KICKASS Lithium LiFePO4 Power Station User Manual

Lithium LiFePO4 Power Station
User Manual PATENT PENDING © 2022, KickAss Products Pty Ltd. All rights reserved.

Congratulations On Purchasing Your New KickAss LiFePO4 L1 Power Station

Why KickAss?
What makes KickAss different is the fact that we offer the complete solution: KickAss Lithium Power Station, Solar Panels, Portable Fridges, AC Chargers, and everything you need to get your off-grid camping needs solved in one place.

Designed by the KickAss Team
The KickAss Lithium Power Station has been designed in-house by the KickAss Team and has taken over 4 years of hard work and dedication to complete. We listened to our customers over many years to make a feature-rich and practical portable power station.

IMPORTANT SAFETY INSTRUCTIONS

• For charging 12V KickAss 120Ah LiFePO4 batteries.
• The total current draw from the battery must not exceed 100 Amps. Should the current draw exceeds 100 Amps, the internal BMS will shut down
• Never attempt to recharge non-rechargeable batteries.
• The lid of the battery box must remain shut at all times whilst charging a battery or powering a device from an outlet.
• Do not allow any metal objects to fall into the battery box or enter any of the ports.
• Never insert anything other than a compatible electrical plug into any of the ports on the battery box.
• Ensure that the battery box is shut and the screws are tight before powering any devices.
• Do not try to jumpstart a vehicle with this battery box.

OVERVIEW

GETTING STARTED

Step 1: Peel off plastic film to expose the non-slip surface of silicone pads.

Note: the pads may be washed to regain stickiness.
Step 2: Lower your battery into the battery box base carefully, locating it as centrally as possible on the non-slip pads.

Step 3: Secure the battery in place by tightening the velcro strap over the battery.

Step 4: Install the battery cables onto the terminal posts of the battery. Ensure the red cable is connected to the positive (+) terminal, both black cables are connected to the negative (-)  terminal and the black data connector on the lid is connected to the data connector on the battery

Step 5: Tuck cables in under the battery box lid, lowering the lid carefully onto the box – ensuring the lid is correctly oriented.

Step 6: Install the 4 provided screws to fasten the lid to the base, being sure not to over-tighten with the supplied Allen key.

Step 7 ATTENTION: Ensure Lithium is selected as the battery type. If it is not, select Lithium as the battery type on the DCDC charger by holding the MODE button for 5 seconds or until the battery light starts flashing. Then select LITHIUM and wait for the battery light to stop flashing. When this occurs, your selection is saved.

BATTERY

Features

• 120Ah Lithium Iron Phosphate (LiFePO4) battery
• 100A Internal Battery Management System (BMS)
• BMS supervised Lithium Battery Protection and alarms
• Bluetooth compatibility with the KA app (Android and iOS)
• LCD screen unit connection to BMS
• Approximately 2000 Cycles at 1C discharge, and up to 4000 cycles at lower discharge rates.
• Low self-discharge and long shelf life

Note: The total current draw from the battery must not exceed 100 Amps. Exceeding 100A will trigger the BMS over the current protection feature.

BMS Protection Features

• Battery over and under-voltage protection
• Battery over and under temperature protection
• Battery over charge and discharge protection
• Battery short circuit protection

Applications

• Solar System
• Telecommunications
• 4WD Dual Battery Systems
• Caravan, Motorhome Systems
• Emergency Power System

Charge: 0 – 45°C
Self Discharge| <3% of capacity declined per month at 25°C

OPTIONAL ACCESSORIES

MOUNTING TRAY (OPTIONAL)
Step 1:
Confirm install location of the tray, drilling any required holes.

Install the strap under the tray, sliding the strap into the slots on either side.
Ensure the strap is oriented correctly so that the hooks face toward the Power Station when installed.
Securely affix the tray in position using bolts or screws, whichever is applicable.
Ensure that washers are used when installing the tray, to avoid damage.
Note: We do not provide the screws or bolts for this installation.

Step 2: Ensure straps are laying outside the tray before lowering the battery box carefully onto the tray. Attach each strap hook to the corresponding slot in the Power Station.

Step 3: For ease of tightening, place thumbs in each strap loop, pushing firmly downwards. The strap should tighten and hold the Power Station firmly in place. To release,  depress the buckle and pull the strap to loosen.

Inverter Cables (Optional)
KickAss Inverter leads have been designed to allow you to easily connect a high-powered inverter to the battery box. When it comes to Inverter cables, there is no substitute for quality and these KickAss Inverter Cables have been designed to work flawlessly and to provide a high current flow to your inverter.
Note:

• The internal BMS will not allow more than 100 amps to be drawn from the battery, do not exceed a 1200W inverter load.

SWITCHES

The Master Switch
The master switch disconnects everything (except for the large 175 amp Anderson style plug and the LCD screen) from the battery, including the DCDC Charger. Turning it off is a quick way to disconnect all devices to ensure your battery is not being drained. Note: The DCDC Charger + Solar Regulator cannot charge the internal battery while the Master Switch is in the OFF position, and neither can an externally connected charger.
Note: Only turn this switch off when placing the battery in storage and not attempting to charge.

LCD SCREEN

The KickAss Lithium Battery Box Monitor has a display and two buttons. The screen is used to monitor the state and condition of the battery. The display features the following:

• Battery State of Charge (SoC).
• Instantaneous Current Flow, positive when charging, negative when discharging
• Battery pack voltage and individual cell voltages
• Battery Temperature
• Remaining time to full/empty at the current rate of charge/discharge
• Total Capacity of Battery
• A number of full cycles the battery has completed. A full cycle is defined by 100% discharge and re-charge of a battery. Depleting a battery to 50% and recharging it twice will result in 1 cycle.
• Mutable Low Battery Alarm
• Battery Capacity Condition State (Excellent, Good, Fair, Bad)
• Battery Protection Alarms

Turning the screen on/off
The screen can be turned on/off by clicking Button B. To save power, the screen will turn off automatically after prolonged inactivity. To set the duration of the screen “On”  time before turning off, hold Button B for five seconds until the Screen time menu appears. Navigate through the menu using the buttons. To confirm selection, wait 5 seconds for the home screen to return.

Switching between Displays
The display can be switched between Page 1 and Page 2 by clicking Button A.

Low Battery Alarm & Muting Feature
A low battery alarm will sound when the battery’s state of charge falls below 10%. To mute the alarm, press and hold button A for 5 seconds or until the muted symbol is displayed on page 1 of the display. The alarm will stay muted for 8hrs or until the battery is charged sufficiently.

KickAss LITHIUM APP

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Connecting to the App
To get started please download the KA Outback Proof Gear app from the Google Play store or the Apple iTunes Store. If the app is already downloaded on your device for use with your KickAss Bluetooth fridge, you must ensure that any updates to the app are installed prior to connecting. Once the APP is installed, locate your battery’s serial number on the side of your battery. On the KA Outback Proof Gear app, find the device ID that corresponds to the first 10 digits and the last 4 digits of the battery’s serial number and click connect the device.

Rename Device ID
To rename your Bluetooth device, connect to the device and then navigate to the fourth tab on the bottom toolbar. Click the pencil icon next to the connected device, edit the name and then click Save.

https://play.google.com/store/apps/details?id=app.com.kickass&hl=en
https://apps.apple.com/au/app/ka-fridge/id1387751159

Note: Editing your device’s name, will only edit it on your device. It will not change the name of the battery for other people who try to connect to it.

KickAss LITHIUM BMS ALARM MODES

CONNECTIONS

OUTPUTS
2 X CIGARETTE SOCKET OUTPUTS

• Maximum 10A output per socket
  

2 X DUAL USB / QC3.0 OUTPUTS

• 2 x 2.4A High Powered USB (White)
• 2 x Quick Charge QC 3.0 Ultra High Powered USB Outputs (5V/3.1A, 9V/2A, 12V/1.5A – Blue)
  

Benefits of Quick Charge
When paired with compatible devices, a Quick Charge-enabled charger delivers more power, allowing the connected device to charge faster. As one of the most widely used fast charging technologies, Quick Charge is already in many of your favorite smartphones. If your smartphone is Quick Charge 3.0compatible, you can charge up to 80% in just 35 minutes.
To future-proof your chargers, each new Quick Charge generation is backward compatible, meaning it will work with the generations that came before.

INPUTS/OUTPUTS
6 X (50A) ANDERSON STYLE PLUGS

• Input / Output Capable.
• All Anderson Plugs combined must not exceed 50A total current.

WARNING:

1. Do not plug in multiple chargers as inputs.
2. Do not use an external charger while the DCDC Charger is operating.
3. Exceeding the 50A combined current rating will trigger the safety breaker. The safety breaker will auto-reset in time.

NOTE: THE 6 ANDERSON PLUGS INDICATED CAN NOT EXCEED A TOTAL OF 50 AMPS COMBINED.

1 X (175A) ANDERSON STYLE PLUG

• High Current Inverter Output
• Connected directly to the battery

WARNING:

1. Combined battery box current output must not exceed 100A.
2. A master switch does not disconnect the battery from this connector.
3. KickAss Lithium batteries should not be used for jump-starting a vehicle’s battery.

INPUTS
ALTERNATOR
1 X TRIPLE ANDERSON STYLE PLUG

• 9-32V DC Starter Battery Input (+/-)
• Ignition source connection

MPPT SOLAR
1 X (50A) ANDERSON STYLE PLUG

• Minimum Solar Input Voltage: 9V DC
• Maximum Solar Input Voltage: 23V DC
• Maximum Solar Input Current: 25A

Unregulated Solar Input – utilizes in-built DCDC MPPT regulator.
Not suitable for regulated solar input, connect to a standard in/out connector when using an external or panel-mounted solar controller/regulator.
WARNING:

1. Do not exceed the Maximum Voltage of 23V DC
2. Do not exceed the Maximum Input Current of 25A
   

CONNECTING TO EXTERNAL CHARGERS

The KickAss Lithium Power Station may be charged in a number of ways:

• Connecting alternator power to inbuilt DCDC Charger in a vehicle.
• Connecting an unregulated solar panel input to a dedicated solar input connector on the back of the DCDC Charger (fig 1.2).
• Connecting a solar panel with lithium compatible regulator/controller to any of the in/out Anderson style connectors (fig 1.1).
• Connecting an external 240V Lithium Compatible charger to any of the in/out Anderson Style Connectors (fig 1.1).

Warning:

• Do not connect an external charger that is not lithium compatible
• Do not connect multiple external chargers.
• Do not connect an external 240V Mains Powered charger or similar while the DCDC Charger is operating.
• Do not connect an unregulated solar panel directly to the battery via any of the in/out connectors.
• Do not connect a solar panel with a regulator/controller to the unregulated solar connector.

CONNECTING DCDC CHARGER

The KickAss Lithium Power Station includes a built-in DCDC Charger suitable for charging from a vehicle alternator.
The easiest way to connect the Power Station to your vehicle is by using the KickAss Plug & Play Wiring Kit (sold separately).
The triple Anderson style connector fitted to the Power Station interfaces with the KickAss Plug & Play Wiring Kit, providing a simple, quick-release vehicle charging solution.  This triple connector and cable provide alternator power to the DCDC on the Power Station, along with an Ignition Source for charging in vehicles that are fitted with a Smart or Temperature Compensating Alternator.
For more information on installing a Dual Battery Wiring Kit and Ignition Wire, please visit KickAssproducts.com.au/support

TYPICAL DIAGRAMS

DCDC CHARGER GUIDE

UNDERSTANDING SOLAR, ALTERNATOR & CHARGING LIGHTS

• The alternator has priority over solar therefore if both solar and alternator are connected, only the alternator LED is solid and the alternator is charging.
• The 30-sec delay between cut-in voltage being reached and charging beginning & a 60-second delay before disconnecting when under cut-out voltage

ALTERNATOR LED BATTERY STATUS

Alternator voltage 12V

| Alternator voltage 24V| Alternator LED|

Status

---|---|---|---
0-8.9 Volts| 12-17.9 Volts| OFF| Under operating voltage
9-12.6 Volts| 18-25.2 Volts| Flash 1 sec on 5 sec off| Under cut-out voltage
12.7-13.1 Volts| 25.3-26.3 Volts| Flash 1 sec on 1 sec off| Under cut-in voltage
13.2 Volts| 26.4 Volts| Solid on| Cut-in voltage reached, charging will start after a 30-second delay

ALTERNATOR LED BATTERY STATUS WITH IGNITION WIRE CONNECTED

Alternator voltage 12V| Alternator voltage 24V| Alternator LED| Status
---|---|---|---
0-8.9 Volts| 12-17.9 Volts| OFF| Under operating voltage
9-11.6 Volts| 18-23.2 Volts| Flash 1 sec on 5 sec off| Under cut-out voltage
11.7-12.1 Volts| 23.3-24.3 Volts| Flash 1 sec on 1 sec off| Under cut-in voltage
12.2 Volts| 24.4 Volts| Solid on| Cut-in voltage reached, charging will start after 30 second delay

SOLAR LED STATUS

after 10 sec
delay (please note alternator has priority over solar)
23V +| Solar LED is Off
Stage 1 & 3 LED Fault Code Indication| Solar Input Voltage Exceeded

BATTERY TYPE
The KickAss 25A DCDC charger is capable of charging other Battery Chemistries. The charger must be initially set to Lithium and will remain as such once selected. In an emergency situation another battery type could be used in the battery box, however, make sure the correct battery type is selected
To set the battery type, press and hold the mode button for 5 seconds or until the battery light starts flashing. Then select from either GEL, AGM, WET, CALCIUM, or LITHIUM and wait for the battery light to stop flashing. When this occurs, your selection is saved.

Current Until 15.4V
ABSORPTION| Constant 14.4V Until 3.8A| Constant 14.1V Until 3.8A| Constant 14.4V Until 3.8A| Constant 15.4V Until 3.8A
FLOAT| 13.7V at 100% Current Max
PULSE| Begins after a continuous float stage of 10 days and pulses power through the battery using the same current and voltage as the absorption stage to maintain charge and sulfate. During this time, if the voltage of the auxiliary battery drops below 12.6V, the charger will restart the charge cycle at Bulk. Once the pulse is completed, the charger reverts to the float stage.

NOTE: When in the float stage, the battery is fully charged. At the float stage, when battery voltage drops to 12.7V, the charger will restart charging from the BULK stage.

Lithium BMS Sleep Mode & Recovery Feature:
KickAss Lithium Batteries are built with a Battery Management System (BMS) inside to protect the battery from overcharging, over-discharging, and extreme temperature changes.
One of the key functions of the BMS is to protect your battery by internally disconnecting the load¹ when the State of Charge drops below specific parameters, this will then result in the battery entering into a “sleep” mode.
¹ (Load includes any accessories and/or device/s drawing charge from the battery. Eg: fridges, pumps, food sealers, inverters, etc).
The KickAss DCDC MPPT Solar Battery Charger has a lithium battery recovery function. This function has been designed to recover lithium batteries from a sleep mode.
Lithium Battery Sleep Mode Indication:
When the lithium battery has entered sleep mode, the charger will show fault codes of the output open circuit, until all loads¹ are disconnected and a sufficient charge source is connected.

How to Wake a Lithium Battery to Begin Recovery Mode:
First, disconnect any load connected to the lithium battery.
Secondly, connect Alternator Input or Solar Input² to the KickAss DCDC MPPT Solar Battery Charger.
The Charger will have all battery types (GEL, AGM, WET CALCIUM, LITHIUM) flashing, and the BULK and PULSE LED lights will remain on for 30 seconds (Indicated in the diagram above,) before entering Recovery Mode.
²(Alternator and Solar inputs must be above cut-in voltage for DCDC Charger)

Recovery Mode Indicator:
When the lithium battery has entered recovery mode, the KickAss DCDC MPPT Solar Battery Charger display will have the source indicator illuminated (eg; SOLAR) and the battery type LITHIUM will be flashing. See the diagram below.

When the battery voltage has been recovered, the DCDC charger will automatically change to normal stage charging programs and loads may be reconnected.

FAULT CODES
If all battery type selection lights are flashing simultaneously please see the troubleshooting guide below.

There are error codes that may be displayed. These will be displayed in the following way:

Stage LED| S1
LED| S2
LED| S3
LED| S4
LED| Cause| Remedy
---|---|---|---|---|---|---
Solar input high voltage| | | | | Over voltage is detected at solar input| Check solar panel open circuit voltage
Solar input reverse| | | | | Solar input is reversely connected| Check solar input connection
Alternator high voltage| | | | | Overvoltage is detected at alternator input| Check vehicle battery voltage
Alternator input reverse| | | | | Alternator input is reversely connected| Check alternator input connection
Output fault mode| | | | | Output battery is reversely connected| Check output cable connection
Overvoltage is detected at the output| Check auxiliary battery voltage
Output open circuit or dead battery| Check auxiliary battery voltage & cable connections

TECHNICAL SPECIFICATIONS

BATTERY BOX INFORMATION

Material| ABS
Temperature Range| -10ºC – +60ºC
BATTERY INFORMATION
Battery Dimensions:| 329mm L x 171mm W x 222mm H
Battery Weight:| 14.3Kg
Battery Chemistry:| Lithium LiFePO4
Battery Nominal Voltage:| 12.8V
Battery Capacity:| 120Ah
Operating Temperatures| Discharge: -20 – 60°C
Storage: -20 – 45°C
Charge: 0 – 45°C
PORTS (INPUT/OUTPUT)
6 x (50A) Anderson Style Plugs| 1 x (175A) Anderson Style Plug
 Input / Output Capable
Maximum Combined 50A Current Rating
WARNING:
1. Do not plug in multiple chargers as inputs
2. Do not use an external charger while the DC-DC
Charger is operating
3. Exceeding 50A combined current rating will
trigger the safety breaker|  High Current Inverter Output
WARNING:
1.  Output must not exceed 100A
2.  Master switch does not disconnect the battery
from this connector.
3. KickAss Lithium batteries should not be used
for jump-starting.
2 x Cigarette Socket Outputs|  Maximum 10A output per socket
2 x Dual USB / QC 3.0 Outputs|  2 x 2.4A Standard USB Output
2 x QC 3.0 Output (5V/3.1A,  9V/2A, 12V1.5A)
ALTERNATOR INPUT
1 x Triple Anderson Style Plug|  9-32V DC Starter Battery Input (+/-)
Ignition Override Input (I)
SOLAR INPUT
1 x (50A) Anderson Style Plug| Minimum Solar Input Voltage: 9V DC
Maximum Solar Input Voltage: 23V DC
Maximum Solar Input Current: 25A
WARNING:
1. Do not exceed the Maximum Voltage of 23V DC
2. Do not exceed the Maximum Input Current of 25A

FREQUENTLY ASKED QUESTIONS

Q. If storing my KickAss Lithium Power Station for long periods, what should I do to look after my battery’s health?
A lithium battery can be stored at any state of charge due to a very low rate of discharge. It is recommended that if storing for long periods, the battery be charged to approximately 70% before switching off the Master Switch and storing.
NOTE: The battery will not go into storage mode if:

• There are loads connected to it.
• It is being charged
• It is communicating with the LCD
• It is communicating to App.

Q. Is my KickAss Lithium Power Station Water Proof
The KickAss Lithium Power Station has been designed to be as resistant to moisture and dust as possible,
though it is not waterproof. Do not leave exposed to rain or weather, and do not submerse. For more information visit us at kickassproducts.com.au/support.

Q. Can I Jump Start with my KickAss Lithium Power Station
The KickAss Lithium Battery has been designed with a battery management system (BMS) to protect your lithium battery. Should more then 100A be drawn from your battery,  the BMS will alarm and shut down the load to protect your battery. Jump starting will often require more than 100A draw from your battery so it is not recommended to jump start with the Lithium Battery Box.
The information in this document is subject to change without prior notice.

THANK YOU FOR CHOOSING

LITHIUM
LiFePO4 POWER STATION

YOUR COMPLETE
12-VOLT POWER
SOLUTION

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