Xantrex Freedom EX 4000 Owner's Manual
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Xantrex Freedom EX 4000 Owner's Manual

Xantrex Freedom EX 4000 Owner's Manual

Inverter/charger with 48vdc-to-12vdc converter
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Freedom EX 4000 Inverter/Charger
with 48VDC-to-12VDC Converter
Owner's Guide
Freedom EX 4000
PN: 820-4080-41

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Summary of Contents for Xantrex Freedom EX 4000

  • Page 1 Owner’s Guide Freedom EX 4000 Freedom EX 4000 Inverter/Charger PN: 820-4080-41 with 48VDC-to-12VDC Converter...
  • Page 2 ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED CONTENT 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 Product Documents panel for a translation of the English guide, if available.
  • Page 3 Information About Your System As soon as you open your product, record the following information and be sure to keep your proof of purchase. Serial Number ____________________________ Product Number ____________________________ Purchased From ____________________________ Purchase Date ____________________________ To view, download, or print the latest revision, visit the website shown under Contact Information. 975-0999-01-01...
  • Page 4 Installing and configuring lead-acid and/or lithium-ion batteries. Related Information Selecting and using PPE and following safety work code You can find more information about Xantrex products and practices. See NFPA 70E or CSA Z462. services at http://www.xantrex.com/. Freedom EX 4000 Owner's Guide...

  • Page 5: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS ’ READ AND SAVE THIS WNER UIDE FOR FUTURE DANGER REFERENCE DANGER indicates a hazardous situation which, if not avoided, will result in This guide contains important safety instructions for the Freedom death or serious injury. EX 4000 that must be followed during installation, operation, maintenance, and troubleshooting.
  • Page 6 Internal capacitors remain charged after all power is disconnected. 7. To reduce the risk of electrical shock, disconnect both AC and DC power to or from the inverter/charger/converter before attempting any maintenance or cleaning or working on any components connected to the Freedom EX 4000 Owner's Guide...
  • Page 7 ELECTRICAL SHOCK AND FIRE HAZARD Installation must be done by qualified personnel to ensure compliance with all applicable installation and electrical codes and regulations. Instructions for installing the Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC Converter are provided here for use by qualified personnel only.
  • Page 8 Keep unqualified personnel away from batteries. Disconnect the charging source prior to connecting or disconnecting battery terminals. Never attempt to charge a frozen battery. Failure to follow these instructions will result in death or serious injury. viii Freedom EX 4000 Owner's Guide...
  • Page 9 WARNING CAUTION ELECTRICAL SHOCK HAZARD HAZARD OF ELECTRICAL SHOCK AND FIRE Replace the wiring compartment cover before turning on Do not open. No serviceable parts inside. Provided with power to this equipment. integral protection against overloads. Bonding between Use a torque screwdriver to tighten the captive nut panel conduit connections is not automatic and must be provided screw to 5 in-lb (0.56 N-m) torque to ensure a proper ground as part of the installation.
  • Page 10 PHYSICAL INJURY HAZARD Review cautionary markings on these products and on the This Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC engine. Converter is not intended for use by persons (including children)

  • Page 11: Precautions When Working With Batteries

    Precautions When Working With Batteries Precautions When Working With NOTES: 1. Mount and place the Freedom EX 4000 Inverter/Charger with Batteries 48VDC-to-12VDC Converter unit away from batteries in a well ventilated compartment. IMPORTANT: Battery work and maintenance must be done by 2.

  • Page 12: Precautions When Placing The Unit

    FIRE HAZARD Never place the Freedom EX 4000 unit directly above batteries; gases from a battery will corrode and damage the Do not install the inverter/charger/converter or any part of its inverter/charger/converter.

  • Page 13: Fcc (Emi) Information To The User

    Many of the electrical components used in the Freedom EX 4000 However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful...
  • Page 14 This page is intentionally left blank. [2]...

  • Page 15: Table Of Contents

    DC-to-DC Converter Power Output Communications Panel Input Voltage LED Panel Overload Conditions Operation High Surge Loads LED Status Indicators and Power Button Over-temperature Conditions Operating in Battery Mode Configuration Turning Inverter Operation ON and OFF Freedom EX 4000 Remote Display Panel Search Mode 975-0999-01-01...
  • Page 16 Function Buttons LCD Screen LCD Screen Icons Adjusting Settings in Configuration Mode General Settings Routine Maintenance Maintaining the Freedom EX 4000 Unit Troubleshooting Pre-service Checklist Inverter Applications Resistive Loads Motor Loads Problem Loads Warning Messages Troubleshooting Reference Specifications Environmental Specifications...

  • Page 17: Introduction

    Converter is designed with integrated inverting and charging functions and power management features suitable for marine, recreational, and commercial/fleet vehicle installations. Please read this section to familiarize yourself with the main performance and protection features of the Freedom EX 4000. This section includes: Materials List Key Features...

  • Page 18: Materials List

    Figure 1 Materials List NOTE: If any of the items are missing, contact Xantrex or any authorized Xantrex dealer for replacement. See  Accessories on page 1. IMPORTANT: Keep the carton and packing material in case you need to return the inverter/charger/converter for servicing.
  • Page 19 Materials List Back-up If incoming shore power is interrupted by Comprehensive The Freedom EX 4000’s built-in protection Capability external events like brownouts, the Freedom Protection features safeguard your batteries (from EX 4000 automatically becomes an unnecessary drain) such as the following:...
  • Page 20 Formulas at the highest level, the batteries must be alerts you if the loads that are connected and charged correctly. The Freedom EX 4000 has drawing power from the unit are close to optimized algorithms for flooded, gel, AGM, approaching the maximum operating limit. If...
  • Page 21 AC loads. or a manually operated remote switch. The Freedom EX 4000 has a power Configurable AC The Freedom EX 4000 is factory set to 60 Hz share feature which prioritizes your AC Output Voltage AC output frequency and 120 V AC output loads by reducing the charge current voltage.
  • Page 22 Materials List Split-phase In Battery (or Inverter) Mode, a single Inverter capability Freedom EX 4000 can only produce a single phase 60Hz 120V AC output voltage configurable between 105 and 130 volts. For installations that require 60Hz 240V AC output voltage in Battery (or Inverter) Mode, two Freedom EX 4000 inverter units are required.

  • Page 23: Features

    2 FEATURES This section identifies the default settings and the hardware features of the Freedom EX 4000 Inverter/Charger with 48VDC- to-12VDC Converter. This section includes: AC/DC Panel Communications Panel LED Panel 975-0999-01-01...

  • Page 24: Ac/Dc Panel

    Using the captive nut panel screw, the cover can be opened and lifted out during wiring. Figure 2 AC/DC Panel See WARNING on this page. Freedom EX 4000 Owner's Guide...
  • Page 25 12V DC loads. c Do not use for charging. injury, or equipment damage. Grounding lug provides a ground path for the Freedom EX 4000 chassis to the DC system ground. See WARNING. Cooling fans turn on when the internal temperature reaches a set point temperature.

  • Page 26: Communications Panel

    RV-C ports. Use the top and bottom ports to connect an RV-C device. Sync ports. Use either top or bottom ports to connect a second Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC Converter unit for series or parallel stacking. Figure 3 Communications Panel  RV-C is a communications protocol based on the Controller Area Network (CAN) bus protocol.
  • Page 27 Communications Panel Feature Description Captive nut panel screw holds the wiring compartment cover in place. See WARNING above. USB port can only be used for updating the unit’s firmware. c Do not use for powering or charging USB devices. Remote port allows you to connect the Freedom EX Remote Panel (PN: 808-0817-03) (sold separately) which is a remote display and control device accessory.

  • Page 28: Led Panel

    Table 3 LED Indicator Panel Features Item Name AC source LED (shore power) Inverter LED (house power) DC-DC Converter LED (12 VDC output) Alert LED Power [Standby] button NOTE: For more information, see LED Status Indicators and Power Button on page 14. Freedom EX 4000 Owner's Guide...

  • Page 29: Operation

    3 OPERATION This section includes descriptions of the different modes and Overload Conditions settings of the Freedom EX 4000 Inverter/Charger with 48VDC- High Surge Loads to-12VDC Converter. This section includes: Over-temperature Conditions LED Status Indicators and Power Button Operating in Battery Mode...

  • Page 30: Led Status Indicators And Power Button

    AC power is passed through to the load and/or charging the battery. Inverter Battery mode or Inverter mode is enabled and Battery is not connected. the unit is inverting power from the house LED (house battery. power) Freedom EX 4000 Owner's Guide...
  • Page 31 LED Status Indicators and Power Button Item LED Name Steady  Flashing  Off  DC/DC The 48VDC-to-12VDC converter function is The 48VDC-to-12VDC converter enabled. function is disabled. Converter An event condition such as ground fault or error An event condition, such as a No events are detected.

  • Page 32: Operating In Battery Mode

    AC power, powering equipment and appliances connected to the AC output terminal of the unit. The green status LED lights up to indicate the Freedom EX 4000 is using the battery to power the equipment and appliances.

  • Page 33: Search Mode

    To prevent unnecessary battery discharge, press the Power The search mode feature is only valuable if button to Standby when you are not using the Freedom EX 4000. When to set up the inverter can spend a fair amount of time Search mode “sleeping”...

  • Page 34: Power Save Mode

    Disable search mode from the main battery by reducing the output from 120 volts to 108 volts when Freedom EX 4000 Setup menu, causing the the loads are consuming less than 100 watts. When the Freedom inverter to remain at full output voltage.

  • Page 35: Checking Battery Status

    Operating in Battery Mode Checking Battery Status Checking Output Power During inverter operation (in battery mode), sufficient battery When the inverter/charger/converter is operating in battery mode, capacity is indicated by a steady DC source LED. A low battery inverter power is indicated by a steady Inverter LED as shown capacity is indicated as an event condition on the LED panel with below.

  • Page 36: Operating Several Loads At Once

    4000, turn them on one at a time after you have turned the inverter/charger/converter on. Turning loads on separately helps to ensure that the inverter/charger/converter does not have to deliver the starting current for all the loads at once, and will help prevent an overload shutdown. Freedom EX 4000 Owner's Guide...

  • Page 37: Operating During Transition Between Shore Mode And Battery Mode

    When the unit is operating in shore mode and shore power is lost, Battery Mode the Freedom EX 4000 has less than 20 milliseconds (default) to The Freedom EX 4000’s advanced power management is capable switch to operating in battery mode (if the Power button is pressed of transitioning power from an AC source to DC source within a in the On position) and starts drawing power from the battery.

  • Page 38: Transitioning From Battery Mode To Shore Mode

    If shore power remains stable for a 20-second countdown, at the end of the countdown, the Freedom EX 4000 will switch to shore power mode within 20 milliseconds and start drawing power from the AC source.

  • Page 39: Operating Limits

    Operating Limits Operating Limits Inverter Power Output The Freedom EX 4000 can deliver up to 4000 watts of continuous These are the operating limits of the Freedom EX 4000: utility grade sine wave AC power. The wattage rating applies to Inverter Power Output resistive loads such as a heater element.

  • Page 40: Input Voltage

    Operating Limits Input Voltage Operating Battery Voltage Comment The allowable Freedom EX 4000 input battery voltage ranges are Condition shown in the following table: If installed, the display on the Table 6 Input battery voltage range Freedom EX Remote Panel (PN: 808-0817-03) shows...

  • Page 41: Overload Conditions

    Loads connected to the inverter are seldom constant, and large The Event LED turns on.  loads are often operated for short periods. To accommodate larger High loads, the Freedom EX 4000 can temporarily exceed its Voltage > 64.0 volts continuous output power rating.

  • Page 42: High Surge Loads

    Some induction motors used in freezers, pumps, and other motor- operated equipment require high surge currents to start. The Freedom EX 4000 may not be able to start some of these motors even though their rated steady state current draw is within the inverter/charger/converter’s limits.

  • Page 43: Configuration

    This section includes descriptions on how to change the various IMPORTANT:  The Freedom EX 4000 Inverter/Charger with settings of the Freedom EX 4000 Inverter/Charger with 48VDC- 48VDC-to-12VDC Converter can be to-12VDC Converter using the optional Freedom EX Remote configured using the Freedom EX Remote Panel (PN: 808-0817-03).

  • Page 44: Freedom Ex 4000 Remote Display Panel

    Freedom EX 4000 Remote Display Panel Freedom EX 4000 Remote Function Buttons Display Panel Button Definition Figure 7 Display Panel Return to default screen or exit setting mode. Scroll to next screen or next selection. Press and hold for three seconds to scroll back one step.

  • Page 45: Lcd Screen Icons

    Freedom EX 4000 Remote Display Panel LCD Screen LCD Screen Icons The LCD Screen changes depending on the operating mode of the Icon Definition inverter/charger/converter. Figure 8 Parts of the LCD Screen AC input and output indicator. The wrench icon underneath a number is displayed during configuration mode.
  • Page 46 Freedom EX 4000 Remote Display Panel Icon Definition Icon Definition The load icon is displayed if there is This icon shows when there is power voltage available at the AC output. conversion from AC to DC - charging. This icon shows when there is power conversion from DC to AC - inverting.

  • Page 47: Adjusting Settings In Configuration Mode

    Adjusting Settings in Configuration Mode Adjusting Settings in To change the default value to a different value: 1. Press and hold the button for three seconds to enter the Configuration Mode Configuration mode. 2. Press the Scroll button to scroll through the different , Scroll , and buttons can be used to cycle...

  • Page 48: General Settings

    Enable Search mode in parallel stacking*. Search mode is not supported in series stacking*. * Contact Xantrex prior to stacking two Freedom EX 4000 units together. Stacking configuration via USB is a required step to enable stacking. 50.0 3.0 to 50.0...
  • Page 49 Enables or disables Charger mode. When (enable) CHD (disable) enabled and when AC source power is present and qualified, the Freedom EX 4000 charges the connected battery until fully charged. FCO (no effect) Force Charge Forces the charging algorithm to a specific FC1 (force bulk stage) stage.
  • Page 50 For sub-settings, see Invert Sub-settings on page 37. Custom settings For sub-settings, see Custom Sub-settings on page 39. AC settings For sub-settings, see AC Sub-settings on page Device settings For sub-settings, see Device Sub-settings on page 41. Freedom EX 4000 Owner's Guide...
  • Page 51 USE (Custom), LFP (LiFePO ) is a pre-set battery type that LFP (LiFePO requires a compatible Xantrex Battery with AGn (AGM), BMS. Other lithium-ion batteries with BMS should be set as USE (Custom) battery type with parameters set according to the battery manufacturer's specifications.
  • Page 52 HOT(Hot) (BTS) is not installed. In the absence of a BTS, the charger uses either Cool = 5 °C, Warm = 25 °C, or Hot = 40 °C. Not applicable when LFP battery type is selected. Freedom EX 4000 Owner's Guide...
  • Page 53 Adjusting Settings in Configuration Mode Invert Sub-settings Setting Default Setting Name Range of Values Description Unit Step Number Value 44.0 36.0 to 50.0 Low Battery Cutout  Controls when the inverter turns off due to a low (LBCO) battery voltage condition. The inverter will turn off only after this level has been reached for the period of time set by the LBCO Delay.
  • Page 54 Sets the time between search pulses. When searching for loads, the Freedom EX 4000 sends out search pulses to determine if a load is present. If the Freedom EX 4000 finds a load above the Search Threshold setting, the inverter turns on.
  • Page 55 Adjusting Settings in Configuration Mode Custom Sub-settings NOTE: These settings appear only when the battery type is set to USE (custom). Setting Default Setting Name Range of Values Description Unit Step Number Value 64.0 54.0 to 64.0 Equalization Sets the equalization voltage. Voltage 57.6 40.0 to 65.0...
  • Page 56 Generator Support Enables or disables Generator support mode. (enable) 65d (disable) Mode 0 to 40 Generator Support Sets the generator load level at which the Current inverter supplies power from the batteries to support the generator. Freedom EX 4000 Owner's Guide...
  • Page 57 Adjusting Settings in Configuration Mode Device Sub-settings Setting Default Setting Name Range of Values Description Unit Step Number Value SAF (standby) Operating Mode Sets the operating mode of the system to (operating) OPE (operating) either Standby or Operating. ENA (enable) Select Ena to clear the faults and warnings on Clear Faults and (disable)
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  • Page 59: Routine Maintenance

    5 ROUTINE MAINTENANCE Regular maintenance is required to keep your Freedom EX 4000 operating properly. This section includes: Maintaining the Freedom EX 4000 Unit 975-0999-01-01...

  • Page 60: Maintaining The Freedom Ex 4000 Unit

    WARNING ELECTRICAL SHOCK HAZARD Turning the Power k button to Standby does not disconnect DC battery power from the Freedom EX 4000. You must disconnect from all power sources before working on any circuits connected to the unit. Failure to follow these instructions can result in death, serious injury, or equipment damage.

  • Page 61: Troubleshooting

    6 TROUBLESHOOTING This section will help you narrow down the source of any problem you encounter. Before contacting customer service, please work through the steps listed in Pre-service Checklist on page 46. This section includes: Pre-service Checklist Inverter Applications Resistive Loads Motor Loads Problem Loads Warning Messages...

  • Page 62: Pre-Service Checklist

    LED panel, check the following to make sure the present ELECTRICAL SHOCK HAZARD state of the installation allows proper operation: Do not disassemble the Freedom EX 4000. It does not contain any Is the inverter/charger/converter located in a clean, user-serviceable parts. Attempting to service the unit yourself could dry, adequately ventilated place? result in an electrical shock or burn.

  • Page 63: Inverter Applications

    Long Transfer Times required would be impractical if the load is to be run for long The Freedom EX 4000 may take a long time (~ 0.1–0.2 s) to periods. transfer to Battery Mode when shore power is cut off while powering a motor load.

  • Page 64: Problem Loads

    50 W must be used to bring the Freedom EX 4000 out of search mode, or the Freedom EX 4000 may be programmed to remain on by disabling search mode.

  • Page 65: Warning Messages

    Warning Messages Warning Messages Warning messages in the form of audible alarms and error codes that appear on the LCD screen to alert you to an impending system change. Warnings do not affect operation. The error codes are listed in Table 1. The text in the Error Code column appears on the LCD screen of the display panel.
  • Page 66 The AC L1L2 transfer relay is bad or an AC source was wired directly to the AC output. Disconnect the inverter’s output wiring. If error continues, have unit serviced. See 17. Relay(s) Welded Shore (AC) mode Freedom EX 4000 Owner's Guide...
  • Page 67 Warning Messages Table 7 Event codes displayed on the LCD screen Event Code Event Type Condition Mode Action E - Escalating Auto Fault. See Action for more detail. F - Manual fault. Unit operation stops. See Action to remedy the condition and clear the Alert LED on the unit. See Clear Faults and Warnings on page 41. W - Warning.
  • Page 68 Check for loads above the inverter’s capacity, turn off some loads if AC Overload Line 1 Any mode necessary. Power down and restart the unit to clear the manual fault. AC Overload Line 2 Any mode Freedom EX 4000 Owner's Guide...
  • Page 69 Warning Messages Table 7 Event codes displayed on the LCD screen Event Code Event Type Condition Mode Action E - Escalating Auto Fault. See Action for more detail. F - Manual fault. Unit operation stops. See Action to remedy the condition and clear the Alert LED on the unit. See Clear Faults and Warnings on page 41. W - Warning.
  • Page 70 Operating Temperature Range, press the Power [Standby] button twice (toggle the switch) on the unit or the remote display panel to restart operation. Freedom EX 4000 Owner's Guide...
  • Page 71 Warning Messages Table 7 Event codes displayed on the LCD screen Event Code Event Type Condition Mode Action E - Escalating Auto Fault. See Action for more detail. F - Manual fault. Unit operation stops. See Action to remedy the condition and clear the Alert LED on the unit. See Clear Faults and Warnings on page 41. W - Warning.

  • Page 72: Troubleshooting Reference

    Troubleshooting Reference WARNING ELECTRICAL SHOCK HAZARD Do not disassemble the Freedom EX 4000. It does not contain any user-serviceable parts. Attempting to service the unit yourself could result in an electrical shock or burn. Failure to follow these instructions can result in death, serious injury, or equipment damage.
  • Page 73 Troubleshooting Reference Table 8 Troubleshooting reference Problem Possible Cause Solution Alarm on the Freedom EX Remote Alarm buzzer is turned OFF. See Device Sub-settings on page 41 and follow Panel (PN: 808-0817-03) does not instructions to turn the alarm buzzer on again. sound when an error is encountered.
  • Page 74 Battery voltage is too low Check DC connections and cable. (depending on setting, see Recharge battery. Maintaining the Freedom EX 4000 Unit on page 44) to start inverting. LCD screen may show DC voltage as 000. No output voltage is shown in the LCD AC shore power is not available or Check AC shore power.

  • Page 75: Specifications

    NO CIRCUMSTANCES SHOULD THIS STATUS DATA BE USED FOR PRECISE EVALUATION OF THE FREEDOM EX 4000 SYSTEM PERFORMANCE, INCLUDING EFFICIENCY CONSIDERATIONS. IN SYSTEMS WITH A SINGLE FREEDOM EX 4000, THE MEASUREMENT NOTE: Specifications are subject to change without prior notice. CAPABILITIES OF THE INVERTER/CHARGER/CONVERTER ALLOW FOR For a complete list of hardware, hardware accessories, and DEVIATIONS OF UP TO 5% OF ACTUAL VALUES.

  • Page 76: Environmental Specifications

    Operation may be limited based on the battery chemistry. For example, Lithium Iron Phosphate batteries have a limited charging temperature range. Follow specific battery manufacturer recommendations for the Circuit breakers shall not carry more than 80% of their UL current rating continuously. applicable chemistry. Freedom EX 4000 Owner's Guide...
  • Page 77 Cooling Fan, activated by any of the following: High internal temperature High AC output power  Contact Xantrex prior to stacking two Freedom EX 4000 units together. Stacking configuration via USB is a required step to enable stacking. 975-0999-01-01...
  • Page 78 GFCI protection customer-provided Wave shape True Sine Wave Total Harmonic Distortion < 5% at rated power  Power derates to 85% when output voltage is set to 110/108 VAC.  See Ground Fault Circuit Interrupters (GFCIs) for approved device/s. Freedom EX 4000 Owner's Guide...
  • Page 79 Output Frequency 60 Hz  Contact Xantrex prior to stacking two Freedom EX 4000 units together. Stacking configuration via USB is a required step to enable stacking.  Contact Xantrex prior to stacking two Freedom EX 4000 units together. Stacking configuration via USB is  L1-N must be within the single-phase qualification voltage range, 80–138 VAC, for split-phase to operate...

  • Page 80: Regulatory 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 CFR 47, (FCC) Part 15, Subpart B, Class B CAN ICES-3(B)/NMB-3(B) Freedom EX 4000 Owner's Guide...
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  • Page 82 (Toll Free USA/Canada) +1 800 670 0707 (Outside USA/Canada) +1 408 987 6030 975-0999-01-01 Rev C Printed in: 30948...

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