KiloVault HLX+ User manual

KiloVault HLX+
Lithium Iron Phosphate
Deep Cycle Solar Batteries
Installation and User Manual
Revision 1.0, 06/2021
KiloVault®LLC • 330 Codman Hill Road, Boxborough, MA 01719 • [phone] • [email protected] •www.kilovault.com
Revision 1.0, 06/2021
Page 1 of 29

KiloVault®LLC • 330 Codman Hill Road, Boxborough, MA 01719 • [phone] • [email protected] •www.kilovault.com
Revision 1.0, 06/2021
Page 2 of 29

**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® HLX+ 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.
1 - About the HLX+ 3
1.1 - Features 3
1.1.1 - Battery Management System 4
1.1.2 - HLX iT, the Bluetooth Monitoring Mobile Application 4
1.1.3 - HLX+Bridge (coming soon) 4
1.1.4 - Heating System 4
1.2 - Contact Us 5
2 - Safety Information 5
2.1 - Symbols Used in This Manual 5
2.2 - Warnings 5
3 - Installation 6
3.1 - Before You Install Your Batteries 6
3.2 - Location 7
3.3 - Cabling 7
3.4 - Configurations 8
3.4.1 - Without the HLX+ Bridge 8
3.4.2 - With the HLX+ Bridge 9
4 - Operation 9
4.1 - Inverter/Charger Settings 10
4.2 - Solar Charge Controller Settings 11
4.3 - Battery Monitor Settings 12
4.4 - Generator/Automatic Generator Control Settings 12
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4.5 - HLX iT Bluetooth Mobile Application 13
4.5.1 - Introduction 13
4.5.2 - Screens & Operation 13
5 - Troubleshooting / Q&A 17
6 - Storage and Recommissioning 20
7 - Specifications 20
7.1 - Electrical 21
All Models 21
1200 HLX+ 21
2400 HLX+ 22
3600 HLX+ 23
7.2 - Environmental 24
7.3 - Physical 24
8 - Certifications 27
9 - Disposal 27
10 - Limited Warranty 27
10.1 - Non-Transferrable 27
10.2 - Warranty Exclusions and Limitations 27
1 - About the HLX+
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.
1.1 - Features
●12 V Lithium Iron Phosphate (LiFeP04), a.k.a. LFP, with Bluetooth
●Models: 1200 HLX+ (100 Ah/1200 Wh), HLX+ 2400 (200 Ah/2400 Wh), and HLX+ 3600 (300
Ah/3600 Wh).
●Flexible: Works in 12 Volt (V), 24 V, or 48 V configurations
●Gives You More: Use the full battery capacity if necessary. HLX+ withstands occasional 100%
discharges. Please Note: frequent 100% discharges will decrease battery life.
●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: 94.5%, providing up to 12% more usable stored energy
●Smart Investment: Lower cost per watt-hour/cycle and longer lifespan than lead batteries
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●Safer: No thermal run-away issues as with other lithium technologies
●Heavy Duty:
○The 1200 HLX+ takes up to 80 amps of continuous charging/discharging current.
○The 2400 HLX+ takes up to 150 amps of continuous charging/discharging current.
○The 3600 HLX+ takes up to 200 amps of continuous charging/discharging current.
●Internal heater allows the battery to continue charging, even when the ambient temperature is
below freezing.
●Integrated Battery Management System (BMS)
●HLX iT Bluetooth Monitoring Application (iOS and Android)
●7.5 Years Limited Manufacturer’s Warranty
1.1.1 - Battery Management System
Every HLX+ 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.
1.1.2 - HLX iT, the Bluetooth Monitoring Mobile Application
The HLX iT 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 name assigned at the factory.
1.1.3 - HLX+Bridge (coming soon)
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interdum neque. Aliquam cursus facilisis nulla, eu tincidunt libero suscipit et. Aenean volutpat, erat non
dapibus sodales, nunc lacus fermentum urna, id semper orci ipsum sit amet lacus. Curabitur a nisl ac
lectus varius fermentum. Curabitur venenatis elementum porttitor. Maecenas at lectus gravida, egestas
enim congue, consectetur lectus. Nunc venenatis dolor felis, sed blandit turpis sodales at.
1.1.4 - Heating System
The 1200 HLX+ heater is 64 W. The 2400 HLX+ heater is 96 W, and the 3600 HLX+ heater is 192 W. The
heater is powered by charging current, not by the battery. The battery does not self-discharge to warm
itself.
In all of the batteries the heater starts at an internal temperature of 0°C (32°F) and stops at an internal
temperature of 5°C (41°F). At external temperatures below -30°C (-22°F), the heat dissipation is too great to
bring the battery up to temp.
It will take about 1.5 to 2 hours to warm the battery from an internal temperature of -20°C (-4°F) to 5°C
(41°F).
When the batteries are charging with solar, it might take a longer time, depending upon the charger
output.
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1.2 - Contact Us
KiloVault® LLC
330 Codman Hill Road, Boxborough, MA 01719
[phone]
[email protected]
www.kilovault.com
2 - Safety Information
2.1 - Symbols Used in This Manual
Warning:
Indicates a condition that can cause personal risk or injury.
Caution:
Indicates a condition that can cause equipment damage.
Note:
Indicates points of interest of particular emphasis that make operation more efficient or
convenient.
2.2 - Warnings
High Voltage Risk. Improper use may cause personal injury or death.
Do not use a battery that appears damaged in any way.
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.
High voltage connections of batteries (configurations of greater than 36 V DC nominal) are dangerous. DC
voltages over 52 V can stop the adult human heart and a fully charged 48 V nominal system is over this
level. Use appropriate safety measures including the removal of metal personal items and insulated
gloves.
A small risk of spark exists while making electrical connections.
Ensure the installation area is free of explosive gases 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.
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In the unlikely event of a fire, when possible first shut off the source of electricity. Class ABC extinguishers
are recommended in close proximity to your power generating equipment and are best suited for
multipurpose fire types such as wood, flammable liquids, and electrical appliances.
Respiratory irritation may be caused if the battery is punctured or cracked.
Skin contact with a punctured or otherwise open battery can cause irritation.
To avoid risk of shock or fire, ensure all wires are properly sized and in good condition.
Verify all equipment to be connected to the batteries is turned off before making any electrical
connections.
Do not submerge the batteries. This can cause personal injury and will void your warranty.
Do not attempt to disassemble the batteries. This can cause personal injury and will void your warranty.
KiloVault® batteries can be used in RV applications for electrical appliances ONLY. They can NOT be used
to crank over motors in such vehicles.
3 - Installation
3.1 - Before You Install Your Batteries
1. When gathering your tools for your installation, please make sure that you have a digital
multimeter with a 0.1 V accuracy. It will help you to verify battery polarity before you make any
connections. You can also use the multimeter to ensure that your batteries are at the same
voltage.
2. Please write down and save the serial numbers of your batteries along with the rest of your system
information. If you have already downloaded and installed the HLX iT battery monitoring
application, also write down and save the battery names.
3. Each battery must be commissioned by individually charging it to exactly 14.1 V before placing it
into operation with other batteries. Otherwise, the batteries will be fully charged or fully
discharged at different times and could cause a low voltage or high voltage disconnect.
a. You will see 14.1 V while the battery is still on the charger and actively charging. When
charging is finished and the charger shuts off or the battery is disconnected, the voltage
will slump to 13.3 > 13.6 V. This is normal. The battery is still fully charged.
b. Due to transportation regulations, lithium 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 14.1 V before using.
c. Many automotive type battery chargers will not reach 14.1 V. Please check charger
specifications when selecting your charge. You can contact your KiloVault® distributor for
a list of recommended chargers.
d. An acceptable charger:
i. Must be a 12 V charger.
ii. Maximum charge voltage - 14.1 V.
iii. Must have Equalization disabled.
iv. 1200 HLX+ maximum charge amperage - 80 A.
v. 2400 HLX+ maximum charge amperage - 150A.
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vi. 3600 HLX+ maximum charge amperage - 150A.
vii. Charger must taper the amps as the battery approaches 14.1 V.
e. After batteries are fully charged and disconnected from the charger, allow them to rest for
a minimum of two hours. During this time, the voltage will relax, even as low as 13.3 V.
Your batteries are still fully charged. This is normal.
3.2 - Location
Locate your battery bank in a place that is dry and as well protected from extreme
temperatures as possible. No ventilation is required as these do not off-gas like lead-acid
batteries do.
HLX+ batteries must be placed flat on their bottoms. Any other orientation will void the
warranty. Also, do not stack them one directly on top of another.
Batteries warm up while in use. Please consider your local average and seasonal
temperature when positioning your battery bank. If they will be in a warmer environment
you may want to leave a minimum of one inch spacing between each of the batteries.
If they will be subjected to cold temperatures you may want to place them as closely as
possible to each other. Consider adding insulation or an insulated enclosure around the
batteries if they will be exposed to temperatures that approach 32°F (0°C). The BMS will not
allow charging when the internal temperature is below freezing. Using insulation when it is
cold will maintain more of the heat generated during normal charging and reduce the
chance of the BMS shutting the battery down to protect the battery cells.
Please note: Battery capacity is reduced by 20% as its internal temperature falls between
room temperature (approximately 77°F (25°C)) and just above 32°F (0°C).
Please remember to remove the insulation in warmer months. Overheating the batteries
will shorten their life and the BMS will shut down the battery in temperatures above 149°F
(65°C).
3.3 - Cabling
All wire must be the appropriate gauge and construction to handle the loads that will be placed upon it.
Heavy gauge, fine stranded copper wire is the industry standard. A minimum of 2/0 or 4/0 AWG copper
cable is recommended for battery interconnect cables.
The cables connecting batteries in series into rows must be the same length. The cables connecting the
rows in parallel must be the same length. The home run cables to the inverter must be the same length.
Cables of different lengths will cause voltage differences in your battery bank. The rows in your battery
bank must be kept within 0.2 V of each other to ensure that they work correctly and that large currents
between rows aren’t generated.
If your battery bank suddenly shuts down as one or more rows approaches fully charged or fully
discharged, it is likely either the batteries are not all at the same state of charge or, if they are measured
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with a multimeter to be all the same voltage, the voltage drop across the cables connecting the rows is not
equal. Also use the voltmeter to make sure that the voltage drops across each battery interconnect is very
close.
Torque all bolts and battery terminals to between 7.38 and 8.11 ft-lbs (88.51 to 97.36 in-lbs OR 10 to 11
nm). Terminals left insufficiently tightened will lead to overheating, melting the battery terminals and
potentially causing a fire. Be careful when using thin washers. You may think you're applying sufficient
torque, but if the washers are too thin, the cable lugs can still move. Add additional washers until you can
tighten and the cable lugs cannot move.
3.4 - Configurations
The KiloVault® HLX+ series of batteries can be used in 12 V, 24 V, 36 V, and 48 V configurations where
one, two, three or four batteries are connected in series, plus to minus, in a row. The maximum number of
batteries in a bank is sixteen, 4 in parallel strings of 4 batteries in series. Each row of batteries must be
kept within 0.2 V of each other or the battery bank may prematurely shut down during charging and
discharging. There are configuration limitations depending on the temperature range of the installation
location and whether or not you are using the HLX+ Bridge. The HLX+ Bridge helps the HLX+ batteries
coordinate their heaters.
3.4.1 - Without the HLX+ Bridge
If you are not using the HLX+ Bridge, and the installation location will stay above freezing (32°F (0°C) ,
then the HLX+ batteries can be wired together up to 4 parallel strings of 4 batteries each.
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If you are not using the HLX+ Bridge, and the installation location will go below freezing , then the
configuration is limited to 4 HLX+ in parallel or 4 HLX+ in series, but not both, because the HLX+ cannot
coordinate their heaters beyond these configurations.
3.4.2 - With the HLX+ Bridge (coming soon)
The HLX+ Bridge allows the batteries to coordinate their heaters beyond a single string or 4 or 4 single
batteries in parallel. If you are using the HLX+ Bridge with your bank of HLX+ batteries, then you can use
the maximum configuration of 4 parallel strings of 4 batteries in series, even if the installation location
will go below freezing.
4 - Operation
It is very important that your battery chargers (solar charge controller, inverter/charger or AC) can be set
to settings appropriate for the HLX+. If it cannot, please contact KiloVault Technical Support for guidance.
Adjust your settings as necessary until your system performance best fits your power use patterns and
needs.
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Also, some chargers just have settings for broad battery types like; flooded, gel, agm or lithium. Before
using these chargers on your battery, please contact KiloVault technical support for guidance.
Note: If you cannot find a specific setting, remember to check the settings for guidance. Also, please don’t
hesitate to contact KiloVault technical support for help.
4.1 - Inverter/Charger Settings
Setting
Values:
Volts are per HLX+ in a single string.
Amps are per parallel string.
1200 - Battery Capacity
1200 Wh, 100 Ah
2400 - Battery Capacity
2400 Wh, 150 Ah
3600 - Battery Capacity
3600 Wh, 300 Ah
1200 - Max Charge Current
80 A
2400 - Max Charge Current
150 A
3600 - Max Charge Current
200 A
Absorb End Amps
2 A
Absorb Time (some controllers do not allow a
selection under 6 minutes, please contact
KiloVault for additional information)
2 minutes or less
Absorb Voltage
14 V
Battery Temperature Compensation
0 mV/°C
Battery Type
Lithium or Custom, whichever lets you set the
recommended settings
Bulk Voltage
14 V
Charge Cycle
2 stage no float
Default Battery Temperature
Warm
Equalization
Disabled
Float Voltage
13.6 - Normally the inverter/charger is set to
2-Stage-No-Float, but if it has to be set then
used this value
HBCO (High Battery Cut Out)
14.4 V
LBCO (Low Battery Cut Out)
12.25 V (or as close as it can be set)
LBCO Delay
5 seconds
LBCO Hysteresis
0.5 V
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Max Bulk Current
Set the inverter max bulk current so that when
it is added to the charge controller current,
together they add up to less than the max
charge current for your battery bank.
Peukert Factor
1.05
Recharge/Re-Bulk Volts (≈80% DoD)
12.75 V
1200 - Recommended Charge Current
50 A or less per HLX in Parallel
2400 - Recommended Charge Current
100 A or less per HLX in Parallel
3600 - Recommended Charge Current
200 A or less per HLX+ in Parallel
4.2 - Solar Charge Controller Settings
Setting
Values:
Volts are per battery in a single string
Amps are per string in parallel
1200 - Battery Capacity
1200 Wh, 100 Ah
2400 - Battery Capacity
2400 Wh, 200 Ah
3600 - Battery Capacity
3600 Wh, 300 Ah
Absorb Time
2 minutes or less
Absorb Voltage
14 V
Battery Temperature Compensation
Do not use a battery temperature sensor
with these batteries!
If the sensor or compensation value is required
for a charge controller or inverter charger to
work, set the battery temperature compensation
to 0mV/°C
Battery Temperature Compensation
0.00 mV/degC
Battery Type
Lithium or Custom, whichever lets you set the
recommended settings
Battery Voltage - Nominal
12 V
Bulk Termination Voltage (if applicable)
13.9 V
Bulk Voltage
14 V
Charge Cycle
3 stage
Equalization
Disabled
Float Voltage (set below the resting voltage of
the battery bank)
≈13.4 V or lower. Low enough to not trigger
float when the battery "relaxes" after charging
stops.
Max Float Current
10 A
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Maximum Charge Rate - 1200
80 A, C/1.25
Maximum Charge Rate - 2400
150 A, C/1.3
Maximum Charge Rate - 3600
200 A, C/1.5
Recharge Volts (≈80% DoD)
Just above your inverter/charger
recharge/rebulk volts so it starts charging from
the sun before the inverter starts charging from
the grid or generator.
4.3 - Battery Monitor Settings
Setting
Values:
Volts are per battery in a single string.
Amps are per string in parallel
1200 Battery Capacity
1200 Wh, 100 Ah
1200 C-Rating
C/1.25
2400 Battery Capacity
2400 Wh, 200 Ah
2400 C-Rating
C/1.3
3600 Battery Capacity
3600 Wh, 300 Ah
3600 C-Rating
C/1.5
Battery Efficiency
94.50%
Charge Ending Amps
2 A
Charger Float Current - 1800 - 1% of capacity
1 A
Charger Float Current - 2400 - 1% of capacity
2 A
Charger Float Current - 3600 - 1% of capacity
3 A
Charger Float Voltage
≈13.4 V
Fully Charged Voltage
14 V
Nominal Temperature
77°F (25°C)
Peukert's Exponent
1.05
Recharge / Re-Bulk Volts (≈80% DoD)
12.25 V
Self Discharge Rate
≤2% per month
Temperature Coefficient
0 mV / °C
Battery Temperature Sensor
Do not use a battery temperature sensor
with these batteries!
4.4 - Generator/Automatic Generator Control Settings
The battery related settings for using a generator and/or an automatic generator start/stop (AGS) control
with HLX+ batteries can usually be found in the inverter/charger and solar charge controller settings.
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Some generators and/or AGS have settings for 2 minute, 2 hour and 24 hours (or similar duration) start
voltages. They set time limits the battery voltage can sit at before activating the generator. They are
related to the Low Voltage Disconnect/Cut-Off voltage and the Recharge/Re-bulk voltage. Expect to adjust
any or all of them over time to get exactly the generator behavior you wish. Depending on the make and
model of the generator or AGS, you may need to have more spacing between these settings.
●2 minutes - Set just above the inverter/charger Low Voltage Disconnect (12.25 V) so the generator
starts before the inverter stops inverting.
○Start at approx. 12.3 V and adjust as necessary.
●2 hours - Set above the 2 minutes volts.
○Start at approx. 12.4V.
●24 hours - Set just below the Recharge/Re-bulk voltage. If the Recharge/Re-bulk setting hasn’t
already started the generator at this time, the generator will start.
○Start at approx. 12.7 V if Recharge/Rebulk is 12.75 V.
4.5 - HLX iT Bluetooth Mobile Application
4.5.1 - Introduction
Disclaimer:
The KiloVault® Bluetooth® mobile application is provided as is and is solely
intended to gather general information. It is not intended to replace a
voltmeter, ammeter, or any other testing / measurement device. Nor is it
guaranteed to work with every mobile device.
The KiloVault® HLX iT 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 as a free download for both Android and iOS devices on the iOS
and Google Play app stores.
Your Android / iOS mobile device must support Bluetooth® 4.0 and Bluetooth® Low Energy (BLE). The iOS
version requires iOS 10.0 or later and is compatible with iPhone, iPad, and iPod touch. The Android
version requires Android 4.3 (Jelly Bean) and up. Additionally, the Android version must have permission
to access both Location and Local Storage.
4.5.2 - Screens & Operation
When you first start HLX iT, if you have bluetooth enabled, the screen will show all of the HLX batteries
within a 100m radius, depending on the physical or electrical interference.
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Battery List Screen
Basic Information
Closeup - Tabs
Tap on any of the batteries shown. The Basic information screen will load, along with 4 menu tabs or
buttons or icons at the top of the screen.
The Basic Information screen shows the voltage , state of charge, capacity, status (charging / discharging
1
/ standby), and health of that battery. The state of charge (SoC) is an estimated value and does not drive
any battery behaviors / performance. To get back to your list of batteries, tap the arrow in the lower left
corner of the screen.
From the Basic screen you can also get detailed information on battery current alarms, individual battery
cells and if you wish, rename your batteries.
1There can be as much as 0.3 V difference between the volts shown in the app and the volts measured at
the terminals, especially in the middle of a charge / discharge cycle. At the beginning and end of the
voltage range, the values converge.
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Location of the "⋮" Symbol
Login Dialog
Battery Information Button
To get information on individual cells, first tap the "⋮" symbol in the lower right corner of the Basic
Information screen. A login dialog will appear. Type “1234” into the login dialog and tap “confirm”. A
button called “Battery Information” will appear. Tap that button. A semi-transparent screen will appear with
8 button-like icons. They indicate if the battery has any active alarms. The indicators are normally green.
They will be red if there is an alarm. They are High Voltage (HV), Low Voltage (LV), Overcurrent Charging
(OCC), Overcurrent Discharging (OCD), Low Temperature Discharging (LTD), Low Temperature Charging
(LTC), High Temperature Discharging (HTD), High Temperature Charging (HTC).
Below the alarm indicators are 4 battery shaped icons. They represent the 4 cells that make up the battery.
Their color does not indicate anything. They are always the same color. Below each battery icon is a
number showing each cell’s voltage in mV (millivolts). The color of the numbers do not mean anything.
They're always the same color. The difference between the highest and lowest should be 300mV or less.
Tap anywhere to dismiss this screen.
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Battery Details Screen
To rename your batteries, first write down the original battery name, the battery serial number, and store
this information in a safe place. Then tap the "⋮" symbol in the lower right corner of the Basic Information
screen. A login dialog will appear. Type “5678” into the login dialog and tap “confirm”. A button called
“Rename Device” will appear. Tap that button. The “Rename” dialog will appear. Type in the new name and
tap “Confirm”. The battery is now renamed.
Location of the "⋮"
Symbol
Login Dialog
Rename Device Button
Rename Dialog
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Tap the dial shaped tab (the second from the left) at the top of the screen or swipe across the screen to
get to the Advanced information screen. It shows the battery voltage, amps, the battery internal
temperature and the cycle life (number of times cycled).
Tap the paper shaped tab (the third from the left) at the top of the screen, or swipe across the screen to
get to the alerts screen. Here you’ll find any active Events on the HLX. Events are not saved into any kind
of history.
Tap the telephone tab (the fourth from the left) at the top of the screen, or swipe across to get to the
KiloVault communications screen. Here you’ll find links to email or call KiloVault directly.
Advanced Information Screen
Events Screen
Communications Screen
5 - Troubleshooting / Q&A
1. Why is the battery bank suddenly shutting off?
○Likely, one or more of your batteries are not at the same voltage as the others. Those
batteries are hitting the upper or lower voltage cutoffs ahead of the others. When those
batteries shut themselves off to protect themselves, the battery bank drops below the
operating voltage of the inverter. Check all of the battery connections. Charge each
battery up to 14 V. If the problem persists, please contact KiloVault.
○Your loads (DC load or inverter) have exceeded the current capacity of the battery bank.
The 1200 HLX+ maximum continuous discharge current is 80 A per 1200 in parallel.
The 2400 HLX+ maximum continuous discharge current is 150 A per 2400 in parallel.
The 3600 HLX+ maximum continuous discharge current is 200 A per 3600 in parallel
If your known loads are close to your battery bank’s max continuous discharge current or
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if you have very high surge loads like pumps or HVAC systems, your loads may simply be
too high for your bank. Please contact KiloVault about adding an additional parallel row of
KiloVault batteries to your bank.
2. Why aren’t the battery voltages staying equal over time?
○The battery cables are not of equal length or are damaged. Check to make sure that all
battery interconnects are of equal length, gauge and are in good condition.
○Cable terminal hardware is not tightened properly. Check to make sure that all terminal
hardware is tightened to between 7.38 and 8.11 ft-lbs (88.51 to 97.36 in-lbs OR 10 to 11
nm). Check to make sure all of the crimps on all cables are tight and solid. Use the Ohms
(Ω) setting on a voltmeter to measure the resistance of the battery interconnect cables.
They should all be within 0.1 ohms of each other.
3. Why has the battery reversed polarity?
○Verify the voltmeter probe orientation.
○The battery has dropped into the low voltage protection range and the BMS has shut down
the battery. If so, you can wait for the battery to reset or you can connect the battery to a
14V charge.
4. Why is the battery turning off and off when it is connected to a small DC device or inverter?
○HLX+ batteries have an automatic standby mode where they will shut themselves down if
they do not see a load of more than 200-250 mA. That is about 3 Watts per series battery
(i.e. 3 watts for a single 12 V battery, 6 watts for 24 V series, and 12 watts for 48 V). In
the standby mode the battery turns back on about every 15-20 seconds to search and see
if there is load connected to it. If your load is not larger than this minimum current then
the battery will not stay on.
○Consider connecting an additional small DC load to the batteries to increase the current
draw to over 250 mA. If you are using an inverter, it is possible that it is going into its
own standby mode and it is consuming less than the minimum current required to keep
the batteries on. Also, for this case of the inverter, consider adding another small
additional DC load to increase the current draw to over 250 mA.
5. Can an HLX+ battery be charged with an auto / RV alternator?
○Yes, as long as the alternator provides the appropriate charging current for your battery
and does not exceed 14.0 V.
6. What is the terminal mounting hardware size?
○M8 - 1.25 x 16 mm bolts. In all models, the terminals extend 1 mm above the case.
7. What are the recommended voltage settings for a generator?
○We recommend a low-voltage start of 12.3V and a cut-off voltage of 13.9V (multiply those
numbers by 2 for 24V and 4 for 48V systems). Please see the Generator/Automatic
Generator Start settings in section 4.
8. What voltage settings are recommended for an 80% depth of discharge?
○We recommend a Recharge / Re-Bulk voltage of 12.15 V per HLX+ in series for an 80%
Depth of Discharge.
9. Is there a special mobile application to connect to the batteries via Bluetooth?
○HAB iT, the KiloVault® mobile bluetooth application, 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 as a
free download for both Android and iOS devices on the iOS and Google Play app stores.
○Your Android / iOS mobile device must support Bluetooth® 4.0 and Bluetooth® Low
Energy (BLE). The iOS version requires iOS 10.0 or later and is compatible with iPhone,
iPad, and iPod touch. The Android version requires Android 4.3 (Jelly Bean) and up.
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Additionally, the Android version must have permission to access both Location and Local
Storage.
○Please note that the app is provided as is to serve as a free troubleshooting tool. Also,
please be aware that a good voltmeter provides a more accurate voltage reading than the
Bluetooth application.
10. Is there a desktop or Wi-Fi application to connect to the batteries?
○No, there are neither desktop nor Wi-Fi applications for the HLX+.
11. What do I do if my inverter does not have an AC charger?
○Use a 12 V AC charger (capable of charging up to 14 V) connected to a generator or the
utility company’s power to charge each battery. We recommend the Iota Engineering DLS
series of 12 V AC Chargers that are capable of being configured for this slightly higher
voltage.
○Use a 12 V solar charge controller (set to 14 V or ‘sealed battery’ charging, as long as it
gets to 14 V) with a solar panel to charge up the batteries individually. This method will
take longer than an AC charger unless you are using a high amperage charge controller
with sufficient solar panels.
12. Why is the battery turning on and off when it is connected to a simple battery monitor?
○The HLX+ needs at least a 250mA load or they will go into their power saving, standby
mode. The simplest solution is to connect additional loads to reach at least 250mA (3
Watts).
13. Why does the battery voltage momentarily drop when a load is initially connected?
○This is the normal result of the battery switching from its pre-charge function to providing
enough current to devices that have input capacitors and draw high current surges in an
extremely short period of time. The battery will resume its normal voltage within a few
seconds.
14. Why isn’t the battery working when it is connected to the inverter?
○Some inverters have higher input capacitors whose current draw overwhelms the
pre-charge function of the HLX+. To minimize the initial draw when the batteries are
initially connected to the inverter, make sure that the inverter is off while connecting.
Then wait at least 45 seconds before powering up the inverter.
15. Why does the HLX iT show short circuit events in the log?
○When the battery is connected to a DC load or a charging current the pre-charging
function of the battery is enabled. That pre-charging function is used to compensate for
the surge capacitors on the input side of inverters and other devices. The order of
connecting devices may trigger the short circuit protection in the BMS once the high
inrush device (usually an inverter) is connected. The solution here is to disconnect all
devices from the battery (even battery monitors), first connect the inverter, wait 45
seconds and then connect the remaining devices.
16. Do high temperatures affect how the batteries perform?
○Yes, the battery cycle life will be reduced if they are regularly charged and discharged
above ambient temperatures of 100 degrees F. Please see the environmental
specifications.
17. Do low temperatures affect how the batteries perform?
○At 0°C (32°F), if there is a charging current, the HLX+ will try and warm themselves up to
5°C (41°F).
18. Why is the voltage shown in HLX iT not the same as what is measured at the terminals?
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