ionGen GTX12V315A-E2107-CS200RV Assembly instructions

GTX12V315A-E2107-CS200RV INSTALLATION KIT
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Installer's Guide
Revision 04
XANTREX 2000 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..........................................
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Table of Contents
2
4
6
8
10
12
14
15
18

Safety Information
1
!
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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
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.

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.
2
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Introduction

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

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 4/0 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 amp fuse and an isolation switch. The fuse should be mounted as close as possible to the fuse block. The isolation switch
allows you to isolate the inverter in case of a malfunction as well as disabling the inverter if you need to work on the AC system.
If the inverter is installed more than five feet 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. If the 2/0 positive cable suppling 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 Victron Smart MPPT charger is connected to the positive distribution buss 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.
Main Diagram

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

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 6
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 beyond the inverters capacity 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 buss). 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

INVERTER DIAGRAM
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 7

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 8
The Sterling Battery to Battery charger charges the house battery via the vehicles 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
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.

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

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 buss 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

SOLAR DIAGRAM
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 11

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Battery/IonGage Diagram
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 DIAGRAM
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 13

QTY PART NUMBER DESCRIPTION COMMENTS
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Parts List
14

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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.
15

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.
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Battery Installation
16

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.
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Battery Installation
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
17

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