ionGen VICTRON 3000 Assembly instructions

LITHIONICS BATTERY, CLEARWATER, FL 33765 USA | PH: 727.726.4204 | FAX: [phone] | WEB: LITHIONICSBATTERY.comRevision 03
Installer's Guide
MODULE WITH EXTERNAL BMS INSTALLATION KIT
VICTRON 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....................................................
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 it is 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 BMS 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 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 Victron MultiPlus 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, adaptive
charging, power assist, and many system integration
features.

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 main 4/0 positive cable is 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 two 175A class T fuses and an isolation switch. The fuse
blocks 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 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.

Main Diagram
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The inverter is controlled by the Digital Multi Control Panel. The front mounted switch is used to turn the system on, off or
to charger only operation. The shore current limit is set by the control knob. Turning the knob to the right or left sets the
desired value. The current limit is shown on the 7-segment display.
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 buss 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.

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 AC input
must be protected by a magnetic circuit breaker rated at 50A or less, and the cable
cross-section must be sized accordingly. Make all connections using proper crimp-on
connectors (do not use twist on connectors).
The inverter has a power assist feature and when enabled can add up to 2kVA (that is
2000 / 120 = 17A) to the output during periods of peak power requirement. Together
with a maximum input current of 50A this means that the output can supply up to 67A
(50+17).

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.
An RCD (Residual Current Device) 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 (Residual Current Device) 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 ground 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 neutrals 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 blue tooth 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 mounted 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 do 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. Never 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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