ionGen KISAE 3000 Assembly instructions

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.comRevision 03
Installer's Guide
KISAE 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...............................................
KISAE DMT-1250 DIAGRAM...................................
BMS/IONGAGE DIAGRAM.....................................
PARTS LIST.............................................................
BATTERY INSTALLATION.......................................
SYSTEM OPERTATIONS..........................................
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 Kisae 3000 watt inverter / charger. 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
Kisae DMT-1250 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 4/0 positive cables are connected to the main positive
distribution buss via a 400A class T fuse and an isolation switch. The inverter is connected to the positive distribution buss
via a Class T 350A amp fuse and an isolation switch. The Class T fuse block and isolation switch should be mounted as close
as possible to the positive distribution buss. 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. 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 Multi-Function Display. The display is used to provide information about the inverters
status and can be used to customize its features.
The Lithionics IonGage monitors battery voltage, current, power, amp-hours consumed and state of charge.
The DMT-1250 charger is connected to the positive distribution buss via a 60A circuit breaker (Ch-1). The PV solar array is
connected to the MPPT charger input (Ch-2) via a circuit breaker. Please note that the maximum PV solar array voltage is
45VDC. The alternator / start battery input (Ch-3) is connected to the start battery via a 70A circuit breaker, this circuit
breaker must be installed as close to the battery as possible.

MAIN DIAGRAM
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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 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 30A. Make all connections using proper crimp-on connectors (do not use twist on
connectors).
A Residual Current Device (RCD) type circuit breaker rated at 30A must be wired in series with the output. 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 neutral conductor of the Kisae inverter / charger AC output circuit is connected to the chassis ground during inverter operation.
When AC utility power is present this connection is disconnected by the transfer relay so that the utility neutral is only connected to
the utility ground at the source. 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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Kisae DMT-1250
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com 8
The DMT-1250 DC to DC Battery Charger is a fully automatic multi-stage, multi-input battery charger with the ability to charge
from either an alternator linked to a battery, or via solar power with the Maximum Power Point Tracking (MPPT) Solar Controller.
With two inputs available, the house battery will be charged from either the engine while underway, or via the solar panels when
stationary. The process to choose either engine or solar is fully automatic and both functions are controlled from
within the unit itself without the need for external relays.

KISAE DMT-1250
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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
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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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Battery Installation
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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
BMS Unit I/O Connector
Some systems have a rectangular I/O connector to extend the BMS Unit features remotely such as remote Power/Reset
switch, LED indicator, or serial data logging. Be sure to connect the I/O connector if so equipped.
Initial Charge Cycle
Initially the system must be FULLY charged once to calibrate the BMS Unit to the Battery Module.
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System Operation
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Powering the System On
Short press the Power switch for 1 second. The switch will illuminate once power is enabled. You may notice
an audible “thunk” noise of the internal contactor switching on. Check that there is voltage at the Power Terminals
with a voltmeter.
Powering the System Off
Long press the Power switch for 3 seconds. The switch will cease to illuminate once power is disabled. You
may notice an audible “thunk” noise of the internal contactor switching off. Check that there is 0V at the output
terminals with a voltmeter.
Charging
The charging device(s) connected to the Lithium Battery System must be programmed to the correct
parameters for the battery. Charging may be performed at any time the system is powered ON.
NOTE – The Lithium Battery System will disconnect power if the voltage, amperage, or temperature limits are exceeded
during charging. Only use a Lithionics Battery approved charging source. Please contact Lithionics Battery for charger
approval.

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
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System Operation
Initial Charging Cycle
The initial charging cycle is required as it calibrates the NeverDie BMS to the Battery Module for accurate State of Charge
percentage monitoring. During the initial charging cycle, the system must reach a voltage level that is equal to the Standard
Full Charging Voltage indicated. Enable the charging device(s) so that they may complete a charge cycle. It is recommended
to not have any discharge loads active during the initial charging cycle, especially towards the end of charging.
Discharging
Discharging may be performed at any time the system is powered On.
NOTE - The Lithium Battery System will disconnect power if the voltage, amperage, or temperature limits are exceeded during
discharging. This NeverDie feature allows the system to have a “reserve” amount of energy left in the battery. Once the system is
discharged to 12.0V or 10% State of Charge, whichever comes first, power will be disabled to leave a “reserve” amount of energy
still left in the battery. To enable the remaining reserve energy of the system, short press the Power switch for 1 second.
NOTE - Once the reserve range is enabled the battery should be charged as soon as possible.
WARNING - If the reserve energy is used and the battery module is left in a deeply discharged state without immediate
charging, the battery module will become permanently damaged.

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Please see below the web links for the manufacturer equipment manuals.
LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.com
Equipment Manuals
Kisae Inverter Kisae DMT-1250Lithionics Battery