Kilowatt Labs SIRIUS 5000-384-A-1C-TM-SD-A-X-X-G User manual

Sirius Capacitor Module –User Manual Model Number -5000-384-A-1C-TM-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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SIRIUS CAPACITOR MODULE
User Manual
Model number: 5000-384-A-1C-TM-SD-A-X-X-G
Version 1.2; Release Date: October 2020
Author:
Mamoona Khalid

Sirius Capacitor Module –User Manual Model Number -5000-384-A-1C-TM-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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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 -5000-384-A-1C-TM-SD-A-X-X-G
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Contents
1Safety Instructions:...................................................................................................................... 5
1.1 Symbols Convention: ............................................................................................................ 5
1.2 Safety Precautions: ............................................................................................................... 6
1.3 Module Connection Safety Precautions: .............................................................................. 7
1.4 Shipping:................................................................................................................................ 7
1.5 Qualified Installer:................................................................................................................. 7
2Product Introduction:................................................................................................................ 8
2.1 Part Number:......................................................................................................................... 8
2.2 Product Overview: ................................................................................................................ 9
2.2.1 Appearance:....................................................................................................................... 9
2.2.2 Mechanical Drawings:..................................................................................................... 10
2.2.3 Dimension and Weight:....................................................................................................... 11
2.3 Parts Description:............................................................................................................... 12
3Module Installation:.................................................................................................................. 17
3.1 Inspection:........................................................................................................................... 17
3.2 Safety Gear:......................................................................................................................... 17
3.3 Unpacking and Contents Check: ......................................................................................... 17
4Electrical Installation:................................................................................................................ 18
4.1 Connecting Module to Power Supply:.................................................................................... 18
4.3 Connecting Module to Load:............................................................................................... 19
4.4 Connecting Modules in Parallel: ......................................................................................... 20
5Operation Procedures:.............................................................................................................. 22
5.1 Module Configuration:........................................................................................................ 22
5.2 Software Configuration:...................................................................................................... 23
6Recovery Procedure:................................................................................................................. 24
7Automatic Safety Shutdown:..................................................................................................... 26
8Trouble Shooting:...................................................................................................................... 28
9Features:....................................................................................................................................29

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9.1 Key Features:......................................................................................................................29
9.2 Physical features:............................................................................................................... 29
9.3 Technical Features:............................................................................................................ 30
10 Shelf Life:................................................................................................................................. 31
11 Maintenance:.......................................................................................................................... 31
12 Disposal:.................................................................................................................................. 31
13 Test Procedures:...................................................................................................................... 32
13.1 Round Trip Efficiency Test: ............................................................................................... 32
13.2 Test Method for Self-Discharge:....................................................................................... 33
14 FAQs:.................................................................................................................................... 34

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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.
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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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.
→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 the Module at more than 15A.
→Under no circumstances discharge the Module at more than 15A.
→Under no circumstances must the charging voltage exceed 432 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 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.

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→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.
→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 parallel.
→Do not connect 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 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.

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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 Back Side
4) Maximum Charge Rate of the Module
5) Total Monitoring
6) With Safety
7) With Alarm
8) Not Available
9) Not Available
10) General Module

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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:
Back View
Front View
Side View

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Isometric View
2.2.3 Dimension and Weight:
Width
567 mm
Depth
660 mm
Height
931.50 mm
Weight
178 kg

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2.3 Parts Description:
Object
Mark
Description
1
DIN Connector
For Dry Contact A & B
2
Circuit Breaker
C10A Circuit Breaker
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
Terminals
HVIL125A-S-1S
10
DC Circuit Breaker
2× 125A 2P DC circuit
breakers
11
DIN Connector
For Recovery
12
Fan
12V
  

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1. DIN Connector:
The DIN connector on the front panel of the Module is used for Dry Contact A and B. See the configuration
below:
2. 10A Circuit Breaker:
10 A Circuit breaker is used to power ON the LCD.
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:

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After 1 second, the following two LCD screens get switched with each other.
4. 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 last page of 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.
 
 
 
 

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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.
5. Auxiliary USB:
This is an auxiliary connector with isolated UART or Serial Communication for wireless monitoring, Module
Combiner and future functions.
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
Module is communicating with Sirius VIEW Software.
Red
Steady
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 terminal status.
Color
Status
Indication
Green
ON
Module terminal is active
Green
OFF
Module terminal is not active.
Note!
Make sure that there is no external load or charger before setting the current to
zero.

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9. Terminal:
HVIL125A-S-1S are the output terminals of the Module that are used to connect the load or charger to the
Module. The red one is positive (+), the black one is negative (-).
10. Circuit Breaker:
2 x 125A 2P circuit breaker is used to activate the terminals of 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.
11. DIN Connector:
When the Module drops to a certain threshold voltage, control electronics will turn OFF. In this case, DIN
Connector will be used to recover the Module.
12. Fan:
Four fans are installed inside the Module which will automatically turn ON when the temperature reaches
40°C and will turn OFF once the temperature goes down to 35°C and below.

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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 the Module
enclosure.
3.3 Unpacking and Contents Check:
Check the contents of the package.
•Sirius Capacitor Module: 5000Wh, 384VDC
•USB Cable A-B
•35mm² Charging Cables
Note!
Read the safety Instruction section before installation.

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4Electrical Installation:
4.1 Connecting Module to Power Supply:
1. Connect positive and negative terminals of charger to the positive and negative terminals of the Sirius
Module respectively.
2. Turn ON the Circuit breakers.
3. Make sure to activate the Module by turning ON the power switch to get the output from the
terminal.
4. Turn ON theCharger.

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4.3 Connecting Module to Load:
•Connect positive and negative terminals of discharger to the positive and negative terminals of the
Sirius Module respectively.
•Turn ON the Circuit Breakers.
•Make sure to activate the Module by turning ON the power switch to get the output from the
terminals.
•Turn ON thedischarger.

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4.4 Connecting Modules in Parallel:
Any number of Modules can be connected in parallel.
•Steps to Connect Modules in Parallel:
Refer to the parallel combination of the Sirius Modules as shown below and make your connection
accordingly.
•Connect the positive (+) terminal of all Modules.
•Connect the negative (-) terminal of all Modules.
•Take out the output positive terminal and output negative terminal from the respective common
point.
Caution!
Charge all the Modules to 100% SOC or same voltage level before
connecting them in Parallel.