Xantrex Freedom e-GEN User manual

DANGER
HAZARD OF FIRE, ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
This Freedom e-GEN System End-of-Line Checklist is in addition to, and incorporates by reference, the relevant product manuals for each product in the power system. After reviewing this guide you must
read the relevant product manuals. Unless specified, information on safety, specifications, installation, and operation is as shown in the primary documentation received with the product. Ensure you are familiar
with that information before proceeding.
Failure to followthese instructions willresult in death orseriousinjury.
Important Safety Information
READ AND SAVE THESE INSTRUCTIONS
Electrical equipment shall be installed, operated, serviced, and maintained only by qualified personnel. Certain configuration tasks shall only be
performed by qualified personnel in consultation with your local utility and/or an authorized dealer. Servicing of batteries and the BMS shall only be
performed or supervised by qualified personnel with knowledge of lithium-ion batteries and their required precautions. Qualified personnel have training,
knowledge, and experience in:
• Installing electrical equipment
• Applying applicable installation codes
• Analyzing and reducing the hazards involved in performing electrical work
• Installing and configuring lithium-ion batteries
• Selecting and using Personal Protective Equipment (PPE)
No responsibility is assumed by Xantrex LLC for any consequences arising out of the use of this material.
DANGER
HAZARD OF FIRE, ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E or CSA Z462.
• Equipment must only be installed and serviced by qualified electrical personnel.
• Equipment may be energized from multiple sources. Never operate equipment energized with covers removed.
• In case of fire, use only a Class ABC type (dry chemical) fire extinguisher. Water can be a dangerous extinguishing medium for energized equipment
because of the risk of electrical shock.
• Always use a properly rated voltage sensing device to confirm all circuits are de-energized.
• Do not short-circuit the battery.
• Do not expose the battery to flames.
• Do not attempt to open or dismantle the lithium-ion battery. If the battery is damaged, do not touch the corrosive electrolyte or powder. In case battery
content comes in contact with skin or eyes, immediately flush the affected area with large amount of clean water and seek medical help.
• Upon disposal, do not crush, puncture, drop, disassemble, dispose of in fire, or similar actions.
Failure to follow these instructions will result in death or serious injury.
WARNING
HAZARD OF FIRE, ELECTRIC SHOCK, EXPLOSION, BURN, OR PERSONAL INJURY
• Always use the Xantrex Battery with the BMS. Never bypass the BMS. The BMS must always be connected to the lithium-ion battery and in the circuit
for proper operation and safety.
• Do not connect other battery types to the system DC load or the system DC bus.
• Do not expose any of the equipment to rain, snow, or liquids of any type. Products are designed for indoor use only.
• Do not operate the battery or other equipment with damaged or substandard wiring.
• Do not replace the battery fuses or any other fuses in the system by yourself.
• Do not obstruct the air ventilation openings on the system devices. Do not install or operate any of the system devices in compartment containing
flammable materials or in locations that require ignition-protected equipment.
• When the lithium-ion battery becomes damaged, it can release harmful gases. In such a case, ventilate the area whenever possible but evacuate the
vicinity immediately.
Failure to follow these instructions can result in death or serious injury.
CAUTION
RISK OF PERSONAL INJURY OR EQUIPMENT DAMAGE
• Use the right tools for the job. Use of improper tools may result in damage to equipment and personal injury.
• Do not lift heavy equipment by yourself. Use two or more people to lift and mount heavy equipment such as the inverter and battery. Use proper lifting
techniques during installation to prevent injury and equipment damage.
• Mount and fasten all devices securely according to their installation guides.
Failure to follow these instructions can result in personal injury and/or damage to equipment and may void the warranty.
Freedom e-GEN System End-of-Line Checklist 976-0361-01-01
Rev B

NOTICE
RISK OF EQUIPMENT DAMAGE
• Do not physically modify the system devices, wiring harness, and accessories.
• Do not alter the factory settings on any of the system devices including the BMS.
• Do not disassemble the Xantrex Battery or the BMS. They contain non-serviceable parts.
• Only charge the Xantrex Battery with an approved charger. Contact Xantrex for details.
• Do not operate or store the battery outside of the specified environmental limits.
•Do not charge the battery in ambient temperature below freezing.
• Do not charge the battery above 14.8V.
• Do not allow the battery to be completely depleted.
• Do not disconnect the battery while it is being charged.
• Always use the Xantrex Battery with the BMS.
• Components which can be recycled must be recycled and those that cannot be recycled must be disposed of according to local, regional, and national
environmental regulations.
Failure to followthese instructions can result in damageto equipment and may void the warranty.
End-of-Line Functional Check
Refer to the Freedom eGEN System Installation Guide, Step 13 of the Installation Procedure (in section 4), and perform the
following end-of-line check step-by-step.
The eGEN system must be de-energized prior to performing the end-of-line check including removing AC power, turning off
vehicle ignition, turning off the battery disconnect switch, and making sure the BMS Power button is in the Off position.
Follow all necessary safety precautions, use personal protective equipment (PPE), and perform a lock-out, tag-out (LOTO).
1. £Check main battery fuse.
lCheck that all fuses are installed and are of the correct type and rating.
lCheck that the fuse replacement label adjacent to the associated fuseholder matches the fuse installed.
lUse a multimeter and check the continuity across the main battery fuse.
2. £Check that all power sources (AC and DC) have their appropriate means of disconnection (Disconnect Devices)
installed and located as close to the source as practical. Disconnect devices must be AC-rated for AC disconnection
and DC-rated for DC disconnection.
3. £Check resistance across system DC bus.
lWithout powering up the system, use a multimeter (Ohm) and measure the resistance between the positive and
negative DC bus bars.
lIf the resistance measures less than 10 Ohm then there is potentially a short circuit in the system. Locate the
short circuit and remove it before proceeding further.
4. £Check BMS operation.
lRemove all DC loads.
lPress the Power button on the BMS to turn it on and listen for the clicking sound when the BMS internal
contactor closes.
lThe battery SoC gauge on the remote panel should light up once battery power is engaged.
5. £Check the battery SoC gauge.
lWhen BMS is turned on, the battery SoC gauge should automatically start displaying battery status.
lPress the buttons on the SoC gauge to cycle through battery information and make sure the information is
correct.
lMake sure the battery capacity is set correctly.
6. £Power up the system.
lTurn on the battery disconnect switch to apply battery power to system DC bus.
lThe Freedom SW (FSW) Inverter/Charger should automatically begin the power-up sequence (the front LEDs
and unit fans should come on briefly upon applying DC power).
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Freedom e-GEN System End-of-Line Checklist

7. £Check FSW settings.
lUsing the ComBox tablet, make sure the configurations on the FSW Inverter / Charger are set correctly as
follows.
Parameters Setpoint
Inverter Settings
Low Batt Cut Out 10.5V
LBCO Delay 10s (min)
High Batt Cut Out 14.8V
Charger Settings
Battery Type Custom
Equalize Support Disabled
Bulk Voltage 14.6 V
Absorb Voltage 14.6 V
Float Voltage 13.4 V
Batt Capacity 600 Ah or
450Ah
Max Charge Rate 100%
Charge Cycle 3-Stage
Default Batt Temp Warm
ReCharge Volts 12.4 V
Absorb Time 30 min
Auto Charge Enable Enabled
8. £Check the 2nd alternator’s mechanical connection to the main engine.
lMake sure there are no objects, parts, or wires that can interfere with the auxiliary alternator belt.
lMake sure there are no fluids that have leaked or came into contact with the auxiliary belt or pulleys.
lCheck the 2nd alternator’s engine belt. Use a straight edge or laser alignment tool to ensure pulleys are within
0.5 degrees of alignment. Then check the alignment of all the other belts including tension according to their
manufacturer's specifications. Correct as necessary.
lWhen you start the vehicle, make sure the auxiliary belt, pulleys, and tensioner do not show excessive noise or
vibration.
9. £Check Balmar regulator operation.
lTurn on the vehicle’s engine ignition.
lOnce the engine and the second alternator are running, the 7-segment display on the Balmar regulator should
light up and begin cycling information.
lVisually check the Balmar regulator display. However, skip this step if the Balmar regulator is installed in the
engine compartment and cannot be viewed safely.
10. £Check alternator charging.
lWhen the second alternator is running, monitor the battery voltage and current information displayed on the
battery SoC gauge located on the remote display panel. As the alternator is charging, the battery voltage should
slowly rise and a charging current shown with “+” sign will be displayed on the SoC gauge.
11. £Check combiner operation.
lWith the engine running, verify that the combiner LED is blinking.
lIf the Xantrex Battery is below 12V, verify that the combiner is "combining" the currents by placing a current
clamp on the cable from the solenoid to the Xantrex Battery. It should read above 30A.
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Freedom e-GEN System End-of-Line Checklist

12. £Test FSW inverter.
lEnable FSW inverter through the ComBox tablet, or using the button on the front of the FSW unit.
lRun your desired AC appliance to make sure there is AC output from the inverter.
lMonitor the inverter status on the ComBox tablet.
13. £Test FSW charger.
lApply AC shore power to the FSW AC input.
lEnsure FSW charger is enabled on the ComBox tablet. After a brief moment to qualify AC shore power, the FSW
should begin charging.
lIf you already have AC appliances running on inverter power, they should not be interrupted as FSW
automatically and seamlessly transfers shore power to support AC loads.
lMonitor the FSW charger status on the ComBox tablet.
lAlso, monitor the battery SoC gauge on the remote panel to ensure the battery information is displayed correctly
there.
14. £Test full load operation.
lRun DC and AC loads on the vehicle for one complete discharge cycle of the battery as a system burn-in test.
lPay attention to any abnormal operations as well as overheating on all wiring and connections.
15. £Fully charge the battery.
lAfter testing the system at full load condition, turn off all DC and AC loads. Charge the Li-ion battery until it
reaches 100% SoC.
16. £Safely power down the system.
lShut down and de-energize the system.
lRemove AC shore power.
lRemove all DC and AC loads.
lTurn off the vehicle’s engine ignition.
lCheck the Balmar regulator display is off.
lTurn off the BMS using the the Reset button on the remote panel or by using its Power button. If the vehicle is to
be stored for longer than 3 months, refer to the Xantrex Battery Storage and Maintenance Guide (975-1005-01-
01) for more information.
Copyright © 2019 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.
Contact Information
Telephone: [phone]
Email: [e-mail],
http://www.xantrex.com/power-products-support/
Web: http://www.xantrex.com
976-0361-01-01 Rev B Copyright © 2019 Xantrex LLC. All Rights Reserved 4
Freedom e-GEN System End-of-Line Checklist