KBi KAPower MKSM Series User manual

KBI® KAPower® © 2020 KBI Form #131498
KAPower Starting Module
MKSM Models
INSTALLATION – OPERATION MANUAL
Gen 3 (12 Volts or 24 Volts)
KBI/Kold-Ban International, Ltd.
8390 Pingree Road, Lake In The Hills, Illinois 60156-9637 U.S.A.
[phone], [phone], Fax [phone], www.koldban.com
ATA VMRS - T44 KLDBN

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SAFETY INFORMATION
WARNING and CAUTION symbols are used in this document to alert the reader of possible safety
hazards. The reader is responsible for reading and following these alerts.
WARNING indicates a hazardous situation which, if not avoided will result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided could result in equipment damage
and/or equipment failure.
KBI/Kold-Ban International, Ltd. accepts no responsibility or liability for any of its products that are
improperly used. The safety information in this manual is provided as a guide for the
user, and is not a substitute for proper training and usage.
NOTE: The information contained in this document is copyright and patent protected. This
document may not be copied without express, written permission of KBI/Kold-Ban International, Ltd.
Patent information can be found at: http://www.koldban.com/about_KBi_s/1.htm
WARNING

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TABLE OF CONTENTS
1.0 PARTS LIST..........................................................................................................................................................................4
2.0 ITEMS NEEDED FOR INSTALLATION........................................................................................................................4
3.0 INTRODUCTION.................................................................................................................................................................5
3.1 KAPower Advantages ...............................................................................................................................................6
3.2 KAPower Basic Description....................................................................................................................................6
3.3 The KAPower Module ...............................................................................................................................................6
3.4 Electrochemical Double-Layer Capacitor (EDLC) .......................................................................................6
4.0 INSTALLATION ..................................................................................................................................................................6
4.1 Electrical Cable Selection........................................................................................................................................8
4.2 Mounting the MKSM Unit.........................................................................................................................................9
4.3 General Wiring Installation Procedure............................................................................................................13
5.0 OPERATION......................................................................................................................................................................29
6.0 TROUBLESHOOTING AND MAINTENANCE ......................................................................................................... 30
6.1 To Check MKSM Internal Circuit.......................................................................................................................31
7.0 STORAGE ........................................................................................................................................................................... 32
8.0 TRANSPORTATION........................................................................................................................................................32
9.0 OPTIONAL VOLTMETER HARNESS......................................................................................................................... 33
10.0 LIMITED WARRANTY...................................................................................................................................................34
Table 1: Specifications..................................................................................................................................................................7
Table 2: LED Flash Sequence.................................................................................................................................................31
Figure 1: Parts List Items ...........................................................................................................................................................4
Figure 2: Typical Cable Installations...................................................................................................................................10
Figure 3: Six (6) Cell KSM........................................................................................................................................................11
Figure 4: Ten (10) and Twelve (12) Cell KSM.................................................................................................................12
Figure 5: General Wiring Installation.................................................................................................................................15
Figure 6: Standard MKSM Schematic..................................................................................................................................17
Installation Variation #1: For Boats using a Push button or Key-Switch for Single Engine Starting......... 18
Installation Variation #2: For Boats using a Push Button or Rocker Switch for Engine Starting With
Multiple Engines.......................................................................................................................................................................... 21
Installation Variation #3: For vessels using a keypad, or digital switching for engine starting.
Also used for boats with multiple engines not using the DPST installation method........................................25

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1.0 PARTS LIST
1. MKSM Enclosure (See Figure 1)
2. Double Pole Single Throw (DPST) switch (See Figure 1)*
3. Pre-wired harness (Not Shown)
4. Terminal grease (Not Shown)
5. Protective boots (Not Shown)
6. Emergency push button switch (Not Shown) **
2.0 ITEMS NEEDED FOR INSTALLATION
1. Battery cables (See Section 4.1 for cable recommendations)
2. Terminals for battery cable
3. Torque wrench with ¾ inch socket, or 11/16th depending
on MKSM model
4. Minimum 16-gauge wire for harnesses
MKSM Enclosure DPST Rocker Switch
(IP 67 Rated)
Figure 1: Parts List Items
NOTE: Not all scenarios and installation methods are covered in this document. If
your application does not match any identified in this document, please
contact KBI for assistance.
* Not included with: MKSMXXX01
** Not Included with: MKSMXXX02

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3.0 INTRODUCTION
The MKSM enclosure houses a KAPower module, contactor, PLC Module (Programable
Logic Controller), circuit breaker, cables, conductors, and connectors.
KAPower is designed as an auxiliary power source to be installed in parallel with cranking
batteries. It derives its power from batteries or an 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. This capability may allow for
removal of half or most existing starting batteries.
KAPower is not a high voltage device. It supplies the same amount of voltage as its
charge. A charged module should be treated as a fully charged battery.
Do not short circuit KAPower module terminals. Burning or igniting of combustible
materials adjacent to the point of short circuit may result from a short circuit. Do not
place any conductive objects or materials across terminal posts. In case of accidental
short-circuiting of the KAPower module, or individual capacitors, immediately mitigate
short by removing the object causing short.
Noncompliance with the requirements set forth in this manual may result in
KAPower module failure. Such requirements shall be reviewed and followed
during KAPower module operation and installation.
The KAPower module is polarity sensitive. Polarity shall be strictly observed when
connecting the KAPower module.
WARNING
WARNING
CAUTION
CAUTION

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3.1 KAPower Advantages
• 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 and Easy to Install
3.2 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-volt 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.
3.3 The KAPower Module
The KAPower module, which is housed within the MKSM enclosure, represents an internal
bank of 6, 10, or 12 capacitor cells series-connected to each other.
3.4 Electrochemical Double-Layer Capacitor (EDLC)
An Electrochemical Double-Layer Capacitor represents a device capable of storing and
delivering electric power. This is 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.
4.0 INSTALLATION
Visually inspect the external case prior to mounting the module. Make sure that no traces of
physical damage are present on the external case of the KAPower MKSM module.
Before installation, review the KAPower MKSM module specifications. Ensure that the proper
device for the specific application is being used.(See Table 1.)

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Table 1: Specifications
Specifications
12V
6 Cell Unit
12V
10 Cell Unit
24V
10 Cell Unit
24V
12 Cell Unit
Electrical Characteristics
Operating Voltage Window
6 – 14.5V
6 – 14.5V
12 – 29V
12 – 29V
Maximum Voltage
18V
18V
30V
33V
Minimum Voltage
0V
0V
0V
0V
Internal Resistance
0.0011 ohms
0.0008 ohms
0.0019 ohms
0.0022 ohms
Capacitance
525 F
1250 F
315 F
263 F
Energy Stored within Operating
Voltage Window
42.3 kJ
101.6 kJ
122.4 kJ
102 kJ
Energy Stored at Max Voltage
85.1 kJ
141.8 kJ
141.8 kJ
142.9 kJ
Maximum Power
47 kW
112 kW
112 kW
94 kW
Leakage Current at Max Voltage
4.5 mA
4.5 mA
4.5 mA
4.5 mA
Operating Conditions
Operating Temperature Range
-40° – 149°F
(-40° – 65°C)
-40° – 149°F
(-40° – 65°C)
-40° – 149°F
(-40° – 65°C)
-40° – 149°F
(-40° – 65°C)
Cycle Life
>1,000,000
>1,000,000
>1,000,000
>1,000,000
Dimensions and Weight
Length x Width x Height (IN)
14.79” x 7.75” x 8”
19.44” x 7.75” x 8”
19.44” x 7.75” x 8”
19.44” x 7.75” x 8”
Length x Width x Height (MM)
375.7 x 196.8 x
203.2
493.8 x 196.8 x
203.2
493.8 x 196.8 x
203.2
493.8 x 196.8 x
203.2
Weight
22 lb. (10Kg)
32.5 lb. (14.75Kg)
32.5 lb. (14.75Kg)
34.5 lb. (15.6Kg)
Module Application and Part Number Reference Guide:
MKSM
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12
00
00: Single Engine Models
01: Multi Engine Models for Applications Not Using Push Button or Key Switch Starting
02: Multi Engine Models for Push Button or Key Switch Applications
Number of Capacitor Cells
System Voltage
The M Signals a Marine Unit

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Electrical resistance in a circuit is the consumer of the electrical energy. When installing a
KAPower Module, keep resistance to a minimum. Short, heavy cables, and clean cable
connections are essential to reducing the amount of resistance in a circuit.
When selecting a location for installation, make sure that the KAPower MKSM module will
clear any lids and other movable parts. Install the KAPower MKSM 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 example),
road dirt, ice, and snow. Prevent the external case of the KAPower MKSM module from
physical impacts.
4.1 Electrical Cable Selection
1. Electrical resistance in a circuit is a significant consumer of the power available in the
KAPower device. Create and keep the integrity of the circuit to the highest possible
standards. Use high strand count cable that is abrasion resistant.
2. Use the heaviest gauge cable available. For 24-volt (and 10 cell units), use at least 2/0,
with 4/0 being recommended. A six cell, 12-volt unit may use 4 gauge to 2/0 cables.
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. Marine applications should utilize tinned cable and dielectric grease.
5. The quality of the cable connections from the MKSM to the vehicle’s or vessel’s
battery/starter circuit, or equipment, is critical. Make sure to provide good, clean, robust
cable interface connections. The cables between the MKSM module and the battery
are cranking motor conductors, and therefore are typically not equipped with a 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-inches, and protected from damage and chafe. For marine
installations, follow American Boat and Yacht Council Guidelines found in chapter E-11
(not included in this document).
CAUTION
CAUTION

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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 may 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.
4.2 Mounting the MKSM Unit
Using the dimensions shown in Figures 3, and 4, use four (4) ¼” bolts, nuts, and lock washers
(not supplied) to mount the MKSM unit to vehicle, vessle, or equipment chassis.If mounting on
a soild bulkhead or other location without backside acsess, other fasteners such as suitably-
sized self tapping screws can be used.
When selecting a location for installation, make sure that the MKSM 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 MKSM 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 MKSM are IP67 rated, but the MKSM itself is not IP
rated. Take care to prevent the external case of the MKSM module from receiving any
physical impacts.
CAUTION

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Figure 2: Typical Cable Installations