KiloVault HAB Sol-Ark 12K UL9540 Installation Manual Download

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INSTALLATION &

INTEGRATION
GUIDE

KiloVault®

HAB™ - Sol-Ark 12K UL9540 Base Kit

JUNE 2022 / Rev: 1.0

Summary of Contents for HAB Sol-Ark 12K UL9540

Page 1: ...INSTALLATION INTEGRATION GUIDE KiloVault HAB Sol Ark 12K UL9540 Base Kit JUNE 2022 Rev 1 0 ...

Page 2: ...oVault 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...

Page 3: ...t 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 Simplified Wiring Diagram 27 4 6 5 Multiple Inverter Simplified Wiring Diagram 28 4 6 6 Optional Battery Combiner Box and Bus Bar 28 4 6 7 Setting the KiloVault HAB Address 29 ...

Page 4: ...s Direct Current JUNE 2022 Rev 1 0 5 4 Starting the KiloVault HAB for the first 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 44 6 4 1 Resetting the KiloVault HAB 44 7 1 TroubleShooting 44 8 1 S...

Page 5: ... 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 clarifies or simplifies a procedure WARNINIG The KiloVault HAB or Sol Ark inverter are not intended for use in connection with li...

Page 6: ...nd 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 ...

Page 7: ... 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 Warn...

Page 8: ...s 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 sti...

Page 9: ...uids and electrical appliances 1 3 4 Qualified 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 sa...

Page 10: ...loVault 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 ...

Page 11: ...rical Specifications 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 Specification Battery Type LiFePO4 Internal Resistance 15mΩ JUNE 2022 Rev 1 0 2022 9 ...

Page 12: ...cation protocol CAN Bus HAB to Inverter communication protocol Modbus Can bus 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...

Page 13: ...f no activity Item Specification 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 ma...

Page 14: ...tem Specification 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 ...

Page 15: ...Torque 15 Nm 11 06 ft lb 132 76 in lb Large power ports PG42 Approx 2 1 in 55mm Small communication ports PG21 Approx 1 1 in 28mm 3 4 Certifications Cell Certifications 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...

Page 16: ...h 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 inst...

Page 17: ...nd 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 flowchart provid...

Page 18: ...ning 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 al...

Page 19: ...This manual is for use by qualified personnel only JUNE 2022 Rev 1 0 2022 17 ...

Page 20: ...ses 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 si...

Page 21: ... flammable or explosive items Keep out of the reach of children and animals Do not install near a transformer or any other strong electromagnetic field Strong electro magnetic fields can disrupt the HAB communication system Choose a wall capable of supporting the full weight of the HAB over 300 lb with one or more of the following characteristics wood studs at regular intervals plywood sheeting at...

Page 22: ...This manual is for use by qualified personnel only 4 5 Install the HAB Wall Mounting Plate The HAB comes with the single mounting plate option JUNE 2022 Rev 1 0 20 ...

Page 23: ...mark your pilot holes on the mounting surface Choose holes so that you can mount the plate using at least four of the widely spaced holes Use a level to ensure that the plate is level Refer to Section 4 5 1 Mounting Surface for information regarding mounting surface requirements JUNE 2022 Rev 1 0 2022 21 ...

Page 24: ...the weight must be attached to the wall prior to installing 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 included M8 30 expansion screws into the wall Attach the...

Page 25: ...se them remove the plugs from the relevant access ports and replace them with the included strain reliefs The large strain relief will accept up to 2 0 wire 4 6 Connecting the HAB to Your Inverter NOTE Note When making the connections be sure to observe correct hard ware stacking and proper polarity and ensure that nothing obstructs the connection between the terminal surface and the battery cable...

Page 26: ...loVault HAB is provided with ground terminals that must be reliably connected to ground protective earth by appropriately sized equipment grounding conductors System grounding for the AC and DC systems must be done according to all applicable NEC and local installation codes To connect the HAB to the DC grounding system use the ground lug at the bottom of the chassis see Figure below The terminal ...

Page 27: ...supported inverters 4 Connect the power cables from the HAB to the inverter or to the DC bus if installing to multiple units making sure to use overcurrent protection as required Torque the battery cable terminals to 15Nm 11 ft lb or 132 in lbs Note Only 1 0 or 2 0 battery cables are permitted 5 Close switch to On the Inverter main DC Breaker 6 Close switch to On the battery breaker on the side of...

Page 28: ...g more than one HAB power off the other units one by one by pressing each unit s power button 2 Set the disconnect switch on the side of the HAB to the OFF position 3 Disconnect all communication cables as applicable 4 Disconnect the DC power cables from the HAB to the inverter or to the DC bus as appli cable making sure to use overcurrent protection as required 4 6 3 RJ45 120 Ω Resistor Plug Resi...

Page 29: ...pecific system and may not include all the safety equipment required by regional authority This is purely a graphical representation It is extremely important to make all conductors to each battery the same length to help ensure they contribute balanced current JUNE 2022 Rev 1 0 120 Ω ResistorPlug 120 Ω ResistorPlug 120 Ω ResistorPlug 2022 27 ...

Page 30: ... L1 N in the previous diagram refer to the wires in a standard 3 phase system Different inverters may have different wiring 4 6 6 Optional Battery Combiner Box and Bus Bar When using a battery combiner box and bus bar it is still critical to get all circuits to each battery the same length to help ensure they contribute equal current to the total current The following figure shows a typical instal...

Page 31: ...han one HAB and connecting them with the communication cable the Leader address must be on off off off Module Number DIP Switch Settings Switch 1 Switch 2 Switch 3 Switch 4 Leader Singles KIloVault HAB OFF OFF OFF OFF Leader Multiple KIloVault HAB ON OFF OFF OFF 1st OFF ON OFF OFF 2nd ON ON OFF OFF 3rd OFF OFF ON OFF 4th ON OFF ON OFF 5th OFF ON ON OFF 6th ON ON ON OFF 7th OFF OFF OFF ON 8th ON OF...

Page 32: ...The provided battery to inverter Modbus communication is a custom RJ485 non standard Warning Do not plug the HAB to Inverter Modbus cable into the CAN Bus port Do not plug the HAB to HAB CAN bus cable into the Modbus port CAN Bus Pin Number CAN Bus Definition 1 NC 2 NC 3 CANL 4 CANL 5 CANH 6 CANH 7 NC 8 NC This manual is for use by qualified personnel only JUNE 2022 Rev 1 0 30 ...

Page 33: ...6 NC 7 BMS debug RS485A 8 BMS debug RS485B 5 Operation Maintenance Monitoring 5 1 HAB Control Panel The KiloVault HAB control panel displays a variety of useful information regarding the operation of your system This manual is for use by qualified personnel only JUNE 2022 Rev 1 0 2022 31 ...

Page 34: ...h a local connection Flashing The status can be checked only through the unit s Wi Fi hotspot using the mobile application On Steady Normal Wi Fi status Number of semi circles 1 to 3 indicates the Wi Fi signal strength Alarm or Warning Indicators The HAB will light these indicators when a warning or alarm condition occurs HV Battery High Voltage LV Battery Low Voltage HT Battery High Temperature L...

Page 35: ...oltage rises above 49 6 V 5 V o If a high voltage alarm occurs you can ignore it You will still be below the high voltage protection Note If this does occur the alarm will not clear until the voltage falls below 54 4 0 5 V The HAB unit s SoC and capacity should now be calibrated 5 3 Charging Settings Your battery charger solar inverter or AC should be set to stop charging at a maximum voltage and ...

Page 36: ... Equipment LBCO Low Battery Cut Out 48 2 V 48V for Sol Ark Equipment LBCO Delay 3 seconds LBCO Hysteresis 2 V Max Bulk Current Set to whatever percentage of the inverter current plus the charge controller current is less than or equal to 100 A Absolute Maximum Charge Rate 120A per HAB in Parallel Solar Charge Controller Amps Percentage of Inverter Charger Max DC Output Example For a single HAB sys...

Page 37: ...ate 1C Recharge Rebulk Volts Set to start charging from solar before charging by AC just above the inverter charger s recharge rebulk voltage of 51 4 V Battery Monitor Midpoint Sensor If you are using a battery monitor with midpoint sensors secure the midpoint sensor leads out of the way and electrically isolate the midpoint sensors with electrical tape shrink wrap or any other appropriate method ...

Page 38: ...n Figure 20 KiloVault HAB iT Basic Screen Slider Switch The status should change to No charge or discharge Figure 20 HAB iT Basic Screen Slider Switch KiloVault HAB firmware updates take about 10 minutes Firmware updates are usually timed to take place during the evening in North America Depending on what part of the BMS is being updated either the red ALARM LED will flash by itself or the red ALA...

Page 39: ...ess the HAB unit s power button the control panel will again light for 1 minutes If there is an alarm condition the RED Alarm LED will light plus one or more of the alarm or pro tection state indicators at the right of the control panel will light Please see the BMS Alarm and Protection table for details To turn off the HAB press the power button for three seconds The run LED will flash five times...

Page 40: ...l solid waste recycling agency for recycling instructions Do not dispose of this equipment with household waste 6 Troubleshooting 6 1 BMS Protection Alarm Conditions Alarm events cause the ALARM LED on the front panel to flash Protection events cause the ALARM LED to flash and will cause the HAB to shut down for the indicated time period HAB Power Button Amount of Time Number of Times Pressed Resu...

Page 41: ...or 1s Low Displayed Capacity Alarm 10 of Capacity or lower Low Voltage alarm for each cell 3 00 0 03 V Low Voltage protection for each cell 2 70 0 03 V Delay time 1s Low Voltage release for each cell 3 10 0 03 V Low Voltage alarm for total voltage 48 0 V 0 5 V Low Voltage protection for total voltage 45 5V 0 5 V Delay time 1s Low Voltage release for total voltage 49 6 V 0 5 V Low Voltage release m...

Page 42: ...C Discharge High Temperature alarm 140 F 5 4 F 60 C 3 C Discharge High Temperature protection 149 F 5 4 F 65 C 3 C Discharge High Temperature release 131 F 5 4 F 55 C 3 C Charge Low Temperature Alarm 37 4 F 5 4 F 3 C 3 C Charge Low Temperature Protection 32 F 5 4 F 0 C 3 C Charge Low Temperature Release 41 F 5 4 F 5 C 3 C Discharge Low temperature alarm 5 F 5 4 F 15 C 3 C Discharge Low temperature...

Page 43: ...ises above the recover tem perature Charge or Discharge Over Current Reduce the charging or discharging current The battery will auto release in one minute Battery Short Circuit Check the external power connections of the battery Eliminate the short circuit Flashing State of Charge Bar The LCD control panel and or the State of Charge light bar have lost connection to the BMS Restart the battery us...

Page 44: ...o a unique address Restart the units using the front panel power switch If the problem persists you have the option of op erating your bank without interbattery communication You can do this by removing all of the communication cables port ter minators then set each units address to OFF OFF OFF OFF 0 0 0 0 Units are con nected in parallel Units are con nected in parallel and have similar voltages ...

Page 45: ...ns are lit High voltage units are discharging Low voltage units are not discharging Low voltage RUN LED flashing The low voltage unit has been re moved from parallel connection with the rest of the bank When the rest of the bank is dis charged to within 1 V of the low voltage unit it is added back into parallel connection Normal operation No action needed HABs connected in parallel HABs dischargin...

Page 46: ...for iOS and Android mobile devices can be down loaded from both the iOS and Android app stores There is not a desktop version of KiloVault HAB iT 7 3 Contact Us Email info kilovault com Phone 1 888 218 5924 KiloVault LLC 330 Codman Hill Road Boxborough MA 01719 6 5 Initial HAB Unboxed Voltage If your HAB has a low initial voltage when unboxed refer to the following information 6 5 1 Low HAB voltag...

Page 47: ...for any consequences arising out of the use of this material ForinformationaboutoperatingtheSol ArkHybridinverter seetheSOl Ark Owner sGuide 8 1 SOL ARK Installation This guide provides explanations and procedures for installing Sol Ark Hybrid Inverter Before in stalling the Sol Ark Hybrid inverter read all instructions and cautionary markings in this Guide For information about operating the Sola...

Page 48: ...HOCK EXPLOSION AND ARC FLASH Do Not Mount Outdoors Do Not Expose to Moisture System Must Have Ground System Must Have Neutral Solar PV PV Are Ungrounded Ground Must be Bonded to Neutral Once in Home Failure to follow these instructions can result in equipment damage 8 3 FCC Information to the User This equipment has been tested and found to comply with the limits for a Class B digital device pursu...

Page 49: ...x2 b Limiter Sensors if purchased 15 16 CT sensors x2 c Limiter Sensors if purchased 2 CT sensors x2 d Battery Temperature Sensor for voltage adjustment e Battery Cable Toroid x2 f CAT 5 cable for parallel communications g Allen Key for opening the user area of the system h French Cleat For wall mounting the Sol Ark 12K i WIFI Plug For software updates and remote monitoring use screws to hold in 8...

Page 50: ...e in rush current Failure to follow these instructions can result in equipment damage 9 Installation and Commissioning Protection Coordination Inrush Current NOTICE RISK OF BATTERY AND INVERTER DAMAGE Always follow the recommended start up sequence and minimum batter ies This is required to avoid excessive in rush current Failure to follow these instructions can result in equipment damage 9 1 Clea...

Page 51: ...lace a GFI breaker with a normal breaker installing GFI outlets instead or you can move GFI breaker into 10 circuit SW If applicable low load circuits can be combined b Important Make sure to keep within inverter amperage limits per inverter On Grid 50A continuous pass through Off Grid 33A continuous 83A peak c Verify each load circuit by measuring typical and max Amps with a clip on Amp meter Amp...

Page 52: ... in attic OR WARRANTY WILL BE VOID AND DAMAGE WILL LIKELY OCCUR c The system weighs 74lbs 34kg be sure to attach it securely to the wall You may need to affix a mounting board to your wall first using 6 8 screws into studs d Then use 2 3 screws appropriate in length and type for your mounting surface to mount the French Cleat to the board wall washers recommended e Mount the Sol Ark on the install...

Page 53: ...m installs i All systems in parallel are connected to the same battery bank with each system having its own battery cables to connect to the same large battery bank Do not use separate battery banks for parallel systems WARNING RISK OF FIRE ELECTRIC SHOCK EXPLOSION AND ARC FLASH Do NOT reverse polarity of batteries Damage will occur Failure to follow these instructions can result in equipment dama...

Page 54: ...ernate cable to modify 3 If providing your own RJ45 cable and routing alongside the battery power conductors it is best but not required to use a shielded cable Notes You will need to use the HAB iT app to set the HAB to the Sol Ark communication protocol Con nect your HAB to the HAB iT app and use it to connect your HAB to the internet to make sure it is updated to the most recent firmware 1 Foll...

Page 55: ... manual is for use by qualified personnel only 53 2022 JUNE 2022 Rev 1 0 Launch HAB iT select the leader battery from the list Goes to this page Press the circle with the three dots in the top right corner ...

Page 56: ...ailure to follow these instructions can result in death serious injury or equipment damage Connect communications cables to their components after AC and DC connections are made The HAB to Inverter cable shipped with the later V3 and V4 HABs has RJ485 connectors on both ends The ends are identical That brings you to this page Towards the bottom right side of the screen you can see inverter pro toc...

Page 57: ...0 Program the Inverter 1 Start by pressing the gear icon on the top right of the inverter screen and then pressing the battery setup menu or use the online interface 3 Program the Charge tab in Battery Setup menu 4 Program the Discharge Tab a Set float to 54 4V and absorb to 55V ...

Page 58: ... system but that will prevent that battery range to be used The correct shutdown level is specific to the project site b Low battery is an alarm also specific to the project site integrated with the Sol Ark monitoring app We suggest a 20 state of charge as a good low battery alarm level but it can be higher c The battery empty voltage should not be lower than 48V If increasing the reserve capacity...

Page 59: ...older Sol Ark inverter plug into the RJ45 485 or RS485 port To confirm BMS communication enable BMS Lithium Battery 05 in the Sol Ark battery setup menu That will enable a Lithium Battery Info screen under the main Sol Ark setup menu Click on the gear icon to reveal the Lithium Battery Info menu If the battery is communicating to the inverter a line of battery data will appear across line 2 of the...

Page 60: ...22 Rev 1 0 12 Sol Ark 12K Indoor The Sol Ark 12K can communicate through the RJ 45 ports labeled RS 485 and CAN The ports are shown below in detail alongside pin diagrams and detailed pin configura tions for each port ...

Page 61: ...ms PowerF actor Response Time Grid Tied toO Grid 0 9 1 0 Output Power9 000W Dimensions H xW x D 30 0 x 18 3 x 10 0 Weight 78 lbs Enclosure NEMA 3R AmbientT emperature 25 55 C 45 C Wall Mounted Wi Included 10 Years General Type Lead Acid or Li Ion 48V Nominal DCI nput Capacity5 0 9 900Ah Voltage Range4 3 0 6 3 0V 185A Charging Curve 3 96 0 External Temperature Sensor Included Integrated Current Shu...

Page 62: ...iloVault HAB Series Lithium Iron Phosphate LiFePO4 Deep Cycle Solar Batteries KiloVault LLC 330 Codman Hill Road Boxborough MA 01719 1 888 218 5924 info kilovault com www kilovault com JUNE 2022 Rev 1 0 ...

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