15
Expion360 Battery Manual, G24 and G27
Rev 2
07/18/2022
5.2
Circuit Protection
Properly sized circuit protection must consider the battery bank’s maximum DC output, the inverter’s maximum DC input,
the size, length, and rating of the cables being used. The fuse or circuit breaker must be able to withstand the maximum
continuous current that can be supplied by the battery bank and must be located as close to the battery bank as is safely
possible. Use Blue Sea Systems fuses provided in the table below or an equivalent by an approved manufacturer.
Fuse Rating
Class T Fuse P/N
ANL Fuse P/N
60 A
N/A
5123
80 A
N/A
5124
100 A
N/A
5125
110 A
5112
N/A
125 A
5113
N/A
150 A
5114
5127
175 A
5115
5128
200 A
5116
5129
225 A
5117
N/A
250 A
5118
5131
300 A
5119
5133
350 A
5120
5135
400 A
5121
5136
500 A
N/A
5137
600 A
N/A
5161
750 A
N/A
5163
For Class T fuses between 110 to 200 A, use Blue Sea Systems fuse holder 5007100
For Class T fuses between 225 to 400 A, use Blue Sea Systems fuse holder 5502100
For ANL fuses between 60 to 200 A, use Blue Sea Systems fuse holder 5005
For ANL fuses between 225 to 750 A, use Blue Sea Systems fuse holder 5503
Class T fuses are recommended to protect the power system due to their lower voltage drop and higher efficiency. For
the budget-conscious consumer and lower current applications, ANL fuses are sufficient (at the cost of reduced system
efficiency). Use fuse and breakers from the following approved manufacturers to protect against overcurrent events and
ensure the safety of your Expion360 battery system: Blue Sea Systems, Littlefuse, Eaton, or Bussman.
Single String Battery Bank:
For small battery banks that have fewer than four batteries or have a single string configuration, circuit protection (fuse
or circuit breaker) should be installed close to the battery bank’s positive terminal before connecting to the load. The
fuse rating is based on the maximum continuous discharge rate of the battery bank. For example, if the maximum
continuous discharge rate of a 400 Ah battery bank is 400 A, this battery bank should be paired with a 400 A DC fuse. In
this example, any wires connecting the battery bank to the inverter must also be properly sized for a 400 A continuous
current.