Kilowatt Labs 7100-48-B-2C-TM-SD-A-G User manual

SIRIUS CAPACITOR MODULE
User Manual
Model number: 7100-48-B-2C-TM-SD-A-G
Version 1.0; Release Date: July 2019
Author:
Mamoona Khalid

Introduction
The Sirius Capacitor Module (“Sirius”) is supercapacitor-based storage that uses supercapacitors as storage
cells instead of chemical cells. Kilowatt Labs’ proprietary balancing, control and charge retention algorithms
control the operation of the supercapacitor-based Modules, making Sirius a safe, efficient and effective
alternative to chemical batteries wherever chemical batteries are deployed.
Legal Provisions
No part of this User Manual (“Manual”) may be reproduced, or transmitted, in any form or by any means,
without the prior written permission of Kilowatt Labs, Inc. (“Kilowatt” or the “Company”). Specifications in
this Manual are subject to change without notice. While every attempt has been made to make the Manual
accurate and up-to-date, users are cautioned that product improvements may cause the Company to make
changes to specifications without advance notice. Users are encouraged to consult the Company or its
Resellers before using the Manual. Neither the Company nor its Resellers shall be liable for any indirect,
incidental, or consequential damages under any circumstances caused by reliance on the material presented,
including, but not limited to, omissions, typographical errors, arithmetical errors or listing errors in the content
material. The content of this manual shall not be modified without the written authorization of the Company.
Trademarks
All trademarks are recognized, even if not explicitly identified as such. Kilowatt Labs® is a registered
trademark of the Company.

Contents
1. Safety Instructions:.................................................................................................................................5
1.1 Symbols Convention:......................................................................................................................5
1.2 Safety Precautions:.........................................................................................................................5
1.3 Module Connection Safety Precautions:........................................................................................6
1.4 Shipping..........................................................................................................................................7
1.5 Qualified Installer ...........................................................................................................................7
2. Product Introduction..............................................................................................................................7
2.1 Part Number...................................................................................................................................7
2.2 Product Overview:..........................................................................................................................8
2.2.1 Appearance: .................................................................................................................................8
2.2.2 Mechanical Drawings: ..................................................................................................................9
2.2.3 Dimension and Weight.............................................................................................................. 11
2.3 Front Panel Description:.............................................................................................................. 11
3. Module Installation: ............................................................................................................................ 14
3.1 Inspection:...................................................................................................................................... 14
3.2 Safety Gear: .................................................................................................................................... 15
3.3 Unpacking and Contents Check:..................................................................................................... 15
4. Operation Procedures:........................................................................................................................ 16
4.1 Module Configuration: ................................................................................................................... 16
4.2 Software Configuration:.............................................................................................................. 17
5. Recovery Procedure: ........................................................................................................................... 20
6. Connecting the Module in Parallel or in Series:.................................................................................. 21
6.1 Parallel Connection of Sirius Modules:........................................................................................... 21
6.2 Series Connection of Sirius Modules:............................................................................................. 22
7. Automatic Safety Shutdown................................................................................................................ 25
8. Trouble Shooting................................................................................................................................. 26
9. Features:.............................................................................................................................................. 27
9.1 Key Features:................................................................................................................................... 27
9.2 Physical features:............................................................................................................................. 27
9.3 Technical Features:.......................................................................................................................... 28
10. Shelf Life:............................................................................................................................................. 28
11. Maintenance: ...................................................................................................................................... 29
12. Disposal: .............................................................................................................................................. 29

13. Test Procedures:.................................................................................................................................. 29
13.1 Round Trip Efficiency Test:.............................................................................................................. 29
13.3 Test Method for Self-Discharge: ................................................................................................. 30
14 FAQs: ................................................................................................................................................... 30

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1. Safety Instructions:
This manual contains instructions for unpacking, mounting, installation and operation of a Sirius Module.
Please read this manual carefully before operating the system and follow all warnings and safety instructions
to prevent accidents. The Sirius Module must be installed by trained personnel.
1.1 Symbols Convention:
Safety instructions and general information that appears in this manual are described.
1.2 Safety Precautions:
The Sirius Modules are designed to provide years of trouble-free operation. Proper handling is required to
avoid damage to the Module. In particular the following precautions should be observed.
•Personal Safety:
→Always wear proper personal protective equipment (eyes protection, gloves and safety shoes).
→Always make sure charger is set as recommended.
→Always make sure chargers are disconnected while working on Modules.
•Module Safety:
→Do not subject the Module to strong impact.
Caution!
‘’Caution” indicates hazardous situation which, if not avoided could
result in minor or moderate injury.
Warning!
‘’Warning” indicates hazardous situation which, if not avoided could
result in major injury or death.
Danger!
‘’Danger” indicates hazardous situation which, if not avoided could
result in serious injury or death.
Note!
‘Note” provides tip that are valuable for optimal operation of your
product.

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→Do not dispose the Module in a fire.
→Do not crush or puncture the Module.
→Do not charge the Module when the temperature is below -30oC.
→Do not charge the Module when temperature is above 80oC.
→Do not operate the Module above the specified voltage.
→Under no circumstances charge/discharge the Module at more than 296A.
→Under no circumstances must the charging voltage exceed 55 Vdc for more than 60 seconds.
→Do not expose the Module to temperature in excess of 80°C.
→Do not place the Module near a heat source, such as a fireplace.
→Do not disassemble the Module under any circumstances.
→Do not touch the Module with wet hands.
→Do not expose the Module to moisture or liquids.
→Keep the Module away from children and animals.
→Ensure precautions to prevent short-circuit under all circumstances.
→Do not connect or disconnect terminals from the Module without first disconnecting the load.
→Do not touch the terminals with conductors while the Module is charged. Serious burns, shock, or
material fusing may occur.
→Protect surrounding electrical components from incidental contact.
→When connecting to external devices ensure that galvanic isolation does not exceed 1000V.
→Do not use the Module in open-environment, in rain, or in a place exposed to water and other liquids.
→Do not subject the Module to high pressure.
→Do not place any object on top of the Module.
→It is not recommended to stack more than 3 Modules.
→Do not step on the Module.
→Do not drop the Module. Internal damage may occur that will not be visible.
→Do not stack Modules once they have been removed from the packaging, instead the Modules should be
placed on shelving.
→In case the Module is physically damaged due to any event, do not install and energize the Module under
any circumstances and immediately contact your Reseller.
1.3 Module Connection Safety Precautions:
→All Modules must be at 100% SOC before connecting in series or in parallel.
→The maximum number of Modules that can be connected in series is 8 with a Module Combiner.
Please contact your Resellers for the Module Combiner.
→Do not connect more than 8 Modules in Series.
→Modules cannot be connected in Series-Parallel combination under any circumstance.

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1.4 Shipping
Sirius Capacitor Modules are shipped out via Air and Sea.
If the Modules are shipped via Air, please follow the instructions given below:
•Carefully remove the nails from all the four sides of the wooden box and open it.
•Remove the foam and shrink wrap and open the carton box and lift the Module manually.
If the Modules are shipped via Sea, please follow the instructions given below:
•Carefully remove the Module from the pallets after cutting the packing strip holding the Modules to
the shipping pallets.
•Open the carton box and lift the Module manually.
1.5 Qualified Installer
Selling and installation of this Module is only through the Company’s Resellers who are trained on
installation, operation and maintenance of the Sirius Modules.
2. Product Introduction
2.1 Part Number
1) Capacity of Module in Wh
2) Nominal Voltage of the Module
3) Terminals are on the Front Side
4) Maximum Charge Rate of the Module
5) Total Monitoring
6) With Safety
7) With Alarm
8) General Module
Note!
If you want to connect more than 8 modules in series, please contact your
Reseller.

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2.2 Product Overview:
2.2.1Appearance:
The appearance of the Sirius Module is shown below:

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2.2.2Mechanical Drawings:
Front View
Isometric View

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Side View
Top View

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2.2.3Dimension and Weight
Width
608mm
Length
530mm
Height
345mm
Weight
125 kg
2.3 Front Panel Description:
Object
Mark
Description
1
Circuit Breaker
C100A Circuit Breaker ×2
2
Bypass Breaker
C20A
3
Fault Reset
Fault Reset Button
4
LCD
(16 ×2) LCD
5
Aux
Auxiliary USB
6
Comm Connector
Communication Connector
USB
7
Comm Status
Communication Status LED
8
Terminal Status
Terminal Status LED
9
Terminals
F12 Terminals

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1. Circuit Breaker:
Circuit breaker is used to power ON the Module. It also acts as a second line of protection, if the circuit fails to
protect the Module from over current, the circuit breaker will trip.
2. Bypass Circuit Breaker:
The Bypass Circuit breaker is used to bypass electronic switch. It is used for Series connection and recovery of
the Module.
3. Fault Reset:
Fault Reset is a push button which is used to turn ON the terminal manually after it turns OFF due to any error.
The additional features of fault reset are as follows:
a) Hold fault reset for 5 seconds to toggle the terminal.
b) Hold fault reset for 3 seconds to reset fault if there is/are any.
c) We can set the Current reading to zero.
d) Press fault reset button to check the state of charge and instantaneous power.
•To make the current zero, follow the steps below:
→When current is not zero, the LCD will display the following message.
→To make the current zero, hold the fault reset button for 3 seconds and the LCD will display the following
message.
This means that the current is now zero.
To return back to the normal screen, press the fault reset button once more or leave the Module idle for 5
seconds.
Note!
Make sure that there is no external load or charger before setting the
current to zero.

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4. LCD Description:
→Once the power is switched ON from the circuit breaker, the Module gets power and the LCD shows the
following message after 3 seconds under normal operation:
→
→After 1 second, the following two LCD screens get switched with each other.
5. Auxiliary USB:
This is an auxiliary connector with isolated UART or Serial Communication for wireless monitoring, Module
Combiner and future functions.

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6. COMM Connector USB:
This is a COMM connector to monitor the Module using the Sirius software. FTDi chip is used for this USB.
7. COMM Status LED:
COMM Status LED indicates the communication status.
•LED Status Indication:
Color
Status
Indication
Red
Blinking
Control Module is communicating with Sirius VIEW Software.
Red
Steady
Control Module is not communicating with Sirius VIEW
Software.
Red
Dimming
Module is in power down state.
8. Terminal Status LED:
Terminal status LED indicates the F12 terminal status.
Color
Status
Indication
Green
ON
The F12 terminal is active
Green
OFF
The F12 terminal is not active.
9. F12 Terminals:
These are the output terminals of the Module having electronic switch protection that is limited to 100VDC
only. F12 terminals are used to connect the load or charger to the Module. There are also positive and negative
cables in the jumper cable set. The red one is positive (+), the black one is negative (-).
3. Module Installation:
3.1 Inspection:
Inspect the shipping carton for visible damage including cracks, dents, deformation and other visible
abnormalities prior to unpacking the Module. Document (photograph) any damage and report this to your
Reseller as well as to the shipping agent immediately. Remove the Module from the shipping carton and retain
the shipping materials until the unit has been inspected and is determined to be operational.
Never connect the red cable to the negative terminal of
the Module.

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3.2 Safety Gear:
Installation must strictly follow the national safety regulations in compliance with the enclosure, installation,
creepage, clearance, casualty, markings and segregation requirements of the end-use application. Installation
must be performed by professional installers only. Switch OFF the system and check for hazardous voltages
before altering any connection! Sirius Modules must be handled only by qualified and trained personnel.
Installation should not exert bending or twisting torque to the Module enclosure.
3.3 Unpacking and Contents Check:
Check the contents of the package.
1) Sirius Capacitor Module: 7.1KWh48VDC 3) USB Cable A-B
2) Bolts × 2 4) Washers × 4
Note!
Read the safety Instruction section before installation.
1
2
3
4

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4. Operation Procedures:
4.1 Module Configuration:
Follow the steps below to switch ON the Module.
Step 1: Connecting the Load:
Connect the F12 terminals of the Module to the load. F12 terminals are shown in picture below:
Step 2: Module Start-Up:
1. Turn ON the Circuit breaker by pushing the Blue buttons upwards as shown in the picture below:
2. The picture below shows that the Module is turned ON.

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3. Wait till the LCD screen on the Module displays initial values.
4. Be sure you are able to see the terminal status LED OFF.
5. Press and hold the fault reset button, after 3 seconds the terminal status LED will change to Green.
6. Release the fault reset button.
Step 3: Module Shut-Down:
1. Press and hold the fault reset button to turn OFF the terminal. After 3 seconds the terminal status LED will
go OFF.
2. Make sure every indicator on the Module is OFF.
3. Turn OFF the Module by moving the Circuit breaker button to the OFF position.
4.2 Software Configuration:
To configure Sirius VIEW application, please follow the steps below.
1. Install the Sirius VIEW application on your system.
2. Connect the USB cable to the COMM connector USB slot to start communication and monitoring.
3. Turn on the Sirius Module by pressing the fault reset button on front panel.
4. Wait till the LCD screen on the Module displays initial values.
5. Double click on the Sirius VIEW application to execute it.
Note!
Use the Bypass circuit breaker button to connect the Modules in Series
and for recovery purpose.
Note!
Always turn OFF the Module when not in use because it is Self-
Powered. If left ON, the self-discharge rate will increase.
Note!
Due to shipping laws and regulations, the Module may be shipped in
partial State of Charge.

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6. When the Log-In appears, enter the default username and password as shown below.
Default Username: admin
Default Password:123
7. By clicking on Login, the below pop-up messages will appear.
8. Keep on clicking OK until Sirius VIEW Monitoring Software window appears as shown below. Select Sirius VIEW
and left click.

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9. Follow instructions and press Run button on interface. (Auto Pop-up dialogs).
10. When the connection between PC and Module is established successfully, INIT.LED will be constantly
turned ON.
11. For getting measurement, press RUN button.
12. If there is any problem during connection, check USB cable and ensure the Module is working properly.
13. While getting measurement, MEASURING LED should blink every 1 second. If blinking has stopped, it will
represent measurement interrupt or technical issues.
14. While getting measurement, COMM LED on front panel of the Module will blink.

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5. Recovery Procedure:
When the Module voltage drops below a certain threshold, the control electronics turn OFF. To restart the
control electronics, follow the steps below.
1. Use the Bypass circuit breaker to turn the Module ON as shown below.
2. A power supply having voltage range of 44Vdc to 54Vdc and current range of 1A to 10A will be required.
3. Connect the positive terminal of the power supply to the positive terminal of the F12 terminal and
negative terminal of the power supply to the negative terminal of the F12 terminal.
4. Move the lock screw of the Bypass Circuit breaker upward with the help of screw driver.
5. Once the connection is done, turn ON the circuit breaker as shown below. The Module will recharge and
the control electronics will turn ON.
6. The event may take several minutes depending on the power supply used.
Note!
Please read the Application manual to configure the software thoroughly.
The Application manual is downloaded automatically when you install
Sirius VIEW application.