KiloVault HAB Series User manual

Draft Date: 12/5/2019
Version: Rev 0.3
KiloVault® HAB™ Series
Lithium Iron Phosphate (LiFePO4)
Deep Cycle Solar Batteries
Installation and User’s Manual

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KiloVault®LLC • 330 Codman Hill Road, Boxborough, MA 01719 • [phone] •
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™ system concepts and installation instructions. Details may vary
slightly depending upon the market region and the product version.
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.
Disclaimer:
This document is a draft and is provided for information only. The information contained herein
is subject to change and the final version of this Installation and User’s Manual will be published
when available.

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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................................................................................................... 6
1.3.1. Transportation........................................................................................................... 7
1.3.2. Storage ...................................................................................................................... 7
1.3.3. Response to Emergency Situations........................................................................... 7
1.3.4. Qualified Personnel................................................................................................... 7
Overview.................................................................................................................................. 92.
2.1. Features........................................................................................................................... 9
Specifications......................................................................................................................... 103.
3.1. Electrical Specifications................................................................................................. 10
3.2. Environmental Specifications / Operating Environment .............................................. 10
3.3. Physical Specifications................................................................................................... 11
Installation............................................................................................................................. 124.
4.1. Installation Flowchart ................................................................................................... 12
4.2. Unpacking the HAB™.................................................................................................. 13
4.2.1. Package Contents.................................................................................................... 13
4.3. Tools, Materials, and Safety Equipment Required for Installation ............................... 15
4.4. Suitable Installation Locations ...................................................................................... 16
4.5. Install the HAB™ Mounting Plates............................................................................. 16
4.5.1. Mounting and Securing the HAB™.......................................................................... 19
4.6. Connecting the HAB™ to Your Inverter ......................................................................... 20
4.6.1. Connecting the HABTM ............................................................................................ 20
4.6.2. Disconnecting the HABTM ........................................................................................ 21
4.6.3. Simplified Wiring Diagrams..................................................................................... 21
4.6.4. Setting the HAB™ Address....................................................................................... 23
Operation, Maintenance & Monitoring................................................................................. 265.

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5.1. The HAB™ Control Panel............................................................................................ 26
5.1.1. HAB™ Control Panel Details .................................................................................... 26
5.2. Commissioning.............................................................................................................. 28
5.2.1. Operation ................................................................................................................ 28
5.2.2. Monitoring .............................................................................................................. 31
5.3. Using the HAB iT Application ........................................................................................ 31
5.3.1. Using the HAB iT Application in the “Local Control” Mode.................................... 31
5.3.2. Using HAB iT Application While Connected to the Internet................................... 33
5.4. Maintenance ................................................................................................................. 42
5.5. Disposal......................................................................................................................... 42
Troubleshooting..................................................................................................................... 436.
6.1. BMS Protection /Alarm Conditions............................................................................... 43
6.2. Warning / Alarm Indicators........................................................................................... 44
Technical Support .................................................................................................................. 457.
7.1. Downloads .................................................................................................................... 45
7.2. Documentation ............................................................................................................. 45
7.3. Software........................................................................................................................ 45
7.4. Contact Us..................................................................................................................... 45
Revision History ..................................................................................................................... 478.

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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 HAB™ out of the reach of children and animals.
Warning:
The HAB™ is heavy, over 207 lb (94 kg), and may cause serious back injury. Lift with
multiple people and lifting equipment rated to lift and support at least 210 lb.
Warning:
Do not dispose of this product with household waste.
Caution:
Risk of electric shock.
Attention:
Disconnect the HAB™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the HAB™.
Note:
Indicates points of particular emphasis that make operation more efficient or
convenient.
Recyclable:
Please contact KiloVault® for recycling instructions.

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1.2. General Safety Precautions and Instructions
Attention:
Read this instruction manual before installing and operating the HAB™.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the HAB™ out of the reach of children and animals.
Warning:
The HAB™ is heavy, over 207 lb (94 kg), and may cause serious back injury. Lift with
multiple people and lifting equipment rated to lift and support at least 210 lb.
Warning:
Do not dispose of this product with household waste.
Do not attempt to use any battery that appears damaged during shipment or otherwise.
Do not submerge the HAB™. This could cause personal injury and will void your warranty.
Do not attempt to disassemble the HAB™. 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™.
Verify that all equipment that is going to be connected to the HAB™ is turned off before
making any connections.
A small risk of spark does exist while making connections. Ensure that the area is free of
explosive gasses and liquids and is not installed in a confined areas that contains explosive
substances. This includes flammable fuel powered machinery, holding tanks, pipe fittings
and connectors.
Respiratory irritation may be caused if the HAB™ is punctured or cracked.
Skin contact with a punctured or otherwise open battery can cause irritation.
If the HAB™becomes punctured or cracked use appropriate respiratory and hand
protection.
High voltage connections of batteries (configurations of greater than 36V DC nominal) can
be dangerous in any DC system. DC voltages over 52V can stop the human adult heart. The
HAB™ is a 48V nominal battery system. Note that a fully charged 48V nominal system is over
36V; handle with care and wear insulated gloves.
1.3. Battery Handling Guide

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In addition to the General Safety Precautions and Instructions the following guidelines should
be observed when handling the HAB™.
1.3.1. Transportation
The HAB™ should kept horizontal while being moved, except when it is being lifted into
place for mounting.
Because the HAB™ weighs over 200 lb, it should be moved with the help of multiple people
and moving / lifting equipment rated over 210 lb.
Do not drop the HAB™.
If you are transporting HAB™ batteries while they are still in the packing crate, do not stack
them more than 5 layers high.
Only transport the HAB™ face up.
Check the HAB™ immediately after transporting it.
If the HAB™ 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™.
The HAB™ should be stored in a clean dry shaded and well ventilated area, like a warehouse,
at a temperature between 15 °C and 35 °C.
The HAB™ must be charged to at least 70% (the state of charge upon delivery) before
storage.
Store the HAB™ no longer than 6 months.
Repeated (100%) discharges will decrease battery capacity (3000 100% discharge cycles will
reduce amp hours capacity by 75%.
Fully charge the battery within 15 days of a deep discharge of 90% or more
Do not drop, stack or turn the HAB™ upside down.
Store the HAB™ away from children and animals.
1.3.3. Response to Emergency Situations
The HAB™ comprises multiple batteries and is designed to prevent hazards resulting from
failures. However, KiloVault LLC cannot guarantee its absolute safety.
In the unlikely event of a fire, if possible, first shut off the source of the electricity. We
recommend having a fire extinguisher in close proximity of your power generating equipment.
Class ABC extinguishers are easily obtainable and are best suited for multipurpose fire types
such as wood, flammable liquids and electrical appliances.
1.3.4. Qualified Personnel

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This guide and the tasks and procedures described in this manual are intended for use by
qualified personnel only. Only qualified personnel can install, operate, overhaul or maintain the
HAB™. 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 of 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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Overview2.
KiloVault® HAB™ Series wall-mount energy storage systems provide a 7.5 Kilowatt-hour battery
in a single package. Up to eight units can be used together for additional capacity. The HAB
Series has been designed for trouble-free mounting and is easy to connect with other system
components.
2.1. Features
High safety LiFePO4 battery
Wall mounted all-in-one design
Integrated inverter CAN-bus support
Integrated WiFi and Bluetooth communications
Long cycle life (≥4000cycles)
Advanced High/Low temperature cycle performance
Intelligent LED & LCD display
Support for up to 8 HAB™ battery modules in parallel

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Specifications3.
3.1. Electrical Specifications
Note:
Specifications are subject to change without prior notice.
The following specifications describe the HAB™ system.
Item
Specification
Model
HAB™ 7.5
Battery Type
LiFePO4
High Voltage Cutout
59.0 V
Low Voltage Cutout
48.0 V
Maximum Continuous Charge Current
120 A
Maximum Continuous Discharge Current
150 A
Maximum Continuous Discharge Power
7.5 kW
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)
25 kW
Recommended Floating Charge Voltage
55.2 V
Standard Charge Voltage
56.4 V
Weight
Over 207 lb (94 kg)
Refer to Troubleshooting for a complete list of protection limits.
3.2. Environmental Specifications / Operating Environment

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Item
Specification
Working Environment
Indoors or outdoors, away from direct exposure to rain or sun
Operating Temperature
32° to 113° F (0° to 45° C)
Recommended Operating
Temperature
77° (F25° C)
Storage Temperature
-4 to 110° F (-20° C to 45° C)
Maximum Altitude
Under 9843 feet (3000 m)
3.3. Physical Specifications
Figure 1: HAB™ Physical Specifications
Item
Specification
Weight
Over 207 lb (94 kg)
Height
25.09 in (637.4 mm)
Width
19.78 in (502.4 mm)
Depth
8.79 in (223.4 mm)
Hanging Bracket Depth
0.51 in (13 mm)
Ingress Rating
IP51

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Installation4.
4.1. Installation Flowchart
The following flowchart provides an overview of the installation process.
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 HAB™ out of the reach of children and animals.
Warning:
The HAB™ is heavy, over 207 lb (94 kg), and may cause serious back injury. Lift with
multiple people and lifting equipment rated to lift and support at least 210 lb.
Warning:
Do not dispose of this product with household waste.
Caution:
Risk of electric shock.
Attention:
Disconnect the HAB™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the HAB™.

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Figure 2: Installation Flowchart
4.2. Unpacking the HAB™
The HAB™ is heavy, over 207 lb (94 kg). Wear appropriate protective equipment such as gloves
and protective footwear when handling this unit. Only move the HAB™ with enough personnel
to safely lift and steady the HAB™. We strongly recommend using lift equipment and straps to
secure and steady the HAB™.
Keep the HAB™ in its box until you are ready to install it. Open the box and inspect all contents
to make sure that all of the items in the box are undamaged. Remove the foam packing material
to uncover the HAB™.
The box contains two lift handles exclusively for lifting the HAB™ out of the box, not on to the
wall. When you are ready to remove the HAB™ from its box, attach the lift handles to the lifting
screws located on the sides of the HAB™. Only when you have a sufficient number of personnel
to do so, lift the HAB™ from its box using the lift handles.
4.2.1. Package Contents

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The standard HAB™ packaging includes the battery unit, mounting brackets and screws,
communications cables, and lift handles.
Figure 3: Standard HAB™ Packaging

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Figure 4: HAB™ partially unboxed showing the lower mounting bracket
Part
Quantity
HAB™ to HAB™ communication cable (RJ11)
1 each
HAB™ to inverter CAN Bus communication
cable - Amphenol AT06-6S
1 each
Upper Wall Mounting Plate
1 each
Lower Wall Mounting Plate
1 each
Expanding screw M8*30
12 each
Screw M8*16 mm
2 each
Screw M6*16 mm
2 each
Optional Communication Debug Cable
1 each (Optional)
Lift Handles
2 each
Lift Handle Screws (Installed Into The HAB™
Case): M6x12mm, Fine Thread, 0.75 Pitch,
Internal Hex Button Head
6 each
4.3. Tools, Materials, and Safety Equipment Required for Installation
Personal protective equipment, including but not limited to; safety glasses, insulated gloves,
protective footwear)
Lift equipment capable of lifting and supporting at least at least 210 lb
Drill and drill bit for drilling pilot holes for the mounting plate

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If you will be mounting onto concrete or masonry, you will need a 12 mm drill bit for the
M8*80 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 there are more than one HAB™ batteries are being used)
Level
Pencil or marker
4.4. Suitable Installation Locations
The HAB™ should be installed with at least 40 inches (approx. 1000 mm) above the floor and 12
inches (approx. 300 mm) of clearance on both sides. Particular care should be taken to ensure
that the bottom right corner of the HAB™, where the power and communication cable access is
located, is clear. It should be installed in a cool, dry, ventilated space. The HAB™ should not be
installed near a heat source and away from direct sunlight, to prevent the HAB™ from derating
its output or shutting down due to overheating.
Choose a wall capable of supporting the full weight of the HAB™ (over 207 lb.) with one more of
the following characteristics: wood studs at regular intervals, plywood sheeting at least ¾ inch
thick, solid concrete or masonry, or metal studs of sufficient gauge.
The HAB™ communication and power cable entries are located in the bottom right corner of the
unit. There must be enough clearance for the conduit and fittings.
Do not install the HAB™ near a transformer or any other strong electromagnetic field. Strong
electromagnetic fields can disrupt the HAB™ communication system.
Keep the HAB™ away from fire, flammable, or explosive items.
The HAB™ must be out of the reach of children and animals.
4.5. Install the HAB™ Mounting Plates
The HABTM mounting plates are fitted together (the top plate rests in the upper notch of the
bottom plate) and then used as a template to mark your pilot holes on the mounting surface.

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Figure 5: Upper Wall Mounting Plate
Figure 6: Lower Wall Mounting Plate

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Figure 7: Upper and Lower Mounting Plates Fitted Together
Use the plates as a template to mark the wall you’ll be mounting the HAB™ onto. Choose holes
so that you can mount each plate using at least 4 (four) of the widely spaced holes in each plate.
Use a level to ensure that both plates are level.
If you are anchoring the mounting plate into wood studs use at least four (one at each corner) ¼
inch wood screws with washers. The screws must be long enough to be screwed at least 1½
inches into the studs.
If you are anchoring into plywood wall material, the plywood must be at least ¾ inch thick. Use
four (one at corner) ¼ inch wood screws with washers. The screws must be long enough to
penetrate at least ¼ inch beyond the backside of the plywood. You can also use four (one at
each corner) heavy duty ¼ inch toggle bolts, rated for at least 250 lb.
If you are anchoring into metal studs, the studs must be a minimum of 18 gauge. Use at least
four (one at each corner) #14 sheet metal screws with washers. The screws must be long
enough to penetrate at least 3 threads beyond the stud.

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If you are anchoring into concrete or masonry, the minimum strength of the concrete must be
at least 2500 PSI while the minimum strength of the masonry must be at least 1500 PSI. Drill
holes into the concrete or masonry with the 12 mm drill bit at the marks you made earlier.
Hammer the M8*80 expansion screws into the wall. Attach the plate onto the wall with the M8
bolts.
4.5.1. Mounting and Securing the HAB™
Using sufficient personnel to do so safely, remove the HAB™ from its box using the lifting
handles.
Tilt and rotate the HAB™ as necessary until it is upright with its back towards the mounting
location.
Using sufficient personnel, lift the HAB™ until the unit’s upper and lower mounting flanges are
just above the upper mounting plate’s upper and lower lips and the HAB™ is between the short
arms of the lower mounting plate. We strongly recommend using lift equipment and straps to
secure and steady the HAB™.
Remove and save the lift handle screws.
Lower the HAB™ onto the upper mounting plate’s upper and lower lips, making sure that both
of the HAB’s upper and lower mounting flanges are securely resting on both of the upper
mounting plate’s upper and lower lips. The holes in the lower mounting plate’s arms should
align with the lift handle screw holes. Attach the HAB™ to the lower mounting plate using 4 of
the 6 lift handle screws with washers.
Figure 8: Upper and Lower Mounting Plates Fitted

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4.6. Connecting the HAB™ to Your Inverter
Figure 9: HABTM Side Panel Connection Area
4.6.1. Connecting the HABTM
NEVER reverse the polarity (positive and negative) of your units connections. NEVER short
circuit your HAB™.
Step
Description
1
Set the HAB™'s address using the address DIP switch (refer to 4.6.4 Setting the
HAB™ Address).
2
If you are installing multiple HAB™ units, connect the Module COM cable
between the HABs (refer to 4.6.3 Simplified Wiring Diagrams).
3
Connect the CAN Bus communication cable between the Master HAB™ and the
Inverter.
4
Connect the power cables from the HAB™ to the inverter (or to the DC bus if
installing more than one HAB™), making sure to use overcurrent protection as
directed by the authority having jurisdiction.
5
Flip the disconnect switch on the side of the HAB™ into the ON position.
6
If installing more than one HAB™, start the other units one by one by pressing
the power button on the front of the HAB™ for at least 3 seconds. The "Run"
LED will flash five times, the HAB™ control panel will light up, indicating the
HAB™ is operating and supplying power to the inverter.