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STUDER Innotec

Xtender

User manual V.3.1.0 1

SUMMARY

1INTRODUCTION...................................................................................................................................3

2GENERAL INFORMATION....................................................................................................................3

2.1Operating instructions.......................................................................................................................3

2.2Conventions.......................................................................................................................................4

2.3Quality and warranty........................................................................................................................4

2.3.1Exclusion of warranty....................................................................................................................4

2.3.2Exclusion of liability........................................................................................................................5

2.4Warnings and notes..........................................................................................................................5

2.4.1General...........................................................................................................................................5

2.4.2Precautions for using the batteries.............................................................................................6

3ASSEMBLY AND INSTALLATION...........................................................................................................6

3.1Handling and moving.......................................................................................................................6

3.2Storage................................................................................................................................................6

3.3Unpacking..........................................................................................................................................6

3.4Installation site....................................................................................................................................6

3.5Fastening.............................................................................................................................................7

3.5.1Fastening XTH model....................................................................................................................7

3.5.2Fastening XTM model ...................................................................................................................7

3.6Connections.......................................................................................................................................7

3.6.1General recommendations ........................................................................................................7

3.6.2Device connection compartment.............................................................................................9

4CABLING ...........................................................................................................................................10

4.1Choice of system.............................................................................................................................11

4.1.1Hybrid type stand-alone systems..............................................................................................11

4.1.2Grid-connected emergency systems......................................................................................11

4.1.3Integrated mobile systems ........................................................................................................11

4.1.4Multi-unit systems.........................................................................................................................11

4.2Earthing system................................................................................................................................11

4.2.1Mobile installation or installation connected to the grid via plug connector ..................12

4.2.2Stationary installation .................................................................................................................12

4.2.3Installation with automatic PE-neutral switching ...................................................................12

4.3Recommendations for dimensioning the system.......................................................................13

4.3.1Dimensioning the battery..........................................................................................................13

4.3.2Dimensioning the inverter..........................................................................................................13

4.3.3Dimensioning the generator .....................................................................................................13

4.3.4Dimensioning the renewable energy sources........................................................................13

4.4Wiring diagrams...............................................................................................................................14

4.5Connecting the battery.................................................................................................................14

4.5.1Battery cable cross-section and DC protective devices.....................................................14

4.5.2Connecting the battery (Xtender side)...................................................................................15

4.5.3Fuse mounting on battery positive pole (XTM only)..............................................................15

4.5.4Battery-side connection ............................................................................................................15

4.5.5Earthing the battery....................................................................................................................16

4.5.6Connecting the consumers at the 230 V AC output ............................................................16

4.5.7Connecting the AC supply sources.........................................................................................17

4.5.8Wiring auxiliary contacts............................................................................................................17

4.5.9Connecting the communications cables...............................................................................17

4.5.10Connecting the temperature sensor (BTS-01)....................................................................17

4.5.11Connecting the remote command module RCM10 (XTM only)....................................18

5POWERING UP THE INSTALLATION....................................................................................................18

6DESCRIPTION AND FUNCTIONING...................................................................................................19

6.1Circuit diagram................................................................................................................................19

6.2Description of the main functions.................................................................................................19

6.2.1Inverter..........................................................................................................................................19

6.2.2Automatic load detection ........................................................................................................20

6.2.3Transfer relay................................................................................................................................20

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Xtender

2 V.3.1.0 User manual

6.2.4Battery charger...........................................................................................................................21

6.2.5Limiting the input current by limiting the charger current....................................................22

6.2.6The inverter as source backup (“smart boost” function) .....................................................23

6.2.7Input current controlled by input voltage...............................................................................23

6.2.8Battery protection.......................................................................................................................24

6.2.9Xtender protection .....................................................................................................................24

6.2.10Auxiliary contacts ...................................................................................................................24

6.2.11The real time clock.................................................................................................................25

6.2.12Entry command (Remote control on/off) ..........................................................................25

6.3Multi-unit configurations.................................................................................................................25

6.3.1Three-phase system....................................................................................................................26

6.3.2Increasing the power by paralleling units...............................................................................26

6.3.3Combined system.......................................................................................................................27

6.4Accessories.......................................................................................................................................27

6.4.1Control centre and RCC-02/03 (remote control) display ....................................................27

6.4.2BTS-01 temperature sensor.........................................................................................................28

6.4.3Remote command Module RCM-10......................................................................................28

7CONTROL ..........................................................................................................................................29

7.1Main on/off control.........................................................................................................................29

7.2Display and control panel..............................................................................................................29

8MAINTENANCE OF THE INSTALLATION.............................................................................................31

9PRODUCT RECYCLING......................................................................................................................31

10EC DECLARATION OF CONFORMITY................................................................................................32

11COMMENTS OF ANNEXES’ FIGURES.................................................................................................33

12FIGURE’S ELEMENTS (DC PART).........................................................................................................35

13FIGURE ELEMENT'S (AC PART)...........................................................................................................36

14ELEMENTS OF CONNEXION CABINET (FIG 4A)................................................................................37

15CONTROL AND DISPLAY PARTS FOR THE XTENDER (FIG. 4B) ..........................................................38

16MODEL IDENTIFICATION (FIG. 1B)....................................................................................................39

17TABLE OF STANDARD CONFIGURATIONS.........................................................................................40

18TECHNICAL DATA – XTH....................................................................................................................42

19TECHNICAL DATA – XTM...................................................................................................................44

20NOTES................................................................................................................................................46

STUDER Innotec

Xtender

User manual V.3.1.0 3

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 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 on 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 configurations in

the installation.

In order to guarantee perfect 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 accessories1:

Inverter/charger: XTH 3000-12 – XTH 5000-24 – XTH 6000-48 – XTH 8000-48

Inverter/charger: XTM 1500-12, XTM 2000-12, XTM 2400-24,

XTM 3500-24, XTM 2600-48, XTM 4000-48

Temperature sensor: BTS-01

Remote command module: RCM-10

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

1Also for 120Vac model (-01)

STUDER Innotec

Xtender

4 V.3.1.0 User manual

usage must conform to the local safety instructions and applicable standards in the country

concerned.

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.

All values mentioned hereafter, followed by a configuration no. indicate that this value may be

modified with the help of the RCC-02/03 remote control.

In general, the default values are not mentioned and are replaced by a configuration no. in the

following format: {xxxx}. The default values for this configuration are specified in the configuration

table, p. 40.

All configuration values modified by the operator or installer must be transferred into the

same table. If a parameter not appearing in the list (advanced configurations) has been

modified by an authorised person with technical knowledge, they will indicate the

number of the modified parameter(s), the specifications of the configuration(s) and the

new value set, at the end of the same table.

All figures and letters indicated in brackets refer to items of figures in the separate manual

“Appendix to the installation and operating instructions” supplied with the device.

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.

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 I – 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.

The warranty period for the Xtender is 2 years.

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)

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Xtender

User manual V.3.1.0 5

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. For this reasons 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.

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.

We assume 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 configuration table available at the end of the manual (p. 40) must be kept up to date in the

event of modification of the configurations 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 ongoing 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.

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 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.

STUDER Innotec

Xtender

6 V.3.1.0 User manual

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.

2.4.2 Precautions for using the batteries

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. Consequently occurring sparks

may cause the battery to explode.

When working with the batteries, all metal jewellery such as rings, bracelet watches, earrings, etc.,

must be taken off. The current output by the batteries during a short-circuit is sufficiently powerful to

melt the metal and cause severe burns.

In all cases, the instructions of the battery manufacturer must be followed carefully.

3ASSEMBLY AND INSTALLATION

3.1 HANDLING AND MOVING

The weight of the Xtender is between 35 and 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 – fig. 2a (18)

2 conduit glands for the battery cable

3.4 INSTALLATION SITE

The installation site for the Xtender is of particular importance and must satisfy the following criteria:

Protected from any unauthorised person.

Protected from water and dust and in a place with no condensation.

STUDER Innotec

Xtender

User manual V.3.1.0 7

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 15cm from any obstacle that may

affect the ventilation of the equipment according to fig. 2b.

In mobile applications it is important to select an installation site that ensures as low a vibration level

as possible.

3.5 FASTENING

The Xtender is a heavy unit and must be mounted to a wall designed to bear such a

load. A simple wooden panel is insufficient.

The Xtender must be installed vertically with sufficient space around it to guarantee adequate

ventilation of the device (see figs. 2a and 2b).

3.5.1 Fastening XTH model

Firstly fix the mounting bracket (18)) 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.

3.5.2 Fastening XTM model

Screw on a solid wall (concrete or metallic wall) an M8 screw without washer up to a distance of

1.6 mm of the wall.

Hang the apparatus by having care to release beforehand the trap door of access (17) 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 (16) 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.

In motor vehicles or when the support may be subject to strong vibrations, the Xtender must be

mounted on anti-vibration supports.

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 between the two fastening screws at the bottom of the unit (fig. 2b-(17)).

STUDER Innotec

Xtender

8 V.3.1.0 User manual

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 and those for

the “REMOTE ON/OFF” (7) and “AUX.CONTAC” (8) by means of a no. 1 screwdriver.

The cable 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 section must conform with the applicable

regulations and standards. Sufficiently tighten the clamps on the “battery” inputs (fig. 4a (11) and

(12)).

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