KiloVault HAB SCHNEIDER XW PRO UL9540 User manual

INSTALLATION &
INTEGRATION
GUIDE
KiloVault®
HAB™ - SCHNEIDER XW PRO UL9540 Base Kit
JUNE 2022 / Rev: 1.0

**WARNING High Voltage Risk of Personal Injury or Death**
As is the case with all batteries, the risk of shock is present. When handling batter-
ies, use protective measures including, but not limited to, safety glasses, insulated
gloves, and protective footwear.
When working with or installing batteries, use electrically insulated gloves and tools.
Remove personal metal items such as watches, rings, bracelets, etc.
The information included in this manual is accurate at the time of publication.
However, this manual is subject to change without prior notice as we continuously
improve our products.
Additionally, the illustrations in this manual are for demonstration only and are
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.
This publication could include technical or other inaccuracies or typographical errors.
Changes are periodically added to the information herein; these changes will be
incorporated in new editions of the publication. KiloVault® may make improvements
and/or changes in the services, facilities or specifications described in this publica-
tion at any time.
Please note: If this unit is installed by someone other than the end-user, the installer
must explain the contents of this installation and user’s manual to the end-user.
No responsibility is assumed by KiloVault® or Schneider Electric for any
consequences arising out of the use of this material.
This manual is for use by qualied personnel only
Read and keep this Installation Guide for future reference.
JUNE 2022 / Rev: 1.0

This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0
1. Safety Information ................................................................................................................ 4
1.1. Symbols Used in this Manual ............................................................................................ 4
1.2. General Safety Precautions and Instructions .................................................................... 5
1.3. Battery Handling Guide ..................................................................................................... 6
1.3.1. Transportation................................................................................................................. 6
1.3.2. Storage........................................................................................................................... 6
1.3.3. Response to Emergency Situations ............................................................................... 7
1.3.4. Qualied Personnel ........................................................................................................ 7
2. Overview............................................................................................................................... 8
2.1. Features ............................................................................................................................ 8
3. Specications ....................................................................................................................... 9
3.1. Electrical Specications..................................................................................................... 9
3.2. Operating Environment Specications .............................................................................11
3.3. Physical Specications.................................................................................................... 12
3.4. Certications.................................................................................................................... 13
4. Installation .......................................................................................................................... 14
4.1. Installation Flowchart....................................................................................................... 15
4.2. Unpacking the KiloVault® HAB™.................................................................................... 15
4.2.1. Package Contents ........................................................................................................ 16
4.3. Tools, Materials, and Safety Equipment Required for Installation ................................... 18
4.4. Suitable Installation Locations......................................................................................... 19
4.5. Install the KiloVault® HAB™ Wall Mounting Plate........................................................... 20
4.5.1. Mounting Surface ......................................................................................................... 22
4.5.2. Mounting and Securing the KiloVault® HAB™............................................................. 22
4.6. Connecting the KiloVault® HAB™ to Your Inverter ......................................................... 22
4.6.1. Connecting the KiloVault® HAB™................................................................................ 25
4.6.2. Disconnecting the KiloVault® HAB™ ........................................................................... 26
4.6.3. RJ45 120 Ω Resistor Plug Resistor Plug Installation ................................................... 26
4.6.4. Single Inverter Simplied Wiring Diagram.................................................................... 27
4.6.5. Multiple Inverter Simplied Wiring Diagram.................................................................. 28
4.6.6. Optional Battery Combiner Box and Bus Bar ............................................................... 28
4.6.7. Setting the KiloVault® HAB™ Address......................................................................... 29
4.6.8. HAB to HAB and HAB to Inverter Communication Cable Pin Denitions..................... 30
5. Operation, Maintenance & Monitoring................................................................................ 31
5.1. KiloVault® HAB™ Control Panel ..................................................................................... 31
5.1.1. KiloVault® HAB™ Control Panel Details ...................................................................... 32
5.2. Calibrating Your KiloVault® HAB™.................................................................................. 33
5.3. Charging Settings............................................................................................................ 33
5.3.1. Firmware Updates ........................................................................................................ 36
5.4. Starting the KiloVault® HAB™ for the rst time............................................................... 37
5.5. Monitoring........................................................................................................................ 38
5.6. Maintenance.................................................................................................................... 38
5.7. Disposal........................................................................................................................... 38
6. Troubleshooting.................................................................................................................. 38
6.1. BMS Protection / Alarm Conditions ................................................................................. 38
6.2. Warning / Alarm Indicators .............................................................................................. 41
6.3. Parallel Alarm Conditions and Connection Test............................................................... 42
6.4. Resetting / Recalibrating the KiloVault® HAB™.............................................................. 45
6.4.1. Resetting the KiloVault® HAB™................................................................................... 45
Contents

This manual is for use by qualied personnel only
WARNINIG
The KiloVault® HAB™ or Conext XW Pro inverter are not intended for
use in connection with life support systems or other medical equipment
or devices.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.
JUNE 2022 / Rev: 1.0
5.4. Starting the KiloVault® HAB™ for the rst time............................................................... 37
5.5. Monitoring........................................................................................................................ 38
5.6. Maintenance.................................................................................................................... 38
5.7. Disposal........................................................................................................................... 38
6.1 Troubleshooting................................................................................................................ 38
6.2. BMS Protection / Alarm Conditions ................................................................................. 38
6.2. Warning / Alarm Indicators .............................................................................................. 41
6.3. Parallel Alarm Conditions and Connection Test............................................................... 42
6.4. Resetting / Recalibrating the KiloVault® HAB™.............................................................. 45
6.5. Initial HAB™ Unboxed Voltage .................................................................................... 45
7.1. TroubleShooting ............................................................................................................. 45
7.2 Downloads and Documentation ..................................................................................... 45
7.3 Software .......................................................................................................................... 45
7.4 Contact Us ...................................................................................................................... 45
8.1 XW PRO Installation ........................................................................................................ 45
8.2.Audience .......................................................................................................................... 45
9.1. Conext XW Pro Features. .............................................................................................. 46
9.2 Single XW Pro with Single LEADER KiloVault® HAB™
(Split-Phase and Single-Phase) with AC Coupling .......................................................... 47
10.1 FCC Information to the User........................................................................................... 48
11.1 Installation and Commissioning Protection Coordination ...............................................49
12.1 Clearance Requirements ................................................................................................49
12.2 Wall-Mounting ................................................................................................................49
12.3 AC Connections ..............................................................................................................49
13.1 AC Connections ..............................................................................................................49
13.2 Grounding AC Equipment ...............................................................................................49
14.1 XW Pro Multi-unit Design Guide......................................................................................49
15.1 Making DC Connections .................................................................................................49
16.1 Battery Cable Requirements ...........................................................................................49
17.1 DC Wiring for a Dual-Inverter System ............................................................................ 49
18.1 Wiring Interface .............................................................................................................. 49
19.1 Applying DC Power to the Inverter ................................................................................ 49
20.1 Basic Functional Test - Multiple Inverters ...................................................................... 49
21.1 Schneider XW-Pro Specications....................................................................................49

"DO NOT DISCARD CRATE AND INTERNAL PACKAGING."
Congratulations on your KiloVault® product purchase.
Product registration is required for warranty coverage
and allows for easier customer and technical support.
https://kilovault.com/register/
“VERIFY that your HAB rmware is Up To Date”
This manual is for use by qualied personnel only
Read these instructions carefully and look at the equipment to become familiar
with the device before trying to install, operate, service or maintain it. The following
special messages may appear throughout this bulletin or on the equipment to warn of
potential hazards or to call attention to information that claries or simplies a
procedure. Please refer to “Firmware Updates” on page 36 of this guide.
Abbreviations and Acronyms
Name Abbreviations or Acronyms
UNIT KiloVault® HAB™
CEC California Energy Commission
CSA Canadian Standards Accociation
GT Grid Tie
LCD Liquid Crystal Display
LED Light Emitting Diode
MPPT Maximum Power Point Tracking
NEC US National Electrical Code NFPA-70
PV Photovoltaic
PVGFP PV Ground Fault Protection
UL Underwriters Laboratories
ETL Intertek Testing Laboratories
VAC Volts Alternating Current
VDC Volts Direct Current
JUNE 2022 / Rev: 1.0

This manual is for use by qualied personnel only
1. Safety Information
1.1. Symbols Used in this Manual
It is essential to read, understand, and follow these instructions prior to installing or
operating KiloVault® batteries.
Warning:
This is a hazardous situation which, if not avoided, could result in serious injury
or death.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB™ out of the reach of children and animals.
Warning:
The KiloVault® HAB™ 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™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the KiloVault®
HAB™ .
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.
JUNE 2022 / Rev: 1.0 4

This manual is for use by qualied personnel only
1.2. General Safety Precautions and Instructions
• Do not attempt to use any battery that appears damaged during shipment or otherwise.
• Do not submerge the HAB™. 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™.
Warning:
Failure to follow the instructions in this manual may result in serious injury
or death.
Warning:
Never connect KiloVault® HAB™ units in series!
Warning:
After powering down a 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 cir-
cuit events and causing damage to its internal resistors.
Caution:
Risk of electric shock.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB™ out of the reach of children and animals.
Warning:
The KiloVault® HAB™ 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™.
JUNE 2022 / Rev: 1.0
2022 5

• Verify that all equipment that is going to be connected to the KiloVault® HAB™ is turned off
before making any connections.
• A small risk of spark does exist while making connections. Ensure the area is free of explo-
sive gasses and liquids and is not installed in confined areas. This includes flammable fuel
powered machinery, holding tanks, pipe fittings, and connectors.
• Respiratory irritation may be caused if the HAB™ is punctured or cracked; use appropriate
respiratory and hand protection.
• Skin contact with a punctured or otherwise open battery can cause irritation.
• High voltage battery connections (configurations of greater than 36 V DC nominal) can be
dangerous in any DC system. The HAB™ 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 hu-
man adult heart; please be careful and wear insulated gloves.
1.3. Battery Handling Guide
In addition to the General Safety Precautions and Instructions, the following guidelines should be
observed when handling the HAB™ .
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 230 lb., it should be moved with the help of multiple peo-
ple and moving / lifting equipment rated over 300 lb.
• Do not drop the HAB™ or damage will occur.
• If you are transporting HAB™ batteries while they are still in the packing crate, do not stack
them more than two layers high and ensure they are strapped together to prevent tumbling.
• Only transport the HAB™ face up.
• Check the HAB™ immediately after transporting.
• If the HAB™ is damaged in any way, do not use it;
contact KiloVault® immediately.
1.3.2. Storage
In addition to the General Safety Precautions and Instructions, the following guidelines should be
observed when storing the HAB™ .
• Long-term storage (between one and six months) of the HAB™ 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 HAB™ no longer than 6 months.
• The HAB™ must be charged to at least 70% (the state of charge upon delivery) before
storage.
This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0 6

• Repeated 100% discharges will decrease the battery capacity. For example, 3000, 100% dis-
charge cycles will reduce the battery capacity to about 75% of the original amp hour capacity.
• Fully charge the battery within 15 days of a deep discharge of 90% or more.
• Do not drop, stack, or turn the KiloVault® HAB™ upside down.
• Store the KiloVault® HAB™ away from children and animals.
1.3.3. Response to Emergency Situations
The HAB™ is comprised of multiple batteries and is designed to prevent hazards resulting
from failures; however, no battery system is 100% safe, and KiloVault®, LLC cannot guarantee
its absolute safety.
In the unlikely event of a fire first shut off the source of the electricity if possible. We recom-
mend a fire extinguisher in close proximity of your power generating equipment. Class ABC
extinguishers are best suited for multipurpose fire types such as wood, flammable liquids, and
electrical appliances.
1.3.4. Qualied Personnel
This guide, and the tasks and procedures described in this manual, are intended for use by qual-
ified personnel only. Only qualified personnel shall 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 the following skills and experience:
• Knowledge of the functional principles and operation of on-grid and off-grid (backup) electri-
cal systems.
• Knowledge of the dangers and risks associated with installing and using electrical devices
and acceptable mitigation methods.
• Knowledge of the installation of electrical devices.
• Knowledge of and adherence to the information in this guide, to all applicable safety precau-
tions, and to electrical industry best practices.
This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0
2022 7

2. Overview
KiloVault® HAB™ 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 HAB™ 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™ 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 HAB™ battery (Leader plus 13 Followers) modules in parallel
The wiring panel of the HAB™ has been designed for function and convenience.
• The HAB™ wiring panel has access ports on the left and right sides, and the bottom
• Power and communication cables are now more easily attached
• The HAB™ case has integrated handles that fold completely out of the way when not in use
• The HAB™ now comes with replaceable vents for different operating environments:
o Vented plates for warmer environments
o Solid plates for cooler environments
Warning:
Never connect HAB™ units in series!
This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0 8

This manual is for use by qualied personnel only
3. Specications
3.1. Electrical Specications
The following specifications describe the HAB™ system.
Note:
• Specifications are subject to change without prior notice.
• The following are specifications only, NOT set points.
Item Specication
Battery Type LiFePO4
Internal Resistance ≤15mΩ
JUNE 2022 / Rev: 1.0
2022 9

This manual is for use by qualied personnel only
Item Specication
Battery Efciency 94.5%
DC Direct current
Fully Charged Resting Voltage 53.6 V
Full Charge Voltage 56 V
HAB™ to HAB™
(inter-battery) communication cable
RJ45 120 Ω Resistor Plug, 6-position, 4-conductor,
male connectors both ends. Straight through. Maxi-
mum length, 10 feet
HAB™ to HAB™
(inter-battery) communication protocol CAN Bus
HAB™ to Inverter
communication protocol Modbus / Canbus
High Voltage Cutout 60.0 ± .5 V (not a set point)
Low Voltage Cutout 48.0 V (not a set point)
Maximum Cell Balancing Current 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 HAB™ to HAB™ Cable Length 9.84 ft (3 m)
Minimum Cell Balancing Voltage 3350 mV
Minimum Discharge Voltage 48.0 V
Nominal Capacity 150 Ah
Nominal Energy 7.68 kWh
Nominal Voltage 51.2 VDC
JUNE 2022 / Rev: 1.0 10

This manual is for use by qualied personnel only
Item Specication
Operational Temperature Range 32° to 113°F (0° to 45°C)
Peak Discharge Current (3s) 500 A
Peak Discharge Power (3s) 25k W
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™ is put to sleep by pressing
down the Power button for
3 seconds.
• The KiloVault® HAB™ will automatically shut
down after 15 minutes of no activity.
Item Specication
Operational Temperature Range 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 Tempera-
ture -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
Refer to Section 6 Troubleshooting for a complete list of protection limits.
3.2. Operating Environment Specications
JUNE 2022 / Rev: 1.0
2022 11

This manual is for use by qualied personnel only
3.3. Physical Specications
Item Specication
KiloVault® HAB™ Weight 230 lb (105 kg) net
286 lb (130 kg) gross
KiloVault® HAB™ Height 32 in (812.8 mm)
KiloVault® HAB™ Width 22.5 in (571.5 mm)
KiloVault® HAB™ Depth 9.2 in (233.7 mm)
Mounting Plate Height 18 in (458.1 mm)
Mounting Plate Width 22.3 in (565.5 mm)
JUNE 2022 / Rev: 1.0 12

This manual is for use by qualied personnel only
Item Specication
Mounting Plate Ears 1.7 in (42.5 mm)
Mounting Plate Lips 0.5 in (12.7 mm)
KiloVault® HAB™ Ingress Rating - Vents Installed IP54
KiloVault® HAB™ Ingress Rating - Solid Plates
Installed IP55
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. Certications
• Cell Certifications
o UL1642
o UL9540
o IEC62619
o UN38.3
• Complete Unit Certifications
o cETLus UL 1973
o UN DOT 38.3 (acceleration three times each side)
o 50 gn for 11 ms
o 150 gn for 6 ms
o IP54 – Vented plates installed
o IP55 – Solid plates installed
o OSHAS 18001 / ISO 45001
o ISO 9001 / 14000
JUNE 2022 / Rev: 1.0
2022 13

This manual is for use by qualied personnel only
4. Installation
Warning:
This is a hazardous situation which, if not avoided, could result in serious injury
or death.
Warning:
Do not place or install near flammable or explosive materials.
Warning:
Install the KiloVault® HAB™ out of the reach of children and animals.
Warning:
The KiloVault® HAB™ 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™ before carrying out maintenance or repair.
Attention:
Read this instruction manual before installing and operating the KiloVault®
HAB™.
JUNE 2022 / Rev: 1.0 14

This manual is for use by qualied personnel only
Note:
• Prior to installing your HAB™, please take pictures of the label on the left
side, including the serial number, serial number barcode, QR code, and
MAC address. Store this information for your records, it is valuable and
may be necessary for system configuration or troubleshooting. Depending
on your HAB™ 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 HAB™ with the handles.
4.1 Installation Flowchart
The following owchart provides an overview of the installation process.
JUNE 2022 / Rev: 1.0
2022 15

This manual is for use by qualied personnel only
The HAB™ weighs 230 lb. (105 kg); wear appropriate protective equipment, such as gloves and
protective footwear, when handling this unit.
Keep the HAB™ 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.
Do not attempt to lift or move the battery without sufficient equipment and human resources. Lifting
equipment that is capable of securing the battery from tipping while moving and positioning is high-
ly recommended.
There are built-in handles o the sides of the HAB to assist when lifting. The built-in side handle are
designed to help lift the battery once up-righted but are of only partially helpful while the battery is
still laying on it’s back. At least 2 to 3 people are necessary to lift and upright the battery from its
crate. The use of heavy gloves is highly recommended.
Retain all packaging material for the duration of your warranty period.
4.2.1. Package Contents
The standard HAB™ packaging includes the battery unit, mounting brackets and screws, commu-
nications cables, and built-in lift handles.
Figure 4: Standard KiloVault® HAB™ Packaging
4.2. Unpacking the KiloVault® HAB™
JUNE 2022 / Rev: 1.0 16

This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0
2022 17

Part Quantity
59 in (1.5 m) HAB™ HAB™ CAN Bus cable. 1 each
59 in (1.5 m) RJ45 HAB™ 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 2 each
PG42 (2.1 in, 28mm) Strain Relief 1 each
Optional Vented Side 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 in-
cluded 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™ batteries are being used)
• Level
• Pencil or marker
This manual is for use by qualied personnel only
JUNE 2022 / Rev: 1.0 18