Kilowatt Labs 7100-48-B-3.3C-M-SD-A-FL User manual

SIRIUS CAPACITOR MODULE
User Manual
Model number: 7100-48-B-3.3C-M-SD-A-FL
Version 1.0; Release Date: May 2019

Dear Customer
Thank you for choosing the Sirius Capacitor Module (“Sirius” or the “Module”). Our products are
manufactured to the highest design and technology specifications and standards and every Module has
been fully tested for performance and safety before it leaves our factory. Please take the time to read this
manual, which guides you through all the functionalities, operations and safeties of the Module so that you
get optimal performance. Our priority is to provide a safe and a great user-friendly experience. If you have
any comments, please contact your Reseller.
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.

1. Introduction...................................................................................................................................................4
2. Safety Instructions.........................................................................................................................................4
2.1 Symbol Convention ...............................................................................................................................4
2.2 Safety Precautions.................................................................................................................................4
2.3 Module Connection Safety Precautions ...............................................................................................5
2.4 Qualified Installer ..................................................................................................................................6
2.5 Shipping .................................................................................................................................................6
3. Product Introduction.....................................................................................................................................6
3.1 Part Number ..........................................................................................................................................6
3.2 Product Overview..................................................................................................................................7
3.2.1 Appearance...........................................................................................................................................7
3.2.2 Mechanical Drawings ...........................................................................................................................7
3.2.3 Dimension and Weight.........................................................................................................................9
3.3 Front Panel Description.........................................................................................................................9
4. Module Installation......................................................................................................................................13
4.1 Inspection ............................................................................................................................................13
4.2 Safety Gear ..........................................................................................................................................14
4.3 Unpacking and Contents Check ..........................................................................................................14
5. Operation Procedures .................................................................................................................................15
6. Software Configuration ...............................................................................................................................18
7. Recovery Procedure ....................................................................................................................................19
8. Connecting the Modules in Parallel or in Series.........................................................................................20
9. Automatic Safety Shutdown........................................................................................................................22
10. Trouble Shooting .........................................................................................................................................23
11. Features .......................................................................................................................................................24
12. Shelf Life.......................................................................................................................................................26
13. Maintenance................................................................................................................................................26
14. Disposal........................................................................................................................................................26

Sirius Capacitor Module –User Manual Model Number -7100-48-B-2C-M-SD-A-FL
This manual is subject to change without notice and at the sole discretion of Kilowatt Labs, Inc.
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Caution!
‘Caution” indicates hazardous situations which, if not avoided, could
result in minor or moderate injury.
Danger!
‘Danger” indicates hazardous situationswhich, if not avoided, could
result in serious injury or death.
1. Module Introduction
The Sirius Module 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 Module, making Sirius a safe, efficient and effective alternative to chemical batteries
wherever chemical batteries are deployed.
2. 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.
2.1 Symbol Convention
Safety instructions and general information that appear in this manual are described:
2.2 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
oAlways wear proper personal protective equipment (eye protection, gloves and safety shoes).
oAlways make sure the charger is set as recommended.
oAlways make sure the charger is disconnected while working on the Modules.
oMake sure the Module is properly grounded.
Note!
‘Note” provides tips that are valuable for optimal operation of the
Module.
Warning!
‘Warning” indicates hazardous situations which, if not avoided, could
result in major injury or death.

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•Module Safety
oDo not subject the Module to strong impacts.
oDo not crush or puncture the Module.
oDo not dispose the Module in a fire.
oDo not charge the Module when the temperature is below -30oC.
oDo not charge the Module when temperature is above 80oC.
oDo not operate the Module above the specified voltage.
oUnder no circumstances charge/discharge the Module at more than 500A.
oUnder no circumstances must the charging voltage exceed 55 Vdc for more than 60 seconds.
oDo not expose the Module to temperatures in excess of 80°C.
oDo not place the Module near a heat source, such as a fireplace.
oDo not disassemble the Module under any circumstances.
oDo not touch the Module with wet hands.
oDo not expose the Module to moisture or liquids.
oKeep the Module away from children and animals.
oEnsure precautions to prevent short-circuit under all circumstances.
oDo not connect or disconnect terminals from the Module without first disconnecting the load.
oDo not touch the terminals with conductors while the Module is charged. Serious burns,
shock, or material fusing may occur.
oProtect surrounding electrical components from incidental contact.
oWhen connecting to external devices ensure that galvanic isolation does not exceed 1000V.
oDo not use the Module in open-environment, in rain, or in a place exposed to water and other
liquids.
oDo not subject the Module to high pressure.
oDo not place any objects on top of the Module.
oDo not step on the Module.
oDo not drop the Module. Internal damage may occur that will not be visible.
oDo not stack Modules once they have been removed from the packaging, instead the Modules
should be placed on shelving.
oIn 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.
2.3 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.

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Note!
If you want to connect more than 8 modules in series, please contact your
Reseller.
•Modules cannot be connected in Series-Parallel combination under any circumstance.
2.4 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.
2.5 Shipping
Sirius Capacitor Modules are shipped to you either by air or by sea.
If you receive the Modules shipped by 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 you receive the Modules shipped by 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.
3. Product Introduction
3.1 Part Number
7100 –48 –B –3.3C –M –SD –A –FL
Capacity of Module in Wh
Nominal Voltage of the
Module Terminals are on the
Front Side Charge Rate of the
Module Individual Cell
Monitoring with Safety
With Alarm
Forklift
4
7
6
5
4
3
2
1
7
8
6
3
5
4
1
2

Sirius Capacitor Module –User Manual Model Number -7100-48-B-2C-M-SD-A-FL
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3.2 Product Overview
3.2.1 Appearance
The appearance of the Sirius module is shown below:
3.2.2 Mechanical Drawings
Front View

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Top View
Side View
Isometric View

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3.2.3 Dimension and Weight
Width
608mm
Length
530mm
Height
345mm
Weight
130 kg
3.3 Front Panel Description
Object
Mark
Description
1
Circuit Breaker
C100A Circuit Breaker ×2
2
Fault Reset
Fault Reset Button
3
LCD
(16 ×2) LCD
4
Aux
Auxiliary USB
5
Comm Connector
Communication Connector
USB
6
Comm Status
Communication Status LED
7
Terminal Status
Terminal Status LED
8
Protected Terminals
Protected Terminals
9
Unprotected Terminals
Unprotected Terminals
1. Circuit Breaker
Circuit breaker is used to power ON the Module. This also acts as a second line of protection, if
the circuit fails to protect the Module from over current, the circuit breaker will trip.

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2. Fault Reset
Fault Reset is a push button which is used to turn ON the protected 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 protected 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.
e) Press the Fault Reset button to see the individual cell voltages.
•Checking for individual Cell Voltage
When the fault reset button is pressed, the LCD after displaying the state of charge and
instantaneous power, will display the cell voltages of the first four cells as shown below:
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
following the steps below:
Step 1: When the current is zero, the LCD will display the following message :
Step 2: After this message appears, hold the fault reset button for 5 seconds, then the LCD will
display the following message:

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This means that 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 cell balancing has been disabled.
Step 5: To make the current zero, follow the steps below:
•When the 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!
Balancing is automatically disabled if there is a current reading greater
than zero.
Note!
To enable and disable balancing, the current should always be zero.

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•LCD Description
•Once the power is switched ON from the circuit breaker, the Module gets power and the
LCD shows the following message after 3seconds under normal operation:
•After 1 second, the following two LCD screens gets switched between each other.
3. Auxiliary USB
This isanauxiliaryconnectorwith isolated UART orSerial Communication for wireless monitoring, Module
combiner and future purposes.
Note!
Make sure that there are no external loads or charger before setting the
current to zero.

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4. COMM Connector USB
This is a COMM connector to monitor the Module using the SiriusView software. FTDi chip is used for
this USB.
5. COMM Status LED
COMM Status LED indicates the communication status.
•LED Status Indication
Color
Status
Indication
Red
Blinking
Control module is communicating with SiriusView software.
Red
Steady
Control module is not communicating with SiriusView
software.
Red
Dimming
Module is in power down state.
6. Terminal Status LED
Terminal status LED indicates the protected terminal status.
Color
Status
Indication
Green
ON
The protected terminal is active
Green
OFF
The protected terminal is not active
7. Protected Terminal
This is the output terminal of the module which has electronic switch protection that is limited to
100VDC only.
8. Unprotected Terminal
This is the second terminal of the module which is used for series connection and recovery.
Although the name implies unprotected, this terminal is still protected with the DC circuit
breaker.
4. Module Installation
4.1 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 by your Reseller and is
determined to be operational.
Note!
Do not use this terminal when connecting the module in series.

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4.2 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.
4.3 Unpacking and Contents Check
Check the contents of the package.
1) Sirius capacitor Module: 7.1kWh48VDC
2) Cable tie support
3) Anderson Connectors with lug
4) USB cable A-B
5) Cable tie
1
2
3
4
5
Note!
Read the safety Instruction sheet before installation.

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5. Operation Procedures
5.1 Module Setup
Follow the steps below to switch ON the Module.
Step 1: Connection of Cables to Anderson Connectors
First connect the Anderson Connector to the Cables of the Module, by following the steps below:
•Take Anderson Connector as shown in the picture.
•Strip the insulation from the cable and gently twist the wire strands to keep them in contact (as
shown in pic below).
•Put the wire strands into the Anderson connector lugs and crimp tightly down. Once crimped,
pull the connector to make sure it is firmly attached to the wires. After crimping, the connector
is as shown in the picture.

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•Hold the housing and place the connector into the back of the housing and push it tightly. Make sure
the Anderson connector is firmly hooked.
Step 2: Connecting the Load
Connect the Anderson Connector to the Protected Terminal of the Module as shown in picture below:
Note!
Use the Unprotected terminals to connect the Modules in series and for
recovery purpose.

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Step 3: Module Start-Up
1. Turn ON the circuit breaker by pushing the Blue button upwards as shown in the picture below:
2. The picture below shows that the module is turned ON.
3. Be sure you are able to see the terminal status LED OFF.
4. Wait till the LCD screen on the Module displays initial values.
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 4: 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.
Note!
Due to shipping laws and regulations, the module may be shipped in partial
state of charge.

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6. Software Configuration
To configure the SiriusVIEW application, please follow the steps below:
1. Install the SiriusVIEW application on your computer.
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.
4. Wait till the LCD screen on the Module displays initial values.
5. Double click on the SiriusVIEW application to execute it.
6. When the login appears, enter the default username and password:
Default Username: admin
Default Password:123
7. Select SiriusVIEW as shown below and left click.
8. Enter Serial Port (COM) that Module is using at the beginning of application and select the
type of module from drop down menu.
Note!
Always turn OFF the Module when not in use because the Module is self-
powered. If left on, the self-discharge rate will increase.

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INIT DONE
9. Follow instructions and press Run on interface. (Auto Pop-up dialogs)
10. When the connection between the computer and the Module is established successfully,
then the LED will be continually turned on.
11. For getting measurements, 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.
7. Recovery Procedure
When the Module voltage drops below a certain threshold, the control electronics are turned OFF. To
restart the control electronics, follow the steps below:
1. Use the Unprotected terminal to turn the module ON.
2. A power supply having a 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
Unprotected terminal and negative terminal of the power supply to the negative terminal of
the Unprotected terminal using the lead provided.
4. Once the connection is done, turn ON the circuit breaker, the module will recharge, and the
control electronics will turn ON.
5. The event may take several minutes depending on the power supply used.
6. At this stage, remove the power supply and leave the module for normal recharge.
Note!
Please read the Application manual to configure the software thoroughly.
The Application manual is downloaded automatically when you install
SiriusVIEW application.

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•Recommended Charger for Recovery:
Maximum Current
10 A
Recommended Voltage
44V-54V
8. Connecting the Modules in Parallel or in Series
The capacity or voltage of the Modules can be increased by connecting them in parallel or series
respectively.
8.1 Parallel Connection of Sirius Modules
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 connections
accordingly.
Caution!
Do not use more than 10A to recover the module.