iONGEN GTX12V315A-E2107-CS200RV Kisae 3000 Watt Lithionics Battery Installation Guide

iONGEN GTX12V315A-E2107-CS200RV Kisae 3000 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 Kisae 3000 kit is based on one GTX12V315A-E2107- CS200 battery (315-amp hours) and a Kisae 3000 watt inverter/charger. 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
• Kisae DMT-1250 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 300A post-mounted fuse and an isolation switch. The inverter is connected to the positive distribution bus via a 250A 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 inverter is controlled by the Multi-Function Display. The display is used to provide information about the status of the inverter and can be used to customize its features. The Lithionics IonGage monitors battery voltage, current, power, amp-hours consumed and state of charge. The DMT-1250 charger is connected to the positive distribution bus via a 60A circuit breaker (Ch-1). The PV solar array is connected to the MPPT charger input (Ch-2) via a circuit breaker. Please note that the maximum PV solar array voltage is 45VDC. The alternator/start battery input (Ch-3) is connected to the start battery via a 70A circuit breaker, this circuit breaker 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 size determined by distance run. See Kisae DMT 1250 diagram for details.
2. Mount the circuit breaker as close to the battery as possible, preferably within 7 inches.
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. Circuit breaker rating dependent on solar array. See solar panel manufacturer specifications.
5. See Inverter diagram for AC wiring details.
6. All high current DC cables should have a temperature rating of 105 degrees Celsius.
7. A class “T” fuse is prefered 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. Minimum run from the battery to the positive distribution bus to be 2 ft or greater, to provide extra resistance for the inverter inrush management.
10. 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 eight feet the cable size can be increased to 4/0.
11. Switch is required for inverter Isolation and inrush management when first turning 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 inverter’s capacity such as a water heater or an electric stove. The inverter AC input must be protected by a circuit breaker rated at 30A. Make all connections using proper crimp-on connectors (do not use twist-on connectors). A Residual Current Device (RCD) type circuit breaker rated at 30A must be wired in series with the output. 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 neutral conductor of the Kisae inverter/charger AC output circuit is connected to the chassis ground during inverter operation.

When AC utility power is present this connection is disconnected by the transfer relay so that the utility neutral is only connected to the utility ground at the source. 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 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.

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. Use only stranded, copper wire rated at 75 °C minimum. Do not use twist on connectors.
2. A warning label must be displayed at the main electrical panel to indicate that the electrical system includes an inverter.
3. The AC main panel circuit breaker supplying the Inverter I charger must be rated at no more than 30A.
4. The DC cables must be stranded, copper, and rated at 105°C.
5. The neutral conductor of the Kisae inverter/ charger AC output circuit is connected to the safety ground during inverter operation. When AC utility power is present this connection is disconnected by the transfer relay so that the utility neutral is only connected to the utility ground at the source.
6. 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.
7. Inverter neutrals must return to the inverter AC panel and not the main AC panel.
8. An RCD (Residual Curent Device) type circuit breaker rated to support the expected load must be included in series with the output. 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.

Kisae DMT-1250

The DMT-1250 DC to DC Battery Charger is a fully automatic multi-stage, multi- input battery charger with the ability to charge from either an alternator linked to a battery, or via solar power with the Maximum Power Point Tracking (MPPT) Solar Controller. With two inputs available, the house battery will be charged from either the engine while underway, or via the solar panels when stationary. The process to choose either engine or solar is fully automatic and both functions are controlled from within the unit itself without the need for external relays.

DIAGRAM

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.

DIAGRAM

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 the 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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