ionGen XANTREX 3000 Assembly instructions

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Revision 05
Installer's Guide
XANTREX 3000 WATT
MODULE WITH EXTERNAL BMS INSTALLATION KIT

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....................................................
BMS/IONGAGE DIAGRAM......................................
PARTS LIST.............................................................
BATTERY INSTALLATION.......................................
SYSTEM OPERATION..............................................
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 quite detailed, it is meant only as an overall guide to the
installation and not to replace the manuals supplied by the original 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 BMS to isolate it from other electrical circuits before performing any
repairs or maintenance on the system.
Always use correct 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 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 Module and External BMS kit is based on a
large format GT or GTX series lithium ion battery module
and a Xantrex XC 3000 watt inverter. This combination is
capable of providing enough power to run your 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
BMS/IonGage Diagram
Wiring Diagrams
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 3

Main Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 4
The main diagram depicts the general layout of the system. The 2/0 positive cable is connected to the main positive
distribution bus via a Class T 400A fuse and an isolation switch. The fuse block should be mounted as close to the BMS
as is practicable.
The inverter is connected to the positive distribution bus via a Class T 350A fuse and an isolation switch. The fuse block
and isolation switch 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
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. 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 fuse without melting and possibly causing a fire.
The inverter is controlled by the Freedom X Control Panel.

Main Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 5
The Lithionics IonGage monitors battery voltage, current, power, amp-hours consumed and state of charge.
The Solar 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 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.
The Sterling Battery to Battery charger is connected to the positive distribution buss 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 6

Inverter Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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.
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Inverter Diagram
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 8
A warning label should be installed at the main AC panel to indicate that there is an
inverter in the system.
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 buss). 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.