Kilowatt Labs SIRIUS 1860-24-B-1C-M-SD-A-X-X-G User manual

SIRIUS CAPACITOR MODULE
User Manual
Model number: 1860-24-B-1C-M-SD-A-X-X-G
Version 1.0; Release Date: June 2020
Author:
Mamoona Khalid

Sirius Capacitor Module –User Manual Model Number - 1860-24-B-1C-M-SD-A-X-X-G
This manual is subject to change without notice and at the sole discretion of Kilowatt Labs, Inc.
Kilowatt Labs, Inc. | www.kilowattlabs.com
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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.

Sirius Capacitor Module –User Manual Model Number - 1860-24-B-1C-M-SD-A-X-X-G
This manual is subject to change without notice and at the sole discretion of Kilowatt Labs, Inc.
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3
Contents
1 Safety Instructions: .........................................................................................................................5
1.1 Symbols Convention: ..............................................................................................................5
1.2 Safety Precautions: .................................................................................................................5
1.3 Modules Connection Safety Precautions:...............................................................................7
1.4 Shipping: .................................................................................................................................7
1.5 Qualified Installer:...................................................................................................................7
2 Product Introduction:......................................................................................................................8
2.1 Part Number:.................................................................................................................................8
2.2 Product Overview: ........................................................................................................................8
2.2.1 Appearance:...............................................................................................................................8
2.2.2 Mechanical Drawings:..............................................................................................................9
2.2.3 Dimensions and Weight:......................................................................................................11
2.3 Product Description: ...................................................................................................................12
3 Module Installation:......................................................................................................................18
3.1 Inspection:...................................................................................................................................18
3.2 Safety Gear:.................................................................................................................................18
3.3 Unpacking and Contents Check: .................................................................................................18
4 Electrical Installation:....................................................................................................................19
4.1 Cable Size:...................................................................................................................................19
4.2 Connecting Cable Lugs, Washers and Bolts to Module Terminals:.............................................19
4.1 Connecting Module to Power Supply: ............................................................................................20
4.2 Connecting Module to Load:...........................................................................................................21
4.3 Connecting Modules in Parallel: .....................................................................................................22
4.4 Connecting Modules in Series:........................................................................................................23
4.4.1 Steps to Operate Modules in Series:............................................................................................23
5 Operation Procedures:..................................................................................................................25
5.1 Module Configuration:....................................................................................................................25
5.2 Software Configuration:..................................................................................................................27
6 Recovery Procedure:.....................................................................................................................30
7 Automatic Safety Shutdown: ........................................................................................................32
8 Trouble Shooting:..........................................................................................................................34
9 Features: .......................................................................................................................................35
9.1 Key Features:.............................................................................................................................35
9.2 Physical features: ......................................................................................................................35

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9.3 Technical Features: ...................................................................................................................36
10 Shelf Life:.......................................................................................................................................37
11 Maintenance:................................................................................................................................37
12 Disposal:........................................................................................................................................37
13 Test Procedures: ...........................................................................................................................38
13.1 Round Trip Efficiency Test:........................................................................................................38
13.2 Test Method for Self-Discharge:...............................................................................................39
14 FAQs:.............................................................................................................................................40

Sirius Capacitor Module –User Manual Model Number - 1860-24-B-1C-M-SD-A-X-X-G
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1Safety 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).
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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→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.
→Do not crush or puncture the Module.
→Do not dispose the Module in a fire.
→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 80 A.
→Under no circumstance must the charging voltage exceed 27 Vdc for more than 60 seconds.
→Do not expose the Module to temperatures 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 step on the Module.

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→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 Modules Connection Safety Precautions:
→All Modules must be at 100% SOC or same level of voltage before connecting in Series or in
Parallel.
→The maximum number of Modules that can be connected in series is 8 with Module Combiner.
→Do not connect more than 8 Modules in Series.
→Modules cannot be connected in Series-Parallel combination under any circumstance.
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 cling wrap and open the carton box and lift the Module manually.
•If the Modules are shipped via Sea, please follow the instructions 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.
Note!
If you want to connect more than 8 Modules in Series, please contact your
Reseller.

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2Product 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) With Individual Cell Monitoring
6) With Safety
7) With Alarm
8) Not Available
9) Not Available
10) General Module
2.2 Product Overview:
2.2.1 Appearance:
The appearance of the Sirius Module is shown below:

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2.2.2 Mechanical Drawings:
Front View

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Side View
Top View

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2.2.3 Dimensions and Weight:
Width
419 mm
Depth
474 mm
Height
200 mm
Weight
41 kg
Isometric View

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2.3 Product Description:
Object
Mark
Description
1
Circuit Breaker
Two C100A Circuit breakers for switch
ON/OFF Module.
2
Bypass Circuit Breaker
C100A Circuit breaker for bypassing
electronic switch.
3
LCD
(16×2) LCD
4
Fault Reset
Fault Reset Button
5
Aux
Auxiliary USB
6
Comm Connector
Communication Connector USB
7
Comm Status
Communication Status LED
8
Terminal Status
Terminal Status LED
9
F08 terminals
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
breaker 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. 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.

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4. Fault Reset:
Fault Reset is a push button which is used to turn ON the terminals 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 terminals.
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.
e) Press the fault reset button to see the individual cell voltages.
5. Checking for Individual Cell Voltages:
When the fault reset button is pressed, the LCD after displaying the state of charge (SOC) and
instantaneous power, will display the cell voltages of the first four cells as shown below:
Whereas:
01=Voltage of 1st Cell
02=Voltage of 2nd Cell
03=Voltage of 3rd Cell
04=Voltage of 4th Cell
By continuously pressing, the cell voltages will be displayed for all the cells.
•Enabling/Disabling Cell Balancing:
After scrolling through the individual cell voltages, cell balancing can be enabled/disabled by the
following steps below:
Step 1: When current is zero, LCD will display the message as illustrated below.

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Step 2: After this message appears, hold fault reset button for 5 seconds, then the LCD will display the
following message which means that the cell balancing has been enabled.
Step 3: To disable cell balancing, when current is zero, the LCD will display the following message.
Step 4: After this message appears, hold the fault reset button for 5 seconds, then when the LCD
displays the following message, it means that balancing has been disabled.
Note!
To enable and disable balancing, the Current should always be zero.
Note!
Balancing is automatically disabled if there is a Current reading
greater than zero.

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Step 5: 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.
6. Auxiliary USB:
This is an auxiliary connector with isolated UART or Serial Communication for wireless monitoring,
Module Combiner and future functions.
7. COMM Connector USB:
This is a COMM connector to monitor the Module using the Sirius software. FTDi chip is used for this
USB.
8. COMM Status LED:
COMM Status LED indicates the communication status.
Note!
Make sure that there is no external load or charger before setting the current
to zero.

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•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.
9. Terminal Status LED:
Terminal status LED indicates the F08 terminal status.
Color
Status
Indication
Green
ON
The F08 terminal is active
Green
OFF
The F08 terminal is not active.
10. F08 Terminals:
These are the output terminals of the Module having electronic switch protection that is limited to
100VDC only. F08 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 (-).
Note:
Never connect the red cable to the negative terminal of the Module.

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3Module 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.
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 theModule
enclosure.
3.3 Unpacking and Contents Check:
Check the contents of the package.
1) Sirius Capacitor Module: 1.86KWh24VDC
2) Bolts × 2
3) Washers × 4
Note!
Read the safety Instruction section before installation.
1
2
3

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4Electrical Installation:
4.1 Cable Size:
We recommend a cable size of 35mm2thick and 1m length to hold current up to 150A. Please use
thick cable size for lengths longer than 1m.
4.2 Connecting Cable Lugs, Washers and Bolts to Module Terminals:
Follow the sequence below to connect the washers, lugs and bolts to the positive and negative
terminals of the Sirius Module. Make sure connection is not loose.
Connecting washers, lugs and bolts to negative terminal of Module
Connecting washers, lugs and bolts to positive terminal of Module
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4.1 Connecting Module to Power Supply:
•Connect positive and negative terminals of charger to the positive and negative terminals of the
Sirius Module respectively.
•Turn ON the Circuit breaker.
•Make sure to activate the Module by pressing the fault reset button to get the output from
the terminal.
•Turn ON theCharger.