ionGen GTX12V630A-E2112-CS200RV Assembly instructions

GTX12V630A-E2112-CS200RV INSTALLATION KIT
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Installer's Guide
Revision 05
XANTREX 3000 WATT

S A F E T Y I N F O R M A T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
I N T R O D U C T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
W I R I N G D I A G R A M S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAIN DIAGRAM.......................................................
INVERTER DIAGRAM...............................................
STERLING DIAGRAM................................................
SOLAR DIAGRAM....................................................
BATTERY/IONGAGE DIAGRAM.............................
PARTS LIST.............................................................
BATTERY INSTALLATION.......................................
EQUIPMENT MANUALS..........................................
Table of Contents
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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Safety Information
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LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Links to the installation manuals relevant to this kit are listed at the back of this manual.
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.

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LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Introduction
The Lithionics GTX12V630A-E2112-CS200 Xantrex 3000
kit is based on a GTX12V630A-E2112- CS200 battery
(630 amp hours) and a XC Pro 3000-watt inverter (a 2000-
watt inverter/charger may be substituted without any
change in wiring). 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.

Main Diagram
Inverter Diagram
Sterling Diagram
Solar Diagram
Battery/IonGage Diagram
Wiring Diagrams
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 3

Main Diagram
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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 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/

MAIN DIAGRAM
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 5

Inverter Diagram
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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.

INVERTER DIAGRAM
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Sterling Diagram
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Sterling Power Battery to Battery Charger 12V input to
12V output 30amps
Sterling Power Battery to Battery Charger 12V input to
12V output up to 60amps.
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.

STERLING DIAGRAM
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 9

Solar Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 10
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.

SOLAR DIAGRAM
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Battery/IonGage Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 12
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.

BATTERY/IONGAGE BATTERY
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QTY PART NUMBER DESCRIPTION COMMENTS
Parts List
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Battery Installation
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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.
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Battery Installation
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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 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.
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Battery Installation
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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
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LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 18
Please see below the web links for the manufacturer equipment manuals.
Equipment Manuals
Xantrex Inverter Victron MPPT Solar ChargerSterling ChargerLithionics Battery