Kbi Kapower mksm series User manual

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.

(800) 527-8278, (847) 658-8561, Fax (847) 658-9280, www.koldban.com

ATA VMRS - T44 KLDBN

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

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

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

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

CAUTION

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.)

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

12 – 29V

Maximum Voltage

18V

30V

33V

Minimum Voltage

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

142.9 kJ

Maximum Power

47 kW

112 kW

94 kW

Leakage Current at Max Voltage

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

Dimensions and Weight

Length x Width x Height (IN)

14.79” 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)

34.5 lb. (15.6Kg)

Module Application and Part Number Reference Guide:

MKSM

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

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

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

Figure 2: Typical Cable Installations

Figure 3: Six (6) Cell MKSM

Material:

Shell: 16ga SS 304 2B

Cover: 18ga SS 304 2B

Weight: 21.5lb (9.75Kg)

Figure 4: Ten (10) and Twelve (12) Cell MKSM

Material:

Shell: 16ga SS 304 2B

Cover: 18ga SS 304 2B

Weight: 32.5lb (14.75kg)

4.3 General Wiring Installation Procedure

The following is the standard MKSM installation method. However, many vessels will use a

variation of this method. After reading the Theory of Operation below, see the following

sections if any of these apply to your vessel:

Installation Variation #1 found on page 18. For vessels using a push button, or key-switch for

single engine starting.

Installation Variation #2 found on page 21. For vessels using push button or rocker switch

starting with multiple engines.

Installation Variation #3 found on page 25. For vessels using a keypad, or digital switching for

engine starting. Also used for boats with multiple engines not using the DPST installation

method.

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.

Theory of Operation, Explaining how the MKSM Module Works:

Once installed and wired properly, the LED on the end-faceplate of the MKSM will be

illuminated green whenever the MKSM 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.

Pressing the DPST switch closes the contactor inside the MKSM enclosure, using power from

the KAPower module, regardless of the state of charge of the vessel or equipment’s batteries.

Pressing the DPST switch also engages the cranking motor circuit, just as if the key switch to

the crank/start position had been turned, or the vehicle’s or vessel’s start button (if so

equipped) had been pressed. As such 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 schematics in Figure 5 (page 15), and Figure 6 (page 17).This creates a

parallel circuit with the OEM (Original Equipment Manufacturer) electrical circuit, allowing both

the MKSM and the OEM cranking motor circuit to be engaged, simultaneously. Once the

engine starts, the Programmable Logic Controller (PLC) inside the MKSM monitors the

condition of the KAPower Module, and will close or open the contactor relay inside the MKSM,

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 Pre-programmed Functions:

The PLC has been preprogrammed to monitor and control the state-of-charge of the KAPower

capacitor module based on temperature, voltage, and 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. Anytime the LED Status Indicator is illuminated,

the contactor is closed. In a typical engine-starting event, the LED will 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/vessel, or

system voltage during the recharging events.

The J1939 connector is used for KBI factory programing only. Contact KBI for details.

Figure 5: General Wiring Installation

Engine Start Signal Input

CONNECTORS LOCATED ON THE END-FACEPLATE OF THE MKSM ENCLOSURE

4.4 Wiring Installation Procedure

1. Before attaching the large battery cables to the MKSM posts, slide included protective

boots onto the cables. The first cable shall be connected to the positive (+) terminal of

the MKSM, and then connected to the positive (+) terminal of the battery, or starter.

2. Slide included protective boot onto the negative (–) cable. This second cable shall be

connected to the negative (–) clamp, or terminal of the battery, engine, or chassis

ground and then connected to the negative (–) terminal of the MKSM module.

3. As based on Figure 5, and Figure 6 create and wire the harnesses to the Deutsch

connector. The MKSM Deutsch connector has been provided with a 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, 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 7-inches of the

power source. Use care not to disturb or compromise the engine’s own wiring harness,

or connections.

NOTE: The PLC inside the MKSM needs power (approximately 2.5 amps) from a

source, such as a key switch, that provides power only when the vehicle or boat is in

operation. Consider this additional 2.5 amps of power and how it may influence the

source. This new circuit should be protected with a 5-amp fuse or circuit breaker per

ABYC standards in marine applications.

5. Wire the DPST switch by replacing the existing vehicle, vessel, or equipment push

button engine starting switch with the KBI supplied DPST switch. Then find and wire the

appropriate PLC input (pin 4) as based and depicted on Figure 5, and Figure 6.Do not

connect 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 MKSM positive (+) and negative (–) terminals.

7. Attach provided protective boots to terminals on MKSM module.

8. To monitor the MKSM state of charge, order and install the KBI Voltmeter wire-harness,

and connector accessory kit, KBI part number 302809.See page 33. The meter

used may be digital, or analogue; however, it must be activated only with a momentary

ON switch or button. Permanently wiring a voltmeter to the MKSM will accelerate the

depletion of its charge.

9. Wiring is complete and the unit is now ready to operate.

After the installation and wiring are complete, and whenever the DPST switch is pressed, the

MKSM positive (+) and negative (–) terminals will be live. Do not short-circuit the terminals.

WARNING

Figure 6: Standard MKSM Schematic

(MKSMXXX00 Models)

Installation Variation #1: Supplement for boats using a key-switch for single engine starting.

For use with MKSMXXX00 Models

NOTE: The PLC inside the MKSM needs power (approximately 2.5 amps) from a source, such

as a key switch, that provides power only when the boat is in operation. Consider this

additional 2.5 amps of power and how it may affect the reliability of the source. This

new circuit should be protected with a 5-amp fuse or circuit breaker per ABYC

standards, and it should in no way affect the integrity of the engine’s starting or running

operation.

NOTE: The following install variation is an alternate method for installations on vessels with

key-switch starting.

When installing MKSM on a boat that incorporates key switch starting, no rocker switch or

push button replacement switch is required.

NOTE: If the OEM engine manufacturer or the boat builder reviews the KBI MKSM Theory of

Operation (page 13 + 14) and the requirements for DPST-type functionality, then

incorporating the DPST-type function and engineering it into the factory build key-

switch should be no problem. However, when installing a MKSM on a boat that has

already been built with key-switch starting, the following procedure and hardware

(wiring) should be used.

NOTE: If battery power was insufficient (˂7 volts), too weak to enable an engine start or

provide adequate power to the “S” terminal, an emergency start button should be

installed (installed near the controls) and would supply capacitor power to enable the

entire MKSM system when the button is pushed.

Figure A1: Typical Boat Key-Switch Schematic.............................................................................................................. 19

Figure A2: Schematic, Alternate Source for Start Signal............................................................................................ 20