Xtender XTS 900-12 User manual

Studer Innotec SA 2015 –V4.6.0
4O9A
Xtender, Unit combining inverter,
battery charger and transfer system
User manual
XTS 900-12
XTS 1200-24
XTS 1400-48
XTM 1500-12
XTM 2000-12
XTM 2400-24
XTM 3500-24
XTM 2600-48
XTM 4000-48
XT H 3000-12
XTH 5000-24
XTH 6000-48
XTH 8000-48
Common Accessories
Temperature sensor.............................................. BTS-01
Accessories XTM/XTS
Remote command module................................ RCM-10
Accessories XTS
External cooling fan............................................. ECF-01
External auxiliary relay module........................... ARM-02

Studer Innotec SA
Xtender

Studer Innotec SA
Xtender
User manual V4.6.0 3
SUMMARY
1INTRODUCTION.......................................................................................................................................5
2GENERAL INFORMATION .......................................................................................................................5
2.1 Operating instructions .........................................................................................................................5
2.2 Conventions ..........................................................................................................................................6
2.3 Quality and warranty...........................................................................................................................6
2.3.1 Exclusion of warranty.......................................................................................................................7
2.3.2 Exclusion of liability...........................................................................................................................7
2.4 Warnings and notes .............................................................................................................................7
2.4.1 General ..............................................................................................................................................7
2.4.2 Precautions when using batteries.................................................................................................8
3ASSEMBLY AND INSTALLATION .............................................................................................................9
3.1 Handling and moving..........................................................................................................................9
3.2 Storage ...................................................................................................................................................9
3.3 Unpacking..............................................................................................................................................9
3.4 Installation site .......................................................................................................................................9
3.4.1 XTM and XTH .....................................................................................................................................9
3.5 Fastening................................................................................................................................................9
3.5.1 Fastening of the XTH model .........................................................................................................10
3.5.2 Fastening of the XTM model ........................................................................................................10
3.5.3 Fastening of the XTS model..........................................................................................................10
3.6 Connections ........................................................................................................................................11
3.6.1 General recommendations .........................................................................................................11
3.6.2 Connection compartment, XTH and XTM models ..................................................................12
3.6.3 Connection compartment, XTS model .....................................................................................13
3.6.4 Elements of the connection compartments ............................................................................14
3.6.5 Tightening torque...........................................................................................................................15
3.6.6 Max permissible cable cross-sections ........................................................................................15
4CABLING...............................................................................................................................................16
4.1 Choice of system ................................................................................................................................16
4.1.1 Hybrid stand-alone systems .........................................................................................................16
4.1.2 Grid-connected back-up systems..............................................................................................16
4.1.3 Integrated mobile systems ...........................................................................................................16
4.1.4 Multi-unit systems............................................................................................................................16
4.1.5 Distributed minigrid ........................................................................................................................17
4.2 Earthing system ...................................................................................................................................17
4.2.1 Mobile installation or installation connected to the grid via plug connector ...................17
4.2.2 Stationary installation ....................................................................................................................18
4.2.3 Installation with automatic PE-neutral switching .....................................................................18
4.2.4 Lightning protection ......................................................................................................................18
4.3 Recommendations for dimensioning the system .........................................................................18
4.3.1 Dimensioning the battery.............................................................................................................18
4.3.2 Dimensioning the inverter.............................................................................................................19
4.3.3 Dimensioning the generator........................................................................................................19
4.3.4 Dimensioning the renewable energy sources..........................................................................19
4.4 Wiring diagrams ..................................................................................................................................19
4.5 Connecting the battery ....................................................................................................................19
4.5.1 Battery cable cross-section and DC protective devices.......................................................20
4.5.2 Connecting the battery (Xtender side).....................................................................................20
4.5.3 Fuse mounting on battery positive pole (XTM only) ................................................................21
4.5.4 Battery-side connection ...............................................................................................................21
4.5.5 Earthing of battery.........................................................................................................................22
4.5.6 Connecting the consumers at the AC output .........................................................................22
4.5.7 Connecting the AC supply sources ...........................................................................................23
4.5.8 Wiring auxiliary contacts...............................................................................................................23
4.5.9 Connecting the communications cables.................................................................................23
5XTENDER PARAMETER SETTINGS ..........................................................................................................24
5.1 Basic parameter settings in the XTS.................................................................................................24

Studer Innotec SA
Xtender
User manual V4.6.0 4
6POWERING UP THE INSTALLATION.......................................................................................................25
6.1 Connecting the battery ....................................................................................................................25
6.2 Putting the Xtender(s) in operation using the main ON/OFF switch (1) if present .................25
6.3 Connecting the consumers at the output ....................................................................................25
6.4 Activating the input circuit breaker(s) (H) .....................................................................................25
7DESCRIPTION OF THE MAIN FUNCTIONS ............................................................................................26
7.1 Inverter..................................................................................................................................................26
7.1.1 Automatic load detection (load search) .................................................................................26
7.2 Transfer relay........................................................................................................................................26
7.2.1 Type of detection of AC input loss (UPS)...................................................................................27
7.2.2 Limiting the AC input current "Input limit" ..................................................................................27
7.3 Battery charger...................................................................................................................................28
7.3.1 Working principle ...........................................................................................................................28
7.3.2 Battery charger current setting ...................................................................................................30
7.3.3 Battery protection..........................................................................................................................30
7.4 Xtender protection............................................................................................................................30
7.4.1 Protection in case of overload....................................................................................................30
7.4.2 Protection against overvoltage ..................................................................................................30
7.4.3 Protection against overheating ..................................................................................................30
7.4.4 Protection against battery reverse polarity ..............................................................................31
7.5Auxiliary contacts ...............................................................................................................................31
7.6 Real time clock ...................................................................................................................................31
7.7 Remote entry (Remote control on/off) ..........................................................................................32
7.7.1 XTH model........................................................................................................................................32
7.7.2 XTM and XTS models......................................................................................................................32
7.7.3 Remote entry controlled by an auxiliary relay .........................................................................33
8MULTI-UNIT CONFIGURATION .............................................................................................................33
8.1 Three-phase system............................................................................................................................34
8.2 Increasing the power by paralleling units......................................................................................34
8.3 Combined system ..............................................................................................................................34
8.4 Enlargement of an existing installation...........................................................................................34
9ACCESSORIES .......................................................................................................................................35
9.1 Remote control RCC-02/-03 .............................................................................................................35
9.2 BTS-01 temperature sensor...............................................................................................................36
9.2.1 Connecting the temperature sensor (BTS-01) ..........................................................................36
9.3 Remote control module RCM-10 (XTM/XTS)..................................................................................36
9.3.1 Connection of the RCM-10 module...........................................................................................36
9.4 Time and communication module TCM-01(XTS)..........................................................................37
9.5 Auxiliary relay module ARM-02 (XTS)...............................................................................................37
9.6 External cooling fan unit ECF-01 (XTS) ............................................................................................37
10 OTHER XTENDER SYSTEM COMPATIBLE DEVICES ...............................................................................38
10.1 Battery status processor BSP-500/-1200 ..........................................................................................38
10.2 Communication module Xcom-232i ..............................................................................................38
10.3 MPPT solar charge controller VarioTrack/VarioString ..................................................................38
10.4 Communication sets Xcom-LAN/-GSM ..........................................................................................38
10.5 Communication module Xcom-SMS ..............................................................................................38
11 CONTROL ..............................................................................................................................................39
11.1 Main on/off control ............................................................................................................................39
11.2 Display and control panel ................................................................................................................39
12 MAINTENANCE OF THE INSTALLATION ...............................................................................................41
13 PRODUCT RECYCLING .........................................................................................................................41
14 EC DECLARATION OF CONFORMITY ..................................................................................................41
15 COMMENTS TO DRAWINGS IN THE APPENDIX...................................................................................42
16 DRAWING ELEMENTS (DC SIDE) ..........................................................................................................44
17 FIGURE ELEMENTS (AC PART) ..............................................................................................................45
18 MECHANICAL DIMENSION AND MOUNTING ELEMENTS...................................................................46
19 NAMEPLATE (FIG. 1B)...........................................................................................................................46
20 TABLE OF FACTORY DEFAULT PARAMETER SETTINGS .........................................................................47
21 TECHNICAL DATA .................................................................................................................................54

Studer Innotec SA
Xtender
User manual V4.6.0 5
1INTRODUCTION
Congratulations! You are about to install and use a device from the Xtender range. You have chosen
a high-tech device that will play a central role in energy saving for your electrical installation. The
Xtender has been designed to work as an inverter / charger with advanced functions, which can be
used in a completely modular way and guarantee the faultless functioning of your energy system.
When the Xtender is connected to a generator or network, the latter directly supplies the consumers,
and the Xtender works like a battery charger and backup device if necessary. The powerful battery
charger has an exceptionally high efficiency and a power factor correction (PFC) close to 1. It
guarantees excellent battery charging in all situations. The charge profile is freely configurable
according to the type of battery used or the method of usage. The charge voltage is corrected
depending on the temperature, thanks to the optional external sensor. The power of the charger is
modulated in real time dependent according to the demand of the equipment connected at the
Xtender output and the power of the energy source (network or generator). It can even temporarily
backup the source if the consumer demand exceeds the source capacity.
The Xtender continuously monitors the source to which it is connected (network or generator) and
disconnects itself immediately if the source is missing, disturbed or does not correspond to the quality
criteria (voltage, frequency, etc.). It will then function in independent mode, thanks to the integrated
inverter. This inverter, which has an extremely robust design, benefits from Studer Innotec’s many
years of experience and expertise in this area. It could supply any type of load without faults, enjoying
reserves of additional power that is unmatched in the market. All your equipment will be perfectly
provided with energy and protected from power outages in systems where energy supply is
unpredictable (unreliable network) or voluntarily limited or interrupted, such as hybrid installations on
remote sites or mobile installations.
The parallel and/or three-phase network operation of the Xtender offers modularity and flexibility and
enables optimum adaptation of your system to your energy requirements.
The RCC-02/-03 control, display and programming centre (optional) enables optimum configuration
of the system and guarantees the operator continuous control for all important parameters in the
installation.
In order to guarantee flawless commissioning and functioning of your installation, please read this
manual carefully. It contains all the necessary information relating to the functioning of the
inverters/chargers in the Xtender series. The setting up of such a system requires special expertise and
may only be carried out by qualified personnel familiar with the applicable local regulations.
2GENERAL INFORMATION
2.1 OPERATING INSTRUCTIONS
This manual is an integral part of each inverter/charger from the Xtender series.
It covers the following models and accessories
1
:
Inverter/charger:
XTH 3000-12 –XTH 5000-24 –XTH 6000-48 –XTH 8000-48
XTM 1500-12, XTM 2000-12, XTM 2400-24,
XTM 3500-24, XTM 2600-48, XTM 4000-48
XTS 900-12, XTS 1200-24, XTS 1400-48
External cooling fan: ECF-01
Temperature sensor: BTS-01
Remote command module: RCM-10
Auxiliary relay module: ARM-02
For greater clarity, the device is referred to in this manual as Xtender, unit or device, when the
description of its functioning applies indiscriminately to different Xtender models.
These operating instructions serve as a guideline for the safe and efficient usage of the Xtender.
Anyone who installs or uses an Xtender can rely completely on these operating instructions, and is
bound to observe all the safety instructions and indications contained. The installation and
commissioning of the Xtender must be entrusted to a qualified professional. The installation and
usage must conform to the local safety instructions and applicable standards in the country
concerned.
1
Also for 120Vac model (-01)

Studer Innotec SA
Xtender
User manual V4.6.0 6
2.2 CONVENTIONS
This symbol is used to indicate the presence of a dangerous voltage that is sufficient to
constitute a risk of electric shock.
This symbol is used to indicate a risk of material damage.
This symbol is used to indicate information that is important or which serves to optimise your
system.
This symbol placed on the product indicates that its surfaces may reach temperatures
higher than 60°C.
This symbol placed on the product indicates that its use must follow the instructions in the
user’s manual.
All values mentioned hereafter, followed by a parameter number indicate that this value may be
modified using the RCC-02/-03 remote control.
In general, the default values are not mentioned and are replaced by a parameter number in the
following format: {xxxx}. The default values for this parameter are specified in the defaults parameter
table, p. 47.
All parameter values modified by the operator or installer must be transferred into the same
table. If a parameter not appearing in the list (advanced parameters) has been modified
by an authorised person with technical knowledge, they will indicate the number of the
modified parameter(s), the specifications of the parameter(s) and the new value set, at the
end of the same table.
All figures and letters indicated in brackets or in square brackets refer to items that can be found in
the separate manual "Appendix to the installation and operating instructions" supplied with the
device. In this appendix, these figures and letters are encircled.
The figures in brackets refer to elements belonging to the Xtender.
The uppercase letters in brackets refer to AC cabling elements.
The lowercase letters in brackets refer to battery cabling elements.
The comments on figures and items of the appendix are given starting on p. 42.
2.3 QUALITY AND WARRANTY
During the production and assembly of the Xtender, each unit undergoes several checks and tests.
These are carried out with strict adherence to the established procedures. Each Xtender has a serial
number allowing complete follow-up on the checks, according to the particular data for each
device. For this reason it is very important never to remove the type plate (appendix 1 –fig. 3b) which
shows the serial number. The manufacture, assembly and tests for each Xtender are carried out in
their entirety by our factory in Sion (CH). The warranty for this equipment depends upon the strict
application of the instructions appearing in this manual.

Studer Innotec SA
Xtender
User manual V4.6.0 7
2.3.1 Exclusion of warranty
No warranty claims will be accepted for damage resulting from handling, usage or processing that
does not explicitly appear in this manual. Cases of damage arising from the following causes are
notably excluded from the warranty:
Surge voltage on the battery input (for example, 48 V on the battery input of an XTH 3000-12)
Incorrect polarity of the battery
The accidental ingress of liquids into the device or oxidation resulting from condensation
Damage resulting from falls or mechanical shocks
Modifications carried out without the explicit authorisation of Studer Innotec
Nuts or screws that have not been tightened sufficiently during the installation or
maintenance
Damage due to atmospheric surge voltage (lightning)
Damage due to inappropriate transportation or packaging
Disappearance of original marking elements
2.3.2 Exclusion of liability
The placement, commissioning, use, maintenance and servicing of the Xtender cannot be the
subject of monitoring by Studer Innotec. Therefore, we assume no responsibility and liability for
damage, costs or losses resulting from an installation that does not conform to the instructions,
defective functioning or deficient maintenance. The use of a Studer Innotec inverter is the
responsibility of the customer in all cases.
Studer Innotec shall in no event be liable for consequential, incidental, contingent or special
damages, even if having been advised of the probability of such damages. This equipment is neither
designed nor guaranteed to supply installations used for vital medical care nor any other critical
installation carrying significant potential damage risks to people or the environment.
Studer Innotec assumes no responsibility for the infringement of patent rights or other rights of third
parties that result from using the inverter.
Studer Innotec reserves the right to make any modifications to the product without prior notification.
2.4 WARNINGS AND NOTES
2.4.1 General
This manual is an integral part of the device and must be kept available for the operator
and installer. It must remain close to the installation so that it may be consulted at any time.
The parameter table available at the end of the manual (p. 47) must be kept up to date in the event
of modification of the parameters by the operator or installer. The person in charge of installation
and commissioning must be wholly familiar with the precautionary measures and the local
applicable regulations.
When the Xtender is running, it generates voltage that can be potentially lethal. Work on or
close to the installation must only be carried out by thoroughly trained and qualified
personnel. Do not attempt to carry out on-going maintenance of this product yourself. The
Xtender or the generator connected to it may start up automatically under certain
predetermined conditions.
When working on the electrical installation, it is important to be certain that the source of
DC voltage coming from the battery as well as the source of AC voltage coming from a
generator or network have been disconnected from the electrical installation.
Even when the Xtender has been disconnected from the supply sources (AC and DC), a
dangerous voltage may remain at the outputs. To eliminate this risk you must switch the
Xtender OFF using the ON/OFF button (1). After 10 seconds the electronics is discharged
and intervention may take place without any danger.

Studer Innotec SA
Xtender
User manual V4.6.0 8
All elements connected to the Xtender must comply with the applicable laws and regulations.
Persons not holding written authorisation from Studer Innotec are not permitted to proceed with any
change, modification or repairs that may be required. Only original parts may be used for authorised
modifications or replacements.
This manual contains important safety information. Read the safety and working instructions carefully
before using the Xtender. Adhere to all the warnings given on the device as well as in the manual,
by following all the instructions with regard to operation and use.
The Xtender, except XTS, is only designed for indoor use and must under no circumstances be
subjected to rain, snow or other humid or dusty conditions. The maximum specifications of the device
shown on the type plate, as at fig. 1b, must be adhered to.
In the event of use in motorised vehicles, the Xtender must be protected from dust, splash water and
any other humid condition. It must also be protected from vibration by installing absorbent parts.
The Xtender can be installed at altitudes up to 3000m. For installations at higher altitudes,
please contact Studer Innotec SA. The Xtender is in overvoltage category III, which
indicates that it can be installed directly after the protection device at the entrance of
a building.
2.4.2 Precautions when using batteries
The batteries should only be chosen, dimensioned and installed by qualified personnel,
trained in this specific area.
Lead-acid or gel batteries produce a highly explosive gas with normal use. No source of
sparks or fire should be present in the immediate vicinity of the batteries. The batteries
must be kept in a well-ventilated place and be installed in such a way as to avoid
accidental short-circuits when connecting.
Never try to charge frozen batteries.
When working with the batteries, a second person must be present in order to lend
assistance in the event of problems.
Sufficient fresh water and soap must be kept to hand to allow adequate and immediate
washing of the skin or eyes affected by accidental contact with the acid.
In the event of accidental contact of the eyes with acid, they must be washed carefully
with cold water for 15 minutes. Then immediately consult a doctor.
Battery acid can be neutralised with baking soda. A sufficient quantity of baking soda
must be available for this purpose.
Particular care is required when working close to the batteries with metal tools. Tools such
as screwdrivers, open-ended spanners, etc., may cause short circuits. Sparks resulting
from these short-circuits can cause the battery to explode. Therefore, tools with insulated
handles should be used and they should never be left to rest on top of the batteries.
When working with the batteries, all metal jewellery such as rings, watches with a metal
bracelet, earrings, etc., must be taken off. The current supplied by the batteries during a
short circuit is sufficiently powerful to melt the metal and cause severe burns.
Batteries at the end of their life-cycle should be recycled in accordance with directives
from the responsible local authorities or the battery supplier. The batteries should never
be exposed to fire as they may explode. Under no circumstances should you try to take
apart or dismantle the battery, as they contain toxic and polluting materials. For
ungrounded battery systems, always check that they are not inadvertently grounded
before starting work on the batteries.
Always follow carefully the instructions of the battery manufacturer.

Studer Innotec SA
Xtender
User manual V4.6.0 9
3ASSEMBLY AND INSTALLATION
3.1 HANDLING AND MOVING
The weight of the Xtender can be up to 50kg depending upon the model. Use an appropriate lifting
method as well as help from a third party when installing the equipment.
3.2 STORAGE
The equipment must be stored in a dry environment at an ambient temperature of between
-20°C and 60°C. It stays in the location where it is to be used a minimum of 24 hours before being set up.
3.3 UNPACKING
When unpacking, check that the equipment has not been damaged during transportation and that
all accessories listed below are present. Any fault must be indicated immediately to the product
distributor or the contact given at the back of this manual.
Check the packaging and the Xtender carefully.
Standard accessories:
Installation and operating instructions, c.f. Appendix 1.
Mounting plate for XTH and XTS–fig. 2a (25)(26).
One set of cable glands on the unit and/or apart.
Four M6 screws and washer for XTS to assemble the support and the enclosure.
3.4 INSTALLATION SITE
3.4.1 XTM and XTH
Devices in the XTM and XTH range are designed for indoor use (IP20) and the place of installation
must satisfy the following criteria:
Protected from any unauthorised person.
Protected from water and dust and in a place with no condensation.
It must not be situated directly above the battery or in a cabinet with it.
No easily inflammable material should be placed directly underneath or close to the Xtender.
Ventilation apertures must always remain clear and be at least 20cm from any obstacle that
may affect the ventilation of the equipment.
In mobile applications, it is important to select an installation site that ensures as low a
vibration level as possible.
According to the IEC/EN 62109-1 norm, the level of pollution at the mounting place should
not exceed PD2 (second-degree environment), which means that there can be pollution as
long as it is not electrically conductive. XTS
XTS range appliances have a high grade of protection (IP54). They can therefore be installed
outdoors, with exposure to dust and water splashes. It is recommended to avoid locations particularly
exposed to salt-water splashes which are extremely aggressive (for instance under a vehicle chassis)
or to solvent (motor oil) that can attack all non-metallic parts of the enclosure. Also avoid installing
the XTS in direct sunlight or near a heat source (i.e. engine compartment). The presence of a heat
source may reduce significantly the nominal power of the unit.
Reduce as much as possible exposure to sudden temperature changes as a variation in temperature
may cause undesired condensation inside the enclosure.
The 4 mounting screws of the enclosure must be completely tightened with a torque of
5Nm in order to guarantee the IP 54 protection index. Any unused cable glands should
be closed in a way that guarantees at least the same level of protection.
3.5 FASTENING
The Xtender is a heavy unit and must be mounted to a non-flammable support (wall)
designed to bear such a load
The Xtender must be installed vertically onto heavy-duty material (concrete or metallic wall) and
positioned vertically with cable glands oriented down. A sufficient space around it must be provided
to guarantee adequate ventilation of the device (see figs. 2a).

Studer Innotec SA
Xtender
User manual V4.6.0 10
3.5.1 Fastening of the XTH model
First fix the mounting bracket (26) supplied with the device using 2 Ø < 6-8 mm >screws**.
Then hang the Xtender on the bracket. Fasten the unit permanently using 2 Ø <6-8 mm> screws** on
to the two notches located at the underside of the case.
Dimensions of the appliances are given on Fig 2a of the appendix 1.
3.5.2 Fastening of the XTM model
First fasten the top screw (6-8mm **) without washer on a solid wall (concrete or metallic wall) up to
a distance of 2mm between head and wall. Hang the device from the screw. If deemed necessary,
the upper support screw can be fully tightened after hanging the device. In theory, this is only
necessary in mobile applications. To access the upper support screw to fully tighten it, remove the
upper plastic grate (see 27 fig. 2a of the appendix).
Dismount the lower plastic grate of the device giving access to the wiring compartment. Carefully
fix the device with two screws (Ø 6-8 mm) in the two holes located at the bottom left and right of the
wiring compartment.
If the Xtender is installed in a closed cabinet this must have sufficient ventilation to guarantee an
ambient temperature that conforms to the operation of the Xtender.
**: These items are not delivered with the device.
It is imperative to ensure complete and safe fastening of the device. A device that is simply
hung may detach and cause severe damage.
3.5.3 Fastening of the XTS model
The XTS enclosure must be first mounted on the support plate with
the 4 screws and washer delivered with the appliance according
with figure aside. Then the unit can be fixed on a heavy-duty
support (concrete or metallic wall) and positioned vertically with
cable glands oriented down. An external ventilation unit (ECF-01,
p. 37) can be installed on top of the unit before or after wall
mounting.
A distance of at least 20 cm in between and/or around the XTH devices is required in order
to guarantee sufficient ventilation.
The envelope of the XTS can reach temperatures higher
than 60°C when used for a long period near its max
power level. These high temperatures may remain
present during several tens of minutes after stopping the
unit. It is recommended to choose a place of installation
in a restricted access area, away from children or any
unauthorized person.