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
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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
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Main Diagram
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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
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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
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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.
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Inverter Diagram
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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.

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
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Solar Diagram
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The Victron Smart MPPT solar charge controller uses maximum power point tracking that 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 buss 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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BMS/IonGage Diagram
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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.

BMS/IONGAGE DIAGRAM
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QTY PART NUMBER DESCRIPTION COMMENTS
Parts List
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Battery Installation
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Battery Module and NeverDie BMS Unit Environment and Mounting orientation
The Battery Module and BMS Unit should be mounted in an environment that does not receive direct sunlight, pressurized water
or road debris. To avoid power interruption, your installation may need to consider controlling the ambient operating
temperature. Mount the Battery Module in an upright position, i.e. black lid faces up. Other orientations are NOT permitted and
will void the warranty. The BMS Unit can be mounted in any orientation as long as all its features are accessible. Ensure that the
BMS Unit is located in close proximity to the Battery Module so that all connectors can be mated securely.
Temperature Sensor Connector
The temperature sensor cable and connector exiting the battery module must be connected to the BMS. Connect the two M8
circular connectors together by first aligning their pins and pressing them together, and then rotate the securing nuts until they
stop snugly. Do not use the temperature probe from the inverter-charger manufacturer.
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Battery Installation
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Main Power Connector
The battery module has a large black female main power connector that must be inserted into the BMS male main power connector.
This is the connector with the large 4/0 red and black wires and single small gauge gray cable. Align the connectors and insert them
together. Use 2 zip ties to bind the connectors together so that they may not separate during use.
NeverDie BMS Unit Power Terminals
Connect the BMS Unit Power Terminals to your DC bus, both Positive (Red) and negative (Black). Use correctly sized wire
conductors for the application. Torque to 80 INCH pounds. Never stack ring terminals or place the stainless-steel washer between
the Power Terminal and ring terminal lug.
Pressure Vent
It is recommended to install a ventilation hose onto the pressure vent barb when the Battery Module is in a location with poor
ventilation. The hose shall direct the gases to the atmosphere.
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