IONGEN GTX12V315A Xantrex 2000 Watt Lithionics Battery Installation Guide

IONGEN GTX12V315A Xantrex 2000 Watt Lithionics Battery

Safety Information

This manual is intended to be used by qualified installers. Although it is quite detailed, it is meant only as an overall guide to the installation and not to replace the OEM manuals supplied by the relevant equipment manufacturers. All electrical work should be performed in accordance with local and national electrical codes. Assume that voltage is present at the battery terminals; use insulated tools and gloves while working on the system. Always turn off equipment connected to the battery to isolate it from other electrical circuits before performing any repairs or maintenance on the system. Always use the appropriate size cable to connect the system to inverters, chargers or other equipment. Always use crimped connections to connect to the battery terminals. Read and follow the inverter, charger or other equipment manufacturer’s safety precautions prior to connecting the battery to that equipment. Always use charging equipment compatible with Lithium Iron Phosphate battery chemistry. Links to the installation manuals relevant to this kit are listed at the back of this manual.

Introduction

The Lithionics GTX12V315A-E2107-CS200 Xantrex 3000 kit is based on two GTX12V315A-E2107- CS200 batteries (630 amp hours) and a XC Pro 3000 watt inverter. This combination is capable of providing enough power to run most AC loads for extended periods of time. The inverter features true sine wave grid quality power and is capable of handling high surge loads.

Wiring Diagrams

• Main Diagram
• Inverter Diagram
• Sterling Diagram
• Solar Diagram
• Battery/IonGage Diagram

Main Diagram

The main diagram depicts the general layout of the system. The 2/0 AWG battery positive cable is connected to the main positive distribution bus via a 400A class T fuse (a mega fuse may be substituted) and an isolation switch. The inverter is connected to the positive distribution bus via a 350A class T fuse and an isolation switch. The class T fuse block should be mounted as close as possible to the positive distribution bus. The inverter switch is required for inverter isolation and inrush management when first turning on the system. The chassis DC grounding cable (green) should be sized not less than one size smaller than the DC positive conductor and have a capacity such that the DC positive fuse has an amperage rating not greater than 135% of the current rating of this ground wire.

If the positive cable supplying the inverter shorts to ground internally, then the chassis ground cable needs to be able to carry enough current to blow the inverter fuse without melting and possibly causing a fire. The Lithionics IonGage monitors battery voltage, current, power, amp-hours consumed and state of charge. The Victron Smart MPPT charger is connected to the positive distribution bus via a 40A Maxi fuse. The PV solar array is connected to the MPPT charger via a circuit breaker. The specified circuit breaker is only rated at 48VDC; if your PV solar array has an open circuit voltage that is higher, then another circuit breaker with a higher voltage rating must be substituted. The Sterling Battery to Battery charger is connected to the positive distribution bus via a 50A Maxi fuse (80A for the Sterling BB1260 charger). It also has a fuse at the starter battery; this fuse must be installed as close to the battery as possible.

Wiring note : A total DC power circuit resistance between a single Lithionics battery and a 3000W inverter can be as low as 5 mOhm (0.005 Ohm), when using short wires to connect the battery to the inverter. With a typical battery voltage of 13.5V, this can result in an inrush peak current of 2,700 Amps (!!!) from the battery to the inverter capacitors. This surge only lasts around 1 millisecond but could be enough to damage the Battery Management System (BMS) or even damage the inverter. The minimum required wire size and length stated in the wiring diagram are provided to ensure minimum circuit resistance of at least 5.6 mOhm to reduce the inrush under 2,400A. For more information refer to Lithionics Support page, FAQ Section at this link https://lithionicsbattery.com/support/

1. Cable and fuse size dependent on Battery to Battery charger used. See Sterling diagram for details.
2. Mount the B to B fuse as close to the battery as possible.
3. Chassis DC grounding conductor should be sized not less than one size smaller than the DC positive conductor and have a capacity such that the DC positive fuse has an amperage rating not greater than 135% of the current rating of this grounding wire.
4. Regenerative braking compatible. See Sterling diagram for wiring details.
5. See Solar diagram for wiring details.
6. See Inverter diagram for AC iring details.
7. A class “T” fuse is preferred but a MEGA fuse may be substituted. Mount the inverter fuse as close to the positive distribution bus as possible.
8. The Lithionics lonGage monitors battery voltage, current, power, amp-hours consumed and state of charge.
9. A class “T” fuse is preferred but a MEGA fuse may be substituted. Mount the main fuse as close to the battery as possible.
10. Minimum run from the battery to the positive distribution bus to be 2 ft or greater, to provide extra resistance tor the inverter inrush management.
11. Minimum run from the positive distribution bus to the inverter to be 2 ft or greater, to provide extra resistance for the inverter inrush management. If the run is longer than 8 ft the cable size can be increased to 4/0.
12. Switch is required for inverter lsolation and inrush management when first tuming on the system.

Inverter Diagram

The inverter diagram depicts a typical AC installation. The main panel has an output breaker for the non-inverter loads. It is used to power the high power loads that are beyond the inverters capacity such as a water heater or an electric stove. The inverter AC input must be protected by a circuit breaker rated at 50A or less, and the cable cross section must be sized accordingly (10AWG for 30A, 6AWG for 50A). Make all connections using proper crimp-on connectors (do not use twist on connectors). A Residual Current Device (RCD) type circuit breaker rated to support the expected load must be included in series with the output, and cable cross-section must be sized accordingly. This breaker should be as close to the inverter as possible. If this breaker is not of the RCD type, GFCI receptacles must be used at all AC outlets. The inverter is provided with a ground relay that automatically connects the neutral output to the chassis if no external AC supply is available.

In an RV installation, the inverter chassis must be connected to the vehicle chassis ground (via the negative distribution bus). The chassis grounding conductor must be not less than one size smaller than the DC positive conductor and have a capacity such that the DC positive fuse has an amperage rating not greater than 135% of the current rating of this grounding wire. When using an inverter sub panel, the inverter neutral cables must return to the inverter sub panel and not the main AC panel. A warning label should be installed at the main AC panel to indicate that there is an inverter in the system.

1. Cable size is determined by the breaker size (10AWG for 30A, 6AWNG for 50A). Use only stranded, copper wire rated at 75 °C minimum Do not use twist on connectors.
2. A waming label must be displayed at the main electrical panel to indicate that the electrical system includes an inverter
3. The AC input must be protected by a magnetic circuit breaker rated at 50A or less, and the cable must be sized accordingly (10AWG for 30A 6AWG for 50A). If the shore power AC supply is rated at a lower value, the circuit breaker should be downsize accordingly.
4. The DC cables must be stranded, copper, and rated at 90 °C minimum. The cables should be terminated with lugs that fit the DC stud teminals snugly (5/16″ hole size) and properly torqued according to the manufacturer-specified torque setting
5. Allow at least 5 inches of clearance at the fan end of the Freedom XC PRO for air flow, 1 inch on each side, and 2 inches at the wiring access (AC and DC) end.The more clearance for ventilation around the unit, the better the perfomance. Do not allow the ventilation openings on the ends of the unit to become obstructed. AC Output Neutral Bonding
6. The neutral conductor of the Freedom XC PRO’S AC output circuit is automatically connected to the safety ground during inverter operation. When AC utility power is present this connection is not present, so that the utility neutral is only connected to utility ground at your source.
7. Chassis DC grounding conductor sized not less than one size smaller than the DC positive conductor and have a capacity such that the DC positive fuse has an amperage rating not greater than 135% of the current rating of this grounding wire.
8. Inverter neutrals must return to the inverter AC panel and not the main AC panel.
9. An RCD (Residual Current Device) type circuit breaker rated to support the expected load must be included in series with the output, and the cable must be sized accordingly (10AWG for 30A, 6AWG for 50A).This breaker should be as close to the inverter as possible. If this breaker is not of the RCD (Residual Current Device) type, GFCI receptacles must be used at all AC outlets.

Sterling Diagram

The Sterling Battery to Battery charger charges the house battery via the vehicle’s alternator. This system uses either the Sterling BB1230 charger (Mercedes recommendation), or the BB1260 charger depending on the size of the alternator. The charger should be programmed to charge the battery using a Lithium battery profile. The charger can also be configured to work with vehicles using regenerative braking

MODE 1-IGNITION TERMINAL DISCONNECTED
Automatic activation (default setting). The most common mode, used in 50% of all installations including vehicles with some EUR0 6/Regen. braking systems (depending on application). This means that the unit is voltage sensitive (no ignition feed required unless Euro 6 vehicles are being used in a stationary application – at idle at the side of the road). When the input voltage exceeds 13.2V-19.0V (x2 for 24V), the unit will start charging. If the voltage drops below 13.0V, the unit will turn off. if the input voltage exceeds 13.2V (2x for 24V) for 5 seconds, the regen-braking timer is activated in standby. The timer becomes active if the input voltage drops down to 12.0V-13.3V. This timer is 240s (default- can be changed) and allows the charger to continue charging at these lower input voltages. If the voltage drops below 11.9V the charger goes to sleep irespective of the timer. If the input voltage remains between 11.9V-13.0V for over 240s the charger also goes to sleep. To wake the charger, the input voltage needs to rise above 13.2V- this shall also reset the regen braking timer.

MODE-2 IGNITION FEED MODE
Apply an ignition feed cable to the “Ignition’ terminal on the connect block. As soon as there is a signal ( 4V) on this connector, the unit will wake up (can take up to 60 seconds) and will start to charge the output battery. The only limit is the input voltage. It will charge down to 10V on the input side. When ignition is turned off (0-4V) the BB shall continue charging at ‘mode 1 charging parameters.

WARNING : If ignition on the vehide is left on and the engine is off, you shall deplete your starter battery down to 10V. Also, if your alternator is less than 60A or can not produce 60A at idle revs you may discharge your starter battery. |

WARNING: the BB shal start up by mode 1 voltage parameters if there is a line feeding the ignition at <4V. We have done this to allow users to put solar or an AC to DC charger onto the starter to enable the BB to charge the leisure/ aux battery without running an additional ignition supply.

Euro 6 vehicle (which to choose)
If your usage of the vehicle includes situation applications where the vehicle engine is being run for long periods at idle and stationary. I.e. you are simply switching the engine on to charge the auxiliary battery system but not driving, then you must use the ignition feed mode, Mode 2.

Solar Diagram

The Victron Smart MPPT solar charge controller uses maximum power point tracking which optimizes the match between the solar array and the battery bank. It converts the higher voltage DC output from the solar panels down to the lower voltage needed to charge the batteries. The PV solar array is connected to the MPPT charger with a circuit breaker (not supplied). The specified circuit breaker is only rated at 48VDC; if your PV solar array has an open circuit voltage that is higher, then another circuit breaker with a higher voltage rating must be substituted. The charger is connected to the positive distribution bus via a 40A fuse. The fuse and wire sizes are based on the Victron MPPT 100/30 charge controller, if a larger controller is used then the fuse and wire sizes should be increased as required. Using the VictronConnect App on your smartphone you can connect via Bluetooth and remotely control and monitor the Smart solar MPPT charger.

1. Total open circuit voltage (Voc) of the PV array multiplied by 1.25 (a 25% safety factor) must not exceed the charge controller’s maximum PV voltage rating of 100V.

2. Output power from the PV array varies depending on PV module size, connection method, and sunlight angle. The minimum wire size may be calculated using the
   short circuit current rating (Isc3 ) of the PV array. Refer to the value of Isc in the manufacturer’s PV module data specification sheet (minimum wire size is 10 AWG and the max wire size is 6 AWG for this MPPT charger).

3. The size of the chassis grounding cable should not be less than 10 AWG and should be connected to the negative distribution buss.

4. Remote control and monitorning of the Smart solar MPPT charger can be done via bluetooth by pairing it with your smartphone or other device via the VictronConnect App. The App is available for iOS & Android devices; as well as macos and Windows computers.

Battery/IonGage Diagram

The Advanced Series BMS includes an integrated SOC Gauge, designed to track battery state of charge (percent of usable energy left in the battery) as well as other useful data parameters. Tracking state of charge is accomplished by a Coulomb counter, based on an internal, high sensitivity hall-effect sensor. The SOC Gauge data will only be correct if the configuration parameters are set correctly, which are pre-set initially by Lithionics Battery, but are user adjustable with supporting hardware. The SOC Gauge will also track and display live amperage (A), live wattage (W), battery voltage (V), temperature (F/C), amp hours (Ah), watt hours (Wh), time remaining (d/h), etc. The meter will be most accurate if the battery is fully charged on a regular basis. If the battery is always partially charged, then the SOC meter reading may drift in the long term and will become less accurate. When the most accurate measurements are required it is recommended to perform a full charge at least weekly

1. lonGage (51-160)
2. CANbus termination incorporated in harness
3. lonGage Harness (75-523-288)
4. Pushbutton On/Off switch
5. AMPSEAL8 connector ( alternator Field Control Circuit, remote LED illuminated On/Off Power switch
6. Circular M12 port (CANbus telemetry in the RVIA RV-C fomat)

Parts List

Battery Installation

Check the battery for visible damage including cracks, dents, deformation and other visible abnormalities. The top surface of the battery and terminal connections should be clean, free of dirt and corrosion, and dry. Battery power should be turned off prior to the installation and for storage. Check the LED integrated into the Power button to make sure it is completely off. If the LED is on or blinking, press and hold the Power button for 3 seconds until LED turns off. Lithium batteries do not release gas during normal use. There are no specific ventilation requirements for battery installation, although enough airflow should be provided to prevent excessive heat build-up. The battery should be stored and installed in a clean, cool and dry place, keeping water, oil, and dirt away from the battery.

If any of these materials can accumulate on the top surface of the battery, current leakage can occur, resulting in self-discharge and possible short circuits The battery is equipped with two flat threaded terminals designed for a 5/16” or M8 size ring terminal lug and secured by included M8 bolts, flat washers and lock washers. When using flat washers, it is critical to place the ring terminal lug in direct contact with the top surface of the power terminal and then place the washers on top of the lug. Connect the positive and negative battery cables with correct polarity and double check the polarity of battery circuit to avoid potential equipment and battery damage.

DO NOT place any washers between the battery power terminal and the ring terminal lug, as this could create a high resistance path and cause excessive heating of the connection which could then lead to permanent battery damage or fire. If you must attach more than one lug to each terminal, make sure at least 1/4” or 6mm of thread is available to secure the connection. Additionally, the ring terminal lugs need to be “clocked” in such a way that they do not interfere with their flat conducting surfaces. Acquire and use longer M8x1.25mm bolts if necessary. Tighten both M8 power terminal bolts to a maximum of 108inlbs/ 12.2Nm to ensure there is good contact with the ring terminal lug. Over tightening terminal connections can cause terminal breakage and loose connections can result in power terminal meltdown or fire.

The battery cables should be sized to handle the expected load. Refer to NEC Table 310.15(B)16 for the maximum amperage based on the cable gauge size. Cable lengths in excess of 6 feet may require heavier gauge wire to avoid unacceptable voltage drop. For more information refer to the National Electrical Code for correct cable size, which can be located at www.nfpa.org The battery circuit must be properly fused to handle the expected load and not to exceed the battery specifications. After installation is complete, turn on the battery power by a short-press of the Power button. The LED indicator should come on to confirm the battery’s state. DO NOT connect multiple batteries in series to get higher voltage as it will damage the internal BMS. DO NOT attempt to disassemble the battery, as it could lead to permanent battery damage and voids your battery warranty!!! A link to the battery installation manual is listed at the back of this manual

Equipment Manuals

Please see below the web links for the manufacturer equipment manuals.

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA

• PH : 727.726.4204
• FAX : 727.797.8046
• WEB : LITHIONICSBATTERY.com

References

• Lithionics Battery
• NFPA | The National Fire Protection Association
• Support | Lithionics Battery

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