iONGEN GTX12V315A-E2107-CS200RV Xantrex 2000 Watt Lithionics Battery Installation Guide
- June 3, 2024
- iONGEN
Table of Contents
iONGEN GTX12V315A-E2107-CS200RV Xantrex 2000 Watt Lithionics Battery
Safety Information
This manual is intended to be used by qualified installers. Although detailed, it is meant only as an overall guide to the installation and not to replace the 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 in addition to turning OFF the Power switch on the battery to isolate it from other electrical circuits before performing any repairs or maintenance on the system.
Always use proper wire sizes 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 manufacturers’ safety precautions prior to joining the battery to that equipment. Always use charging equipment compatible with Lithium Iron Phosphate battery chemistry.
Introduction
The Lithionics GTX12V315A-E2107-CS200 Xantrex kit is based on a single GTX12V315A-E2107-CS200 battery and a Xantrex 2000-watt inverter. The kit is limited to 300Amps DC. If a larger inverter or battery bank is anticipated in a future expansion then one of our larger kits with higher capacity components is recommended.
Wiring Diagrams
- Main Diagram
- Inverter Diagram
- Sterling Diagram
- Solar Diagram
- Battery/IonGage Diagram
Main Diagram
The main diagram depicts the overall layout of the system. The 2/0 AWG positive cable is connected to the MRBF fuse block via a 300A post-mounted fuse and an isolation switch.
The inverter is connected to the non-fused post of the fuse block via a Class T 250A fuse and an isolation switch. The Class T fuse block should be mounted as close as possible to the MRBF fuse block. The inverter switch is required for inverter isolation and inrush management when first turning on the system. If the inverter is installed more than 8ft from the fuse block, the wire size should be increased to 4/0 to compensate for voltage drop. The chassis DC grounding conductor (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.
Suppose the 2/0 positive cable supplies the inverter shorts to ground internally. In that case, the chassis ground cable needs to be able to carry enough current to blow the fuse without melting and possibly causing a fire. The Victron Smart MPPT charger is connected to the positive distribution bus via a 40A 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 main fuse block via a 50A fuse (80A for the BB1260 charger). It also has a fuse at the starter battery. This fuse must be installed as close to the battery as possible. The Lithionics IonGage monitors battery voltage, current, power, amp-hours consumed, and state of charge.
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 the
Lithionics Support page, FAQ Section at this link
https://lithionicsbattery.com/support/.
MAIN DIAGRAM
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 high power loads beyond the capacity of the inverter such as a water heater or an electric stove. A 30A AC breaker supplies power to the inverter (mandatory). The wire supplying the inverter must be no smaller than 10AWG and have a temperature rating of not less than 75C. Make all connections using proper crimp-on connectors (do not use twist-on connectors). The inverter output breaker should be rated at 30A. 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. In smaller installations you can install the optional GFCI receptacle (part #808-9817) on the front panel of the inverter; you can then plug loads of up to 20A directly into the inverter GFCI.
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 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 neutrals must return to the 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.
INVERTER DIAGRAM
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 set up to work with vehicles
using regenerative braking. 
STERLING DIAGRAM
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 and an isolation switch.
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.
SOLAR DIAGRAM
Battery/IonGage Diagram
The Advanced Series BMS includes an integrated SOC Gauge, designed to track the battery state of charge (percent of usable energy left in the battery) as well as other useful data parameters. The 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.
BATTERY/IONGAGE 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 the 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 108in-lbs/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 the 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 the 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 void your battery warranty!
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: 727.797.8046 | WEB: LITHIONICSBATTERY.com.
References
Read User Manual Online (PDF format)
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