Xantrex Freedom EX 4000 User manual

Freedom EX 4000 Inverter/Charger
with 48VDC-to-12VDC Converter
Owner’s Guide
Freedom EX 4000
PN:820-4080-41

ii Freedom EX 4000 Owner's Guide
Copyright © 2019-2021 Xantrex LLC. All Rights Reserved.
All trademarks are owned by Xantrex LLC and its affiliates.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING, SELLER
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS
MANUALS OR OTHER DOCUMENTATION;
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT,
CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE
ENTIRELY AT THE USER’S RISK; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE
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.
Document Number:975-0999-01-01 Rev C Date: July 2021
Product Name and Part Number
Freedom EX 4000 (820-4080-41)
Contact Information
Telephone: (Toll Free USA/Canada) [phone] / (Outside USA/Canada) [phone]
Email: [e-mail],
http://www.xantrex.com/power-products-support/
Web: http://www.xantrex.com/

975-0999-01-01 iii
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.

iv Freedom EX 4000 Owner's Guide
Purpose
The purpose of this Owner’s Guide is to provide explanations and
procedures for operating, configuring, maintaining, and
troubleshooting a Freedom EX 4000 Inverter/Charger with
48VDC-to-12VDC Converter for Recreational, Commercial and
Fleet Vehicle, or Marine installations.
Scope
The guide provides safety and operating guidelines as well as
information on configuring the inverter/charger/converter. It also
provides information about troubleshooting the unit. It does not
provide details about particular brands of batteries. You need to
consult individual battery manufacturers for this information.
Audience
The guide is intended for users and operators of the Freedom EX
4000. A separate Freedom EX Installation Guide (document
number: 975-0998-01-01) is intended for qualified personnel.
Qualified personnel have training, knowledge, and experience in:
lInstalling electrical equipment (up to 1000 V).
lApplying all applicable installation codes.
lAnalyzing and reducing the hazards involved in performing
electrical work.
lInstalling and configuring lead-acid and/or lithium-ion
batteries.
lSelecting and using PPE and following safety work code
practices. See NFPA 70E or 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
DC Direct Current[Z]
GFCI Ground Fault Circuit Interrupter
Hz Hertz (a unit of frequency)
in-lb inch-pound force (a unit of torque)
kW Kilowatts (1000 watts)
LBCO Low Battery Cutout (or Cutoff)
LCD Liquid Crystal Display
LED Light Emitting Diode
LFP LiFePO4(lithium iron phosphate – a battery type)
N-m Newton-meters (a unit of torque)
PN Product Number
PPE Personal Protective Equipment
RV-C Recreational Vehicle CAN Bus Communications protocol
s Seconds (a unit of time)
V, VAC, VDC Voltage, Volts AC, Volts DC
W Wattage, watt (a unit of power)
Related Information
You can find more information about Xantrex products and
services at http://www.xantrex.com/.

IMPORTANT SAFETY INSTRUCTIONS
READ AND SAVE THIS OWNER’SGUIDE FOR FUTURE
REFERENCE.
This guide contains important safety instructions for the Freedom
EX 4000 that must be followed during installation, operation,
maintenance, and troubleshooting.
Read these instructions carefully and look at the equipment to
become familiar with the device before operating, configuring,
maintaining, and troubleshooting it. The following special
messages may appear throughout this documentation or on the
equipment to warn of potential hazards or to call attention to
information that clarifies or simplifies a procedure.
The addition of either symbol to a “Danger” or
“Warning” safety label indicates that an electrical
hazard exists which will result in personal injury if the
instructions are not followed.
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNINGindicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
975-0999-01-01 v

vi Freedom EX 4000 Owner's Guide
Product Safety Information
1. Before using the inverter/charger/converter, read all
instructions and cautionary markings on the unit, the
batteries, and all appropriate sections of this guide.
2. Use of accessories not recommended or sold by the
manufacturer may result in a risk of fire, electric shock, or
injury to persons.
3. The inverter/charger/converter is designed to be connected
to both DC and AC electrical systems. The manufacturer
recommends that all wiring be done by a certified technician
or electrician to ensure adherence to the local and national
electrical codes 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/converter
with damaged or substandard wiring.
5. Do not operate the inverter/charger/converter if it has been
damaged in any way.
6. This unit does not have any user-serviceable parts. Do not
disassemble the inverter/charger/converter except where
noted for connecting wiring and cabling. See your warranty
for instructions on obtaining service. Attempting to service
the unit yourself may result in a risk of electrical shock or
fire. 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
inverter/charger/converter. Do not disconnect under load.
Turning the inverter/charger/converter to Standby using the
Power button on the front panel will not reduce an electrical
shock hazard.
8. The inverter/charger/converter must be provided with an
equipment-grounding conductor connected to the AC input
ground.
9. Do not expose this unit to rain, snow, or liquids of any type.
This product is designed for dry-locations-use only. Damp
environments will significantly shorten the life of this product
and corrosion caused by dampness will not be covered by
the product warranty.
10. To reduce the chance of short-circuits, always use insulated
tools when installing or working with this equipment.
11. Remove personal metal items such as rings, bracelets,
necklaces, and watches when working with electrical
equipment.
12. For marine applications, this unit must be installed with a
drip shield. Refer to the Installation Guide (doc number: 975-
0998-01-01) for details.

975-0999-01-01 vii
DANGER
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.
Failure to follow these instructions will result in death or serious
injury.
DANGER

viii Freedom EX 4000 Owner's Guide
HAZARD OF ELECTRIC SHOCK, EXPLOSION, BURN, OR
ARC FLASH
nApply appropriate personal protective equipment (PPE) and
follow safe electrical work practices. See NFPA 70E or CSA
Z462.
nThis equipment must only be installed and serviced by
qualified electrical personnel.
nTurn off all power supplying this equipment before working
on or inside equipment.
nAlways use a properly rated voltage sensing device to
confirm power is off.
nReplace all devices, doors, and covers before turning on
power to this equipment.
nBatteries can present a risk of electrical shock, high short-
circuit current, and exposure to gasses and chemicals.
nObserve the following precautions when working with
batteries: •Remove watches, rings, or other metal objects;
•Keep sparks and flames away from batteries; •Use tools
with insulated handles; •Do not lay tools or other metal parts
on top of batteries.
nServicing of batteries must only be performed by qualified
personnel knowledgeable of batteries and the required
precautions. Keep unqualified personnel away from
batteries.
nDisconnect the charging source prior to connecting or
disconnecting battery terminals.
nNever attempt to charge a frozen battery.
Failure to follow these instructions will result in death or serious
injury.
WARNING
FIRE AND EXPLOSION HAZARD
nUnit’s components may produce arcs or sparks.
nDo not install near batteries, in machinery space, or in an
area in which ignition-protected equipment is required.
nFor indoor use only.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
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 can result in death, serious
injury, or equipment damage

975-0999-01-01 ix
WARNING
ELECTRICAL SHOCK HAZARD
nReplace the wiring compartment cover before turning on
power to this equipment.
nUse a torque screwdriver to tighten the captive nut panel
screw to 5 in-lb (0.56N-m) torque to ensure a proper 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.
CAUTION
HAZARD OF ELECTRICAL SHOCK AND FIRE
nDo not open. No serviceable parts inside. Provided with
integral protection against overloads. Bonding between
conduit connections is not automatic and must be provided
as part of the installation.
nRead manual before installing or using.
nDo not cover or obstruct ventilation openings.
nDo not mount in zero-clearance compartment – overheating
may result.
nDo not expose to rain or spray.
nInstall GFCI protection of branch circuits connected to the AC
output per electrical code requirements.
nDo not connect AC OUT to any other source of power.
Damage to unit may occur.
nFor AC IN and AC OUT, use wires suitable for at least 75°C.
Failure to follow these instructions can result in minor or
moderate injury.

x Freedom EX 4000 Owner's Guide
NOTES:
nFollow these instructions and those published by the
battery manufacturer and the manufacturer of any
equipment you intend to use in the vicinity of the battery.
Review cautionary markings on these products and on the
engine.
nFreedom EX 4000 Inverter/Charger with 48VDC-to-12VDC
Converter products are designed for deep cycle lead-acid
batteries. See warning below when connecting to lithium ion
batteries.
nDo not use transformerless battery chargers in conjunction
with the inverter/charger/converter due to overheating.
CAUTION
LITHIUM ION BATTERY TYPE HAZARD
Make sure to use a lithium ion battery pack that includes a certified
Battery Management System (BMS) with built-in safety protocols
including 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-charge circuit is a featured built-in contactor by some
battery manufacturers which regulates inrush current from the
inverter's capacitors allowing a smooth transition into full power
system operation.
CAUTION
PHYSICAL INJURY HAZARD
This Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC
Converter is not intended for use by persons (including children)
with reduced physical, sensory, or mental capabilities or lack of
experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be supervised
to ensure that they do not play with the appliance.
Failure to follow these instructions can result in injury or
equipment damage.

Precautions When Working With Batteries
975-0999-01-01 xi
Precautions When Working With
Batteries
IMPORTANT: Battery work and maintenance must be done by
qualified personnel knowledgeable about batteries to ensure
compliance with battery handling and maintenance safety
precautions.
WARNING
BURN FROM HIGH SHORT-CIRCUIT CURRENT, FIRE
AND EXPLOSION FROM VENTED GASES HAZARDS
nAlways wear proper, non-absorbent gloves, complete eye
protection, and clothing protection. Avoid touching your eyes
and wiping your forehead while working near batteries. See
note #4.
nRemove all personal metal items, like rings, bracelets, and
watches when working with batteries. See notes #5 and #6
below.
nNever smoke or allow a spark or flame near the engine or
batteries.
nNever charge a frozen battery.
nNever charge a Lithium Ion type battery with 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-to-12VDC Converter unit away from batteries in a well
ventilated compartment.
2. Always have someone within range of your voice or close
enough to come to your aid when you work near a lead-acid
battery.
3. Always have plenty of fresh water and soap nearby in case
battery acid contacts skin, clothing, or eyes.
4. Keep battery terminals clean from corrosion. If battery acid or
corrosion deposit contacts skin or clothing, wash immediately
with soap and water. If battery acid or corrosion deposit enters
your eye, immediately flood it with running cold water for at
least twenty minutes and have someone within range of your
voice or close enough to get medical attention immediately.
5. Use extra caution to reduce the risk of dropping a metal tool on
the battery. It could spark or short circuit the battery or other
electrical parts and could cause an explosion. Use tools with
insulated handles only.
6. Batteries can produce a short circuit current high enough to
weld a ring or metal bracelet or the like to the battery terminal,
causing a severe burn.
7. When removing a battery, always remove the negative
terminal from the battery first for systems with grounded
negative. Only use this unit in a negative (-) grounded system.
This unit is not designed for a positive (+) grounded system.
Make sure all loads connected to the battery and all
accessories are off so you don’t cause an arc.

Precautions When Placing the Unit
xii Freedom EX 4000 Owner's Guide
Precautions When Placing the
Unit
WARNING
FIRE HAZARD
nDo not install the inverter/charger/converter or any part of its
supplied wiring in engine compartments.
nFor marine installation, always locate the
inverter/charger/converter away from the battery and
mounted separately in a well-ventilated compartment with
adequate space.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
CAUTION
BURN HAZARD
Avoid touching the external surfaces as they may be hot.
Failure to follow these instructions can result in injury or
equipment damage.
NOTICE
RISK OF INVERTER/CHARGER/CONVERTER DAMAGE
nNever allow battery acid to drip on the
inverter/charger/converter when reading specific gravity, or
filling battery.
nNever place the Freedom EX 4000 unit directly above
batteries; gases from a battery will corrode and damage the
inverter/charger/converter.
nDo not place a battery on top of the
inverter/charger/converter.
Failure to follow these instructions can result in equipment
damage.
Regulatory
The Freedom EX 4000 inverter/charger/converter is certified to
appropriate US and Canadian standards. For more information
see Regulatory approvals on page 64.
The Freedom EX 4000 inverter/charger/converter is intended to be
used for recreational, commercial, or other mobile applications.
This inverter/charger/converter is designed for marine applications
only when additional drip protection is installed in certain
orientations. See the Installation Guide (doc number: 975-0998-
01-01) for information.

FCC (EMI) Information to the User
975-0999-01-01 xiii
FCC (EMI) Information to the User
This equipment has been tested and found to comply with the
limits for a Class B digital device, pursuant to part 15 of the
FCC/CAN ICES-003 Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential
environment. This equipment generates, uses, and can radiate
radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference
to radio communications.
However, there is no guarantee 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 and on, the user is
encouraged to try to correct the interference by one or more of the
following measures:
nReorient or relocate the receiving antenna.
nIncrease the separation between the equipment and
receiver.
nConnect the equipment into an outlet on a circuit different
from that to which the receiver is connected.
nConsult the dealer or an experienced radio/TV technician for
help.
CAUTION
Unauthorized changes or modifications to the equipment could
void the user’s authority to operate the equipment.
End of Life Disposal
The Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC
Converter is designed with environmental awareness and
sustainability in mind. At the end of its useful life, the Freedom EX
4000 can be decommissioned and disassembled. Components
which can be recycled must be recycled and those that cannot be
recycled must be disposed of according to local, regional, or
national environmental regulations.
Many of the electrical components used in the Freedom EX 4000
Inverter/Charger with 48VDC-to-12VDC Converter are made of
recyclable material like steel, copper, aluminum, and other alloys.
These materials can be auctioned off to traditional scrap metal
recycling companies who resell reusable scraps.
Electronic equipment such as the circuit boards, connectors, and
fuses can be broken down and recycled by specialized recycling
companies whose goal is to avoid having these components end
up in the landfill.
For more information on disposal, contact Xantrex.

This page is intentionally left blank. [2]

CONTENTS
Important Safety Instructions v
Precautions When Working With Batteries xi
Precautions When Placing the Unit xii
Regulatory xii
FCC (EMI) Information to the User xiii
End of Life Disposal xiii
Introduction 1
Materials List 2
Key Features 2
Features 7
AC/DC Panel 8
Communications Panel 10
LED Panel 12
Operation 13
LED Status Indicators and Power Button 14
Operating in Battery Mode 16
Turning Inverter Operation ON and OFF 16
Search Mode 17
Power Save Mode 18
Checking Battery Status 19
Checking Output Power 19
Operating Several Loads at Once 20
Operating During Transition Between Shore Mode and
Battery Mode 21
Transitioning from Shore Mode to Battery Mode 21
Transitioning from Battery Mode to Shore Mode 22
Operating Limits 23
Inverter Power Output 23
DC-to-DC Converter Power Output 23
Input Voltage 24
Overload Conditions 25
High Surge Loads 26
Over-temperature Conditions 26
Configuration 27
Freedom EX 4000Remote Display Panel 28
975-0999-01-01 xv

xvi Freedom EX 4000 Owner's Guide
Function Buttons 28
LCD Screen 29
LCD Screen Icons 29
Adjusting Settings in Configuration Mode 31
General Settings 32
Routine Maintenance 43
Maintaining the Freedom EX 4000 Unit 44
Troubleshooting 45
Pre-service Checklist 46
Inverter Applications 47
Resistive Loads 47
Motor Loads 47
Problem Loads 48
Warning Messages 49
Troubleshooting Reference 56
Specifications 59
Environmental Specifications 60
System Specifications 60
Regulatory Approvals 64

1 INTRODUCTION
The Freedom EX 4000 Inverter/Charger with 48VDC-to-12VDC
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 2
Key Features 2
975-0999-01-01 1

Materials List
2 Freedom EX 4000 Owner's Guide
Materials List
The Freedom EX 4000 base package includes the following items.
1 Freedom EX 4000
2 Installation guide
3 pair of ½" bushings
4 pair of ¾" bushings
5 one network terminator
1234
5
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.
Key Features
Power for Most
Appliances
The Freedom EX 4000
inverter/charger/converter provides up to
4000wattsaof continuous utility grade, sine
wave power derived from a battery bank. It is
designed to handle loads such as microwave
ovens, TVs, DVD/Blu-ray players, and power
tools. In addition, the Freedom EX 4000’s
high-surge capability lets you handle many
hard-to-start loads, including a full size
residential refrigerator and air conditioning
unit.
The built-in transfer switch automatically
transfers between inverter power and shore
power from recreational facilities such as boat
docks or campsites to ensure power is
always available.
aAs the ambient temperature rises above 40°C, the output power capability will reduce to below 4000W
until the over temperature shutdown occurs.

Materials List
975-0999-01-01 3
Back-up
Capability
If incoming shore power is interrupted by
external events like brownouts, the Freedom
EX 4000 automatically becomes an
independent power sourcebthat supplies
utility grade AC power to your loads.
bAssuming the inverter/charger/converter is connected to a battery source with an adequate charge at the
time of the power interruption.
Comprehensive
Protection
The Freedom EX 4000’s built-in protection
features safeguard your batteries (from
unnecessary drain) such as the following:
nSelectable Low Battery Shutdown:
The low battery shutdown for the
inverter/charger/converter can be
manually selected by the user from 36.0
to 48.0VDC.
nLow Voltage Shutdown Delay Timer:
Configurable from 0 to 600seconds to
reduce an unnecessary shutdown of
inverter operation such as during
cranking or other brief but heavy
discharge of battery.
nInverter Search Mode: Search mode
allows the inverter to selectively power
only items that draw more than a certain
amount of power, which can result in
energy savings. The Freedom EX 4000
has a no-load power draw of about
30watts. Enabling search mode
reduces this power draw to less than
5watts. For more information, see
Search Mode on page 17.

Materials List
4 Freedom EX 4000 Owner's Guide
Overload Alarm
and Shutdown
During Battery Mode (also called Inverter
Mode), the Freedom EX 4000 automatically
alerts you if the loads that are connected and
drawing power from the unit are close to
approaching the maximum operating limit. If
so, inverting and/or charging operation is
temporarily shut down when the maximum
operating limit is exceeded to prevent
overheating. Inverting and/or charging
operation resumes when the shutdown error
is cleared. See Troubleshooting Reference on
page 56 for precautions.
Over temperature
Alarm and
Shutdown
During Battery Mode, the Freedom EX 4000
automatically alerts you if it is overheating
and approaching the over-temperature
shutdown limit. Inverting and/or charging
operation is temporarily shut down when the
limit is exceeded until the shutdown error is
cleared. See Troubleshooting Reference on
page 56 for precautions.
Built-in Charge
Formulas
For the inverter/charger/converter to perform
at the highest level, the batteries must be
charged correctly. The Freedom EX 4000 has
optimized algorithms for flooded, gel, AGM,
and Custom batteries, and lithium iron
phosphate [LFP (or LiFePO4)] Xantrex
Batteries.
Manual
Equalization (for
Flooded, vented
lead-acid
batteries)
Over a period of time, the cells in a flooded
battery can develop uneven chemical states.
This can result in a weak (undercharged) cell
which, in turn, can reduce the overall capacity
of the battery. To improve the life and
performance of a non-sealed, flooded battery,
the Freedom EX 4000 multi-stage charging
cycle includes a manual equalize mode that
can be used, if recommended by the battery
manufacturer.