Xantrex Freedom EX 4000 Installation Manual Download

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Freedom EX 4000
Inverter/Charger with 48VDC-to-
12VDC Converter

Installation Guide

Freedom EX 4000

PN: 820-4080-41

Summary of Contents for Freedom EX 4000

Page 1: ...Freedom EX 4000 Inverter Charger with 48VDC to 12VDC Converter Installation Guide Freedom EX 4000 PN 820 4080 41...

Page 2: ...TENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT http www xantrex com NOTE Visit http www xantrex com click Products select a Product category select a Product and search the Pro...

Page 3: ...CSA Z462 Abbreviations and Acronyms A Amperes Ah Amp hours a unit of battery capacity AC Alternating Current V AGM Absorbed Glass Mat a battery type BTS Battery Temperature Sensor CAN Controller Area...

Page 4: ...applicable in your jurisdiction 4 To avoid a risk of fire and electric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the inverter charger co...

Page 5: ...fuel system WARNING HEAVY EQUIPMENT Always use proper lifting techniques during handling and installation A two person lift is required to prevent personal injury Failure to follow these instructions...

Page 6: ...ith an ambient of 0 C 32 F or colder Failure to follow these instructions can result in death serious injury or equipment damage NOTES 1 Mount and place the Freedom EX 4000 Inverter Charger with 48VDC...

Page 7: ...ee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off...

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Page 9: ...s 10 Step 1 Designing the Installation 11 Step 2 Choosing a Location for the Unit 16 Step 3 Mounting the Unit 16 Step 4 Connecting the AC Input Wires 18 Step 5 Connecting AC Output to an Existing AC C...

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Page 11: ...n All wiring should be done by qualified personnel to ensure compliance with all applicable installation codes and regulations n Do not connect to AC and DC power sources during installation Disconnec...

Page 12: ...page 1 n Lugs for DC cables to fit 5 16 DC stud terminals as well as appropriate tools like a crimping tool n AC and DC disconnects and over current protective devices as appropriate n Drip shields n...

Page 13: ...e and Fleet Vehicle Installation 1 7 10 8 2 5 4 6 11 3 14 13 12 50A 9 1 Communications and Control 20 pin Harness 2 Freedom EX 4000 3 Equipment ground 4 DC fuse disconnect DC circuit breaker 5 48V dee...

Page 14: ...isconnect switches will be needed ahead of the fuses These will have to be a branch circuit rated for 120 volts AC and have an appropriate current rating Surge Arrester In a marine installation each s...

Page 15: ...ration AC Output The output voltage in Battery Invert mode on Freedom EX 4000 is 120 VAC 60Hz n Single AC Line L1 have a Single Input and Dual Output lines L1 and L2 SI DO configuration See Figure 10...

Page 16: ...of 30 C cables Table 2 Required Cable 48VDC Sizes IMPORTANT Using the correct cable size is critical to achieving the rated performance of the Freedom EX 4000 unit When starting a heavy load the Free...

Page 17: ...a pre charge contactor see NOTE below Follow the instructions published by the battery manufacturer Failure to follow these instructions can result in serious injury or equipment damage NOTE A pre cha...

Page 18: ...asoline n Close to the battery compartment and the AC source and load panels Avoid excessive cable lengths which reduce input and output power due to wire resistance Use the recommended cable lengths...

Page 19: ...icle s chassis or DC negative bus ground using recommended copper wire size if insulated then green insulation with or without one or more yellow stripes or larger Make sure to tighten the bolt on the...

Page 20: ...circuits in accordance with the electrical codes or regulations applicable to your installation Table 4 is based on the U S National Electrical Code and the Canadian Electrical Code assuming two condu...

Page 21: ...t in equipment damage When making the AC input and AC output connections observe the correct color code for the appropriate AC wire as described inTable 5 below Color AC Wire Black Red Brown Line Whit...

Page 22: ...Route to circuit breaker 2 Insert the wire fully into the open slot NOTE AC input hole install a bushing supplied or a strain relief device 3 Lower the terminal lever to secure the wire in the slot 7...

Page 23: ...Figure 7 Routing and connecting the AC output wires 4 N L2 G N 2 1 3 N L1 L2 G 1 Lift the terminal lever 4 Route to circuit breaker 2 Insert the wire fully into the open slot NOTE AC Output hole inst...

Page 24: ...ground connection and a required tool access to the wiring compartment Failure to follow these instructions can result in death serious injury or equipment damage 12 Connect the other end of the wires...

Page 25: ...ut terminals F Vehicle s AC Inverter Distribution Panel J 50A RV Vessel Inlet Receptacle C AC Input wires L1 N L2 G G Shore Power Distribution Panel with 20A and 30A standard outlets K 50A AC Load sin...

Page 26: ...reedom EX 4000 supports a series stacking configuration In this configuration two Freedom EX 4000 units may be stacked to form a split phase during Battery mode 120 240VAC 60 Hz 33 3A 8000W system req...

Page 27: ...uctions can result in equipment damage and may void the warranty Figure 11 Series Stacking Using Two Freedom EX 4000s N L1 L2 G N L1 L2 G AC IN AC OUT N L1 L2 G N L1 L2 G AC IN AC OUT B E SHORE NEUTRA...

Page 28: ...r unit 2 to allow the automatic neutral to ground switching to continue for the series stacked pair RJ45 CAT5e 6 network cables For series stacking 120 and 240 volts connect an RJ45 CAT5e 6 network ca...

Page 29: ...ered while AC input is present to the inverters will be in addition to the power being drawn for charging the batteries Each unit in the stack can provide a full pass through current of 30 amps for 12...

Page 30: ...ng n Each inverter must be enabled and turned on individually before AC power becomes available Failure to follow these instructions can result in equipment damage and may void the warranty Figure 14...

Page 31: ...comes available Failure to follow these instructions can result in equipment damage and may void the warranty Figure 15 RJ45 CAT5e 6 network cable for parallel stacking A B C D c Do not connect any wi...

Page 32: ...L1 line can be connected to a single higher rated circuit breaker double the capacity of the source circuit breaker C AC output cable with 3 wires L1 N G connected to the inverter s AC OUT terminals...

Page 33: ...Strip 13 mm to 19 mm insulation from one end of each cable The amount stripped off will depend on the terminals chosen 5 Attach the connectors that will secure the cables to the battery to the discon...

Page 34: ...onverter to the disconnect battery selector switch fuse holder and that the other end of the fuse holder is connected to the positive terminal of the battery WARNING FIRE HAZARD Do not complete the ne...

Page 35: ...relief 7 To the 12V DC load panel WARNING ELECTRICAL SHOCK HAZARD Use a torque screwdriver to tighten the captive nut panel screw to 5 in lb 0 56 N m torque of force to ensure a proper ground connect...

Page 36: ...k cable polarity at both the DC load panel and the Freedom EX 4000 before making the final DC connection Positive must be connected to positive negative must be connected to negative n Reversing the p...

Page 37: ...the stacked system as follows 1 Connect each negative terminal to the battery 2 Connect a Grounding wire to the common negative 3 Connect each positive terminal of the inverter to the battery through...

Page 38: ...ehicle Use 8AWG minimum sized stranded copper wire rated minimum 75 C and connect it between the Chassis Ground lug and the vehicle s DC grounding point usually the vehicle chassis or a dedicated DC g...

Page 39: ...e 23 For marine vessels the NMEA 2000 protocol for marine communication systems will be introduced as an added capability in upcoming releases Figure 23 20 pin Communications Harness Figure 24 20 pin...

Page 40: ...ure 15 on page 29 and Figure 13 on page 26 Apply a similar 120 ohm terminator to the other end device in the CAN network if applicable Connecting to the USB Port The USB port is reserved for firmware...

Page 41: ...ituations on page 40 To mount the sensor on the negative battery terminal 1 Select the battery to be monitored The BTS should be connected to the battery bank that is directly connected to the Freedom...

Page 42: ...d unnecessary battery drain that would otherwise occur if the inverter charger converter was operated without a charging source such as the vehicle alternator 1 Ensure that AC and DC power are both OF...

Page 43: ...disconnect DC or AC input power to the Freedom EX 4000 If shore power is present at AC input terminals it will pass through to the AC output Failure to follow these instructions can result in death s...

Page 44: ...onnected If the Power button on the Freedom EX 4000 is turned ON and shore power voltage is too low less than 80 VAC 1 the unit will transfer to inverter power to continue running your appliances NOTE...

Page 45: ...AC rated SPD TVSS a and branch circuit breakers that supply only loads that run off the Freedom EX 4000 8 AC source shore panel that includes a max 50A breaker IMPORTANT To the installer Affix the pr...

Page 46: ...from this hazard Do not operate the unit when it is wet Failure to follow these instructions can result in death serious injury or equipment damage You may purchase the Drip shield set by contacting...

Page 47: ...Remote port RJ 11 receptacle BTS port RJ 11 receptacle USB port standard USB receptacle to be used for firmware updates only COM port 20 pin receptacle to be used with 20 pin harness optional accesso...

Page 48: ...s Shore to inverter Inverter to shore 10 milliseconds 10 milliseconds with a 20 second delay Transfer voltage V Shore to inverter Inverter to shore Shore voltage less than 60V min 80V default 115V max...

Page 49: ...m EX 4000 Output voltage options 210 to 260 VAC Continuous current 33 3 A Surge power 5 sec 16000 W Output Frequency 60 Hz Table 15 AC output for series stacked i pair inverters Freedom EX 4000 Output...

Page 50: ...latory Approvals Freedom EX 4000 Safety CSA Certified to CSA 107 1 UL458 and UL458 Marine Supplement drip shield with product number 808 9004 required ABYC E 11 A 31 A 32 EMC CFR 47 FCC Part 15 Subpar...

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Page 52: ...975 0998 01 01 Rev D 30948 http www xantrex com Toll Free USA Canada 1 800 670 0707 Outside USA Canada 1 408 987 6030 Printed in...

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