KiloVault HAB-XL Series Operation manual

INSTALLATION &
USER GUIDE
KiloVault® HAB-XL™ Series
Lithium Iron Phosphate (LiFePO4)
Deep Cycle Solar Batteries
Oct 2022 / Rev: 1.1

**WARNING High Voltage Risk of Personal Injury or Death**
As is the case with all batteries, the risk of shock is present. When handling batter-
ies, use protective measures including, but not limited to, safety glasses, insulated
gloves, and protective footwear.
When working with or installing batteries, use electrically insulated gloves and tools.
Remove personal metal items such as watches, rings, bracelets, etc.
The information included in this manual is accurate at the time of publication.
However, this manual is subject to change without prior notice as we continuously
improve our products.
Additionally, the illustrations in this manual are for demonstration only and are in-
tended to help explain the KiloVault® HAB-XL™ system concepts and installation
instructions. Details may vary slightly depending upon the market region and the
product version.
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 publica-
tion at any time.
Please note: If this unit is installed by someone other than the end-user, the installer
must explain the contents of this installation and user’s manual to the end-user.
No responsibility is assumed by KiloVault® for any
consequences arising out of the use of this material.
This manual is for use by qualied personnel only
Read and keep this Installation Guide for future reference.
Oct 2022 / Rev: 1.1

This manual is for use by qualied personnel only
1. Safety Information ................................................................................................................ 4
1.1. Symbols Used in this Manual ............................................................................................ 4
1.2. General Safety Precautions and Instructions .................................................................... 5
1.3. Battery Handling Guide ..................................................................................................... 6
1.3.1. Transportation................................................................................................................. 6
1.3.2. Storage........................................................................................................................... 6
1.3.3. Response to Emergency Situations ............................................................................... 7
1.3.4. Qualied Personnel ........................................................................................................ 7
2. Overview............................................................................................................................... 8
2.1. Features ............................................................................................................................ 8
3. Specications ....................................................................................................................... 9
3.1. Electrical Specications..................................................................................................... 9
3.2. Operating Environment Specications .............................................................................11
3.3. Physical Specications.................................................................................................... 12
3.4. Certications.................................................................................................................... 13
4. Installation .......................................................................................................................... 14
4.1. Installation Flowchart....................................................................................................... 15
4.2. Unpacking the KiloVault® HAB-XL™ .............................................................................. 15
4.2.1. Package Contents ........................................................................................................ 16
4.3. Tools, Materials, and Safety Equipment Required for Installation ................................... 18
4.4. Suitable Installation Locations......................................................................................... 19
4.5. Install the KiloVault® HAB-XL™ Wall Mounting Plate ..................................................... 20
4.5.1. Mounting Surface ......................................................................................................... 22
4.5.2. Mounting and Securing the KiloVault® HAB-XL™ ....................................................... 22
4.6. Connecting the KiloVault® HAB-XL™ to Your Inverter.................................................... 22
4.6.1. Connecting the KiloVault® HAB-XL™ .......................................................................... 25
4.6.2. Disconnecting the KiloVault® HAB-XL™...................................................................... 26
4.6.3. RJ45 120 Ω Resistor Plug Resistor Plug Installation ................................................... 26
4.6.4. Single Inverter Simplied Wiring Diagram.................................................................... 27
4.6.5. Multiple Inverter Simplied Wiring Diagram.................................................................. 28
4.6.6. Optional Battery Combiner Box and Bus Bar ............................................................... 28
4.6.7. Setting the KiloVault® HAB-XL™ Address ................................................................... 29
4.6.8. HAB-XL to HAB-XL and HAB-XL to Inverter Communication Cable Pin Denitions .... 30
5. Operation, Maintenance & Monitoring................................................................................ 31
5.1. KiloVault® HAB-XL™ Control Panel................................................................................ 31
5.1.1. KiloVault® HAB-XL™ Control Panel Details................................................................. 32
5.2. Calibrating Your KiloVault® HAB-XL™............................................................................ 33
5.3. Charging Settings............................................................................................................ 33
5.3.1. Firmware Updates ........................................................................................................ 36
Contents
Oct 2022 / Rev: 1.1

This manual is for use by qualied personnel only
Abbreviations and Acronyms
Name Abbreviations or Acronyms
UNIT KiloVault® HAB-XL™
CEC California Energy Commission
CSA Canadian Standards Association
GT Grid Tie
LCD Liquid Crystal Display
LED Light Emitting Diode
MPPT Maximum Power Point Tracking
NEC US National Electrical Code NFPA-70
PV Photovoltaic
PVGFP PV Ground Fault Protection
UL Underwriters Laboratories
ETL Intertek Testing Laboratories
VAC Volts Alternating Current
VDC Volts Direct Current
5.5. Monitoring........................................................................................................................ 33
5.6. Maintenance.................................................................................................................... 33
5.7. Disposal........................................................................................................................... 33
6. Troubleshooting.................................................................................................................. 33
6.1. BMS Protection / Alarm Conditions ................................................................................. 33
6.2. Warning / Alarm Indicators .............................................................................................. 36
6.4. Resetting / Recalibrating the KiloVault® HAB-XL™ ........................................................ 28
6.5. Initial KiloVault® HAB-XL™ Unboxed Voltage................................................................. 38
6.5.1. Low KiloVault® HAB-XL™ voltage when unboxed....................................................... 38
6.5.2. Reset the State of Charge Estimator............................................................................ 38
7. Technical Support ............................................................................................................... 39
7.1. Downloads and Documentation....................................................................................... 39
7.2. Software .......................................................................................................................... 39
7.0. Contact Us....................................................................................................................... 39
Oct 2022 / Rev: 1.1

"DO NOT DISCARD CRATE AND INTERNAL PACKAGING."
Congratulations on your KiloVault® product purchase.
Product registration is required for warranty coverage
and allows for easier customer and technical support.
https://kilovault.com/register/
“VERIFY that your HAB-XL
rmware is Up To Date”
This manual is for use by qualied personnel only
Read these instructions carefully and look at the equipment to become familiar
with the device before trying to install, operate, service or maintain it. The
following special messages may appear throughout this bulletin or on the
equipment to warn of potential hazards or to call attention to information that
claries or simplies a procedure.
Oct 2022 / Rev: 1.1

This manual is for use by qualied personnel only
1. Safety Information
1.1. Symbols Used in this Manual
It is essential to read, understand, and follow these instructions prior to installing or
operating KiloVault® batteries.
Warning:
This is a hazardous situation which, if not avoided, could result in serious injury
or death.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB-XL™ out of the reach of children and animals.
Warning:
The KiloVault® HAB-XL™ is heavy, over 600lb. (272kg), and may cause serious
back injury. Lift with multiple people and lifting equipment rated to lift and support
at least 1000lb.
Warning:
Do not dispose of this product with household waste.
Caution:
Risk of electric shock.
Attention:
Disconnect the KiloVault® HAB-XL™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the KiloVault®
HAB-XL™ .
Note:
Indicates points of particular emphasis that make operation more efficient or
convenient.
Recyclable:
Please contact your local solid waste recycling agency for recycling instructions.
Oct 2022 / Rev: 1.1 4

This manual is for use by qualied personnel only
1.2. General Safety Precautions and Instructions
• Do not attempt to use any battery that appears damaged during shipment or otherwise.
• Do not submerge the HAB-XL™. This could cause personal injury and will void your
warranty.
• Do not attempt to disassemble the HAB-XL™. Its components are not user serviceable. This
could cause personal injury and will void your warranty.
• To avoid the risk of shock or fire, ensure all wire is properly sized and in good condition.
• Do not impact, pull, drag, or step on the HAB-XL™.
Warning:
Failure to follow the instructions in this manual may result in serious injury
or death.
Warning:
Never connect KiloVault® HAB-XL™ units in series!
Caution:
Risk of electric shock.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB-XL™ out of the reach of children and animals.
Warning:
The KiloVault® HAB-XL™ is heavy, over 600lb (272kg), and may cause serious
back injury. Lift with multiple people and lifting equipment rated to lift and support
at least 1000lb.
Warning:
Do not dispose of this product with household waste.
Attention:
Read this instruction manual before installing and operating the KiloVault®
HAB-XL™.
Oct 2022 / Rev: 1.1
2022 5

• Verify that all equipment that is going to be connected to the KiloVault® HAB-XL™ is turned
off before making any connections.
• A small risk of spark does exist while making connections. Ensure the area is free of explo-
sive gasses and liquids and is not installed in confined areas. This includes flammable fuel
powered machinery, holding tanks, pipe fittings, and connectors.
• Respiratory irritation may be caused if the HAB-XL™ is punctured or cracked; use appropri-
ate respiratory and hand protection.
• Skin contact with a punctured or otherwise open battery can cause irritation.
• High voltage battery connections (configurations of greater than 36 V DC nominal) can be
dangerous in any DC system. The HAB-XL™ is a 48 V nominal battery system and is great-
er than 36 V DC at the terminals when fully charged! DC voltages over 52 V can stop the
human adult heart; please be careful and wear insulated gloves.
1.3. Battery Handling Guide
In addition to the General Safety Precautions and Instructions, the following guidelines should be
observed when handling the HAB-XL™ .
1.3.1. Transportation
• The HAB-XL™ should kept horizontal while being moved, except when it is being lifted into
place for mounting.
• Because the HAB-XL™ weighs over 600 lb., it should be moved with the help of multiple
people and moving / lifting equipment rated over 1000 lb.
• Do not drop the HAB-XL™ or damage will occur.
• If you are transporting HAB-XL™ batteries while they are still in the packing crate, do not
stack them more than two layers high and ensure they are strapped together to prevent
tumbling.
• Only transport the HAB-XL™ in an upright position.
• Check the HAB-XL™ immediately after transporting.
• If the HAB-XL™ 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 HAB-XL™ .
• Long-term storage (between one and six months) of the HAB-XL™ should be stored in-
doors in a clean, dry, shaded, and well-ventilated area at a temperature between 59° and
95°F (15° and 35°C).
• Store the HAB-XL™ no longer than 6 months.
• The HAB-XL™ must be charged to at least 70% (the state of charge upon delivery) before
storage.
This manual is for use by qualied personnel only
Oct 2022 / Rev: 1.1 6

• Repeated 100% discharges will decrease the battery capacity. For example, 3000, 100% dis-
charge cycles will reduce the battery capacity to about 75% of the original amp hour capacity.
• Fully charge the battery within 15 days of a deep discharge of 90% or more.
• Do not drop, stack, or turn the KiloVault® HAB-XL™ upside down.
• Store the KiloVault® HAB-XL™ away from children and animals.
1.3.3. Response to Emergency Situations
The HAB-XL™ 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.
In the unlikely event of a fire first shut off the source of the electricity if possible. We recom-
mend a fire extinguisher in close proximity of your power generating equipment. Class ABC
extinguishers are best suited for multipurpose fire types such as wood, flammable liquids, and
electrical appliances.
1.3.4. Qualied Personnel
This guide, and the tasks and procedures described in this manual, are intended for use by quali-
fied personnel only. Only qualified personnel shall install, operate, overhaul, or maintain the HAB-
XL™. During maintenance or overhaul, at least two people (equipped with protective measures,
including but not limited to, safety glasses, insulated gloves, and safety shoes) must be present.
Qualified personnel are defined as being a trained and locally certified electrician or installer who
has all the following skills and experience:
• Knowledge of the functional principles and operation of on-grid and off-grid (backup) electri-
cal systems.
• Knowledge of the dangers and risks associated with installing and using electrical devices
and acceptable mitigation methods.
• Knowledge of the installation of electrical devices.
• Knowledge of and adherence to the information in this guide, to all applicable safety precau-
tions, and to electrical industry best practices.
This manual is for use by qualied personnel only
Oct 2022 / Rev: 1.1
2022 7

2. Overview
KiloVault® HAB-XL™ Series floor Standing energy storage systems provide a 19.2 Kilowatt-hour
rated (20 kilowatt-hour usable) battery in a single package. Up to 20 units can be connected in
parallel for additional capacity. The HAB-XL™ Series has been designed for trouble-free mounting
and is easy to connect with other system components.
2.1. Features
• High safety Lithium Iron Phosphate (LiFePO4) battery
• Integrated HAB-XL to inverter Modbus communications
• Integrated HAB-XL to HAB-XL CAN bus communications
• Integrated Wi-Fi communications (Please contact your KiloVault® salesperson for details)
• Long cycle life (≥6000cycles)
• Advanced High/Low temperature cycle performance
• Intelligent LED & LCD display
• Support for up to 20 HAB-XL™ battery (Leader plus 19 Followers) modules in parallel
The wiring panel of the HAB-XL™ has been designed for function and convenience.
• The HAB-XL™ wiring panel has access ports on the left and right sides.
• Power and communication cables are now more easily attached
Warning:
Never connect HAB-XL™ units in series!
This manual is for use by qualied personnel only
Oct 2022 / Rev: 1.1 8

This manual is for use by qualied personnel only
3. Specications
3.1. Electrical Specications
The following specifications describe the HAB-XL™ system.
Note:
• Specifications are subject to change without prior notice.
• The following are specifications only, NOT set points.
Item Specication
Battery Type LiFePO4
Internal Resistance ≤15mΩ
Charging Stages
1. Bulk Charge: Charge at Constant Current (CC) to Bulk/Absorb Voltage.
2. Absorption Charge: Maintain Constant Bulk/Absorb Voltage (CV).
3. Terminate when charge current drops below 0.05C.
4. Unlike Lead Acid batteries, Lithium Ferro Phosphate batteries do not require Float
Charge.
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2022 9

This manual is for use by qualied personnel only
Item Specication
Battery Efciency >98%
DC Direct current
Full Charge Voltage 56 V
HAB-XL™ to HAB-XL™
(inter-battery) communication cable
RJ45 120 Ω Resistor Plug, 6-position, 4-conductor,
male connectors both ends. Straight through. Maxi-
mum length, 10 feet
HAB-XL™ to HAB-XL™
(inter-battery) communication protocol CAN Bus
HAB-XL™ to Inverter
communication protocol CAN Bus RS485
High Voltage Cutout 58.4 ± 0.4 V (not a set point)
Recovery 54.0 ± 0.4 V
Low Voltage Cutout 43.2 ± 0.4 V (not a set point)
Recovery 50.4 ± 0.4 V
Maximum Cell Balancing current 150 mA
Maximum Continuous Charge Current 180 A (not a set point)
Maximum Continuous Discharge Current 180 A (not a set point)
Maximum Continuous Discharge Power 10 kW
Maximum HAB-XL™ to HAB-XL™ Cable Length 9.84 ft (3 m)
Minimum Cell Balancing Volts 3350 mV
Minimum Discharge Voltage 48.0V±0.5V
Nominal Capacity 400 Ah
Rated Energy
Usable Energy
19.8 kWh
20 kWh
Nominal Voltage 51.2 VDC
Operational Temperature Range Discharge: -20°C ~60°C (-4°F~140°F)
Charge: 0°C ~ 45°C (32°F~113°F)
Peak Discharge Current (3s) 500 A (3S), 750A (1S)
Oct 2022 / Rev: 1.1 10

This manual is for use by qualied personnel only
Item Specication
Peak Discharge Power (3s) 25KW
Recommended Floating Charge Voltage Floating charge is not recommended for the HAB-XL
Self-Discharge Rate
≤3% per month, ≤15% per year
Note: The KiloVault® HAB-XL™ will enter
sleep mode:
• By pressing down the Power button for 6~8
seconds.
• No current for 7 Days and SOC ≤20%
• UVP is Triggered, and delay 2 Min
Item Specication
Operational Temperature Range Indoors away from direct exposure to rain or sun
Operating Temperature -10°C~ 40°C (14°F~104°F)
Recommended Operating Temperature 15°C to 35°C (59°F to 95°F )
Short Term (less than one month) Storage Tempera-
ture -20°C~45°C (-4°F~110°F)
Absolute Maximum Altitude 200A@ ≤ 2, 000m
180A @ 2,000m~4,000m
Refer to Section 6 Troubleshooting for a complete list of protection limits.
3.2. Operating Environment Specications
Oct 2022 / Rev: 1.1
2022 11

This manual is for use by qualied personnel only
3.3. Physical Specications
Item Specication
KiloVault® HAB-XL™ Weight 449.74Lbs 204kg net
597.45Lbs 272kg gross
KiloVault® HAB-XL™ Height 32 in (1238 mm) With wheels
KiloVault® HAB-XL™ Width 19.48in (495 mm)
KiloVault® HAB-XL™ Depth 15.74in (495 mm)
KiloVault® HAB-XL™ Ingress Rating IP54
Battery Terminal Torque 15 Nm, 11.06 ft-lb, 132.76 in-lb
Large (power) ports PG25: Approx. 0.79 in (20mm)
Small (communication) ports PG21: Approx. 1.1 in (28mm)
Oct 2022 / Rev: 1.1 12

This manual is for use by qualied personnel only
3.4. Certications
• Cell Certifications
o UL1642
o UL9540
o UL9540A
o IEC62619
o UN38.3
• Complete Unit Certifications
o cETLus UL 1973
o UN DOT 38.3 (acceleration three times each side)
o 50 gn for 11 ms
o 150 gn for 6 ms
o IP54
o OSHAS 18001 / ISO 45001
o ISO 9001 / 14000
Oct 2022 / Rev: 1.1
2022 13

This manual is for use by qualied personnel only
4. Installation
Warning:
This is a hazardous situation which, if not avoided, could result in serious injury
or death.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB-XL™ out of the reach of children and animals.
Warning:
The KiloVault® HAB-XL™ is heavy, over 600 lb. (272 kg), and may cause serious
back injury. Lift with multiple people and lifting equipment rated to lift and support
at least 1000 lb.
Warning:
Do not dispose of this product with household waste.
Caution:
Risk of electric shock.
Attention:
Disconnect the KiloVault® HAB-XL™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the KiloVault®
HAB-XL™.
Note:
• Prior to installing your HAB-XL™, please take pictures of the label on the
left side, including the serial number, serial number barcode, QR code,
and MAC address. Store this information for your records, it is valuable
and may be necessary for system configuration or troubleshooting.
Depending on your HAB-XL™ unit’s position, viewing this information
after installation may be difficult.
Oct 2022 / Rev: 1.1 14

This manual is for use by qualied personnel only
Oct 2022 / Rev: 1.1
2022 15

This manual is for use by qualied personnel only
The HAB-XL™ weighs 600 lb. (272 kg); wear appropriate protective equipment, such as gloves
and protective footwear, when handling this unit.
Keep the HAB-XL™ in its box until you are ready to install it. Open the box and inspect all con-
tents to ensure all items in the box are undamaged.
Do not attempt to lift or move the battery without sufficient equipment and human resources. Lifting
equipment that is capable of securing the battery from tipping while moving and positioning is high-
ly recommended.
At least 2 to 3 people are necessary to lift and upright the battery from its crate. The use of heavy
gloves is highly recommended.
Retain all packaging material for the duration of your warranty period.
4.2.1. Package Contents
The standard HAB-XL™ packaging includes the battery unit, mounting Plates and floor securing
plates, screws, communications cables.
4.2. Unpacking the KiloVault® HAB-XL™
Battery parallel communication cable_RJ45
Inverter communication cable_RJ45
Expanding screw M8*60, x rack on the oor
Oct 2022 / Rev: 1.1 16

This manual is for use by qualied personnel only
4.3. Tools, Materials, and Safety Equipment Required
for Installation
• Personal protective equipment, including but not limited to, safety glasses, insulated gloves,
and protective footwear
• Lift equipment capable of lifting and supporting at least at least 1000 lb (453 kg)
• Drill and drill bit for drilling pilot holes for the mounting plate
• If you will be mounting onto concrete or masonry, you will need a 12 mm drill bit for the in-
cluded M8*60 expansion screws
• Conduit and conduit fittings (depending upon local electrical requirements)
• Various sized Phillips and flathead screwdrivers
• Torque wrench and sockets
• 2/0 battery to inverter cables
• Battery combiner box (when more than one KiloVault® HAB-XL™ batteries are being used)
• Level
• Pencil or marker
Oct 2022 / Rev: 1.1
2022 17

4.4. Suitable Installation Locations
The HAB-XL™ must be installed indoors. In addition, make sure that the installation location
meets the following conditions:Observe the following:
• Install indoors in a cool, dry, ventilated space
• Do not install near a heat source, and keep away from direct sunlight; this prevents from
derating the output or shutting down due to overheating
• Keep away from fire, flammable, or explosive items
• Keep out of the reach of children and animals
• The floor is flat and level (Inclination < 15°).
• The optimal ambient temperature is within the range from 59° to 95°.
• The temperature and humidity are maintained at a constant level.
• There is minimal dust and dirt in the area.
• Do not install near a transformer or any other strong electromagnetic field. Strong electro-
magnetic fields can disrupt the HAB-XL™ communication system
The HAB-XL™ communication and power cable entries are located at the upper right corner of the
unit. There must be enough clearance for the conduit and fittings.
This manual is for use by qualied personnel only
Warning:
DO NOT reverse the polarity (positive and negative) of your unit’s connections.
NEVER short circuit your KiloVault® HAB-XL™.
Warning:
The KiloVault® HAB-XL™ is for use with 48 V systems only. DO NOT connect
them in series!
Oct 2022 / Rev: 1.1 18