Xantrex Freedom e-GEN User manual

DANGER
HAZARD OF FIRE, ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
This Freedom e-GEN System User Guide 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.
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
1
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.
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.
2
Introduction
The Freedom e-GEN System solution from Xantrex is a lithium-ion battery-based power
system that offers safe, clean, and efficient onboard power. The system features a 600 Ah
or 450 Ah Xantrex Battery pack and a 3 kW inverter/charger, capable of delivering grid-
quality AC power to run onboard appliances for an extended period of time. The ability to
charge from both the auxiliary alternator and shore power offers flexibility and fast
recharge, further empowering your road experience.
The Freedom e-GEN System consists of the following core components:
lFreedom SW 3012 Inverter/Charger
lConext ComBox for Freedom SW and Tablet*
l600 Ah or 450 Ah lithium-ion Xantrex Battery pack and Xantrex BMS (Battery
Management System)
lAuxiliary Alternator and dedicated regulator
This user guide provides you basic instructions on how to operate and maintain the
Freedom e-GEN System. For more information, refer to each device’s Owner’s Guide.
*Some systems may come with a System Control Panel (SCP).
3
Turn On Battery and Inverter
REMOTE
PANEL
0 A
POWER/
RESET
Turning ON the BMS
•A single, brief press of the POWER/RESET
push button on the remote panel will turn on
the BMS and engage battery power.
Turning OFF the BMS
•Press and hold the POWER/RESET push
button for 3 seconds to turn off the BMS and
disengage battery power.
Once battery power is engaged, you can
enable and disable the Freedom SW
inverter AC output through an Android
tablet using the Conext ComBox app (or
through an SCP). Instant system status
and aggregate usage data are available
to help you monitor and assess your
energy consumption.
NOTICE
RISK OF EQUIPMENT OR BATTERY DAMAGE
• Do not change the factory settings of the Freedom SW.
• Do not leave appliances on if they are not in use as this will drain the battery..
Failure to followthese instructions can result in damageto equipment and may void the warranty.
4
Monitor Xantrex Battery Status
0 A
The SoC LCD Display (PN: 881-0401-12) on the system remote panel
powers up whenever BMS is turned on. Its screen has two lines
where battery information is displayed.
Press the Left (or Right) button to cycle through the following battery
information displayed on the first (or second) line.
Example Description
12.8V Battery voltage (Volts)
77F t1 Battery temperature (t1 = battery one)
R0000100 Battery status code used for troubleshooting
D 225 0d Remaining time until depletion (D) or full charge (C) in days (d) or hours (h)
T0000000 Total amount of amp-hours consumed from the battery since day of manufacture
600.0 Ah Battery amp-hours (Ah) remaining
8040 Wh Battery watt-hours (Wh) remaining
EÛÛÛÛÛÛÛF Battery bar gauge (Empty-Full)
100% BAT Remaining battery capacity before system shutdown
0A Discharging current (Amps) no sign OR charging current (Amps) with “+” sign
0W Load power consumption (Watts)
975-0791-01-01 Rev F
Sep 2019
Copyright © 2019 Xantrex LLC. All Rights Reserved.
All trademarks are owned by Xantrex LLC and its affiliates.
1
Freedom e-GEN System User Guide
http://www.xantrex.com

Freedom e-GEN System User Guide http://www.xantrex.com
2Copyright © 2019 Xantrex LLC. All Rights Reserved.
All trademarks are owned by Xantrex LLC and its affiliates.
975-0791-01-01 Rev F
Sep 2019
8
Troubleshooting
PROBLEM CAUSE SOLUTION
Battery and LCD
Display are turned
off
Battery is low (reserve
shutdown).
Follow the steps in System Charging and charge the
battery immediately.
Battery is critically low
(low voltage shutdown).
Follow the steps in Low Battery Recovery and charge the
battery immediately.
The system is turned off. Press the POWER/RESET button to turn the system on.
BMS will not turn
on.
Battery temperature is
outside normal range.
Apply proper ventilation and make sure ambient
temperature is not too hot or too cold.
Battery is critically low. Follow the steps in Low Battery Recovery and charge the
battery immediately.
Battery fuse is blown due
to overcurrent or short-
circuit.
Call for service. Do not replace fuses in the system by
yourself.
Battery
information on
LCD Display is
inaccurate.
Battery is consistently left
in a partially discharged
state causing SoC
reading to gradually drift.
Perform a full charge cycle to bring battery the SoC to
100% and the voltage to at least 14.2V to allow readings to
recalibrate. Perform weekly to maintain accuracy. Check
that the battery capacity is set correctly.
Charging from the
auxiliary alternator
is slow.
Alternator temperature
is too high.
Allow the alternator to cool down by providing sufficient
ventilation. When idle-charging, park the vehicle in a cool
spot.
No charging from
the auxiliary
alternator
Fuse blown or the
alternator or regulator is
damaged
Call for service
NOTE: Refer to the Troubleshooting chapter in the Freedom SW Owner's Guide for troubleshooting tips for your inverter/charger. Contact
customer service if a problem persists.
9
System and Battery Maintenance
1. Have a qualified service person first check the wiring and connections for wear
and tear during routine vehicle (RV) maintenance.
2. Then, check the second alternator and belt for wear and tear and appropriate belt
tension. Refer to this guide and all applicable guides for safety warning
information.
If the Freedom e-GEN System is in regular use, then it is recommended that the
Xantrex Battery be fully charged a minimum of once per two weeks in order for the
Xantrex BMS to recalibrate its State of Charge (SoC) setting. This process also
ensures that the SoC meter maintains its accuracy.
10
BMS Configuration
Xantrex ships every BMS unit pre-configured for the specific lithium-ion battery. However,
in some cases a customer may need to make changes to those parameters suited to their
system requirements.
The BMS configuration can be done using the two buttons on the SoC LCD Display (sold
separately).
Configuring BMS using the SoC LCD Display
Unit
To enter the BMS Configuration Menu:
1. Long press for six seconds both buttons on the LCD Display. The BMS will enter
Setup mode and will display the first configuration parameter and its current value.
2. Press the left button to scroll through the range of values.
3. Press the right button to lock the value and move to the next parameter screen.
NOTE: If no buttons are pressed within five minutes, the LCD will exit Setup Mode and
switch to Display mode automatically.
The following list describes the setup screens and their variable descriptions.
Pack Size
Battery pack Amp
Hour capacity
Settings are from 1 Ah to 3000 Ah. 0 – 50 Ah are in 1 Ah increments. 50
– 3000 Ah are in 10 Ah increments.
5
Low Battery Alarm (Orange Light)
0 A
REMOTE
PANEL
The orange light on the system remote panel is
illuminated when battery voltage is low (12% battery
capacity left). When this occurs, remove load and
charge the battery either by turning on the vehicle
engine or connecting to shore power.
If you ignore the orange light and continue to drain the
battery, the Freedom SW will stop inverter operation
and cut power to your AC appliances. The BMS also
monitors battery capacity and will trigger shutdown
events to protect the battery.
At 10% battery capacity, a reserve shutdown event occurs. A single press on the
POWER/RESET button will re-engage the battery and allow access to the reserved
capacity. Follow the steps in the “System Charging” section to begin charging the battery.
At 3% battery capacity, the battery is depleted and a low voltage shutdown event occurs.
Follow the steps in the “Low Battery Recovery” section and charge the battery
immediately.
NOTICE
RISK OF BATTERY DAMAGE
Do not allow the battery to be depleted. Charge the battery immediately when the low battery alarm
orange light illuminates.
Failure to followthese instructions can result in damageto the batteryand mayvoid thewarranty.
6
System Charging
When the battery’s SoC is greater than 10% and while battery power is still engaged, you
may charge the battery by engaging power from the charging source.
When SoC is less than 10% but greater than 3%, and the reserve shutdown event has
occurred, press the Power button on the BMS. While battery power is engaged, start
charging the battery from the charging source.
NOTE: When charging, avoid using heavy loads to prevent prolonged charging time. Also,
avoid using heavy DC loads during charging to prevent the system from transitioning to
thermal protection mode.
To stop charging, disengage the power from any and all charging sources. Do not turn off
the BMS to disconnect the battery while the system is charging.
NOTICE
RISK OF EQUIPMENT DAMAGE
Do not disconnect battery while the system is charging.
Failure to followthese instructionscan result in damage to equipment and may void thewarranty.
NOTICE
RISK OF BATTERY DAMAGE
•Fully charge the battery and turn off the BMS when the system is not in use for less than a month.
Observe proper storage instructions from the battery manufacturer for long-term storage.
•Do not charge the battery in ambient temperature below freezing.
• Do not charge the battery above 14.8V.
Failure to followthese instructionscan result in damage to the batteryand mayvoid thewarranty.
7
Low Battery Recovery
NOTICE
RISK OF BATTERY DAMAGE
Turn off (or disconnect) all loads completely before performing a Low Battery Recovery procedure.
Failure to follow these instructions can result in damage to battery.
When SoC is less than 3% and the low voltage shutdown event has occured, charge the
battery immediately through an approved charging source. Follow the steps below.
1. Turn off (or disconnect) all DC and AC loads completely.
2. Start charging.
NOTE: If charging does not commence, then it is possible that the battery has been
completely depleted. The battery including the entire power system has to be serviced by a
qualified person such as an authorized technician. Contact your dealer for service.
NOTICE
RISK OF BATTERY DAMAGE
Do not perform the low battery recovery procedure repeatedly. Contact customer service so they can refer
you to an authorized technician for service.
Failure to follow these instructions can result in damage to battery.

http://www.xantrex.com Freedom e-GEN System User Guide
975-0791-01-01 Rev F
Sep 2019
Copyright © 2019 Xantrex LLC. All Rights Reserved.
All trademarks are owned by Xantrex LLC and its affiliates.
3
11
BMS LED Indicator
The e-GEN Xantrex BMS has an LED indicator integrated into the Power button on the unit
itself. In some cases, there are also optional remote LED indicators – one to indicate power
(On/Off/Alarm) status and one to indicate low battery status. Please refer to your specific
installation to check which LEDs, if any, you have available in your system.
Power On/Off/Alarm – This LED indicator is integrated into the Power button on
the BMS unit or is installed remotely as an option.
lThe LED is off when the BMS is turned off and battery power is disabled.
lThe LED is on when the BMS is on and battery power is enabled.
lThe LED flashes rapidly when BMS is in alarm state and battery power is
disabled.
12
Power and Environmental Specifications
NOTE: Specifications are subject to change without prior notice.
The specifications listed here are for the Freedom e-GEN System. Certain operating
conditions apply. For complete specifications, refer to each device’s datasheet and
Owner’s Guide.
Electrical
Overview
Energy Storage Capacity 600Ah or 450Ah
Nominal System DC Voltage 12.8VDC
Nominal System AC Voltage 120VAC @60Hz
System AC Output Power Rating 3000W up to 40°C (104°F)
Lithium-ion
Battery
Voltage
versus SoC
Battery State Battery Voltage State-of-Charge (SoC)
Fully Charged 14.6V – 13.6V 100%
Nominal Operation 14.6V – 12.2V 100% – 12%
Float Voltage 13.4V 100% – 80%
Low Battery Warning 12.2V 12%
Reserve Shutdown 12.0V 10%
Low Battery Shutdown 11.6V <3%
Temperature Charging range* 0 – 45 °C (32 – 113 °F)
Discharging range* -20 – 55 °C (-4 – 131 °F)
* Staying within the recommended ambient temperature range will yield optimal system performance. For maximum
temperature specifications, refer to each device's datasheet and Owner's Guide.
Storage Recommended temperature and
humidity
15 to 35°C (59 to 95°F)，45 to 75％RH
Temperature range < 1 Month, -20 to 35°C (-4 to 95°F)
< 3 Months, -10 to 30°C (14 to 86°F)
For long term storage, see the Battery
Storage Guide (doc number 975-1005-01-
01).
Battery
Disposal
At the end of the battery’s useful life, proper disposal is required. Do not dispose the battery
with ordinary household waste. Refer to your local codes for proper disposal of lithium-ion
batteries.
Full Vlt
Full Voltage
Set this to the maximum per-cell voltage your battery reaches at the end-
of-charge. This will be used to synchronize the SoC LCD Display’s
100% reading when the battery reaches this voltage level.
Typically, this value is 3.55 V per cell. So, a 12 V (4 cell) battery is 4 x
3.55 = 14.2 V. When the battery reaches this voltage at the end of a
charge cycle, the SoC value will reset to 100%.
NOTE: If you notice that your SoC LCD Display's value never reaches 100% at the
end of a charge cycle, you may need to slightly lower the Full Vlt value to what the
voltage reading is on the LCD Display at the moment, when the charger turns off.
This value must be higher than the resting voltage of the battery since the charger’s
end voltage is higher than its resting voltage. The typical value range should be
between 14.0 and 14.4 V.
Min SoC
Minimal State-of-
Charge
This percentage value sets the Empty Battery level, also known as
Reserve Capacity, so the user can utilize the BAT Gauge reading and
not completely deplete the battery thus, preserving its lifecycles. For
example, if this value is set to 10%, then the BAT Gauge will report 0%
when there is still 10% reserve SoC. If you desire to use your battery to
its full capacity and/or want the BAT Gauge to reflect true SoC, then set
this value to zero.
In addition, when RVC Mode is enabled, the BMS will turn off battery
power when SoC reaches this preset level (assuming it comes before
battery voltage reaches RVC level), typically 3.00VPC. This allows the
Xantrex Reserve feature to act on both voltage trigger and SoC level
trigger, whichever comes first.
AGSR Lvl
Automatic
Generator
Start/Restart level
This percentage value determines the minimal Bat Gauge level at which
the AGS/R circuit is triggered. AGS/R circuit triggers on voltage set to
3.05 V per cell, or the Low Bat level, whichever comes first, hence
allowing flexible control of the generator starting point.
Temp Unit
Temperature Units
Set this to Fahrenheit (°F) or Celsius (°C).
Charge Eff
Charging Efficiency
This percentage value slows down the rate of SoC climb during the
charge to compensate for battery losses during the discharge cycle. The
recommended setting is 98%. In applications with high discharge rates,
energy losses are more pronounced, so this value must be set lower to
accurately report SoC and BAT Gauge values during partial
charges.This setting must be tuned experimentally for best accuracy.
Ideal setting will cause SoC to reach 100% at approximately the same
time as the charger is finishing up the full charge.
Dead Zone Due to thermal drift in Hall Effect sensors when temperature fluctuations
are wide and fast, the BMS might report non-zero current reading when
no current is present. The Dead Zone value allows ignoring small
current readings when they are likely false (such as, when small reading
fluctuates between zero and non-zero values). Default value of 0.3A is
recommended for best zero-point stability.
Idle Load
Shown as mA
This setting represents the constant idle load current powering the BMS
system. This can be measured with a digital multi-meter in DC
amperage mode in series with the BMS’s negative reference wire.
Allowed range is 0 – 200 mA. Since the idle current is usually too low to
register by internal hall-effect sensor but still affects SoC reading over
long time periods when the battery sits idle, setting this value allows for
a better long-term accuracy of the SoC counter.
Alarm
Alarm function
Turns ON or OFF an Alarm function, which drives the internal buzzer as
well as the AUXOUT2 external relay circuit when the BMS is in Alarm
state.
RVC
Reserve voltage
cutoff function
Default setting STD (Standard) would turn off the battery while leaving
reserve charge, which can be accessed by pressing the Reset button.
When set to EXT (Extended), the amount of reserve charge is increased
on voltage-based triggers.