KiloVault HLX Series User manual

KiloVault®- HLX Series
Lithium Iron Phosphate (LiFePO4)
Deep Cycle Solar Batteries
Installation and User’s Manual
Release Date: August 13, 2019
Revision: 20190813

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Contents
1. Safety Information ............................................................................................................................. 5
1.1. Definitions .................................................................................................................................. 5
1.2. Important Safety Information .................................................................................................... 5
2. Overview............................................................................................................................................ 7
2.1. Product Technology .................................................................................................................... 7
2.2. Bluetooth Monitoring Application ............................................................................................. 7
3. Installation Requirements ................................................................................................................. 9
3.1. Pre-Installation ........................................................................................................................... 9
3.1.1. All Batteries Must Be Fully Charged to the Same Voltage Prior to Use .............................. 9
3.1.2. Do Not Use DC Chargers Exceeding 150 Amps ................................................................. 10
3.1.3. Add Batteries of Exact Same Model Together .................................................................. 11
3.1.4. Disable Your Chargers Equalizing Cycle............................................................................. 11
3.1.5. Do Not Use a Battery Temperature Sensor (BTS).............................................................. 11
3.1.6. Temperature and Battery Physical Spacing....................................................................... 12
3.1.7. Insulating Battery Enclosure in Cold Temperatures.......................................................... 12
3.1.8. Battery Interconnect Cabling ............................................................................................ 12
3.1.9. Digital Voltmeters.............................................................................................................. 13
3.1.10. Environmental Conditions for Batteries ........................................................................ 13
3.2. Installation................................................................................................................................ 13
3.2.1. Configurations................................................................................................................... 13
3.2.2. Bolt Tightening .................................................................................................................. 14
4. Operation......................................................................................................................................... 15
4.1.1. Configuring Charge Controller & Inverter Voltage Set-points........................................... 15
4.1.2. Disable Equalization .......................................................................................................... 15
4.1.3. “Gel/Sealed Battery” Settings........................................................................................... 16
4.1.4. Energize Your Inverter First ............................................................................................... 16
4.1.5. Self-Protection Mode by the BMS..................................................................................... 16
4.1.6. Charge Rate ....................................................................................................................... 16
4.1.7. Temperature & BMS Self-Protection................................................................................. 16

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4.1.8. Temperature & Effects on Battery Capacity...................................................................... 16
4.1.9. Charge Slower in Very Cold Conditions............................................................................. 17
4.1.10. Ensure Batteries Are at the Exact Same Resting Voltage Prior to Operation ................ 17
4.1.11. Ensure Parallel Rows of Batteries are Within 0.2V of Each Other................................. 17
5. Specifications................................................................................................................................... 18
6. Storage and Re-Commissioning....................................................................................................... 20
6.1. Disconnect Batteries for Long Term Storage ............................................................................ 20
6.2. Self-Discharge & Maximum Period Between Charging ............................................................ 20
6.3. Temperature & Humidity.......................................................................................................... 20
6.4. Avoid Using Trickle Chargers .................................................................................................... 20
6.5. Re-Commissioning.................................................................................................................... 20
7. Certifications.................................................................................................................................... 22
8. Disposal............................................................................................................................................ 23
9. Troubleshooting and Q&A ............................................................................................................... 24

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The KiloVault® HLX series of solar lithium batteries are specifically designed and tested for the beating
that serious hybrid, off-grid inverters, and solar charge controllers can throw at them. Compared to
traditional deep cycle batteries, the HLX Series’ lithium battery technology more efficiently stores and
delivers the renewable energy that you have generated, with no maintenance on your part.
This manual contains important information regarding the safe use of KiloVault® HLX series batteries.
Your battery is an electrical device that will provide years of useful service with proper care. Ensure you
read and understand the instructions contained in this manual before use.
•Flexible: Works in 12Volt (V), 24V, or 48V configurations
•Gives You More: Use the full battery capacity, discharging it 100%
•Long-life: Even after 2000 full discharges, 80% of the total battery capacity remains
•Maintenance Free: No watering or cleaning of hazardous chemicals required
•High Efficiency: Providing up to 12% more useable stored energy
•Smart Investment: Lower cost per watt-hour/cycle and longer lifespan than lead batteries
•Safer: No thermal run-away issues as with other lithium technologies
•Heavy Duty: Takes up to 150 Amp (A) of continuous charging/discharging current, meeting the
tough demands of serious inverters and chargers
•Integrated Battery Management System (BMS)
•Bluetooth Monitor Application
•3-Year Limited Warranty
KiloVault, LLC
330 Codman Hill Rd
Boxborough, MA 01719
USA
Toll Free: +1.888.218.5924
www.KiloVault.com

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1. Safety Information
1.1. Definitions
Warning:
Indicates a condition that can cause personal risk or injury.
Caution:
Indicates a condition that can cause equipment damage.
Note:
Indicates points of particular emphasis that make operation more efficient or
convenient.
Disclaimer:
Indicates information limiting the scope of responsibility.
1.2. Important Safety Information
It is essential to read, understand, and follow these instructions when using KiloVault® batteries.
Warning:
High voltage risk, improper use may cause personal injury or death.
Warning:
Do not use a battery that appears damaged in any way.
Warning:
All batteries present the risk of shock, use protective measures when handling.
•When working with or installing batteries use electrically insulated gloves and
tools
•Remove personal metal items such as watches, rings, bracelets, etc.
Warning:
High voltage connections of batteries (configurations of greater than 36V DC nominal)
are dangerous. DC voltages over 52V can stop the adult human heart and a fully charged
48V nominal system is over this level. Use appropriate safety measures including the
removal of metal personal items and insulated gloves.

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Warning:
A small risk of spark exists while making electrical connections.
•Ensure the installation area is free of explosive gasses and liquids.
•Ensure the batteries are not installed in confined areas containing explosive
substances. This includes flammable fuel powered machinery, holding tanks, pipe
fittings, and connectors.
Warning:
In the unlikely event of a fire, when possible first shut off the source of electricity. Class
ABC extinguishers are recommended in close proximity of your power generating
equipment and are best suited for multipurpose fire types such as wood, flammable
liquids, and electrical appliances.
Warning:
Respiratory irritation may be caused if the battery is punctured or cracked.
Warning:
Skin contact with a punctured or otherwise open battery can cause irritation.
Warning:
To avoid risk of shock or fire, ensure all wires are properly sized and in good condition.
Warning:
Verify all equipment to be connected to the batteries is turned off before making any
electrical connections.
Warning:
Do not submerge the batteries. This can cause personal injury and will void your
warranty.
Warning:
Do not attempt to disassemble the batteries. This can cause personal injury and will
void your warranty.

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2. Overview
2.1. Product Technology
•12 Volt Lithium Iron Phosphate (LiFeP04) with Bluetooth
•Model Types: KLV1800HLX (150Ah/1800Wh) / KLV3800HLX (300Ah/3600Wh)
•LiFeP04 chemistry prevents thermal runaway as opposed to other lithium technologies.
•IP55 Rated
•KiloVault® batteries can be used in RV applications for electrical appliances ONLY. They can NOT be
used to crank over motors in such vehicles.
2.2. Battery Management System
Every KiloVault® battery contains a BMS that helps protect it from over voltage charging/discharging,
over current charging/discharging, and extreme temperatures while charging and discharging. While
this system is robust, batteries must be installed using appropriate inverter charge controller settings,
devices to protect them from open photovoltaic (PV)/solar panel voltage, and other high voltage
charging sources. Failure to adhere to proper installation requirements will void the warranty and
may damage the system.
2.3. Bluetooth Monitoring Application
The KiloVault® smartphone Bluetooth app enables you to view general information about the selected
individual battery. It can help troubleshoot when attempting to detect the cause of the battery bank
going off-line. The app is available for free download for both Android and iPhone phones. Each
battery is identified by a unique serial number located on the battery label.
Disclaimer:
The KiloVault® Bluetooth Application is provided as is and is solely intended to gather
general information. It is not intended to replace a volt meter, nor guaranteed to work
with every device.
Note:
Your Android/iPhone must support Bluetooth Low Energy (BLE). Additionally, for the
Android app to work you must permit access to Location and Local Storage.

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The information displayed includes:
Basic View
•State of Charge (SOC)
•Voltage
•Capacity
•Status (Charging/Discharging/Standby)
•Health
Advanced View (swipe right to access)
•Voltage
•Amps (Charging or Discharging)
•Temperature (Internal Battery Temperature)
•Cycle life (Number of times cycled)

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3. Installation Requirements
3.1. Pre-Installation
IMPORTANT - PLEASE READ FIRST!
1) Each battery must be individually charged to exactly a voltage between 14.1V and 14.2V
(choose one and use it for all batteries) before placing it into operation with other batteries.
Otherwise, the batteries will independently hit full or empty and shut off before others in the
same battery bank.
2) Equalization charging must be turned off in your solar charge controller or AC charger. If left
on, the equalization charge will raise the voltage too high, damage the batteries, and void the
warranty.
3) Bulk/Absorption charge voltage should be set to no higher than 14.1V for a 12V system, 28.2V
for 24V system, and 56.4V for a 48V system (and lower for high amp chargers). Anything
higher risks one or more batteries automatically shutting off in a high voltage protection mode.
4) Low Voltage Cut-Off on the inverter should be set for no lower than 12.0V, 24.0V and 48.0V for
a 12V, 24V and 48V system, respectively. Voltages lower than this risks one or more batteries
automatically shutting off in a low voltage protection mode.
5) When turning on breakers to inverters, charge controllers, battery monitors, etc. connected to
the batteries wait 45-60 seconds between powering up each device. The KiloVault® battery
management system has special circuitry designed to detect short circuits and protect the
battery. Many brands of inverters, charge controllers and battery monitors will present a very
high but very brief surge that can be interpreted as a short. The BMS can handle one of these
perceived shorts every 45-60 seconds. Alternatively, in most circumstances all devices can be
powered up at once but the batteries will go into auto-protect mode and turn off for 30-60
seconds but then restart normally.
6) Be sure to tighten the battery terminals before operating. Failure to do so will lead to the
terminals overheating, melting the case, and potentially causing a fire.
Note:
Due to transportation regulations, LiFePO4 batteries cannot be shipped fully charged. As
a result, if you have purchased more than one battery for your system all batteries must
be fully charged to exactly the same voltage before using.
3.1.1. All Batteries Must Be Fully Charged to the Same Voltage Prior to Use
It is very important that each battery be individually charged to exactly the same voltage initially and
not less than 14.1 volts before putting the batteries into operation (not applicable if you are using only
one battery). Selecting a voltage at 14.1 to 14.2V is recommended but alternatively a precisely
selected low voltage will work, such as one between 11.5-12.0V.

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Note:
After a 12 to 24 hour rest period following the initial charge the voltage will drop to
approximately 13.3-13.6V. This is normal, the batteries will not require re-charging. The
same holds true when drawing down the batteries. Once the batteries hit the
determined low voltage point and the load is disconnected, the voltages will rise back
up.
Do not charge the batteries initially to just 13.0 - 13.9 volts. There is a very gradual charge voltage
versus capacity curve when charging, especially between 13.6 to 13.9V. Charging them to a value in
this range (unlike lead acid batteries) can result in a very broad difference in the actual state of charge
versus any other battery in your bank. As a result, any one battery in your bank will prematurely shut
down during charging or discharging. See the charging graph below to understand the characteristics
of the LiFePO4 charging curves.
Many automotive type battery chargers will not reach 14.1V. Please check charger specifications
when selecting your charger or you can contact your KiloVault® distributor for a list of recommended
chargers.
3.1.2. Do Not Use DC Chargers Exceeding 150 Amps
Although a nominal charge rate of 100A is recommended on an on-going basis, you can use whatever
is available as long as it does not exceed 150A. After the charger is removed for the initial pre-
installation charge, allow them to rest for a minimum of two hours.
Note:
After the 2-hour rest period, use a DC Voltage meter to ensure that the voltage
difference between each of the batteries is not more than 0.2 volts. Failure to take these
preliminary charging steps will result in reduced capacity, make the batteries
prematurely shutdown during charging or discharging, and could void your warranty.
If the batteries are not charged to exactly the same voltage (preferably above 14.0V), then they are
not truly all at the same state-of-charge. As a result, the BMS in one or more batteries will
protectively shutdown the battery because it has either reached its high voltage maximum ahead of
the other batteries, or prematurely reached its completely discharged voltage. This situation protects
the battery bank by placing it into an open condition.