STUDER XTENDER XTM 4000-48 (01) PDF Document

The following accessories are available for the STUDER XTENDER XTM 4000-48 series:

Common Accessories:

Temperature sensor: BTS-01

Accessories for XTM/XTS models:

Remote command module: RCM-10

Accessories for XTS models:

External cooling fan: ECF-01

External auxiliary relay module: ARM-02

The symbols used with your STUDER XTENDER XTM 4000-48 have the following meanings:

Lightning bolt in a triangle: This symbol is used to indicate the presence of a dangerous voltage that is sufficient to constitute a risk of electric shock.

Exclamation mark in a triangle: This symbol is used to indicate a risk of material damage.

“i” in a circle: This symbol is used to indicate information that is important or which serves to optimize your system.

“SSS” symbol (three wavy vertical lines): This symbol placed on the product indicates that its surfaces may reach temperatures higher than 60°C.

Book symbol: This symbol placed on the product indicates that its use must follow the instructions in the user’s manual.

When working with the STUDER XTENDER XTM 4000-48, please observe the following safety warnings:

The 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.

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 from the battery as well as the source of AC voltage 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. After 10 seconds the electronics are discharged and intervention may take place without any danger.

The following precautions must be followed for batteries used with your STUDER XTENDER XTM 4000-48:

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 neutralized 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 jewelry 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.

The place of installation for the STUDER XTENDER XTM 4000-48 must satisfy the following criteria:

The device must be mounted on a non-flammable support (wall) designed to bear its weight.

It 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.

For XTM and XTH models (indoor use, IP20):

Protected from any unauthorized 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.

In mobile applications, select a 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.

For XTS models (outdoor use, IP54):

Can be installed outdoors, with exposure to dust and water splashes.

Avoid locations particularly exposed to salt water splashes or solvents (motor oil).

Avoid installing in direct sunlight or near a heat source (i.e. engine compartment).

Reduce exposure to sudden temperature changes to avoid condensation.

The 4 mounting screws of the enclosure must be completely tightened with a torque of 5Nm to guarantee the IP 54 protection index. Any unused cable glands should be closed to maintain the same level of protection.

Fastening of the XTH model:

1. First fix the mounting bracket supplied with the device using 2 screws (Ø 6-8 mm).

2. Hang the Xtender on the bracket.

3. Fasten the unit permanently using 2 screws (Ø 6-8 mm) on to the two notches located at the underside of the case.

A minimum distance of 20 cm in between and/or around the XTH devices is required for sufficient ventilation.

Fastening of the XTM model:

1. Screw the top screw (6-8mm) without a washer on a solid wall, leaving a 2mm distance between the screw head and the wall.

2. Hang the apparatus on this screw. If necessary, release the trap door of access by inserting it inside the apparatus using a screwdriver for a complete tightening of this fixing point.

3. Dismount the lower plastic cap to access the wiring compartment.

4. Carefully fix the apparatus with two screws (Ø 6-8 mm) in the two clamp holes down inside the wiring compartment.

Fastening of the XTS model:

1. The XTS enclosure must be first mounted on the support plate with the 4 screws and washer delivered with the appliance.

2. Then the unit can be fixed on a heavy-duty support (concrete or metallic wall) and positioned vertically with cable glands oriented down.

3. An external ventilation unit (ECF-01) can be installed on top of the unit before or after wall mounting.

Follow these general recommendations for connections:

A protective earth must be connected to the AC-In and/or AC-Out PE terminals. An additional protective earth is located at the bottom of the unit.

The PE conductor must be connected for all equipment in protection class I upstream and downstream of the Xtender (equipotential bonding).

Tighten the input (13) and output (14) terminals with a no. 3 screwdriver (minimum 1.2 Nm tightening torque).

Tighten the “Command entry (REMOTE ON/OFF)” (7) and “AUX.CONTAC” (8) terminals with a no. 1 screwdriver (0.55 Nm tightening torque).

All connection cables, including battery cables, must be mounted using cable restraints to avoid traction on the connection.

Battery cables must be as short as possible with a cross-section conforming to applicable standards. Sufficiently tighten the clamps on the “battery” inputs (10 Nm tightening torque).

Before connecting or disconnecting AC-in (13) and AC-out (14) cables, ensure no voltage is present in the cables or on the terminals.

Before connecting the battery, ensure the AC-in source and the AC-out loads are well disconnected.

Pos.	Denomination	Description	Comment
0	Protective earth connection terminal	Protective earth connection terminal	This terminal is used as primary earth connection protection.
1	ON/OFF Main switch	Main on/off switch	In XTM and XTS series, this function is deported on the remote command module RCM-10.
2	Temp. Sens	Connector for the battery temperature sensor	Only connect the original Studer BTS-01 sensor.
3	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.
4	O / T (Open / Terminated)	Switch for terminating the communication bus. Set position O (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).
5	—	3.3 V (CR-2032) lithium ion type battery socket	Used as a permanent supply for the internal clock.
6	—	Jumper for programming the off/on switch by dry contact	Positioned at A-1/2 and B-2/3 by default.
7	Command entry (REMOTE ON/OFF)	Entry command terminals. In XTM series, this entry is deported on the remote command module RCM-10.	Allows the control of a function to be defined by programming.
8	AUXILIARY CONTACT	Auxiliary contact. For XTS model, available only with module ARM-02.	Take care not to exceed the admissible loads.
9	—	Activation indicators for auxiliary contacts 1 and 2	See sect. 7.5 – p. 31.
10	L1/L2/L3	Phase selection jumpers.	Jumper default at position L1.
11	+BAT	Positive pole battery connection terminals	Take care with the polarity of the battery and when tightening the clamp.
12	-BAT	Negative pole battery connection terminals
13	AC Input	Connection terminals for the alternative power supply (generator or public network)	Note: It is imperative that the PE terminal be connected.
14	AC Output	Connection terminals for the device output.	Note: Increased voltages may appear on the terminals, even in the absence of voltage at the input of the inverter.
15	RCM-10	Connector for RCM-10 module	Only on XTM and XTS.
16	I-CHAR	Rotating knob to adjust the battery charge current	Only in XTS model.
17	Protective earth connection	Connection for supplementary protective earth.	This connection can also be used as principal protective earth.
18	INPUT LIMIT	Rotating knob to adjust the input current limit	Only in XTS model. For other models, see sect. 7.2.2 – p. 27.
19	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.
20	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.
21	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 and upstream cause.

The battery cables must be protected by a fuse at each pole, or on the pole not connected to the earth. The following table provides recommended sizes for cable lengths less than 3m.

Range	Battery fuse	Cable cross-section (<3m)
XTS-900-12	100A	25mm²
XTS 1200-24	80A	25mm²
XTS-1400-48	50A	16mm²
XTM-4000-48	200A	50mm²
XTM-2600-48	100A	25mm²
XTM-3500-24	300A	70mm²
XTM-2400-24	200A	50mm²
XTM-2000-12	300A	70mm²
XTM-1500-12	250A	70mm²
XTH-8000-48	300A	95mm²
XTH-6000-48	300A	70mm²
XTH-5000-24	300A	95mm²
XTH-3000-12	350A	95mm²

A fuse delivered with the XTM unit can be mounted directly on the positive connecting pole to the battery. The presence of this fuse does not exempt the installation of a protective device as close as possible to the battery.

Follow this stacking order:

a = M10 cable lug

b = bolt M8 x 30

c = washer

d = ceramic washer

e = fusible

Be careful with the orientation of the ceramic washer. There is a small lip on one side which must fit into the M10 cable lug’s hole.

For XTS models, four basic parameters can be modified directly in the compartment inside the door before powering up. Before opening the enclosure, it is mandatory to disconnect all AC and DC sources (battery) of the product to avoid any risk of electrical shock.

The following parameters can be adjusted:

The battery current charge {1138} using the potentiometer (16).

The max. AC source (input limit) {1107} using the potentiometer (18).

The source current assistance (Smart boost) function {1126} using the slide button (19).

The type of detection of AC-input loss (UPS) Fast/Tolerant/slow {1552} using the slide button (20).

These manual adjustments can be prevented using parameter {1551} on the remote control RCC-02/-03. If parameter {1551} is set to “yes,” the buttons 16, 18, 19, and 20 remain inactive.

The power up of the STUDER XTENDER XTM 4000-48 must be carried out in the order given below. Any power off must be carried out in the reverse order. Ensure the closing cap for the connection compartment is correctly installed and screwed tight before turning on the power.

1. Connecting the Battery: Connect the battery, ensuring correct voltage and polarity. For XTH or XTM models, incorrect polarity will likely blow the protection fuse on the battery cable. The XTS model is electronically protected against reverse polarity and will remain off until corrected.

2. Putting the Xtender(s) in Operation: If you require immediate start-up of the inverter when the battery is powered up, the main switch (1), if present, must be in the “ON” position and the parameter {1111} activated.

3. Connecting the Consumers at the Output: Activate the output protection device (F) if existing, and/or press the ON/OFF button (41). The light indicator “AC-Out” (46) will light up or flash.

4. Activating the Input Circuit Breaker(s) (H): If a valid AC source (generator or grid) is present at the AC input, the device automatically goes into transfer mode and will start to charge the batteries. The consumers at the output are then supplied directly by the power source.

Your installation is now in operation.

To save battery energy, the STUDER XTENDER XTM 4000-48 inverter stops and automatically goes into load search mode when the detected load is lower than the sensitivity set by parameter {1187}. It automatically resumes operation when a power consumer greater than this value demands it. The “AC-Out” indicator (46) flashes if the inverter is in “load search” mode, indicating AC voltage is present at the output intermittently. The detection threshold can be adjusted. When the parameter is set to 0, the inverter will operate even without a consumer. In load search mode, the system consumes minimal power from the battery.

The STUDER XTENDER XTM 4000-48 has two dry reversing contacts that are potential-free (on XTS models, this requires the ARM-02 module). By default, they are programmed for the following functions:

Contact no. 1 (AUX 1): This contact functions as an automatic generator start (two wires). The contact activates when the battery voltage is below a value for a given time, fixed by parameters {1247/48}/{1250/51}/{1253/54}. It deactivates when the charge cycle has reached floating {1516}, or when the “Aux. 1 deactivation voltage” {1255} is reached for a predetermined time {1256}.

Contact no. 2 (AUX 2): This is an alarm contact by default. It is deactivated when the inverter is out of service or working at reduced performance, due to manual control or an operational fault (e.g., overload, under-voltage, over-temperature).

The behavior of these contacts can be freely and individually reprogrammed based on battery voltage, output power, inverter status, the internal clock, and battery state of charge (if a BSP module is present).

To configure a multi-unit system (three-phase or parallel) with your STUDER XTENDER XTM 4000-48, follow these guidelines:

The installation must be performed by qualified personnel.

All units must have a compatible software version. When commissioning, the software version of every unit will be checked, and they may refuse to start if incompatible. An upgrade is required in this case.

All Xtenders in the system must share the same battery bank. Separate battery banks are not allowed.

Units must be connected via a communication bus by a cable (art. no. CAB-RJ45-8-2) of a maximum length of 5 meters.

It is recommended to use the automatic LVD dynamic compensation (parameter {1532}).

For a Three-Phase System:

Three Xtenders of the same voltage (power or type can be different) can be combined to establish a three-phase grid. The wired phases at the input determine the jumper position for selecting the phase (10) for each Xtender. If only a single-phase source is available, it must be connected to phase 1. The other two phases will be supplied by the other two units in inverter mode.

For Increasing Power by Paralleling Units:

Up to three Xtenders of the same type, power, and voltage can be wired in parallel. All AC-in inputs must be wired. The most recent unit (by serial number) in the phase will act as the master. If the source current per phase is greater than 50A (XTH/XTM) or 16A (XTS), a protection device must be installed on each of the 2 or 3 devices connected to that phase. If the source is limited to 50A or 16A respectively, only one protection device is needed.

The indicators on the front panel of your STUDER XTENDER XTM 4000-48 provide the following information:

AC out (46):

Lit continuously: An alternative voltage of 230V is present at the equipment output.

Flashing: The device is in “load search” mode.

AC in (45):

Lit continuously: A valid alternative voltage is present at the AC input, and the user-set current limit has not been reached.

Flashing once: The current limit at the input has been reached. The charger current is reduced to prioritize supply to users.

Blinking 2 times (if grid feeding is allowed {1127}): The unit is feeding energy to the grid.

Charge (44):

Lit continuously: The charger is working and has not yet reached its absorption phase.

Flashing twice: The charger is in the absorption phase.

Flashing once: The charger is in the floating phase.

Flashing 3 times: Equalization is activated.

ON (43):

Glowing continuously: The device is working.

Flashing: The equipment is temporarily stopped due to a fault (see indicator 42), a remote ON/OFF control, or is in idle mode in a parallel system.

OFF (42):

This indicator lights up when the equipment has been stopped manually or due to a fault. The number of flashes indicates the type of fault (see troubleshooting table).

The “OFF” indicator (42) flashes to indicate a fault. The number of flashes corresponds to a specific alarm, as detailed in the table below:

Indicated alarm	Comment
1x flash: (Imminent) stoppage due to a too low battery voltage.	If the inverter has not yet stopped, disconnect non-priority loads and/or start the generator. If stopped, it will restart automatically when the battery voltage reaches the correct value {1110}. It can be restarted manually with the ON/OFF button (41) if the battery voltage is higher than 1.5V/cell.
2x flashes: Stoppage due to overload or short-circuit.	The equipment will attempt to restart 3 times and will stop if the overload remains. Eliminate the cause of the overload before restarting manually by pressing the button (41).
3x flashes: Decrease in the rated output due to high internal temperature.	This may be due to overload, high ambient temperature, or obstructed ventilation. The power output will be limited to around 50% of the nominal power.
4x flashes: Battery voltage higher than the maximum limit set by parameter {1121}.	Check the cause of this excess voltage. The equipment will restart automatically when the voltage falls below the threshold value {1122}.
5x flashes: No transfer. Insufficient power from the source.	The Xtender remains in inverter mode. Increase the input current limit {1107}, authorize exceeding this limit {1436}, authorize source backup {1126}, or disconnect some consumers.
6x flashes: Start-up prevented due to unwanted voltage at the device output.	Voltage is present at the device output. Check your cabling, correct the fault, and restart the installation manually with button (41).
7x flashes: Indicates missing voltage in one of the units in a multi-unit configuration.	Check the input protection devices (H) for all system units.
8x flashes: Software incompatibility in a multi-units system.	The software version of all units in the system must be the same. Upgrade the software according to the RCC-02/-03 user manual.
9x flashes: Loss of synchronization between the units.	Failure of the link between the units. Check the presence and the state of the communication cables between units.

With the exception of periodic checks of connections (tightening and general condition), the STUDER XTENDER XTM 4000-48 does not require any special maintenance.

Elem.	Description	Comment
a	RCC-02/-03 remote control	This device allows complete configuration and display of system behavior. It is recommended but not necessary.
b	Battery	The battery capacity is constituted based on the required voltage. It is vital that the voltage and polarity be checked before connecting.
c	Earthing	See sect. 4.5.5 – p. 22 of the manual.
e	Communications cable	Only an original cable supplied by Studer Innotec may be used. The total length must not exceed 100 m for 3 x RCC-02/-03 or 300 m for a single RCC-02/-03.
f	Protection devices	A fuse-type device (fuse, thermal or magnetic-thermal circuit breaker) must be installed on at least one battery conductor, ideally on the positive pole. The calibre is selected according to cable cross-section.
h	Distribution bar	Positive pole of the battery.
j	Distribution bar	Negative pole of the battery.
k	Wind-powered or/and micro-hydro generator	One or more generators with their own regulation system may be used to directly charge the battery.
m	Solar generator	One or more solar-powered generators with their own regulation system may be used to directly charge the battery.
r	Command Entry	A control device may be connected to the terminals (7) of the Xtender. On XTM and XTS this input is available on an external device RCM-10.
t	BTS-01 temperature sensor	The sensor is placed in the immediate proximity to the battery. If the installation comprises several Xtenders, a single sensor is connected to one of the units.

Pos.	Denomination	Description	Comments
30	Model	Model
31	Pnom*/P30*	Rated power output / power for 30 minutes with external cooling fan ECF-01	Model XTS only
32	Pnom/P30	Rated power output / power for 30 minutes
33	Udc Battery	Rated battery voltage (accepted input range)
34	Idc Charge/inv/inv*	Maximum current in charger/nominal current in inverter/in inverter with external cooling fan for XTS model
35	Uac In	Maximum current at input / output	See sect. 7.2 – p. 26.
36	Iac In	Rated AC input voltage (input range)	See sect. 7.2.2 – p. 27.
37	Uac Out	Rated output voltage in inverter mode (possible adjustment range in inverter mode)	When the transfer relay is activated, the AC output voltage is equivalent to AC input voltage.
38	I AC-Out Inv/Inv*/max	Maximum charger current	See sect. 7.2.2 – p. 27.
39	SN:XXXXXXXXXX	Serial no.
40	IPxx	Protection rating according to IEC 60529

Inverter model	XTM 4000-48
Nominal battery voltage	48Vdc
Input voltage range	38-68Vdc
Continuous power @ 25°C	3500VA
Power 30 min. @ 25°C	4000VA
Power 3 sec. @25°C	10.5kVA
Maximum load	Up to short-circuit
Maximum asymmetric load	Up to Pcont.
Load detection (Stand-by)	2 to 25W
Cos φ	0.1-1
Maximum efficiency	96%
Consumption OFF/Stand-by/ON	1.8W/2.1W/14W
Output voltage	Pure sine wave 230Vac (+/- 2%) / 120Vac (1)
Output frequency	50Hz / 60Hz(1) +/- 0.05% (crystal controlled)
Harmonic distortion	<2%
Overload and short-circuit protection	Automatic disconnection with 3 restart attempts
Overheat protection	Warning before shut-down – with automatic restart
Battery charger
Charge characteristics	6 steps: bulk – absorption – floating – equalization – reduced floating – periodic absorption
Maximum charging current	50A
Temperature compensation	With BTS-01 or BSP 500/1200
Power factor correction (PFC)	EN 61000-3-2
General data	XTM 4000-48
Input voltage range	150 to 265Vac / 50 to 140Vac (1)
Input frequency	45 to 65Hz
Input current max. (transfer relay) / Output current max.	50Aac/56Aac
Transfer time (UPS)	<15ms
Multifunction contacts	Two independent switchover contacts (potential free, 16A-250 Vac / 3A-50Vdc)
Weight	22.9 kg
Dimension h x w x l [mm]	133x322x466
Protection index	IP20
Operating temperature range	-20 to 55°C
Relative humidity in operation	95% without condensation
Ventilation	Forced from 55°C
Acoustic level	<40dB / <45dB (without / with ventilation)