal adapter provided with field termination kit (18-14AWG, tighten to 3.5lb-in) -
Connect AC PASS-THROUGH
(750W max) to load sharing units or SENS-approved external devices -
Remove pluggable terminal block to connect ALARM RELAY Form C contact wires (28-16AWG, tighten to 2lb-in)
See unit label for factory alarm assignments, user configurable with SENS Setup Utility
Operation
- Connect DC wires from 8Z to engine starter / DC bus
- Connect AC power to 8Z to start charging internal battery
- Connect communications wiring (optional)
- Use keypad to configure communications settings (optional)
- Charge for 8 hours minimum prior to placing into service or connecting in parallel
Output settings factory programmed. Attempt no adjustment.
Do not leave AC disconnected. To avoid battery damage, do not drain battery
below 10.5VDC (12V nominal systems) or 21.0VDC (24V nominal systems).
Storage – recharge every 6 months or when open circuit battery voltage drops
below 13.5VDC (12V nominal systems) or 27.0VDC (24V nominal systems).
IMPORTANT SAFETY INSTRUCTIONS
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SAVE THESE INSTRUCTIONS –This guide contains important safety and operating instructions for SuperTorque 8Z genset starting system. Conserver ces instructions.
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Use of an attachment not recommended or sold by the manufacturer may result in a risk of fire, electric shock, or injury to persons.
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This genset starting system is intended for commercial and industrial use.
ONLY TRAINED AND QUALIFIED PERSONNEL MAY INSTALL AND SERVICE THIS UNIT. -
Do not operate genset starting 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.
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To reduce risk of electric shock, disconnect the branch circuit feeding the genset starting system before attempting any maintenance or cleaning.
Turning off controls will not reduce this risk. -
WARNING – RISK OF FIRE, EXPLOSION OR BURNS
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WORKING IN THE VICINITY OF A NICKEL-ZINC BATTERY IS DANGEROUS. STORAGE BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU READ THIS DOCUMENT AND FOLLOW THE INSTRUCTIONS EACH TIME YOU USE THE GENSET STARTING SYSTEM.
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Do not disassemble battery, heat above 75°C, incinerate, puncture or impact.
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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.
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Ensure battery spill control procedures exist in accordance with building, fire and installation codes
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PERSONAL PRECAUTIONS
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Someone should be within range of your voice or close enough to come to your aid when you work near a storage battery.
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Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or eyes.
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Wear complete eye protection and clothing protection. Avoid touching eyes while working near a storage battery.
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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.
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NEVER smoke or allow a spark or flame in vicinity of battery or engine.
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Be extra cautious to reduce risk of dropping a metal tool onto battery.
It might spark or short circuit battery or other electrical part that may cause explosion. Using insulated tools reduces this risk, but will not eliminate it. -
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.
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NEVER charge a frozen battery.
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The charging circuit 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.
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PREPARING BATTERY FOR CHARGE
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Ensure area around battery is well ventilated and in accordance with local fire and installation codes while battery is being charged.
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Ensure battery terminals are clean and properly tightened. Be careful to keep corrosion from coming in contact with eyes.
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Do not operate genset starting system with damaged cables. Defective cables must be replaced before operation.
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Verify that all cables are properly secured and connected.
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INSTALLATION LOCATION
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Operating temperature: -10°C to 55°C
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Do not tip, keep genset starting system level.
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Do not set anything on top of genset starting system.
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WARRANTY AND SERVICE
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Do not open genset starting system, not field servicable.
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Always operate within -10°C to 55°C. Do not operate outside of 0°C to 50°C for more than 10% of operating life.
For information and service on any SENS product, please contact us at:
Sales 1.866.736.7872 • 303.678.7500 • Fax 303.678.7504 • www.sens-
usa.com • info@sens-usa.com
Stored Energy Systems, LLC
1840 Industrial Circle, Longmont, CO 80501 USA