KBi KSM User manual

KAPower Starting Module
KSM & 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
KBI® KAPower® © 2020 KBI Form #131480

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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 protect. 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 KSM Unit.............................................................................................................................................9
4.3 General Wiring Installation Procedure............................................................................................................13
5.0 OPERATION......................................................................................................................................................................18
6.0 TROUBLESHOOTING AND MAINTENANCE ......................................................................................................... 19
6.1 To Check KSM Internal Circuit........................................................................................................................... 20
7.0 STORAGE ........................................................................................................................................................................... 21
8.0 TRANSPORTATION........................................................................................................................................................ 21
9.0 OPTIONAL VOLTMETER HARNESS.........................................................................................................................36
10.0 LIMITED WARRANTY...................................................................................................................................................37
Table 1: Specifications..................................................................................................................................................................7
Table 2: LED Flash Sequence................................................................................................................................................. 20
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................................................................................................................................. 14
Figure 6: Standard KSM Schematic ..................................................................................................................................... 16
Figure 7: Standard MKSM Schematic..................................................................................................................................17
Appendix A: Supplement for Boats using a Key-Switch for Single Engine Starting ......................................... 22
Appendix B: Supplement for Boats using a Push Button or Rocker Switch for Engine Starting (including
Boats with Multiple Engines) .................................................................................................................................................26
Appendix C: Supplement for Boats using Keypad Button or Digital Switch for Engine Starting (including
Boats with Multiple Engines) .................................................................................................................................................31

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1.0 PARTS LIST
1. KSM Enclosure (See Figure 1)
2. Double Pole Single Throw (DPST) switch (See Figure 1)
3. Wiring harness (Not Shown)
4. Terminal grease (Not Shown)
5. Protective boots (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 KSM model
4. Minimum 16-gauge wire for harnesses
KSM Enclosure DPST Switch DPST Switch Marine
Figure 1: Parts List Items

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3.0 INTRODUCTION
The KSM enclosure houses a KAPower module, contactor, PLC Module (Programable Logic
Controller), 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 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.
The KAPower module can produce a significant electric charge.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 in the
course of KAPower module operation and installation.
WARNING
WARNING
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 KSM 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 KSM module.
Before installation, review the KAPower KSM 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
7 – 14.5V
7 – 14.5V
8 – 29V
8 – 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° – 185°F
(-40° – 85°C)
-40° – 185°F
(-40° – 85°C)
-40° – 185°F
(-40° – 85°C)
-40° – 185°F
(-40° – 85°C)
Cycle Life
>1,000,000
>1,000,000
>1,000,000
>1,000,000
Dimensions and Weight
Length x Width x Height
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”
Weight
22 lb.
32.5 lb.
32.5 lb.
34.5 lb.
The KAPower KSM is a product of high electric power. Avoid shorting module
terminals. A brief short circuit will not cause product failure, however, it may result in
burning or igniting of combustible materials adjacent to the point of short circuit.
The KAPower module is polarity sensitive. Polarity shall be strictly observed when
connecting the KAPower module.
WARNING
CAUTION

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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 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 example), road
dirt, ice, and snow. Prevent the external case of the KAPower KSM 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.
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. Do not use welding cable; use high quality, fine strand type II or type III
battery cable. Marine applications should utilize tinned cable and dielectric grease.
5. The quality of the cable connections from the KSM 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 KSM 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 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.
4.2 Mounting the KSM Unit
Using the dimensions shown in Figures 3, and 4, use four (4) ¼” bolts, nuts, and lock
washers (not supplied) to mount the KSM unit to vehicle, vessle, or equipment chassis.If
mounting on a soild bulkhead or other location without backside acsess, other fastiners such
as suitably-sized tapping screws can be used.
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

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Figure 2: Typical Cable Installations

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Figure 3: Six (6) Cell KSM

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

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4.3 General Wiring Installation Procedure
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.
Depressing the DPST switch closes 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. Depressing 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. 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 14), Figure 6 (page 16), or Figure 7 (page 17).
This creates a parallel circuit with the OEM (Original Equipment Manufacturer) 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 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.

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NOTE: The J1939 connector is used for KBI factory programming only. Contact KBI for details.
Figure 5: General Wiring Installation

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4.4 Wiring Installation Procedure
1. Before attaching the large battery cables to the KSM posts, 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, 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 KSM module.
3. As based on Figure 5, Figure 6, or Figure 7 create and wire the harnesses to the
Deutsch connector. The KSM 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 KSM 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, and find and wire the appropriate PLC input (pin 4) as based
and depicted on Figure 5, Figure 6, or Figure 7. 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 KSM positive (+) and negative (–) terminals.
7. Attach provided protective boots to terminals on KSM module.
8. To monitor the KSM state of charge, order and install the KBI Voltmeter wire-harness,
and connector accessory kit, KBI part number 302809.See page 36. 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 KSM 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 depressed,
the KSM positive (+) and negative (–) terminals will be live. Do not short-circuit the terminals.
WARNING

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Figure 6: Standard KSM Schematic
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 DPST
switch.

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Figure 7: Standard MKSM Schematic

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5.0 OPERATION
Do not attempt to bypass the PLC functionality. Charge voltage and
temperature shall not exceed the Maximum Voltage and Temperature as
specified in Table 1. It is important to MONITOR the voltage when charging the
KAPower module to its Maximum Voltage. This is the main purpose and function
of the PLC. If the voltage exceeds these ranges, contact KBI for further
troubleshooting instructions. Failure to adhere to these specifications will result
in premature module failure.
1. Before activation, confirm, using the wiring diagrams on Figure 2 (page 10), and figure
5 (page 14), that the KSM module has been properly installed.
2. Turn the vehicle/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.
3. 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.
4. Whenever the KSM KAPower contactor is closed, the LED on the End-Faceplate
should be illuminated green.
5. The engine should begin to crank-over with power being supplied from both the KSM
capacitor module and the standard battery(ies).
6. 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, or emergency start
switch depressed until the vehicle’s electrical (charging/alternator) system has
become active. The dead batteries, on their own, may not support all the engine’s
electrical power requirements to keep it running. In this case, keep the DPST switch
depressed until the vehicle’s or vessel’s charging system is active. This can be noted
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.
CAUTION

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CAUTION NOTE: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.
7. 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.
6.0 TROUBLESHOOTING AND MAINTENANCE
Maintenance of the KAPower module within the KSM enclosure is not required provided that
the operating conditions are proper, and that the requirements specified in this manual are
observed.
NOTE: During scheduled maintenance you can disconnect the 4-pin deutsch connector from
the KSM faceplate then 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 the condition of the starting battery to be tested.
1. The LED located on the End-Faceplate of the KSM indicates the active condition of the KSM
module. See Figure 5 for location of this light. If the LED is not illuminated when expected
(see Section 4.3, Theory of Operation), 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.
2. This LED is also an indicator for how the KSM is functioning. The LED is connected in
parallel with the contactor, and is also connected to an output on the PLC as shown in the
Figure 6 and Figure 7. The PLC monitors the capacitor voltage during, and after, the
recharge cycle. If the capacitor voltage drops below an acceptable level in the first 5 minutes
after the recharge, the 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 6-
volts (on a 12-volt unit) or 12-volts (on a 24-volt unit), the LED will flash in a sequence that
indicates the fault, see Table 2.

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Table 2: LED Flash Sequence
Priority
Name
Flash Rate
1
Capacitor Over
Temperature
2
5
Temperature
Sensor Error
3
4
Contactor Over
Current Error
4
2
Low Capacitor
Voltage Error
6
3
Rapid Voltage
Decay after
Recharge
7
6.1 To Check KSM Internal Circuit
1. If the wiring and harnesses are in good order, continue troubleshooting by unplugging
the Deutsch connector on the end-faceplate of the KSM, providing access to the pin
terminals on the KSM connector. Refer Figure 5, Figure 6, and Figure 7.
2. With the circuit breaker reset, use a voltmeter to 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 12-volts for the 24-volt models and 6-volts for
the 12-volt models in order to activate the contactor.
3. Jump pins 1 and 2 on the four-pin connector, the contactor should activate and make
a “clunk” sound. If not, contact KBI for assistance.
4. If experiencing problems 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.
5. Check the circuit breaker and contactor relay connections within the KSM module. In
order to service or replace any of these components, remove the cover of the KSM
enclosure, with the assistance of KBI.
6. The PLC Module is a sealed unit. It cannot be serviced. If additional troubleshooting
is required, contact KBI.