Studer XTS 1400-48, XTS 900-12, XTM 4000-48, XTH 5000-24, XTM 3500-24 User Manual

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Studer Innotec SA 2013 – V4.5.0

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

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 V4.5.0 3

SUMMARY

1 INTRODUCTION.......................................................................................................................................5

2 GENERAL 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 for using the batteries ............................................................................................... 8

3 ASSEMBLY 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 Device connection compartment XTH - XTM ...........................................................................12

3.6.3 Device connection compartment XTS ......................................................................................13

3.6.4 Elements of connection cabinet ................................................................................................14

4 CABLING ...............................................................................................................................................16

4.1 Choice of system ................................................................................................................................16

4.1.1 Hybrid type stand-alone systems ................................................................................................16

4.1.2 Grid-connected emergency 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 the 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

5 XTENDER PARAMETER SETTING ............................................................................................................24

5.1 Basic parameter setting in the XTS ..................................................................................................24

6 POWERING UP THE INSTALLATION .......................................................................................................25

6.1 Connecting the battery ....................................................................................................................25

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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

7 DESCRIPTION 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

7.5 Auxiliary contacts ...............................................................................................................................31

7.6 The real time clock .............................................................................................................................31

7.7 Entry command (Remote control on/off) .....................................................................................32

8 MULTI-UNIT CONFIGURATION .............................................................................................................33

8.1 Three-phase system............................................................................................................................33

8.2 Increasing the power by paralleling units......................................................................................33

8.3 Combined system ..............................................................................................................................34

8.4 Enlargement of an existing installation ...........................................................................................34

9 ACCESSORIES .......................................................................................................................................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 .......................................................................................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 OF APPENDIX DRAWINGS ..............................................................................................42

16 DRAWING’S ELEMENTS (DC SIDE) ........................................................................................................44

17 FIGURE ELEMENT'S (AC PART) ..............................................................................................................45

18 MECHANICAL DIMENSION AND MOUNTING ELEMENT .....................................................................46

19 NAMEPLATE (FIG. 1B) ...........................................................................................................................46

20 TABLE OF FACTORY DEFAULT PARAMETER SETTINGS .........................................................................47

21 TECHNICAL DATA .................................................................................................................................53

22 NOTES ....................................................................................................................................................54

Studer Innotec SA

Xtender

User manual V4.5.0 5

1 INTRODUCTION

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 exceptional high efficiency and 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.

2 GENERAL 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 accessories1: 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.

Also for 120Vac model (-01)

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User manual V4.5.0 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.

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Xtender

User manual V4.5.0 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.

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User manual V4.5.0 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 for using the 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.

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Xtender

User manual V4.5.0 9

3 ASSEMBLY 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).

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Xtender

User manual V4.5.0 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

Screw first 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 apparatus by taking care to release beforehand the trap door of access (27 fig. 2a of the appendix) by inserting it inside the apparatus using a screwdriver, if you estimate that a complete tightening of this point of fixing is necessary. In theory complete tightening is necessary only in the mobile installations. Dismount the lower plastic cap of the apparatus giving access to the compartment of wiring. Carefully fix the apparatus with two screws (Ø 6-8 mm) in the two clamp holes down inside the compartment of wiring. 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 minimum distance of 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’s recommended to choose a place of installation

in a restricted access area, away from children or any unauthorized person.

Studer Innotec SA

Xtender

User manual V4.5.0 11

3.6 CONNECTIONS

3.6.1 General recommendations

The Xtender falls within protection class I (has a PE connection terminal). It is vital that a protective earth is connected to the AC-In and/or AC-Out PE terminals. An additional protective earth is located at the bottom of the unit (See sect 3.6.4 – p. 11/13, tag (17)).

In all cases, the PE conductor for the equipment must at least be connected to the PE for all equipment in protection class I upstream and downstream of the Xtender (equipotential bonding). It is mandatory that the legislation in force for the application concerned be adhered to.

Tighten of the input (13) and output (14) terminals by means of a no. 3 screwdriver (minimum 1.2 Nm tightening torque) and those for the “Command entry (REMOTE ON/OFF”) (7) and “AUX.CONTAC” (8) by means of a no. 1 screwdriver (0.55 Nm tightening torque). The cable cross-sections of these terminals must conform to local regulations. All connection cables as well as the battery cables must be mounted using cable restraints in order to avoid any traction on the connection. Battery cables must also be as short as possible and the cross-section must conform with the applicable regulations and standards. Sufficiently tighten the clamps on the “battery” inputs (fig. 4a (11) and (12) (10 Nm tightening torque).

Before connecting or disconnecting the entry or exit cables AC-in (13) and AC-out (14), the installer must make sure that there is no voltage present in the cables OR on the teminals. Before connecting the battery, the installer must make sure that the AC-in source and the AC-out loads are well disconnected.

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Xtender

User manual V4.5.0 12

3.6.2 Device connection compartment XTH - XTM

The unit’s connection compartment must remain permanently closed when in operation. It is imperative to close the protection cap on the connection terminals after each intervention in the device. After opening, check that all sources of AC and DC voltage (batteries) have been disconnected or put out of service. Some accessible part inside the compartment can have surface temperature higher than 60°C. Wait for the complete cooling of the unit before opening the compartment.

Any unused cable entry on the device must be sealed so as to prevent any intrusion. An intrusion of small animals in the unit may cause serious damage not covered by warranty.

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Xtender

User manual V4.5.0 13

3.6.3 Device connection compartment XTS

Any unused cable entry on the device must be sealed so as to prevent any intrusion. An intrusion of small animals in the unit may cause serious damage not covered by warranty.

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Xtender

User manual V4.5.0 14

3.6.4 Elements of connection cabinet

Note: The left part of figure A shows the positions of elements (2, 3, 4, 5 and 15) as placed in recent devices. Figure B shows the positions of elements 2, 3, 4, 5 and 15 as placed on the communication module TCM-01 present in older versions of the device and described in chapter 9.4. The functionalities of the device are identical in both configurations.

Pos.

Denomination

Description

Comment

Protective earth connection terminal

This terminal is used as primary earth connection protection. (see chapter.

3.6.1– p. 11)

ON/OFF Main switch

Main on/off switch

See sect. 11.1 – p. 39. In XTM and XTS series, this function is deported on the remote command module RCM-10. See sect. 9.3 – p. 36.

Temp. Sens

Connector for the battery temperature sensor

See sect. 9.2 – p. 36. Only connect the original Studer BTS-01 sensor.

Com. Bus

Double connector for connecting peripherals such as the RCC-02/03 or other Xtender units

Only Studer compatible device can be connected. The connection of any other device (LAN etc.) may damage the device. See chapter 4.5.9 – p. 23.

O / T (Open / Terminated)

Switch for terminating the communication bus. Set position (open) if the 2 connectors (3) are occupied. Set position T if only one is occupied.

On model XTH the 2 termination switches (4) must be in the same position: either both in position O (open) or both in position T (terminated).

3.3 V (CR-2032) lithium ion type battery socket

Used as a permanent supply for the internal clock. See sect. 7.6 - p. 31.

Jumper for programming the off/on switch by dry contact

See sect. 7.7 – p. 31 and fig. 8b point (6) and (7). They are positioned at A-1/2 and B-2/3 by default.

Command entry (REMOTE ON/OFF)

Entry command terminals. In XTM series, this entry is deported on the remote command module RCM-10. See sect. 9.3 – p. 36

Allows the control of a function – to be defined by programming – by the closing of a dry contact or by the presence of a voltage across these terminals. See sect.

7.7 – p. 31).

AUXILLARY CONTACT

Auxiliary contact For XTS model, available only with module ARM-02 (see sect.

9.5 - p. 37

(See sect. 7.5 – p. 31) Take care not to exceed the admissible loads.

Activation indicators for auxiliary contacts 1 and 2

See sect. 7.5 – p. 31. 10

L1/L2/L3

Phase selection jumpers.

See sect. 8.1. – p. 33. Jumper default at position L1.

+BAT

Positive pole battery connection terminals

Carefully read sect. 4.5 – p.19 Take care with the polarity of the battery and when tightening the clamp.

-BAT

Negative pole battery connection terminals

AC Input

Connection terminals for the alternative power supply (generator or public network)

See sect. 4.5.7 - p. 23. Note: It is imperative that the PE terminal be connected.

AC Output

Connection terminals for the device output.

See sect. 4.5.6 - p. 23. Note: Increased voltages may appear on the terminals, even in the absence of voltage at the input of the inverter.

RCM-10

Connector for RCM-10 module

Only on XTM and XTS. See sect. 9.3 – p. 36

I-CHAR

Rotating knob to adjust the battery charge current

Only in XTS model.

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Connection for supplementary protective earth.

This connection can also be used as principal protective earth. See sect.

3.6.1– p. 11.

INPUT LIMIT

Rotating knob to adjust the input current limit

Only in XTS model. For other models, see sect. 7.2.2 – p. 27.

OFF/ON S/Boost

Activation of source assistance “Smart boost” function

Only in XTS model. For other models, see sect. 7.2.2.4 – p. 28.

OFF/ON UPS

Setting of sensitivity of the detection of AC input loss: OFF=tolerant / ON=Fast

Only in XTS model. For other models, see section. 7.2.1 – p. 27.

16A

AC input protective device: Only on XTS model. This protective device will trip in case of excessive load when the XTS is connected to an unprotected source higher than 16A. It can be reset after removing the default downstream (load too high) and upstream (source greater than 16A. (check the unit is connected thru an upstream protective device (fuse or circuit breaker) max. 16 A.

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4 CABLING

The connection of the Xtender inverter / charger is an important step of the installation. It may only be carried out by qualified personnel and in accordance with the applicable local regulations and standards. The installation must always comply with these standards. Pay attention that connections are completely tightened and that each wire is connected at the right place. All cables must be insulated. The IEC/EN 62109-1 norm states requires that the cables must be insulated with PVC, TFE, PTFE, FEP, neoprene or polyimide.

4.1 CHOICE OF SYSTEM

The Xtender may be used in different system types, each of which must meet the standards and particular requirements associated with the application or site of installation. Only an appropriately qualified installer can advise you effectively on the applicable standards with regard to the various systems and the country concerned. Examples of cabling are presented in appendix I of this manual, fig. 5 and following. Please carefully read the notes associated with these examples in the tables on p. 33 and following.

4.1.1 Hybrid type stand-alone systems

The Xtender can be used as a primary supply system for off- grid sites where a renewable energy source (solar, wind or hydraulic) is generally available and a generator is used as backup. In this case, batteries are generally recharged by a supply source such as solar modules, wind power or small hydropower systems. These supply sources must have their own voltage and/or current regulation system and are connected directly to the battery. (Example, fig. 11) When the energy supply is insufficient, a generator is used as a back-up energy source. This allows the batteries to be recharged and direct supply to consumers via the Xtender transfer relay.

4.1.2 Grid-connected emergency systems

The Xtender can be used as an emergency system, also known as an uninterruptible power supply (UPS) – enabling a reliable supply to a site connected to an unreliable network. In the event of an interruption to the energy supply from the public network, the Xtender, connected to a battery, substitutes the faulty source and enables a support supply to the users connected downstream. These will be supplied as long as the energy stored in the battery is sufficient. The battery will quickly be recharged at the next reconnection to the public grid. Various application examples are described in figs. 8a – 8c in appendix 1.

4.1.3 Integrated mobile systems

These systems are meant to be temporarily connected to the grid and ensure the supply of the mobile system when this is disconnected from the grid. The main applications are for boats, service vehicles and leisure vehicles. In these cases, two separate AC inputs are often required, one connected to the grid and the other connected to an on-board generator. Switching between two sources must be carried out using an automatic or manual reversing switch, conforming to the applicable local regulations. The Xtender has a single AC input. Various application examples are described in figs. 10a – 10b – 10c.

4.1.4 Multi-unit systems

Whatever system is selected, it is possible to realise systems composed of several units of the same type and the same power output. Up to three Xtender in parallel or three extenders forming a threephase grid or three times two or three Xtender in parallel forming a three-phase / parallel grid, may be thus combined.

The use of the Xtender as a UPS must be carried out by qualified personnel who have been checked by the responsible local authorities. The diagrams in the appendix are given for information and as a supplement. The applicable local standards and regulations must be adhered to.

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4.1.5 Distributed Minigrid

The implementation of the Xtender on top of a distributed minigrid (beyond the main building) requires special care in choosing the distribution system. Studer Innotec recommends a TT distribution for the DC grid as well as for the AC grid.

The size of the grid increases greatly the exposure of the inverters to atmospheric overvoltage and to non equipotentiality in the grid. This is particularly noticeable in the aerial distribution grids. In this case very special care must be taken to implement correctly all protection measures of the installation.

4.2 EARTHING SYSTEM

The Xtender is a protection class I unit, which is intended for cabling in a grid type TT, TN-S or TNC-S. The earthing of the neutral conductor (E) is carried out at a sole installation point, upstream of the RCD circuit breaker (D) type A, 30 mA. The Xtender can be operated with any earthing system. In all cases it is imperative that the protective earth be connected in compliance with the applicable standards and regulations. The information, notes, recommendations and diagram mentioned in this manual are subject to local installation regulations in every case. The installer is responsible for the conformity of the installation with the applicable local standards.

4.2.1 Mobile installation or installation connected to the grid via plug

connector

When the input of the device is connected directly to the grid via a plug, the length of the cable must not exceed 2 m and the plug must remain accessible. In the absence of voltage at the input, the neutral and live are interrupted, thereby guaranteeing complete isolation and protection of the cabling upstream of the Xtender. The earthing system downstream of the Xtender is determined by the upstream earthing system when the grid is present. In the absence of the grid, the earthing system downstream of the inverter is in isolated mode. The safety of the installation is guaranteed by the equipotential bonding.

The connection (link) between the neutrals (C) upstream and downstream of the Xtender is not permitted in this configuration.

This connection type guarantees the optimal continuity for supplying the Xtender loads. The first isolation fault will not lead to an interruption in the supply. If the installation requires the use of a permanent isolation controller this would have to be deactivated when the TT network is present at the Xtender input.

All sockets and protection class I devices connected downstream of the Xtender must be properly connected to the earth (earthed socket). The cabling rules above remain valid, including in installations, in all cases where the Xtender input is connected to the grid via a plug connector.

The IT system is not recommended for the distribution. This kind of distribution is most of the time forbidden by the local laws. The achievement of low voltage electric system is always subject to local laws and must imperatively be implemented and controlled by qualified and professionally authorized staff. Studer Innotec accepts no liability for damages due to non-conforming installation and to the lack of compliance with the local rules or with the recommendations of this manual.

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