KiloVault HAB Series User manual

Revision: 4
11/15/2021
KiloVault® HAB™ V4 Series
Lithium Iron Phosphate (LiFePO4)
Deep Cycle Solar Batteries
Installation and User Manual

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Revision 4
KiloVault® LLC • 330 Codman Hill Road, Boxborough, MA 01719 • [phone] •
[email protected] • www.kilovault.com
**WARNING High Voltage Risk of Personal Injury
or Death**
As is the case with all batteries, the risk of shock is present. When handling
batteries, 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
intended to help explain the KiloVault® HAB™ V4 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 publication 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.

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Contents
1. Safety Information ...................................................................................... 5
1.1. Symbols Used in this Manual............................................................ 5
1.2. General Safety Precautions and Instructions.................................... 6
1.3. Battery Handling Guide..................................................................... 8
1.3.1. Transportation.............................................................................. 8
1.3.2. Storage ......................................................................................... 8
1.3.3. Response to Emergency Situations .............................................. 9
1.3.4. Qualified Personnel...................................................................... 9
2. Overview................................................................................................... 10
2.1. Features .......................................................................................... 10
3. Specifications ............................................................................................ 11
3.1. Electrical Specifications................................................................... 11
3.2. Operating Environment Specifications............................................ 13
3.3. Physical Specifications .................................................................... 14
3.4. Certifications................................................................................... 15
4. Installation ................................................................................................ 15
4.1. Installation Flowchart ..................................................................... 16
4.2. Unpacking the KiloVault® HAB™ V4 ................................................ 17
4.2.1. Package Contents ....................................................................... 18
4.3. 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. Connecting the KiloVault® HAB™ V4 to Your Inverter..................... 25

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4.6.1. Connecting the KiloVault® HAB™ V4 .......................................... 27
4.6.2. Disconnecting the KiloVault® HAB™ V4...................................... 28
4.6.3. RJ45 120 Ω Resistor Plug Resistor Plug Installation.................... 28
4.6.4. Single Inverter Simplified Wiring Diagram ................................. 29
4.6.5. Multiple Inverter Simplified Wiring Diagram ............................. 30
4.6.6. Optional Battery Combiner Box and Bus Bar ............................. 31
4.6.7. Setting the KiloVault® HAB™ V4 Address.................................... 32
4.6.8. HAB to HAB and HAB to Inverter Communication Cable Pin
Definitions ................................................................................................ 33
5. Operation, Maintenance & Monitoring .................................................... 34
5.1. KiloVault® HAB™ V4 Control Panel.................................................. 34
5.1.1. KiloVault® HAB™ V4 Control Panel Details................................. 35
5.2. 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
6. Troubleshooting ........................................................................................ 43
6.1. BMS Protection / Alarm Conditions................................................ 43
6.2. Warning / Alarm Indicators............................................................. 45
6.3. Parallel Alarm Conditions and Connection Test .............................. 46
6.4. Resetting / Recalibrating the KiloVault® HAB™ V4.......................... 54
6.4.1. Resetting the KiloVault® HAB™ V4 ............................................. 54
6.4.2. Recalibrating the KiloVault® HAB™ V4 ....................................... 54
6.5. Initial KiloVault® HAB™ V4 Unboxed Voltage.................................. 55

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6.5.1. Low KiloVault® HAB™ V4 voltage when unboxed....................... 55
6.5.2. Reset the State of Charge Estimator .......................................... 55
7. Technical Support...................................................................................... 56
7.1. Downloads and Documentation ..................................................... 56
7.2. Software.......................................................................................... 56
7.3. Contact Us....................................................................................... 56
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™ 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.
Warning:
Do not dispose of this product with household waste.

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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.
Recyclable:
Please contact your local solid waste recycling agency for
recycling instructions.
1.2. General Safety Precautions and Instructions
Warning:
Failure to follow the instructions in this manual may result in
serious injury or death.
Warning:
Never connect KiloVault® HAB™ V4 units in series!
Warning:
After powering down a V4 HAB, you must wait at least 30
seconds before turning it back on again. Failing to wait at least
30 seconds risks causing internal short circuit events and
causing damage to its internal resistors.
Caution:
Risk of electric shock.

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Warning:
Do not place or install near flammable or explosive materials.
Warning:
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.
Warning:
Do not dispose of this product with household waste.
Attention:
Read this instruction manual before installing and operating the
KiloVault® HAB™ V4.
•Do not attempt to use any battery that appears damaged during
shipment or otherwise.
•Do not submerge the KiloVault® HAB™ V4. This could cause personal
injury and will void your warranty.
•Do not attempt to disassemble the KiloVault® HAB™ V4. 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 KiloVault® HAB™ V4.
•Verify that all equipment that is going to be connected to the
KiloVault® HAB™ V4 is turned off before making any connections.
•A small risk of spark does exist while making connections. Ensure the
area is free of explosive 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 KiloVault® HAB™ V4 is
punctured or cracked; use appropriate respiratory and hand
protection.
•Skin contact with a punctured or otherwise open battery can cause
irritation.

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•High voltage battery connections (configurations of greater than 36 V
DC nominal) can be dangerous in any DC system. The KiloVault® HAB™
V4 is a 48 V nominal battery system and is greater 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 KiloVault® HAB™ V4.
1.3.1. Transportation
•The KiloVault® HAB™ V4 should kept horizontal while being moved,
except when it is being lifted into place for mounting.
•Because the KiloVault® HAB™ V4 weighs over 230 lb., it should be
moved with the help of multiple people and moving / lifting
equipment rated over 230 lb.
•Do not drop the KiloVault® HAB™ V4 or damage will occur.
•If you are transporting KiloVault® HAB™ V4 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 KiloVault® HAB™ V4 face up.
•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® HAB™ V4.
•Long-term storage (between one and six months) of the KiloVault®
HAB™ V4 should be stored indoors in a clean, dry, shaded, and well-
ventilated area at a temperature between 59° and 95°F (15° and 35°C).
•Store the KiloVault® HAB™ V4 no longer than 6 months.
•The KiloVault® HAB™ V4 must be charged to at least 70% (the state of
charge upon delivery) before storage.

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•Repeated 100% discharges will decrease the battery capacity. For
example, 3000, 100% discharge 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™ V4 upside down.
•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.
In the unlikely event of a fire first shut off the source of the electricity if
possible. We recommend 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. Qualified Personnel
This guide, and the tasks and procedures described in this manual, are intended
for use by qualified personnel only. Only qualified personnel shall install,
operate, overhaul, or maintain the KiloVault® HAB™ V4. 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) electrical 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 precautions, and to electrical industry best practices.

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2. Overview
Warning:
Never connect KiloVault® HAB™ V4 units in series!
KiloVault® HAB™ V4 Series wall-mount energy storage systems provide a 7.5
Kilowatt-hour (7 kilowatt-hour usable) battery in a single package. Up to 14
units can be connected in parallel for additional capacity. The KiloVault® HAB™
V4 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
•Wall mounted all-in-one design
•Integrated HAB to inverter Modbus communications
•Integrated HAB to HAB CAN bus communications
•Integrated Wi-Fi communications (KiloVault® HAB™ V4 iT – Please
contact your KiloVault® salesperson for details)
•Long cycle life (≥4000cycles)
•Advanced High/Low temperature cycle performance
•Intelligent LED & LCD display
•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
•Power and communication cables are now more easily attached
•The KiloVault® HAB™ V4 case has integrated handles that fold
completely out of the way when not in use
•The KiloVault® HAB™ V4 now comes with replaceable vents for
different operating environments:
oVented plates for warmer environments
oSolid plates for cooler environments

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3. Specifications
3.1. Electrical 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
LiFePO4
Internal Resistance
≤15mΩ
Battery Efficiency
94.5%
BMS Type
Switching Shunt Resistor
Fully Charged Resting Voltage
53.6 V

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Item
Specification
Full Charge Voltage
56 V
KiloVault® HAB™ V4 to KiloVault®
HAB™ V4 (inter-battery)
communication cable
RJ45 120 Ω Resistor Plug, 6-position, 4-
conductor, male connectors both ends.
Straight through. Maximum length, 10
feet
KiloVault® HAB™ V4 to KiloVault®
HAB™ V4 (inter-battery)
communication protocol
CAN Bus
KiloVault® HAB™ V4 to Inverter
communication protocol
Modbus
High Voltage Cutout
60.0 ± .5 V (not a set point)
Low Voltage Cutout
48.0 V (not a set point)
Maximum Cell Balancing Voltage
70 mA
Maximum Continuous Charge
Current
120 A (not a set point)
Maximum Continuous Discharge
Current
150 A (not a set point)
Maximum Continuous Discharge
Power
7.5 kW
Maximum KiloVault® HAB™ V4 to
KiloVault® HAB™ V4 Cable
Length
9.84 ft (3 m)
Minimum Cell Balancing Voltage
3350 mW
Minimum Discharge Voltage
48.0 V
Nominal Capacity
150 Ah
Nominal Energy
7.68 kWh
Nominal Voltage
51.2 VDC
Operational Temperature Range
32° to 113°F (0° to 45°C)
Peak Discharge Current (3s)
500 A
Peak Discharge Power (3s)
25k W

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Item
Specification
Recommended Floating Charge
Voltage
52.8 V
Self-Discharge Rate
≤3% per month, ≤15% per year
•Note: This rate is only achieved
when the KiloVault® HAB™ V4 is
put to sleep by pressing down the
Power button for 10 seconds.
•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.
Refer to Section 6 Troubleshooting for a complete list of protection limits.
3.2. Operating Environment Specifications
Item
Specification
Operating Environment
Indoors away from direct exposure to
rain or sun
Operating Temperature
32° to 113°F (0° to 45°C)
Recommended Operating
Temperature
59 to 95°F (15°C to 35°C)
Short Term (less than one month)
Storage Temperature
-4 to 110°F (-20° to 45°C)
Absolute Maximum Altitude
13,123 feet (4000 m)
•To operate the HAB™at 3000m, limit
the output power to max. 6.48Kw
(max 120A)” to “Between 6561 feet
(2000 m) & 9843 feet 3000 m limit,
the output power to 6.48 kW. Do not
operate above 4000 m

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3.3. Physical Specifications
Figure 2: Physical Specifications
Item
Specification
KiloVault® HAB™ V4 Weight
230 lb (105 kg) net
286 lb (130 kg) gross
KiloVault® HAB™ V4 Height
32 in (812.8 mm)
KiloVault® HAB™ V4 Width
22.5 in (571.5 mm)
KiloVault® HAB™ V4 Depth
9.2 in (233.7 mm)
Mounting Plate Height
18 in (458.1 mm)
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
Installed
IP54
KiloVault® HAB™ V4 Ingress Rating - Solid
Plates Installed
IP55

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Item
Specification
Battery Terminal Torque
15 Nm, 11.06 ft-lb, 132.76 in-lb
Large (power) ports
PG42: Approx. 2.1 in (55mm)
Small (communication) ports
PG21: Approx. 1.1 in (28mm)
3.4. Certifications
•Cell Certifications
oUL1642
oIEC62619
oUN38.3
•Complete Unit Certifications
ocETLus UL 1973
oUN DOT 38.3 (acceleration three times each side)
o50 gn for 11 ms
o150 gn for 6 ms
oIP54 – Vented plates installed
oIP55 – Solid plates installed
oIEC 62619
oOSHAS 18001 / ISO 45001
oISO 9001 / 14000
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.

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[email protected] • www.kilovault.com
Warning:
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.
Warning:
Do not dispose of this product with household waste.
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.
4.1. Installation Flowchart
The following flowchart provides an overview of the installation process.

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Figure 3: Installation Flowchart
4.2. Unpacking the KiloVault® HAB™ V4
Note:
•Prior to installing your KiloVault® HAB™ V4, 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
KiloVault® HAB™ V4 unit’s position, viewing this
information after installation may be difficult.
•It may be easier to open the tabs at the bottom (along
the sides) of the box and remove the box from the
pallet, rather than removing the top lid and lifting the
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.

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Only move the KiloVault® HAB™ V4 with enough personnel to safely lift and
steady the KiloVault® HAB™ V4. We strongly recommend using lift equipment
and straps to secure and steady the 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.
Remove the foam packing material to uncover the KiloVault® HAB™ V4.
The box contains built-in lift handles designed exclusively for lifting the
KiloVault® HAB™ V4 out of the box, not for mounting on to the wall. Do not
attempt to unbox the KiloVault® HAB™ V4 system without sufficient
personnel. When unboxing, use the provided lift handles Section Install the
KiloVault® HAB™ V4 Wall Mounting Plate and place it on a safe, dry, clean
surface.
4.2.1. Package Contents
The standard KiloVault® HAB™ V4 packaging includes the battery unit,
mounting brackets and screws, communications cables, and built-in lift handles.
Figure 4: Standard KiloVault® HAB™ V4 Packaging

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Figure 5: RJ45 HAB to HAB CAN Bus Cable
Figure 6: RJ485 HAB to Inverter Modbus cable
Figure 7: RJ45 120 Ω Resistor Plug
Part
Quantity

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59 in (1.5 m) HAB™ V4 HAB™ V4 CAN Bus cable.
1 each
59 in (1.5 m) RJ485 HAB™ V4 to inverter Modbus cable.
1 each
RJ45 120 Ω Resistor Plug
1 each
Wall Mounting Plate
1 each
M8*30 Expanding Screw
10 each
M8*16 mm Bolt
2 each
PG21 (1.1 in, 28 mm) Strain Relief
1 each
PG42 (2.1 in, 28mm) Strain Relief
1 each
Solid Vent Replacement Plates
4 each
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 230 lb
(105 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 included M8*30 expansion screws
•Conduit and conduit fittings (depending upon local electrical
requirements)
•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