KBi KAPower Starting Module User manual

KAPower Starting Module (KSM)
INSTALLATION – OPERATION MANUAL
Gen 3. Rev E
KBI/Kold-Ban+International,+Ltd.
8390+Pingree+Road,+Lake+In+The+Hills,+Illinois+60156-9637+U.S.A.
(800)+527-8278,+(847)+658-8561,+Fax+(847)+658-9280,+www.koldban.com
ATA+VMRS+-+T44+KLDBN+
+
+
+
KBI® KAPower® ©+2018+KBI+Form+#131400 Rev.+E
+
Gen$3$
12$&$24$Volt$

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2+
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PARTS$LIST:+
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1. KSM+Enclosure.++
2. Double+Pole+Single+Throw+(DPST)+push+button+switch.+
3. Wiring+harness.+(Not+Shown)+
4. Terminal+grease.+(Not+Shown)++
5. Protective+boots.+(Not+Shown)+
ITEMS$NEEDED$FOR$INSTALLATION:+
+
1. Battery+cables,+4/0+cable+is+recommended.++
2. Terminals+for+battery+cable.+
3. Torque+wrench+with+¾+inch+socket.++
4. Minimum+16+gauge+wire+for+harnesses.++
+
+++++++++++++++++++++++++++++++++++++ ++++++++++++++++++++++++++++++++++++ +
+++++
++++++++++++KSM+Enclosure++++++++++++++++++DPST+Switch+++++++++++++++++++++++++++
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++

+
3+
SAFETY AWARENESS
+
SAFETY+AWARENESS+ SYMBOLS+are+inserted+in+this+manual+to+alert+you+
to+possible+SAFETY+HAZARDS.+Whenever+you+see+these+symbols:++
+
or++ heed+their+instructions!+
+
SAFETY+AWARENESS+SYMBOLS+AND+MEANINGS:++
THIS+WARNING+SYMBOL+IDENTIFIES+SPECIAL+
INSTRUCTIONS+OR+PROCEDURES,+WHICH,+IF+NOT+
CORRECTLY+FOLLOWED,+COULD+RESULT+IN+PERSONAL+
INJURY.
+
+
THIS+CAUTION+SYMBOL+IDENTIFIES+SPECIAL+INSTRUCTIONS+OR+
PROCEDURES,+WHICH,+IF+NOT+STRICTLY+OBSERVED,+COULD+RESULT+IN+
DAMAGE+TO+OR+DESTRUCTION+OF+EQUIPMENT.
+
+
+
KAPower+module+is+a+product+of+high+electric+power.
Never+ short+ circuit+ KAPower+ module+ terminals!+ Burning+ or+ igniting+ of+
combustible+ materials+ adjacent+ to+ the+ point+ of+ short+ circuit+ may+ follow+
such+a+short+circuit.+In+case+of+accidental+short-circuit-ing+of+the+KAPower+
module+ or+ individual+ capacitors+ immediately+disconnect+ the+ KAPower+
module+from+ the+ electric+ circuit.+Use+ caution+ when+ doing+ so+ as+ short-
circuited+ cables+ can+ become+ very+ hot,+ while+ spewing+ melting+ insulation+
and+copper+
+
+
+
+
Noncompliance+with+the+requirements+set+forth+in+this+Manual+may+result+in+KAPower+module+failure.+Such+
requirements+shall+be+reviewed+prior+to+and+observed+in+the+course+of+KAPower+module+operation+and+installation.
The+KAPower+module+is+polarity+sensitive.+Polarity+shall+be+strictly+observed+when+connecting+the+KAPower+module!
WARNING
CAUTION
WARNING
CAUTION
WARNING
Note:&&KAPower&is#not#a"high-voltage(device.((It(simply(supplies(the(
same%voltage%that%it%was%charged'up'to.''Treat'it'with'the'same'
respect'you'would'give'to'a'fully'charged'battery.
CAUTION

+
4+
TABLE OF CONTENTS:
+
Parts+list+and+required+items..................................................2+
Introduction...................................................................................5
Installation.....................................................................................6+
Dimensions………………………………………………………8+&+9+
Wiring+Diagram………………………………….…………10+&+13
Operation......................................................................................14
Troubleshooting........................................................................15
Maintenance.....................................................................15+&+16
Storage...........................................................................................16
Transportation...........................................................................16+
Appendix+A…………………………………………………………..18+
Appendix+B…………………………………………………………..19
Notes:
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5+
INTRODUCTION:
The+KSM+enclosure+houses+a+KAPower+module,+a+contactor,+a+PLC+Module,+a+circuit+breaker,+
cables,+ conductors+ and+ connectors.+ The+ cover+ of+ the+ KSM+ enclosure+ can+ be+ removed+ by+
unscrewing+ and+ removing+ the+ ten+ (10)+ fasteners+ found+ on+ the+ top+ and+ sides+ of+ the+
enclosure.+ + The+ cover+ should+ only+ be+ removed+for+ servicing+ or+ troubleshooting+at+ the+
direction+of+KBI.+
KAPower+ is+ designed+ as+ an+ auxiliary+ power+ source+ to+ be+ installed+ in+ parallel+ with+ your+
cranking+batteries.+It+derives+its+power+from+your+batteries+or+engine+charging+system+and+
discharges+this+power+when+needed.+KAPower+is+intended+for+supplying+electric+power+to+
various+ loads+ operated+ in+ high+ pulse+ power+ (engine+ cranking)+ modes.+ KAPower+ will+
enhance+and+provide+for+reliable+cranking+and+starting+of+internal+combustion+engines.+++You+
may+ be+ able+ to+remove+ half+ or+ all+ of+ the+ existing+ starting+ batteries.+ + See+ Appendix+ A+ for+
detail.+
KAPower:+
•Stores+Cranking+Voltage+Until+Needed+•Long+Service+Life+–+Upwards+of+a+Million+Cycles+
•Performance+Virtually+Unaffected+by+Temperatures+•Increases+the+Life+of+Batteries+
•Requires+NO+Maintenance+•Safe+&+Easy+to+Install
+
KAPower$Basic$Description:$
The+KAPower+module+is+an+energy+storage+device.++KAPower+is+a+High+Power+device+with+
Low+ Energy+ density.+ + The+ cranking+ or+ discharge+ periods+ will+ be+ short+ but+ powerful+
(typically+ less+ than+ 30+ seconds)+ with+ the+ time+ to+ full+ recharge+ rated+ in+ tens+ of+ seconds.+
Recharging+ can+ be+ accomplished+ from+ virtually+ any+ 12+ or+ 24+ volt+ DC+ electrical+ power+
source.++Cycling,+charge+and+discharge+events+will+not+wear+out+the+device.++The+Cycle+Duty+
is+rated+in+hundreds+of+thousands+of+cycles+approaching+one+million+cycles.+
+
The$KAPower$Module:$
The+KAPower+module,+which+is+housed+within+the+KSM+enclosure,+represents+an+internal+
bank+of+6,+10+or+12+capacitor+cells+series-connected+to+each+other.++
An$Electrochemical$Capacitor$(EDLC):$
An+ Electrochemical+ Double+ layer+ Capacitor+ represents+ a+ device+ capable+ of+ storing+ and+
delivering+ electric+ power+ due+ mainly+ to+ the+ existing+ capacitance+ of+ the+ double+ electric+
layer,+which+is+formed+by+the+capacitor's+electrodes+being+in+contact+with+electrolyte.+The+
capacitor+ consists+ of+ negative+ and+ positive+ electrodes+ with+ terminals,+ separator,+
electrolyte,+and+a+shell.+
+

+
6+
INSTALLATION:$
+
The+ KAPower+ KSM+ is+ a+ product+ of+ high+ electric+ power.+ Avoid+ shorting+
module+terminals!+A+brief,+short+circuit+will+not+cause+product+failure,+how-
ever,+it+may+result+in+burning+or+igniting+of+combustible+materials+adjacent+to+the+point+of+
short+circuit.+
IMPORTANT!
Remember,+Electrical+ Resistance+ in+ the+ circuit+ created+ is+ the+ consumer+ of+ the+ electrical+
energy+ in+ your+ KAPower+ Module.+ Keep+ the+ resistance+ to+ an+ absolute+ minimum.+ Short,+
heavy+cables+and+good,+clean+cable+connections+are+essential!+
When+selecting+a+location+for+installation,+make+sure+that+the+KAPower+KSM+
module+will+clear+any+lids+and+other+movable+parts.+Install+the+KAPower+KSM+
module+as+close+to+the+engine's+starting+batteries+or+starter+as+possible.+Avoid+
locations+ that+ are+ subject+ to+ extreme+ heat,+ humidity,+ dripping+ water+ (under+ deck+
ventilation+ systems+ aboard+ boats+ for+ instance),+ road+ dirt,+ ice+ and+ snow.+ Prevent+ the+
external+case+of+the+KAPower+KSM+module+from+physical+impacts.+
Visually+inspect+the+external+case+prior+to+mounting+the+module.++Make+sure+that+no+traces+
of+physical+impacts+are+present+on+the+external+case+of+the+KAPower+KSM+module.+
DO+ NOT+ remove+the+ external+ plastic+ case+ cover+ of+ the+ KAPower+ module+
located+within+the+KSM+enclosure.+DO+NOT+short+circuit+terminals.+
Before+ installation,+ familiarize+ yourself+ with+ the+ specifications+ of+ your+ KAPower+ KSM+
module.+Insure+that+you+have+the+proper+device+for+your+application.+++++++ + + +
+ + +
CAUTION
WARNING
WARNING

+
7+
ELECTRICAL CABLE SELECTION:$
$
$
$
1. Electrical+resistance+in+the+circuit+you+create+is+a+significant+consumer+of+the+power+
available+ in+ the+ KAPower+ device.+ Create+ and+ keep+ the+ integrity+ of+ the+ circuit+ you+
create+to+the+highest+possible+standards.+
2. Use+the+heaviest+gauge+cable+available.+It+is+recommended+that+4/0+cable+be+used.++
3. Keep+ cable+ length+ to+ an+ absolute+ minimum.+ The+ circuit+ resistance+ increases+ with+
cable+length.++
4. Ensure+ that+ the+ cable+ termination+ connections+ (terminals)+ are+ properly+ crimped,+
and+ensure+that+the+holes+in+ring+terminals+match+the+size+of+the+studs+over+which+
they+are+placed.++Do+not+use+welding+cable;+use+high+quality,+fine+strand+type+II+or+III+
battery+cable.++For+marine+applications+tinned+cable+and+use+of+a+conductant+paste+or+
dielectric+grease+on+connections+is+recommended.+
5. The+ quality+ of+ the+ cable+ connections+ from+ the+ KSM+ to+ the+ vehicle+ or+ equipment+ is+
critical.++Make+sure+to+provide+good,+clean,+robust+cable+interface+connections.++The+
cables+between+the+KSM+ module+ and+ the+ battery+ do+not+benefit+from+over-current+
protection,+i.e.+they+have+no+fuse+or+circuit+breaker.++If+a+short+circuit+occurs+the+cable+
will+ overheat+ and+ it+ may+ catch+ fire,+ or+ ignite+ nearby+ combustible+ materials.++
Therefore,+make+certain+the+cable+is+well-secured,+at+least+every+18”,+and+protected+
from+damage+and+chafe.++For+marine+installations,+follow+American+Boat+and+Yacht+
Council+Guidelines+found+in+chapter+E-11.++
6. The+4+Pin+Deutsch+connector+has+been+supplied+with+a+mating+connector.++Be+sure+to+
follow+proper+wire+schemes+as+identified+in+the+diagrams.+
7. The+supplied+DPST+switch+will+be+installed+in+addition+to+or+paralleling+the+existing+
key-start+ switch.++Locate+ and+ install+ the+ DPST+ switch+ in+ a+ convenient+ location+
relative+to+the+key+switch.+
$
$
$

+
8+
$
$
MOUNTING THE KSM UNIT:$
$
Using+the+dimensions+shown+below,+use+four+(4)++¼”+bolts,+nuts+&+lock+washers+(not+
supplied)+to+mount+the+KSM+unit+to+vehicle,+vessle+or+equipment+chassis.$$
$
+
When+ selecting+ a+ location+ for+ installation,+ make+ sure+ that+ the+ KSM+ module+ and+
cables+will+clear+any+hoods,+hatches,+lids,+covers+and+other+movable+vehicle,+vessel+or+
equipment+parts.+Avoid+locations+that+are+subject+to+extreme+heat,+dripping+water,+
humidity,+ road+ dirt,+ ice+ and+ snow.+ While+ the+ KSM+ unit+may+ be+ mounted+ in+ any+
position+or+orientation,+do+not+mount+it+directly+over+batteries,+or+under+ventilation+
systems+through+which+water+might+drip.++The+internal+components+of+the+KSM+are+
IP67+rated+but+the+KSM+itself+is+not+IP+rated.++Take+care+to+prevent+the+external+case+
of+the+KSM+module+from+receiving+any+physical+impacts.+
+
+
+
+
+ + + +
CAUTION
6"cell"KSM"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"details
."
+

+
9+
+
10"&"12"cell"KSM"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"details
."
+

+
10+
+
!"#$%&'($
)*+%#,$-%&'($.$/0+1,$
2*34*'$)3*45"*$678$
9:4#;<'($=*1$
>4?'$)*#'?@/;'$A"**';#"?$B4*C=%#$ DEFGF$A"**';#"?$B4*C=%#$
H'%#&;<$A"**';#"?$
HIJKCGB$
GENERAL WIRING INSTALLATION PROCEDURE:
CAUTION!KSM$Power$Stud$Nuts$should$be$torqued$to$180$Inch$Pounds.$
CONNECTORS$LOCATED$ON$THE$END-FACEPLATE$OF$THE$KSM$ENCLOSURE.$
"#$%&'(")*'+"!,&!+-"!
./0!"#(*,/12"3!
The$J1939$connector$is$used$for$KBI$Factory$
programing$only.$$$Contact$KBI$for$details.!
Discrete Signal
See schematic, page 13
#4567!!$)/+!89!:8;6<!=>;>??6?!:85@!
,"0!95>;5!9:85A@!A4BB6AC4B93!

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11+
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GENERAL WIRING INSTALLATION PROCEDURE:$
(CONTINUED)$
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Theory'of'Operation,'explaining'how'the'KSM'module'works:'
Once"installed"and"wired"properly,"the"LED"on"the"End-Faceplate"of"the"KSM"will"
be"illuminated"green"whenever"the"KSM"contactor"relay"is"closed.""When"the"LED"
is"illuminated,"the"contactor"is"closed;"the"KAPower"Module"is"running"parallel"
with"the"vehicle,"vessel"or"equipment"batteries"and"electrical"system."
"
When"the"DPST"switch"is"depressed"you"are"closing"the"contactor"inside"the"KSM"
enclosure,"using"power"from"the"KAPower"module,"regardless"of"the"state"of"
charge"of"the"vehicle"or"equipment’s"batteries.""When"depressing"the"DPST"switch"
you"are"also"engaging"the"cranking"motor"circuit,"just"as"you"would"if"you"turned"
the"key"switch"to"the"crank/start"position,"or"pressed"the"vehicle’s"or"vessel’s"start"
button"if"so"equipped.""The"DPST"switch"is"wired"in"parallel"with"the"existing"
starting"system.""""This"is"done"by"wiring"and"using"the"recommended"electrical"
circuit,"displayed"on"the"schematic"(page"13).""By"doing"so,"you"have"paralleled"
with"the"OEM"(Original"Equipment"Manufacture)"electrical"circuit"allowing"both"
the"KSM"and"the"OEM"cranking"motor"circuit"to"be"engaged,"simultaneously.""
Once"the"engine"starts,"the"Programmable"Logic"Controller"(PLC)"inside"the"KSM"
monitors"the"condition"of"the"KAPower"Module"and"will"close"or"open"the"
Contactor"Relay"inside"the"KSM,"based"on"the"preprogrammed"parameters"inside"
the"PLC."""When"the"engine"is"stopped,"the"equipment"is"turned"off,"the"contactor"
opens"and"the"KAPower"module"remains"isolated,"waiting"for"the"next"engine-
starting"event,"when"the"DPST"switch"is"pressed."""
The'PLC'preprogrammed'functions:'
The"PLC"has"been"preprogrammed"to"monitor"and"control"the"state-of-charge"of"
the"KAPower"capacitor"module"based"on"temperature,"voltage"&"time.""Once"a"
voltage"signal"is"received"at"pin"four"(4)"of"the"Wiring"Interface"Connector"the"
PLC"“wakes-up”"and"will"determine"when"and"how"long"to"keep"the"contactor"
closed.""Remember,"anytime"the"LED"Status"Indicator"is"illuminated"the"contactor"
is"closed."In"a"typical"engine-starting"event"you"will"see"the"LED"illuminate"during"
engine"cranking"and"then"go"out"for"several"seconds"after"the"engine"has"started.""
The"LED"will"then"illuminate"again"and"could"remain"illuminated"for"several"
seconds"based"on"the"condition"of"the"KAPower"module.""The"LED"may"even"begin"
to"“cycle”"depending"on"the"vehicle"or"system"voltage"during"the"recharging"
events."
"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"
details."
+
"

+
12+
GENERAL WIRING INSTALLATION PROCEDURE:$
(CONTINUED)$
1. Before+ attaching+ the+ large+ battery+ cables+ to+ the+ KSM+ posts,+remember+ to+slide+
included+protective+boots+onto+the+cables. The+first+cable+shall+be+connected+to+the+
positive+++terminal+of+the+KSM+and+then+connected+to+the+positive+++terminal+of+the+
battery.+
2. Slide+included+protective+boot+onto+the+negative+-+cable. This+second+cable+shall+be+
connected+to+the+negative+-+clamp+or+terminal+of+the+battery+and+then+connected+to+
the+negative+-+terminal+of+the+KSM+module.+
3. As+based+on+page+10+&+13+create+and+wire+the+harnesses+to+the+Deutsch+connector.++
The+KSM+ Deutsch+ connector+has+been+ provided+ with+ mating+ connector+that+ has+
pigtail+wire+leads+tagged+and+identified+in+order+to+facilitate+installation.
4. For+the+PLC+input,+pin+four+ (4)+ of+the+wire+interface+connector,+you+must+find+a+5-+
amp+power+ source+ from+ the+ vehicle+or+ vessel,+ “key-on”+ ignition+ source+ that+ is+ live+
positive+++only+when+the+ignition+switch+is+on,+and+is+capable+of+delivering+up+to+5+
amps.++This+can+often+be+sourced+at+the+engine.++Install+a+5-amp+fuse+in+this+circuit+
within+seven+[7]+inches+of+the+power+source.++Use+care+not+to+disturb+or+compromise+
the+engine’s+own+wiring+harness+or+connections.
5. Wire+the+DPST+switch+and+find+and+wire+the+appropriate+PLC+input+(pin+4)+as+based+
and+depicted+on+the+diagram+&+schematic+pages+10+&+13.++You+will+not+be+connecting+
any+ wiring+ to+ the+ J1939+ Connector.++The" J1939" CAN-Bus" is" used" for" KBI" Factory"
programming"only.""Contact"KBI"for"details.
6. Apply+provided+protective+grease+on+KSM+positive+++and+negative+-+terminals.
7. Attach+provided+protective+boots+to+terminals+on+KSM+module.++
8. If+ you+ wish+ to+ monitor+ the+ KSM+ state+ of+ charge,+ you+ can+ order+ and+ install+ the+ KBI+
Voltmeter+wire-harness+and+connector+accessory+kit,+KBI+part+number+302809.++See+
Appendix+ B.++The+ meter+ you+ use+ may+ be+ digital+ or+ analogue;+ however,+ it+ must+be+
activated+ only+ with+ a+ momentary+ on+ switch+ or+ button.+ + Permanently+ wiring+ a+
voltmeter+to+the+KSM+will+accelerate+the+depletion+of+its+charge
9. Wiring+is+complete+and+the+unit+is+now+ready+to+operate.
+
+
+
CAUTION
After+the+installation+and+wiring+are+complete,+whenever+the+DPST+
switch+is+depressed+the+KSM+positive++$and+negative+
-+terminals+
will+be+live.++Do+not+short-circuit+the+terminals.+

+
13+
+
NOTE: In Transit bus applications
where the rear-start feature is desired,
a second DPST Switch can be installed
in the rear-start location, wired in
parallel with the front-start DPST
switch.
OEM$
Push$Bu*on$or$
Key$Switch$$
Cranking$/$Start$
Switch'

+
14+
OPERATION
Do+ not+ attempt+ to+ bypass+ the+ PLC+ functionality.+ + Charge+ voltage+and+
temperature+shall+ not+ exceed+ the+ Maximum+ Voltage+and+ Temperature+as+
specified+ in+ the+ Tables+ on+ page+ 6.+ + It+ is+ important+ to+ MONITOR+ the+ voltage+
when+charging+the+KAPower+module+to+its+Maximum+Voltage.+If+the+voltage+exceeds+these+
ranges+contact+KBI+for+further+troubleshooting+instructions.+This+is+the+main+purpose+and+
function+ of+ the+ PLC.+ + Failure+ to+ adhere+ to+ these+ specifications+ will+result+ in+ premature+
module+failure.+
Using$the$system:
•Confirm,+ using+ the+ wiring+ diagram+ on+ page+ 10,+ that+you+ have+ properly+ installed+ the+
KSM+module+before+activation.+
•Simply+ turn+ the+ vehicle+or+vessel+ key+ switch+ to+ the+ on+ position,+ then+ push+ and+ hold+
down+the+DPST+switch+to+engage+the+KAPower+KSM+system+until+the+engine+starts.+
•By+ using+ power+ from+ the+ KAPower+ capacitor,+ the+ KSM+ contactor+will+ close+ and+ stay+
closed+whenever+the+DPST+switch+is+depressed.++The+DPST+switch+is+designed+to+engage+
the+vehicle,+vessel+or+equipment’s+OEM+cranking+motor+circuit.+
•Whenever+the+KSM+KAPower+contactor+is+closed,+the+LED+on+the+End-Faceplate+should+
be+illuminated+green.+
•The+engine+should+begin+to+crank-over+with+power+being+supplied+from+both+the+KSM+
capacitor+module+and+the+standard+batteries.++
•Once+the+engine+starts+and+the+DPST+switch+is+released,+the+KSM+internal+PLC+module+
will+be+ active,+ keeping+ the+ contactor+closed+ when+ required,+ allowing+ the+ KAPower+
module+to+recharge.++
•NOTE:$If$the$vehicle,$vessel$or$equipment’s$batteries$are$completely$discharged,$if$
the$battery$is$dead,$it$may$be$necessary$to$keep$the$DPST$switch$depressed$until$
the$ vehicle’s$ electrical$ (charging/alternator)$ system$ has$ become$ active.$ $ The$
dead$batteries,$on$their$own,$may$not$support$all$of$the$engine’s$electrical$power$
requirements$to$keep$it$running.$ $ In$ this$case,$ keep$ the$DPST$switch$depressed$
until$you$are$sure$the$vehicle’s$or$vessel’s$charging$system$is$active,$you$can$note$
this$by$watching$the$engine’s$volt$or$amp$meter.$$The$KAPower$module$will$have$
enough$ power$ to$ keep$ the$ engine$ running$ until$ the$ engine’s$ charging$ system$
becomes$ active.$ Warning:' This' can' only' be' done' if' the' engine' is' equipped' with'
automatic' starter' disengagement;' if' the' starter' remains' engaged' while' the' start'
button'is'depressed,'after'the'engine'has'started,'the'starter'may'be'damaged,'in'
which'case'this'procedure'cannot'be'used.''''
•When+the+engine+stops+and+the+vehicle+or+equipment+is+turned+off+the+KSM+contactor+
will+open,+keeping+ the+ fully+ charged+KAPower+module+in+reserve+for+the+next+engine-
starting+event.++
+
CAUTION

+
15+
TROUBLESHOOTING AND MAINTENANCE:
Maintenance+ of+ the+ KAPower+ module+ within+ the+ KSM+ enclosure+shall+ not+ be+ required+
provided+that+the+operating+conditions+are+proper+and+that+the+requirements+specified+in+
this+Manual+are+observed.++
For"testing"purposes,"you"may"wish"to"periodically"start"the"engine"using"only"the"vehicle’s"or"
vessel’s"own"key"switch"or"start"button.""Doing"so"will"prevent"the"KSM"from"coming"on"line,"
thereby"allowing"you"to"test"the"condition"of"the"starting"battery.""
•The+LED+located+on+the+End-Faceplate+of+the+KSM+indicates+the+active+condition+of+
the+KSM+module.++See+page+10+for+location+of+this+light.++If+the+LED+is+not+illuminated+
when+the+expected,+(see+Theory+of+Operation,+page+11)+then+ensure+that+all+wiring+
and+connections+are+in+accordance+with+the+instructions+within+this+manual.+Check+
the+integrity+of+the+DPST+switch+and+the+power+supply+to+the+PLC+(sourced+from+the+
engine+ignition+switched+when+on)+wiring+harness+you+created.+
•This+bi-color+(red/green)+LED+is+also+an+indicator+for+how+the+KSM+is+functioning.++
The+green+side+of+the+LED+is+connected+parallel+with+the+contactor.++The+red+side+is+
connected+to+an+output+on+the+PLC+as+shown+in+the+schematic+depicted+on+page+13.+
The+PLC+monitors+the+capacitor+voltage+during+and+after+the+recharge+cycle.++If+the+
capacitor+voltage+drops+to+below+an+acceptable+level+in+the+first+5+minutes+after+the+
recharge,+the+red+LED+will+flash,+indicating+a+fault.++If+at+any+time+while+the+PLC+is+
powered+up+and+the+KSM+Circuit+Breaker+trips+or+the+capacitor+voltage+level+drops+
below+4+volts+the+red+LED+will+flash+in+a+sequence+that+indicates+the+fault,+see+below.+
+
++++++++++++++++++++++++++++++++ +++++++++++++++++++
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+
Priority' Name' Flash'Rate'
!" #$%$&'()*"+,-*".-/%-*$(0*-" 1"
2" .-/%-*$(0*-"3-45)*"6**)*" 7"
8" #)4($&()*"+,-*"#0**-4("
6**)*" 8"
1" 9):"#$%$&'()*";)<($=-"6**)*" >"
7" ?$%'@";)<($=-"A-&$B"$C-*"
?-&D$*=-" E"

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TO$CHECK$KSM$INTERNAL$CIRCUIT:$
$
•If+ the+ wiring+ and+ harnesses+ are+ in+ good+ order+ continue+ troubleshooting+ by+
unplugging+ the+ Deutsch+ connector+ on+ the+ end-faceplate+ of+ the+ KSM,+ giving+ you+
access+to+the+pin+terminals+on+the+KSM+connector.++Refer+to+pages+10+&+13.+
•With+the+circuit+breaker+reset,+using+a+voltmeter+check+voltage+at+Pin+#1+of+the+
Deutsch+four-pin+connector+and+the+KSM+negative+-+ground+power+stud+terminal.+If+
voltage+is+present+the+circuit+is+good.++The+voltage+reading+is+the+actual+KAPower+
module+voltage+and+should+be+at+least+10+volts+for+the+24-volt+models+and+4+volts+for+
the+12-volt+models,+in+order+to+activate+the+contactor.++
•Jump+pins+1+and+2+on+the+four-pin+connector,+the+contactor+should+activate,+you+will+
hear+a+clunk.+If+not,+you+may+need+to+remove+the+KSM+cover+and+check+for+faulty+
contactor+or+internal+wiring.++Before+removing+the+KSM+cover+it+is+recommended+
you+contact+KBI+for+assistance.+
•If+ the+ circuit+ breaker+ continues+ to+ trip+ check+the+ integrity+ of+ the+ vehicle+or+ vessel+
side+ of+ the+ wiring+ harness+ for+ issues+ such+ as+ shorts,+corrosion,+chafing+ or+ bad+
connections+and+components.++
•Check+the+circuit+breaker+and+contactor+relay+connections+within+the+KSM+module.+
In+order+to+service+or+replace+any+of+these+components+you+will+have+to+remove+the+
cover+of+the+KSM+enclosure.++Reference+page+5,+INTRODUCTION:$Again,+contact+KBI+
for+assistance.+
•The+PLC+Module+is+a+sealed+unit.++It+cannot+be+serviced.++If+additional+troubleshooting+
is+required+contact+KBI.$
STORAGE:+
The+ KAPower+ module+should+ be+ discharged+ prior+ to+ storage+and+ for+
prolonged+ periods+ (>1+ year)+ should+ be+ stored+ in+ a+ completely+ discharged+
state.++The+KSM+can+be+discharged+by+hooking+up+the+power+studs+to+any+resistive+load+(a+
light+bulb+or+motor+of+the+appropriate+voltage)+and+activating+the+unit+(jump+pins+1+and+2+
on+ the+ four-pin+ connector,+ the+ contactor+ should+ activate)+ until+ the+ desired+ voltage+ is+
reached+(6+ volts+ for+ 12+ volt+ systems+ and+ 20+volts+ for+ 24+ volt+systems).+ + Voltage+ can+ be+
monitored+at+the+power+studs.+
The+ KAPower+ modules+ shall+ be+ stored+ within+ enclosed+ heated+ or+ unheated+ premises+
outfitted+ with+ a+ natural+ ventilation+ system+ in+ regions+ having+ moderate+ or+ cold+ weather+
conditions.+Climate+control+systems+are+not+required.+The+required++storage+temperature+
range+is+-76º+to+185ºF+(-60º+to+85ºC).+
TRANSPORTATION:+
The+KAPower+KSM+modules+can+be+shipped+in+approved+corrugated+cardboard,+wooden,+
or+plastic+containers.+For+more+information+on+transportation+contact+KBI.++
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CAUTION

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LIMITED WARRANTY
The+KAPower+module+itself,+inside+the+KSM,+is+guaranteed+
against+defects+in+material+and+workmanship+for+three+(3)+
years+from+date+of+purchase.++All+other+KSM+components+are+
guaranteed+against+defects+in+material+and+workmanship+for+
one+(1)+year+from+the+date+of+purchase.+The+KAPower+module+is+
a+sealed+unit+-+do+not+tamper+with.+If+the+KSM+does+not+operate+
properly+within+the+warranty+period,+it+must+be+returned+to+the+
factory,+prepaid,+in+order+to+determine+warranty+disposition.+If+
factory+inspection+determines+the+product+to+be+defective+
under+the+terms+of+this+warranty,+it+will+be+replaced+without+
charge.+
Failure+due+to+accident,+abuse,+neglect,+use+other+than+in+the+
intended+application+specified+in+this+manual,+improper+
installation+or+maintenance,+mishandling,+and+repairs+or+
attempted+repairs+which+have+been+made+by+others,+are+not+
covered+under+the+terms+of+this+warranty.
Kold-Ban+International,+Ltd.+shall+not+be+liable+for+loss+of+use+of+
the+KAPower+KSM+or+other+incidental+or+consequential+costs,+
expenses+or+damages+incurred+by+the+purchaser+or+user.
This+warranty+does+not+include+labor+for+repair+or+replacement.
Kold-Ban+International,+Ltd.
8390+Pingree+Road
Lake+In+The+Hills,+IL+60156-9637
(847)+658-8561+(800)+527-8278+
www.koldban.com

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Appendix+A+

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TM
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M J Burke D R Solberg
Appendix+B+

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