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$

+
2+
+
+
+
PARTS$LIST:+
+
1. KSM+Enclosure.++
2. Double+Pole+Single+Throw+(DPST)+push+button+switch.+
3. Wiring+harness.+(Not+Shown)+
4. Terminal+grease.+(Not+Shown)++
5. Protective+boots.+(Not+Shown)+
ITEMS$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+++++++++++++++++++++++++++
+
++

+
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:
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
+
+
+

+
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!