---
title: "Kakadu 120 — Installation and Operating Manual"
revision: "1.1.1"
publisher: AERL (Australian Energy Research Laboratories)
url: https://www.aerl.com.au/docs/kakadu-user-manual
pdf: https://www.aerl.com.au/documents/manuals/AERL_Kakadu_120V_User_Manual_REV_111.pdf
description: "Installation and operating manual for the Kakadu 120V 88.4kWh commercial battery cabinet, covering safety, installation, commissioning, operation and maintenance."
---

# Kakadu 120 — Installation and Operating Manual

*Rev 1.1.1. Markdown copy of the AERL document at https://www.aerl.com.au/docs/kakadu-user-manual; the PDF (https://www.aerl.com.au/documents/manuals/AERL_Kakadu_120V_User_Manual_REV_111.pdf) is the controlled version.*

# Kakadu 120

Installation and Operating Manual

**Kakadu-120-88.4** **Installation & Operation** V1.1.1, 8 November 2026

### Document

| | |
|---|---|
| Document | Installation and Operating Manual |
| Version | V1.1.1 |
| Released | 8 November 2026 |
| Product | Kakadu 120 · Kakadu-120-88.4 |
| Format | A4 · 30 pages |

> **Read first**
>
> Installation, termination and commissioning must be carried out only by a licensed electrical worker competent in battery energy storage systems, in accordance with AS/NZS 3000 and AS/NZS 5139.

## 01 Introduction

Kakadu 120 is a lithium iron phosphate battery energy storage system housed in an outdoor-rated cabinet. Each cabinet holds two independent battery strings, and up to 16 cabinets can be paralleled into a single system.

Kakadu 120 is named for its 120 V DC class battery voltage. A string consists of one BMS and four battery modules connected in series. Each module is nominally 35.2 V and 11.05 kWh, giving a string a nominal 140.8 V and 44.2 kWh. Each cabinet contains two strings, giving 88.4 kWh (nominal; usable energy at the 90% depth of discharge is 79.6 kWh). Up to 16 cabinets may be connected in parallel, for a maximum system energy of 1.41 MWh.

**88.4 kWh**Nominal per cabinet

**140.8 V**Nominal DC

**300 A**Continuous charge / discharge

**1.41 MWh**Maximum system energy

- Modules slide into the cabinet and connect with quick-connect cabling.
- The two strings in a cabinet operate independently, so the system keeps operating if one string faults.
- The Battery Information Collector (BIC) design makes communication more stable and reduces system stoppages caused by communication faults.

![Kakadu 120 cabinet with the door open, showing two strings of four battery modules above a BMS](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-cabinet-door-open.png)

**Figure 1.1** Kakadu 120 cabinet, door open. Each of the two strings comprises four battery modules above one BMS.

## 02 Glossary

Table 2.1 — Terms used in this manual

| Term | Full name |
|---|---|
| BESS | Battery Energy Storage System |
| BMS | Battery Management System |
| BIC | Battery Information Collector |
| SOC | State of Charge |
| SOH | State of Health |
| LFP | Lithium iron phosphate (LiFePO<sub>4</sub>) |
| Module | One 35.2 V / 11.05 kWh battery module |
| String | One BMS with four modules in series (140.8 V / 44.2 kWh) |
| Cabinet | The enclosure, containing two strings (88.4 kWh) |

## 03 Safety — Intended use, battery module leakage, fire, handling, storage

> **Danger — high voltage**
>
> Installation, termination and commissioning must be carried out only by a licensed electrical worker competent in battery energy storage systems, and must follow AS/NZS 3000 and AS/NZS 5139. Power cables and plugs carry high voltage from the battery at all times, including when the system is switched off.

Follow the safety requirements in this manual strictly when installing, commissioning, operating and maintaining the product. Incorrect operation or work may damage the product and other property, or cause injury or death to the operator or to third parties.

When fixing the product with screws or other fasteners, use the correct tool and tighten to the torque given in this manual or on the product label. Read this manual before installation to ensure the product is installed and used safely.

> **Warning**
>
> 1. Installers and users must familiarise themselves with this manual before starting work.
> 2. Power cables and plugs carry high voltage from the battery. Take care when wiring.
> 3. Ensure correct PPE is used when installing and maintaining the system.
> 4. Battery modules weigh 91 kg. Use a mechanical lifting aid (module trolley, hoist or lifter) to position modules in the cabinet.

### 3.1 Intended Use

- Kakadu 120 is designed to work with inverters rated for a 120 V DC class battery bank, in commercial and industrial (C&I) applications.
- Kakadu 120 is designed to work with the AERL Nexus Gateway as the system EMS (Energy Management System) and with CoolMax SRX 120 V charge controllers for optimum charging. The AERL Nexus platform also provides remote monitoring and firmware updates.
- The IP55 enclosure is rated for indoor or shaded outdoor installation — see section 5.1.
- Kakadu 120 is not suitable for powering life-sustaining medical equipment or mission-critical equipment. A UPS is recommended for those applications.

### 3.2 Battery Module Leakage

Stop using a damaged battery immediately and dispose of it in accordance with local regulations. Damage to the battery may release electrolyte, which can cause breathing difficulties, skin irritation and chemical burns. Consult the Safety Data Sheet for more information.

If you come into contact with battery electrolyte, immediately:

- **Eye contact —** rinse gently with running water for at least 15 minutes and seek medical help promptly.
- **Skin contact —** rinse under running water for more than 15 minutes, remove any contaminated clothing and seek medical attention.
- **Inhalation or ingestion —** leave the contaminated area and seek medical assistance.

### 3.3 Fire

> **Danger — battery fire**
>
> A battery fire may occur if the battery is exposed to flame, an excessive heat source or extreme temperatures. A burning battery may emit carbon monoxide, carbon dioxide and other toxic gases.
>
> **If a fire occurs, dial 000 (or your local emergency number).** Isolate the system if it is safe to do so, then move immediately to a safe location. Firefighters should wear full-face self-contained breathing apparatus (SCBA) and full protective gear, and use a dry chemical extinguisher to cool and extinguish the battery and prevent the fire from spreading.

### 3.4 Handling

- Take care during installation to avoid damaging the battery.
- If a battery is damaged before installation, contact AERL for advice before proceeding.
- Protect the battery from damage during transport and handling.

- DO NOT clean the battery with water or solvents, or allow foreign objects to enter it.
- DO NOT unplug any cable while the battery is operating.
- DO NOT use the battery together with batteries of other brands or types.
- DO NOT short-circuit the battery modules.
- DO NOT subject the battery to external forces, such as dragging it along the ground or placing heavy objects on it.

### 3.5 Storage

- Recharge stored modules at least every six months to prevent irreversible damage from deep discharge. Keep the long-term storage temperature as close as possible to 25 °C.
- For short-term storage, keep the ambient temperature between 0 °C and 35 °C.

- DO NOT store battery modules or BMS units outdoors, or anywhere exposed to direct sunlight, high humidity, heat or water.

## 04 Product Information — What is in the box, functional areas, specifications

### 4.1 What Is in the Box

Kakadu 120 ships as three separate consignments: the cabinet (with the accessories box packed inside), the BMS boxes and the battery boxes. Check all items against the list below before starting installation.

![The cabinet with the accessories box, plus the separately shipped BMS box and battery box](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-shipping-consignments.png)

**Figure 4.1** The cabinet ships with the accessories box. BMS units and battery modules are packed and shipped separately.

Accessories box contents

Table 4.1 — Accessories box checklist

| Item | Length | Qty |
|---|---|---|
| Battery-to-BMS Positive Series Power Cable | — | 2 |
| Battery-to-BMS Negative Series Power Cable | — | 2 |
| Battery Series Power Cable A | 250 mm | 4 |
| Battery Series Power Cable B | 280 mm | 2 |
| Battery Communication Cable A | 250 mm | 4 |
| Battery Communication Cable B | 400 mm | 2 |
| BMS Communication Cable | 280 mm | 2 |
| Terminating Resistor | — | 2 |
| Positive Connector | — | 2 |
| Negative Connector | — | 2 |
| Washer Bolt | — | 40 |

![Accessories box contents laid out: power cables, communication cables, terminating resistors, connectors and washer bolts](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-accessories-box.png)

**Figure 4.2** Accessories box contents.

> **Note**
>
> Communication cables and power cables **between** BMS units are not supplied. The connectors required to make them are in the accessories box — see steps 7 and 9.

- Use only the supplied cables and connectors.

### 4.2 Functional Areas

![BMS front panel with terminals and ports labelled A to K](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-bms-front-panel.png)

**Figure 4.3** BMS front panel.

Table 4.2 — BMS front panel

| Letter | Label | Function |
|---|---|---|
| A | P– | Power terminal, negative (to inverter) |
| B | P+ | Power terminal, positive (to inverter) |
| C | MCB | Main circuit breaker |
| D | ON/OFF | System startup / shutdown |
| E | HMI | Human machine interface |
| F | B– | Power terminal, negative (to battery) |
| G | BATTERY COMM | Communication to battery |
| H | INV | Communication to the AERL Nexus Gateway (inverter CAN) |
| I | OUT | Parallel out |
| J | IN | Parallel in |
| K | B+ | Power terminal, positive (to battery) |

![Battery module front panel with terminals and ports labelled A to D](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-module-front-panel.png)

**Figure 4.4** Battery module front panel.

Table 4.3 — Battery module front panel

| Letter | Label | Function |
|---|---|---|
| A | – | DC negative |
| B | + | DC positive |
| C | COM1 | Communication port |
| D | COM2 | Communication port |

### 4.3 Specifications

Table 4.4 — System specifications

| Kakadu 120 cabinet | Kakadu 120 cabinet |
|---|---|
| Part number | Kakadu-120-88.4 |
| Nominal voltage | 140.8 V DC |
| Operational voltage range | 112.2 V DC to 165 V DC |
| Capacity | 88.4 kWh / 628 Ah |
| Battery module arrangement | 2 strings / 4 modules per string |
| Depth of discharge | Up to 90% |
| Maximum continuous discharge current | 300 A @ 25 °C (150 A per string) |
| Peak discharge current (1 min) | 315 A |
| Maximum continuous charge current | 300 A @ 25 °C (150 A per string) |
| Integrated BMS circuit breaker | 2-pole, 250 A, 200 V DC |
| Lithium chemistry | LiFePO₄ / LFP |
| Cell construction | Prismatic |
| Operating temperature range | Charge −10 to 50 °C / discharge −20 to 50 °C |
| Operating humidity | Up to 95% non-condensing |
| BMS cell over-voltage protection | 3.65 V DC |
| BMS cell under-voltage protection | 2.55 V DC |
| BMS over-temperature cut-off | 56 °C |
| Prospective short-circuit current | 4500 A per string / 9000 A per cabinet |
| Altitude | < 2500 m |
| DC connectors | Quick connect for up to 50 mm² cable |
| IP rating | IP55 |
| Efficiency | > 96% |
| Cooling | Natural convection |
| Scalability | 16 cabinets in parallel |
| Series connection | Not permitted |
| Communications | CAN 2.0A |
| Weight | 970 kg |
| Dimensions (W × H × D) | 795 × 1900 × 1150 mm |
| Certifications — cell | UL 1973, UL 9540A, IEC 62619:2022, UN 38.3 |
| Warranty | 10 years — conditions apply, see chapter 11 |

> **Arc flash**
>
> Calculate the arc flash risk in accordance with AS/NZS 5139:2019 and follow its PPE requirements.

Table 4.5 — Battery module specifications

| Kakadu 35.2 battery module | Kakadu 35.2 battery module |
|---|---|
| Part number | Kakadu-35.2-11S |
| Dimensions (W × H × D) | 295 × 225 × 960 mm |
| Energy | 11.05 kWh |
| Nominal voltage | 35.2 V |
| Continuous current rating | 150 A |
| Battery interconnection | Quick connector with 21 mm² (4 AWG) UL cable |
| Communications | CAN 2.0A |
| IP rating | IP20 |
| Weight | 91 kg |
| Warranty | See chapter 11 |

> **Tech note**
>
> Kakadu 120 requires an AERL Nexus Gateway to manage the battery communications and ensure the correct charging profile is applied by the inverter.

## 05 Installation — Location, tools, placing the cabinet, installation steps, paralleling multiple cabinets

This section gives the requirements and the step-by-step procedure for installing Kakadu 120 safely. Take the installation procedure into account when designing the system.

### 5.1 Requirements for the Installation Location

The installation location must be suitable for safe operation and long-term use, in accordance with AS/NZS 5139 Section 6. Choose a location where the battery can be easily connected and serviced. AERL also recommends the following.

- Keep the battery at least **5 m** from any source of heat, such as fires, transformers and heaters, to avoid overheating.
- Ensure the environment is free of flammable and explosive materials.
- Battery life is maximised at an ambient temperature of 15–30 °C; the system operates from −10 to 50 °C (Table 4.4).
- Ensure the ground is flat and level.
- Keep the location away from sources of dust, corrosive gas and salt spray.
- Shade the cabinet from direct sun with an awning, a roof or its orientation. Direct sun raises the internal temperature and reduces charge and discharge capability.
- Ensure the location is well ventilated with good air circulation.
- Ensure the location is secure and away from children and animals.

### 5.2 Tools

Safety shoes

Insulated gloves

Goggles

Screwdriver

Drill

Torque wrench

Hydraulic crimping pliers

Wire cutter

Utility knife

Adjustable spanner

Spirit level

Module lifter / trolley

### 5.3 Placing the Cabinet

Installation space requirements

**Figure 5.1** Minimum clearances: 200 mm to a firewall, 200 mm between adjacent cabinets, and 1000 mm between rows for door swing and access.

> **Note**
>
> The figures above are the minimum clearances for the installed system. Allow additional temporary working space — approximately 750 mm — to manoeuvre the cabinet into position during installation.

Foundation requirements

> **Notice**
>
> The foundation drawing is for reference only and must not be used as the final construction drawing. Verify the foundation design parameters for the energy storage system against the installation environment, ground load-bearing capacity, geological conditions and seismic requirements of the project site.

1. The energy storage system must be installed on concrete or another non-combustible surface. The installation surface must be level, solid and even, with sufficient load-bearing capacity and no depressions or slope.
2. Design the foundation for the total weight of the equipment.
3. Compact and level the base of the excavation to prevent subsidence or tilting over time.
4. After excavation, protect the foundation from water infiltration and disturbance. If the soil is disturbed by water, excavate further and replace the soil.
5. The level deviation between the foundation surface and the cabinet contact surface must not exceed 3 mm.
6. Build the foundation above the highest recorded flood level for the site, and at least 300 mm above the surrounding ground level.
7. Construct drainage in accordance with local geological conditions and municipal drainage requirements, so that water cannot accumulate around the foundation. The foundation drainage must cope with the highest recorded rainfall for the site, and all discharged water must be treated in compliance with local laws and regulations.
8. Allow for the cable routing of the energy storage system when constructing the foundation, and reserve cable trenches or inlet holes accordingly.
9. Seal all reserved foundation holes and cable inlet openings at the bottom of the equipment.

![Foundation reference drawing: front elevation with 200 mm setbacks and a 300 mm plinth, and plan view with 200 mm setbacks](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-foundation-drawing.png)

**Figure 5.2** Foundation reference drawing — 200 mm setback on each side and a minimum 300 mm plinth above surrounding ground level.

### 5.4 Installation Steps

Each cabinet holds two strings. Carry out steps 1 to 8 for each string, then complete step 9.

> **Danger — battery terminals are always live**
>
> Battery module terminals are permanently energised. Do not insert anything into the quick-connect sockets. Use only the supplied cables and connectors.
>
> **Arc flash PPE:** wear PPE in accordance with AS/NZS 5139 Table 3.3.

1

Install the BMS, then the modules

Install the BMS in the bottom position first, then install all four battery modules above it.

![Two views of the cabinet: the BMS installed in the bottom position, then the four modules above it](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step1-bms-first.png)

**Figure 5.3** The BMS goes in first, at the bottom of the string.

2

Secure every BMS and module

Lock all BMS units and battery modules in place with the washer bolts supplied. **Tighten to 8 N·m.**

![Cabinet with all BMS units and modules bolted in, with the washer bolt and 8 N·m torque called out](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step2-washer-bolts.png)

**Figure 5.4** Washer bolt × 40, torque 8 N·m.

3

Connect the negative battery-to-BMS cable

Connect the **Battery-to-BMS Negative Series Power Cable** from the – port of the battery module at the bottom of the stack to B– on the BMS.

![Cabinet interior with the Battery-to-BMS Negative Series Power Cable connected between the bottom module and the BMS](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step3-negative-bms-cable.png)

**Figure 5.5** Battery-to-BMS Negative Series Power Cable.

4

Link the modules in series

Connect **Battery Series Power Cable A** and **Battery Series Power Cable B** between the battery modules.

> **Caution — polarity**
>
> Always connect the **black** connector to a – port and the **orange** connector to a + port.

> **Install tip**
>
> Battery Series Power Cable A (250 mm) and Battery Series Power Cable B (280 mm) are very similar lengths — double-check which one is which before you start. If your cable is short when connecting the left battery module to the right, you may have them the wrong way around.

![Cabinet interior with Battery Series Power Cable A between modules in each column and Battery Series Power Cable B across the top pair](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step4-series-cables.png)

**Figure 5.6** Battery Series Power Cable A (250 mm) between modules in a column; Battery Series Power Cable B (280 mm) across the top pair.

5

Connect the positive battery-to-BMS cable

Connect the **Battery-to-BMS Positive Series Power Cable** from the + port of the battery module at the bottom of the stack to B+ on the BMS.

![Cabinet interior with the Battery-to-BMS Positive Series Power Cable connected between the bottom module and the BMS](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step5-positive-bms-cable.png)

**Figure 5.7** Battery-to-BMS Positive Series Power Cable.

6

Wire the battery communication chain

The four modules of a string sit in a 2 × 2 grid above the BMS. The communication chain runs from the BMS to the bottom-left module, up to the top-left module, across to the top-right module and down to the bottom-right module, which is the last in the chain.

- Connect the **BMS Communication Cable** between BATTERY COMM on the BMS and COM2 on the bottom-left module.
- Use **Battery Communication Cable A** to connect COM1 on the bottom-left module to COM2 on the top-left module.
- Use **Battery Communication Cable B** (400 mm) to connect COM1 on the top-left module to COM1 on the top-right module.
- Use **Battery Communication Cable A** to connect COM2 on the top-right module to COM1 on the bottom-right module.

> **Install tip**
>
> Battery Communication Cable A (250 mm) and the BMS Communication Cable (280 mm) are similar lengths — make sure to identify which one is which before you start. If your cable is a little short when connecting the BMS to the bottom-left battery module, you may have them the wrong way around.

**Figure 5.8** Battery communication chain as installed — BMS to bottom-left, top-left, top-right, then bottom-right (last module).

7

Link the BMS units

The communication cables between BMS units are not supplied. Cut and crimp them to the length required on site.

The BMS whose INV port is connected to the AERL Nexus Gateway is the master, and its **Master Unit** LED must be lit; on every other BMS, press **Master Unit** so that its LED is off (section 6.3). The other BMS units follow the master through the IN / OUT chain. With the lower BMS as the master, connect OUT on the lower BMS to IN on the upper BMS. For multiple cabinets, continue the chain as described in section 5.5.

![Cabinet interior showing the communication link from OUT on the lower BMS to IN on the upper BMS](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step7-bms-link.png)

**Figure 5.9** BMS-to-BMS communication link, lower OUT to upper IN.

8

Fit the terminating resistors

Fit a **Terminating Resistor** to COM2 on the last module in the communication chain — the bottom-right module — of each of the two strings in the cabinet.

![Cabinet interior with the Terminating Resistor fitted to COM2 on the bottom-right module of each string](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step8-terminating-resistor.png)

**Figure 5.10** Terminating Resistor × 2 — one per string.

9

Make up the BMS parallel power cables

The parallel power cables between BMS units are not supplied; use the supplied connectors. Prepare and crimp the cables to the length required on site, using the **Positive Connector** and **Negative Connector**.

Use a conductor size of up to the **maximum of 50 mm²** that the connectors accept. Size the cable in accordance with AS/NZS 3000.

![Positive and Negative Connectors beside the cabinet, with the P+ and P– terminals on each BMS highlighted](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-step9-parallel-connectors.png)

**Figure 5.11** Positive Connector × 2 and Negative Connector × 2.

### 5.5 Paralleling Multiple Cabinets

Up to 16 cabinets may be connected in parallel. **Series connection is not permitted.**

1. Connect P+ and P– of every BMS to a DC combiner using the parallel power cables made up in step 9. Size the cables and the combiner for the total system current — see the *Kakadu Combiner Box Installation Guide* .
2. Continue the communication chain from cabinet to cabinet: connect OUT on the upper BMS of one cabinet to IN on the lower BMS of the next.
3. Connect the INV port of the first BMS in the chain to the AERL Nexus Gateway. This BMS is the master.
4. On the HMI, leave **Master Unit** lit on the master string only (section 6.3), and leave **Last Unit** lit on the final string in the chain only (section 6.4).
5. Confirm that every string's **Run** indicator is lit and that the inverter reports the combined system capacity before applying load.

![Two cabinets connected in parallel: power cables in red and black, BMS-to-BMS communication in dark blue, Nexus gateway communication in purple](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-parallel-cabinets.png)

**Figure 5.12** Parallel connection between two cabinets — power (red / black), BMS-to-BMS communication (dark blue) and communication to the Nexus Gateway (purple).

## 06 Human Machine Interface — SOC status, black start, Master Unit, Last Unit, alarm, run, module status indicators

The HMI presents real-time system data at a glance and provides direct control of black start and string identification.

It shows the running status and state of charge of the battery, and lets you trigger a black start, set the terminating string and identify individual strings in a paralleled system.

![Kakadu 120 HMI panel: SOC bars, Black Start, WiFi On, Master Unit and Last Unit buttons, Run and Alarm LEDs, and the module status grid](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-hmi-panel.jpg) 1 2 3 4 5 6

1

**SOC indicators**Five bars, each representing 20% of system energy.

2

**Black Start button**Starts the inverter from the battery in an off-grid system.

3

**Master Unit button**Identifies the master BMS and sets the terminating resistor for the Nexus Gateway link.

4

**Last Unit button**Identifies the last string in the system.

5

**BMS status**Run and Alarm indicators.

6

**Module status**One indicator per battery module.

**Figure 6.1** HMI layout.

### 6.1 SOC Status

The SOC indicator shows the current state of charge of the system. Each lit LED represents 20% of the battery's energy.

- While **discharging** , the last lit LED flashes once per second (1 Hz).
- While **charging** , the last lit LED flashes once every two seconds (0.5 Hz).

Table 6.1 — SOC indication

|  |  |
|---|---|
|  | 80% < SOC ≤ 100% |
|  | 60% < SOC ≤ 80% |
|  | 40% < SOC ≤ 60% |
|  | 20% < SOC ≤ 40% |
|  | 0% < SOC ≤ 20% |

### 6.2 Black Start

Black start is designed for off-grid systems. It lets Kakadu 120 supply energy to the inverter so the inverter can start the system.

In an off-grid system, power up the system and then press and hold **Black Start** for three seconds to activate it. Once the inverter starts working, black start terminates automatically and the LED goes out.

Black Start

Default

Black Start

Black start on

### 6.3 Master Unit

**Master Unit** identifies the master BMS — the string connected directly to the Nexus Gateway — and sets the terminating resistor. It should be on for the master BMS only.

All **Master Unit** LEDs are on initially. Press **Master Unit** on each string that is not the master and confirm that its LED goes out, leaving only the master string's LED on.

Master Unit

Default — on

Master Unit

Off

### 6.4 Last Unit

**Last Unit** confirms which string is last in the system and completes the communication circuit.

All **Last Unit** LEDs are solid on by default. To complete the communication circuit, make sure that **Last Unit** is on for the last string only. Press the button on each of the other strings and confirm that its LED goes out.

Last Unit

Default — on

Last Unit

Off

### 6.5 Alarm

When the system is working normally, **Alarm** stays off. An orange light is displayed when a serious fault occurs, such as over-voltage or over-current.

Alarm

Default — normal

Alarm

Fault

### 6.6 Run

When the system is working normally, **Run** lights green. When the system is powered off, **Run** is off.

Run

Power on

Run

Power off

### 6.7 Module Status Indicators

This area shows the status of every module in the string. Kakadu 120 has four battery modules per string, so indicators 1 to 4 correspond to the four modules; indicators 5 to 9 are not used and stay off.

When a module is working correctly, its indicator is off. If a module fails, its number lights orange.

*1* *2**3**4**5**6**7**8**9* Module 2 faulted

## 07 System Startup and Shutdown — System startup, system shutdown

### 7.1 System Startup

Before starting the system, confirm that every cable is connected as described in this manual, and that all MCBs and DC breakers — where fitted — are off.

1. Turn on the MCB on each BMS ①
2. Press the ON/OFF button on each BMS ②

The RUN and SOC indicators light once the system starts working.

![BMS front panel with the MCB marked ① and the ON/OFF button marked ②](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-startup-sequence.png)

**Figure 7.1** Startup sequence — MCB on ①, then ON/OFF ②.

### 7.2 System Shutdown

1. On each BMS, press and hold the ON/OFF button for three seconds ①
2. The MCB trips automatically. Verify that the handle is in the OFF position ②

![BMS front panel with the ON/OFF button marked ① and the tripped MCB handle marked ②](https://www.aerl.com.au/docs/_assets/assets/images/kakadu/kakadu-um-shutdown-sequence.png)

**Figure 7.2** Shutdown sequence — hold ON/OFF ①, then confirm the MCB handle is OFF ②.

## 08 Maintenance — Every six months, every year

> **Warning**
>
> Isolate the system power supply before operating on or maintaining the battery system. Working on energised equipment may damage the battery system or cause electric shock. All work must be carried out by authorised personnel only.

### 8.1 Every Six Months

- Check the system SOC using the SOC indicator on the BMS and in AERL Nexus, and confirm there is nothing abnormal.
- Check every cable connection for damage, looseness and ageing.
- Check the system working logs in AERL Nexus and confirm there are no abnormal events.
- Check that the ON/OFF button and any external emergency stop are working correctly.
- Clean dust from external surfaces and the door vents with a dry cloth or brush.
- Check cell voltages, module temperatures and SOH in AERL Nexus.
- Inspect all metal components for corrosion.

### 8.2 Every Year

Make sure the system is completely shut down before carrying out the following checks. Shutting down opens the MCB but does not de-energise the battery modules. Wear arc flash PPE in accordance with AS/NZS 5139 when working on the battery.

- Check that every quick-connect power plug is fully latched, and that the module and BMS washer bolts are tight (8 N·m).
- Check the power and control cables for damage, particularly where a surface in contact with metal may have been cut.
- Confirm that all cable entry points are properly sealed.
- Check that the cable layout is correct and that there are no short circuits.
- Check for loose screws.

## 09 Disposal

When disposing of Kakadu 120, return the unit to AERL, or follow local regulations for electronic waste and used batteries and observe the following requirements.

- DO NOT dispose of the product with household waste.
- DO NOT leave waste batteries in direct sunlight or at high temperature.
- DO NOT dispose of used batteries in high-humidity or corrosive environments.

## 10 Date of Manufacture

To find the product's date of manufacture, locate the serial number on the nameplate.

## 11 Warranty

Kakadu 120 is covered by a 10-year warranty; conditions apply. The full terms and the claim procedure are in the Kakadu 120 Warranty Statement at [aerl.com.au](https://aerl.com.au). For a claim, contact AERL technical support.

![AERL](https://www.aerl.com.au/docs/_assets/assets/logos/aerl-logo.svg)

Australian Energy Research Laboratories

### Address

1/75 Bluestone Circuit Seventeen Mile Rocks QLD 4073 Australia

[aerl.cloud](https://aerl.cloud)

### Contact

Technical support: [support@aerl.com.au](mailto:support@aerl.com.au) Sales: [sales@aerl.com.au](mailto:sales@aerl.com.au) Hours: Monday to Friday, 9:00–17:00 (AEST)

aerl.com.au Phone (within Australia) **1800 950 865**

© 2026 AERL Pty Ltd Kakadu 120 Installation and Operating Manual **Version V1.1.1 · Released 8 November 2026**