Freedom e-GEN System Installation Guide for OEM Installers
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975-0790-01-01 Rev J
Dec 2020
4. Mount and install the DC wiring components including the battery disconnect switch
(if applicable), fuseholders, and the busbars. Their relative locations are shown in the
system diagram. The battery disconnect switch and the fuseholder for the main
battery fuse should be located as close to the BMS positive terminal as possible. If
applicable, install the fuseholder for the DC load branch fuse on the positive cable
close to the positive DC busbar.
5. Mount and install the second alternator using the tools and instructions provided in
the alternator kit. Follow the steps below as a guide but refer to the manufacturer’s
instructions for complete detail.
a. Install the second alternator using the mounting bracket and pulley provided in
the alternator kit.
b. Ensure the alternator chassis is securely fastened to the vehicle metal chassis.
c. Use a straight edge or laser alignment tool to ensure pulleys are within 0.5
degrees of alignment.
d. Check all pulley grooves to ensure they are clean and undamaged. Check the
belt to make sure there are no visible cracks, splits, or defects before installing
it.
e. Install the belt. Ensure the belt is properly seated in the pulley grooves.
f. Check the belt tension between the engine and second alternator according to
the manufacturer’s recommendations. Adjust accordingly using the provided
tensioner and a tension gauge. Under or over-tensioned belt will cause belt
slippage and premature belt failure. It can also result in overheating of the
alternator leading to equipment damage.
5.
g. Check that the Balmar Regulator has the “LFP” sticker before mounting. Contact
Xantrex if the “LFP” sticker is missing.
h. Mount the Balmar Regulator.
i. Follow the second alternator manufacturer's wiring instructions and use the
wiring harness in the alternator kit to make the connections between the second
alternator and the Balmar Regulator.
j. Make sure the alternator temperature sensor in the wiring harness is installed
on the second alternator’s chassis and connected to the correct pins on the
Balmar Regulator to prevent equipment damage and fire.
k. Make DC cable connections at the alternator. Refer to “DC Cable and Fuse
Requirements” for conductor sizing. Use a separate cable for alternator
negative return to the battery. Ensure all electrical connections are secured. To
protect from dust and water, install a skid plate (not provided but
recommended).
6. Read “DC Cable and Fuse Requirements”. Then, make the DC cable connections
between all system devices by following the “System Diagram for Power Connection”.
Observe correct polarity.
7. Install the required DC fuses on to their respective fuseholders.
8. If applicable, install a venting tube (rubber tubing) to the pressure balancing valve on
the battery and secure it with a clamp.
9. Make AC wiring connections to the Freedom SW according to the “System Diagram
for Power Connection”. Follow the Freedom SW installation guide (document number:
97-0020-01-01) for AC wire sizing instructions.
a. Wire the GFCI kit to the Freedom SW AC INPUT according to the “System
Diagram for Power Connection”. You must wire to the line side of the GFCI
through the 15A supplementary breaker. Use proper wire-splicing technique
and ensure the wire joints are secured and covered with electrical tape.
b. Wire the Freedom SW AC OUTPUT to your AC load panel.
c. Install the GFCI kit to cover the Freedom SW AC terminal.
d. Ensure that all upstream and downstream surge protector and AC circuit
breakers are properly installed. Refer to the Freedom SW installation guide for
breaker sizes.
e. Locate the AC adapter provided in the system wiring harness. Plug it to one of
the two AC receptacles on the GFCI.
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System Devices
Device Name
Part Number
Freedom SW 3012
815-3012
Ford Transit Alternator Kit (option 1)
882-0050-12
Sprinter 6-cylinder Alternator Kit (option 2)
882-0010-12
Sprinter 4-cylinder Alternator Kit (option 3)
882-0020-012
Dodge Promaster Alternator Kit (option 4)
882-0030-12
Xantrex Battery 12V 600Ah (option 1)
880-0600-12
Xantrex Battery 12V 450Ah (option 2)
880-0450-12
Xantrex Battery 12V 630Ah (option 3)
880-0630-12
Xantrex Battery Management System
881-0406-12
Battery Disconnect Switch (12VDC, 450A min)
--
Use one of UL-listed fuses
-- Class T fuse rated 350A, 125VDC
-- Class J fuse rated 400A, 450VDC
-- Class J fuse rated 450A, 450VDC
c
Use of other fuses and
fuseholders voids the UL
listing of the system.
NOTE
: Class J fuses are
only permitted with the
12V 630Ah battery
Fuse holder must be UL Listed (IZLT), suitable for single-pole, Type J
or Type T fuses, rated 600V, 450A
System Wiring Harness
881-0040-12
GFCI Kit
808-9003
Table 1 Required eGEN system devices and components
Device Name
Part Number
ComBox for Freedom SW
809-0918
Skid Plate for the second alternator
--
100A fuse, Littelfuse [Required if the system includes the
Xantrex Battery Combiner (PN: 881-0030-12)]
MEG100
600A Busbars,1 for pos(+) and 1 for neg(-), Blue Sea
2104
Busbar cover, Blue Sea
2708
Xantrex Battery Combiner
881-0030-12
12A Temperature Sensor Switch
Heating Blanket, eGEN 135W (sold together)
881-0240-12
881-0060-12
100W Xantrex Solar Kit / 100W Expansion Kit
780-0100-01 / 780-0100-02
160W Xantrex Solar Kit / 160W Expansion Kit
780-0160-01 / 780-0160-02
110W Xantrex Solar Flex Kit / 110W Expansion Kit
781-0100-01 / 781-0100-02
Xantrex Solar 30A PWM Charge Controller
709-3024-01
Xantrex Solar 30A MPPT Charge Controller
710-3024-01
Android tablet
808-0016
Internet Modem/router
881-0050-12
System Remote Panel including LCD Display
881-0401-12
Freedom SW Remote Panel
808-9002
Router Power Harness
881-0020-12
Xanbus cable (50 ft.)
809-0941
Table 2 Recommended eGEN system devices and components
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Installation
WARNING
HAZARD OF ELECTRIC SHOCK, FIRE, OR PERSONAL INJURY
Read the system installation guide and associated product manuals prior to installation.
Failure to follow these instructions can result in death or serious injury.
1. Prior to installation, identify and isolate all energy sources from the system. De-
energize the system by:
a. removing AC power
b. turning off vehicle ignition
c. turning off the BMS
Keep the system de-energed throughout the installation process.
Follow all necessary safety precautions, use personal protective equipment (PPE) and
perform lock-out, tag-out (LOTO).
2. Plan the mounting locations for all the devices and wiring components prior to wiring.
Follow the mounting instructions for each device, verify the weight-bearing capacity of
each mounting location and orientation, and ensure sufficient clearance for proper air
ventilation.
3. Mount and install the system devices before making cable or wiring connections.
Secure heavy objects such as the inverter and the battery by bolting/strapping them to
the floor.
