Kilowatt Labs SIRIUS 1000-48-B-1C-TM-A-G User manual

SIRIUS CAPACITOR MODULE
User Manual
Model number: 1000-48-B-1C-TM-A-G
Version 1.0; Release Date: March 2020
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.

Sirius Capacitor Module –User Manual Model Number -1000-48-B-1C-TM-A-G
This manual is subject to change without notice and at the sole discretion of Kilowatt Labs, Inc.
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Table of Contents:
1. Safety Instructions ....................................................................................................................4
1.1 Symbol Convention...........................................................................................................4
1.2 Safety Precautions ............................................................................................................4
1.3 Module Connection Safety Precautions ...........................................................................6
1.4 Shipping ............................................................................................................................6
1.5 Qualified Installer..............................................................................................................6
2. Product Introduction ................................................................................................................7
2.1 Product Part Number:.......................................................................................................7
2.2 Product Overview: ..................................................................................................................7
2.2.1 Appearance:.......................................................................................................................7
2.2.2 Mechanical Drawings.........................................................................................................8
2.2.3 Dimensions and Weight.....................................................................................................9
2.3 Product Description................................................................................................................9
3. Module Installation.................................................................................................................12
3.1 Inspection .............................................................................................................................12
3.2 Safety Gear............................................................................................................................12
3.3 Unpacking and Contents Check ............................................................................................13
4. Operation Procedures.............................................................................................................14
4.1 Module Configuration...........................................................................................................14
5. Electrical Installation...............................................................................................................15
5.1 Connecting Module to Power Supply .............................................................................15
5.2 Connecting Module to Load ...........................................................................................16
5.3 Connecting Modules in Parallel ......................................................................................16
5.4 Connecting Modules in Series ........................................................................................17
6. Recovery Procedure................................................................................................................19
7. Automatic Safety Alarm..........................................................................................................20
8. Trouble Shooting.....................................................................................................................25
9. Features ..................................................................................................................................27
9.1 Key Features........................................................................................................................27
9.2 Physical features.................................................................................................................27
10. Shelf Life..................................................................................................................................27
11. Maintenance...........................................................................................................................27
12. Disposal...................................................................................................................................27

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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 appear 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 (eye protection, gloves and safety shoes).
→Always make sure the charger is set as recommended.
→Always make sure the chargers are disconnected while working on the Modules.
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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•Module Safety:
→Do not subject the Module to strong impact.
→Do not crush or puncture the Module.
→Do not dispose of the Module by incineration.
→Do not charge the Module when the temperature is below -30oC.
→Do not charge the Module when the temperature is above 80oC.
→Do not operate the Module above the specified voltage.
→Under no circumstance charge/discharge the Module at more than 20A.
→Under no circumstance must the charging voltage exceed 54 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.
→Do not disassemble the Module under any circumstances.
→Do not lift the Module by the terminal posts.
→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 1500V.
→Do not use the Module in a wet environment, such as in rain or a place exposed to water or other
liquids.
→Do not subject the Module to high pressure.
→Do not place any objects on top of the Module.
→Do not step on the Module.
→Mount the Modules only in a horizontal orientation.
→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.

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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.
→Do not connect more than 8 Modules in Series.
→There is no limit to the number of Modules that can be connected in parallel.
→Modules cannot be connected in Series-Parallel combinations under any circumstance.
1.4 Shipping:
Sirius Modules can be shipped via Air or 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, open the carton box and lift the Module out manually.
•If you receive the Modules by Sea, please follow the instructions below:
•Carefully remove the Modules from the pallets after cutting the packing strip holding the
Modules to the shipping pallets.
•Open the carton and lift the Module out 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.
Danger!
The Module must be removed from the carton by lifting the it from its
base. Do not remove the Module by the terminal posts.
Note!
Do not stack more than 2 Modules.

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2. Product Introduction:
2.1 Product 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 Alarm
7) General Module
2.2 Product Overview:
2.2.1 Appearance:
The appearance of the Sirius Capacitor Module is shown below:

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2.2.2 Mechanical Drawings:
Isometric View
Front View

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2.2.3 Dimensions and Weight:
Width
128 mm
Depth
1420 mm
Height
118 mm
weight
23 Kg
2.3 Product Description:
1. Power Switch
2. LCD
3. Fault Reset
4. Terminals
Side View

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1. Power Switch:
When the power button is switched ON, the Module electronics are powered up and it will raise an
alarm during overvoltage, undervoltage, overcurrent and overtemperature. If the switch is OFF then
there will be no alarm.
2. 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 each 1-second interval, the following two LCD screens rotate with each other.

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3. Fault Reset:
Fault Reset is a push-button switch which is used to reset alarm raised during overvoltage,
undervoltage, overcurrent and overtemperature faults. It is also used to set the offset current to zero.
4. Terminals:
F12 terminals are used to connect the load or charger to the Module. The red terminal is positive (+),
the black terminal is negative (-).
Never connect the red cable to the negative terminal of
Module.

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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.
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.
Note!
Read the safety Instruction sheet before installation.

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3.3 Unpacking and Content Check:
Check the contents of the package. In addition to the Module, two sets of items are included.
1) Sirius Capacitor Module: 1KWh48VDC
2) Bolts × 2
3) Washers × 4
4
1
2
3

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4. Operation Procedures:
4.1 Module Configuration:
Follow the steps below to switch ON the Module.
Step 1: Module Start-Up:
1. Connect the F12 terminals of the Module to the load.
2. Turn ON the power switch button in order to give alarm during overvoltage, undervoltage,
overcurrent and overtemperature faults.
Step 2: Module Shut-Down:
1. The Module can be shut down by disconnecting the load.
Note!
Always turn OFF the Module when not in use because the Module
is Self-Powered, resulting in faster Self-Discharge of the Module.
Note!
The Module should only be operated within the specified voltage
and temperature ratings.
Note!
Observe polarity indicated on Module. Do not reverse polarity.

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5. Electrical Installation:
5.1 Connecting Module to Power Supply:
•Connect positive and negative terminals of charger to the positive and negative terminals of the
Sirius Module respectively.
•Make sure to activate the Module by turning ON the power switch to get the output from the
terminal.
•Turn ON theCharger.

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5.2 Connecting Module to Load:
•Connect positive and negative terminals of discharger to the positive and negative terminals of the
Sirius Module respectively.
•Make sure to activate the Module by turning ON the power switch to get the output from the
terminal.
•Turn ON thedischarger.
5.3 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 connections
accordingly.

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•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.
5.2 Connecting Modules in Series:
A maximum of 8 Modules can be connected in Series.
•Steps to Connect Modules in Series:
Refer to the Series combination of the Sirius Modules as shown below and make your connection
accordingly.
•Connect the positive (+) terminal of the first Module with the negative (-) terminal of the next
Module.
•Take the Output Negative from first Module and Output Positive from the last Module.
Caution!
Charge all the Modules to 100% SOC or same voltage level before
connecting them in Parallel.

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Caution!
Charge all the Modules to 100% SOC or the same voltage level before
connecting them in Series.
Note!
Modules cannot be connected in series-parallel combination under any
circumstance.

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6. Recovery Procedure:
Follow the steps below to recover the Module.
1. Utilize a power supply with a voltage range of 44Vdc to 54Vdc and current range of 1A to 10A.
2. 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.
3. Once the connection is done, turn ON the Charger.
4. Recovery may take several minutes depending on the power supply used.
5. At this stage, remove the power supply and charge the Module as per the normal procedure.
•Recommended Charger for Recovery:
Maximum Current
10 A
Recommended Voltage
44V-54V
Caution!
Do not use more than 10A to recover the Module.

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7. Automatic Safety Alarms:
The Module will automatically raise an alarm under excessive use conditions in order to prevent
damage to itself and connected equipment. Specified limits for excessive current, high voltage and
low voltage are provided in Module’s technical data sheet.
Alarm
LCD warning
Description
OVER-VOLTAGE
When the voltage has increased
beyond the cut-off limit of 54V, the
Module experiences an Over-
Voltage fault. The Module will raise
an alarm which can be reset using
the fault reset button.
UNDER-VOLTAGE
When the voltage falls below the
cut-off limit of 44V, the Module
experiences an Under-Voltage
fault. The Module will give an alarm
which can be reset using the fault
reset button.
OVER-TEMPERATURE
(TERMINAL)
When the Module experiences an
Over-Temperature fault, the buzzer
gives an alarm, which can be reset
using the fault reset button.
OVER-TEMPERATURE
(TERMINAL) &
OVER-VOLTAGE
When the Module experiences an
Over-Temperature and Over-
Voltage fault, the buzzer alarms,
which can be reset using the fault
reset button.
OVER-TEPMERATURE
(TERMINAL) &
UNDER-VOLTAGE
When the Module experiences an
Over-Temperature and Under-
Voltage fault, the buzzer alarms,