KiloVault HAB Series Installation And User Manual
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Summary of Contents for KiloVault HAB Series
- Page 1 KiloVault® HAB™ V4 Series Lithium Iron Phosphate (LiFePO4) Deep Cycle Solar Batteries Installation and User Manual Revision: 4 11/15/2021...
- Page 2 This publication could include technical or other inaccuracies or typographical errors. Changes are periodically added to the information herein; these changes will be incorporated in new editions of the publication. KiloVault® may make improvements and/or changes in the services, facilities or specifications described in this publication at any time.
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Page 3: Table Of Contents
Tools, Materials, and Safety Equipment Required for Installation .. 20 4.4. Suitable Installation Locations ............20 4.5. Install the KiloVault® HAB™ V4 Wall Mounting Plate ...... 21 4.5.1. Mounting Surface ............... 24 4.5.2. Mounting and Securing the KiloVault® HAB™ V4 ....... 24 4.6. - Page 4 Calibrating Your KiloVault® HAB™ V4 ..........36 5.3. Charging Settings ................37 5.3.1. Firmware Updates ..............40 5.4. Starting the KiloVault® HAB™ V4 for the first time ......41 5.5. Monitoring ..................42 5.6. Maintenance ................... 43 5.7. Disposal ................... 43 Troubleshooting ..................
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Page 5: Safety Information
Install the KiloVault® HAB™ V4 out of the reach of children and animals. Warning: The KiloVault® HAB™ V4 is heavy, over 230 lb. (105 kg), and may cause serious back injury. Lift with multiple people and lifting equipment rated to lift and support at least 230 lb. -
Page 6: General Safety Precautions And Instructions
Caution: Risk of electric shock. Attention: Disconnect the KiloVault® HAB™ V4 before carrying out maintenance or repair. Attention: Read this instruction manual before installing and operating the KiloVault® HAB™ V4. Note: Indicates points of particular emphasis that make operation more efficient or convenient. - Page 7 Install the KiloVault® HAB™ V4 out of the reach of children and animals. Warning: The KiloVault® HAB™ V4 is heavy, over 230 lb (105 kg), and may cause serious back injury. Lift with multiple people and lifting equipment rated to lift and support at least 230 lb.
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Page 8: Battery Handling Guide
• Check the KiloVault® HAB™ V4 immediately after transporting. • If the KiloVault® HAB™ V4 is damaged in any way, do not use it; contact KiloVault® immediately. 1.3.2. Storage In addition to the General Safety Precautions and Instructions, the following guidelines should be observed when storing the KiloVault®... -
Page 9: Response To Emergency Situations
Store the KiloVault® HAB™ V4 away from children and animals. 1.3.3. Response to Emergency Situations The KiloVault® HAB™ V4 is comprised of multiple batteries and is designed to prevent hazards resulting from failures; however, no battery system is 100% safe, and KiloVault®, LLC cannot guarantee its absolute safety. -
Page 10: Overview
• Support for up to 14 KiloVault® HAB™ V4 battery (Leader plus 13 Followers) modules in parallel The wiring panel of the KiloVault® HAB™ V4 has been designed for function and convenience. • The KiloVault® HAB™ V4 wiring panel has access ports on the left and right sides, and the bottom •... -
Page 11: Specifications
Note: • Specifications are subject to change without prior notice. • The following are specifications only, NOT set points. Figure 1: Charge/Discharge Graph The following specifications describe the KiloVault® HAB™ V4 system. Item Specification Battery Type LiFePO Internal Resistance ≤15mΩ... - Page 12 Item Specification Full Charge Voltage 56 V RJ45 120 Ω Resistor Plug, 6-position, 4- KiloVault® HAB™ V4 to KiloVault® conductor, male connectors both ends. HAB™ V4 (inter-battery) Straight through. Maximum length, 10 communication cable feet KiloVault® HAB™ V4 to KiloVault®...
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Page 13: Operating Environment Specifications
Power button for 10 seconds. Self-Discharge Rate • If the KiloVault® HAB™ V4 is shut down using the standard, short, 3- second-long, power button push, self-discharge can be as high as 9% per month. -
Page 14: Physical Specifications
Mounting Plate Width 22.3 in (565.5 mm) Mounting Plate Ears 1.7 in (42.5 mm) Mounting Plate Lips 0.5 in (12.7 mm) KiloVault® HAB™ V4 Ingress Rating - Vents IP54 Installed KiloVault® HAB™ V4 Ingress Rating - Solid IP55 Plates Installed... -
Page 15: Certifications
Warning: Do not place or install near flammable or explosive materials. 15 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com... -
Page 16: Installation Flowchart
Install the KiloVault® HAB™ V4 out of the reach of children and animals. Warning: The KiloVault® HAB™ V4 is heavy, over 230 lb (105 kg), and may cause serious back injury. Lift with multiple people and lifting equipment rated to lift and support at least 230 lb. -
Page 17: Unpacking The Kilovault® Hab™ V4
KiloVault® HAB™ V4 with the handles. The KiloVault® HAB™ V4 weighs 230 lb. (105 kg); wear appropriate protective equipment, such as gloves and protective footwear, when handling this unit. 17 of 56... -
Page 18: Package Contents
KiloVault® HAB™ V4. Keep the KiloVault® HAB™ V4 in its box until you are ready to install it. Open the box and inspect all contents to ensure all items in the box are undamaged. - Page 19 Figure 6: RJ485 HAB to Inverter Modbus cable Figure 7: RJ45 120 Ω Resistor Plug Part Quantity 19 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com...
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Page 20: Tools, Materials, And Safety Equipment Required For Installation
Various sized Phillips and flathead screwdrivers • Torque wrench and sockets • 1/0 battery to inverter cables • Battery combiner box (when more than one KiloVault® HAB™ V4 batteries are being used) • Level • Pencil or marker 4.4. Suitable Installation Locations... -
Page 21: Install The Kilovault® Hab™ V4 Wall Mounting Plate
The KiloVault® HAB™ V4 should be installed high enough above the floor to allow the battery cables to bend without kinking and allow easy access to the knockouts on the bottom of the KiloVault® HAB™ V4. There should be about 8 inches (approx. 200 mm) of clearance on both sides. - Page 22 The KiloVault® HAB™ V4 comes with the single mounting plate option. Previous releases used a dual mounting plate system. Figure 8: Wall Mounting Plate 22 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 •...
- Page 23 Figure 9: Wall Mounting Plate Attached to HAB 23 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com...
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Page 24: Mounting Surface
The KiloVault® HAB™ V4 mounting plate can be used as a template to mark your pilot holes on the mounting surface. Choose holes so that you can mount the plate using at least four of the widely spaced holes. Use a level to ensure that the plate is level. -
Page 25: Connecting The Kilovault® Hab™ V4 To Your Inverter
30 seconds risks causing internal short circuit events and causing damage to its internal resistors. Warning: The KiloVault® HAB™ V4 is for 48 V systems only. NEVER connect KiloVault® HAB™ V4 units in series! Figure 10: KiloVault® HAB™ V4 Wiring Panel... - Page 26 There are access ports on the bottom left, bottom right, and on the bottom of the KiloVault® HAB™ V4 wiring panel. One large and two small strain reliefs are included in the KiloVault® HAB™ V4 packaging. To use them remove the plugs from the relevant access ports and replace them with the included strain reliefs.
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Page 27: Connecting The Kilovault® Hab™ V4
Leader KiloVault® HAB™ V4 and the inverter. Connect the power cables from the KiloVault® HAB™ V4 to the inverter (or to the DC bus if installing more than one KiloVault® HAB™ V4), making sure to use overcurrent protection as required. Torque the terminals in the KiloVault® HAB™ V4 connection block to 5.65Nm or 4.17ft-lb or 50in-lbs... -
Page 28: Disconnecting The Kilovault® Hab™ V4
Leader KiloVault® HAB™ V4 and the Inverter (if available). 4.6.3. RJ45 120 Ω Resistor Plug Resistor Plug Installation A clear RJ45 120 Ω Resistor Plug resistor plug is enclosed in each KiloVault® HAB™ V4 unit. Plug one end into the first and last units in the string as shown. -
Page 29: Single Inverter Simplified Wiring Diagram
These diagrams may not exactly match your specific system and may not include all the safety equipment required by regional authority. This is purely a graphical representation. 29 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com... -
Page 30: Multiple Inverter Simplified Wiring Diagram
Figure 14: Single Inverter Installation It is extremely important to make all conductors to each battery the same length to help ensure they contribute balanced current to the KiloVault® HAB™ 4.6.5. Multiple Inverter Simplified Wiring Diagram The following diagram describes a simplified multiple inverter system for installations greater than 7.5kW. -
Page 31: Optional Battery Combiner Box And Bus Bar
The following figure shows a typical installation. Figure 16: Optional Bus Bar 31 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com... -
Page 32: Setting The Kilovault® Hab™ V4 Address
MWT2020010902014, please contact KiloVault® for addressing instructions. • If you are installing a single KiloVault® HAB™ V4 to be used by itself, the address must be set to (off off off off). • If you are installing more than one KiloVault® HAB™ V4 and connecting them with the communication cable, the Leader KiloVault®... -
Page 33: Hab To Hab And Hab To Inverter Communication Cable Pin Definitions
Pin Definitions Figure 18: RJ45 CAN Bus and RS485 Modbus Connector The KiloVault® HAB™ V4 uses the same connector type for both CAN Bus and Modbus communications; however, CAN Bus and Modbus use very different pin definitions. See the Pin Definition Tables. -
Page 34: Operation, Maintenance & Monitoring
BMS debug RS485A BMS debug RS485B 5. Operation, Maintenance & Monitoring 5.1. KiloVault® HAB™ V4 Control Panel The KiloVault® HAB™ V4 control panel displays a variety of useful information regarding the operation of your system. 34 of 56 Revision 4 KiloVault LLC •... -
Page 35: Kilovault® Hab™ V4 Control Panel Details
Figure 19: KiloVault® HAB™ V4 Control Panel 5.1.1. KiloVault® HAB™ V4 Control Panel Details Display Description Notes Battery Voltage Remaining Energy Charge / Negative value = Discharging Discharge Power Positive Value = Charging State of Charge Approximate Percentage Full Number of Cycles... -
Page 36: Calibrating Your Kilovault® Hab™ V4
SC = Short Circuit Refer to Section 6 Troubleshooting for action instructions if the indicators light. 5.2. Calibrating Your KiloVault® HAB™ V4 36 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 •... -
Page 37: Charging Settings
• Then fully discharge the KiloVault® HAB™ V4 all the way down to 49 V. If a low voltage alarm occurs, you can ignore it. You will still be well above the low voltage protection threshold. Note, if this does occur, the alarm will not clear until the voltage rises above 49.6 V ±... - Page 38 Peukert 1.05 Coefficient Internal ≤15mΩ Resistance 100 Ah per KiloVault® HAB™ V4 in Parallel (Solar Charge Controller Amps + Percentage of Inverter/Charger Maximum DC Output). Example: For a single KiloVault® HAB™ V4 Recommended system with an inverter/charger maximum DC Charge Current...
- Page 39 Set to whatever percentage of the inverter Max Bulk Current current plus the charge controller current is less than or equal to 100 A 120A per KiloVault® HAB™ V4 in Parallel (Solar Charge Controller Amps + Percentage of Inverter/Charger Max DC Output. Absolute Example: For a single KiloVault®...
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Page 40: Firmware Updates
Compensation compensation to 0mV / °C 5.3.1. Firmware Updates • Ensure that your KiloVault® HAB™ V4 is connected to the internet and added into KiloVault® HAB™ V4 iT (the KiloVault® HAB™ V4 mobile application). • Ensure your WiFi router and internet connection are not using power from your inverter. -
Page 41: Starting The Kilovault® Hab™ V4 For The First Time
Screen Slider Switch. The status should change to "No charge or discharge.” Figure 20: KiloVault® HAB™ V4 iT Basic Screen Slider Switch • KiloVault® HAB™ V4 firmware updates take about 10 minutes. • Firmware updates are usually timed to take place during the evening in North America. -
Page 42: Monitoring
#2 and save this step for last. 2. Turn on (close) the battery breaker on the side of the KiloVault® HAB™ 3. Press the power button on the control panel at least three seconds. -
Page 43: Maintenance
6.1. BMS Protection / Alarm Conditions Alarm events cause the ALARM LED on the front panel to flash. Protection events cause the ALARM LED to flash and will cause the KiloVault® HAB™ V4 to shut down for the indicated time period. - Page 44 5°F ± 5.4°F (-15°C ± 3°C) Discharge Low temperature protection -4°F ± 5.4°F (-20°C ± 3°C) 44 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com...
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Page 45: Warning / Alarm Indicators
Eliminate the short-circuit. The LCD control panel and/or the State of Charge light bar have lost connection to the Flashing State of Charge BMS. Restart the KiloVault® HAB™ V4 using the power button on the front of the unit. 45 of 56... -
Page 46: Parallel Alarm Conditions And Connection Test
None of the Set the KiloVault® Leader ID address DIP HAB™ V4 units Communicati switch of output power. on address KiloVault® All KiloVault® fault KiloVault® HAB™ V4 HAB™ V4 LCD protection. HAB™ V4 to units screens are lit. No KiloVault® (1,0,0,0) or connected in All KiloVault®... - Page 47 HAB™ V4 HAB™ V4 units Communicati units with by removing all units do not output on ID Address the alarms. of the KiloVault® connected in power Repeated. Set each to a HAB™ V4 to parallel. All KiloVault® More than unique KiloVault®...
- Page 48 ALARM LEDs KiloVault® other, set each parallel. All KiloVault® have lost HAB™ V4 unit address to KiloVault® HAB™ V4 LCD communicatio units are (0,0,0,0) and HAB™ V4 Screens are lit.
- Page 49 120 Ω connected in are not flashing Resistor parallel. charging. ALARM LEDs Plug, 6- KiloVault® All KiloVault® have lost position, 4- HAB™ V4 HAB™ V4 LCD communicatio conductor units with Screens are lit. n with the cable with...
- Page 50 ALARM LEDs charging. KiloVault® have lost All KiloVault® HAB™ V4 communicatio HAB™ V4 LCD units with n with the Screens are lit. similar Leader Leader RUN LED voltages. KiloVault®...
- Page 51 Diagnosis Notes Conditions Rectify The high Power from all voltage KiloVault® KiloVault® HAB™ V4 units. HAB™ V4 has KiloVault® All KiloVault® been HAB™ V4 HAB™ V4 LCD removed units Screens are lit. from parallel connected in Lower voltage connection parallel.
- Page 52 Diagnosis Notes Conditions Rectify The low Power from all voltage KiloVault® KiloVault® HAB™ V4 units. HAB™ V4 has KiloVault® All KiloVault® been HAB™ V4 HAB™ V4 LCD removed units Screens are lit. from parallel connected in High voltage connection parallel.
- Page 53 HAB™ V4 units temperature continue protection is discharging and released. their RUN LEDs are lit. 53 of 56 Revision 4 KiloVault LLC • 330 Codman Hill Road, Boxborough, MA 01719 • +1 (888) 218-5924 • ® info@kilovault.com • www.kilovault.com...
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Page 54: Resetting / Recalibrating The Kilovault® Hab™ V4
The following section describes the reset / recalibration process. 6.4.1. Resetting the KiloVault® HAB™ V4 If necessary, you can reset the KiloVault® HAB™ V4 by first turning it on using the front power button, and then pressing and holding down the power button for 10 seconds. -
Page 55: Initial Kilovault® Hab™ V4 Unboxed Voltage
56.4 V. Ignore the high voltage alarm and the SoC in the display. Then discharge the KiloVault® HAB™ V4 all the way down to 49 V, ignore the low voltage alarm. Then recharge the KiloVault® HAB™ V4 normally. The SoC should now be reset. - Page 56 Downloads and documentation are available on the KiloVault® website: https://kilovault.com/ 7.2. Software The KiloVault® HAB™ V4 iT monitoring software for iOS and Android mobile devices can be downloaded from both the iOS and Android app stores. There is not a desktop version of KiloVault® HAB™ V4 iT.
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