Kold-Ban International, Ltd. KSM PLC User manual

KAPower Starting Module (KSM)
With
Programmable Logic Controller (PLC)
INSTALLATION – OPERATION MANUAL
Gen 3. Rev D
!"#$!%&'(")*+#*,-.*),/%*)&0+1,'2
3456+7/*8.--+9%)'0+1):-+#*+;<-+=/&&>0+#&&/*%/>+?6@A?(5?4B+C2D2E2
F366G+AHB(3HB30+F3IBG+?A3(3A?@0+J)K+F3IBG+?A3(5H360+LLL2:%&'M)*2N%O
E;E+PQ9D+(+;II+!1R"S+
+
+
+
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+
Gen$3$
12$&$24$Volt$

+
H+
+
+
+
PARTS$LISTX+
+
@2 !DQ+71Y+O%'Z&-2++
H2 R%ZM&-+7%&-+D/*8&-+;<.%L+FR7D;G+[Z><+MZ,,%*+>L/,N<2+
42 \/./*8+<).*->>2+FS%,+D<%L*G+
I2 ;-.O/*)&+8.-)>-2+FS%,+D<%L*G++
A2 7.%,-N,/W-+M%%,>2+FS%,+D<%L*G+
ITEMS$NEEDED$FOR$INSTALLATIONX+
+
@2 "),,-.]+N)M&->0+I$6+N)M&-+/>+.-N%OO-*'-'2++
H2 ;-.O/*)&>+^%.+M),,-.]+N)M&-2+
42 ;%._Z-+L.-*N<+L/,<+`+/*N<+>%N:-,2++
I2 @?+8)Z8-+L/.-+^%.+<).*->>->2++
+
+++++++++++++++++++++++++++++++++++++ ++++++++++++++++++++++++++++++++++++ +
+++++
+++++++++++++++++++++++@2++++++++++++++++++++H2+++++++++++++++++++++++++++
+
++

+
4+
SAFETY AWARENESS
+
DEJa;b+E\E9aSaDD+ DbQ"c1D+).-+/*>-.,-'+/*+,</>+O)*Z)&+,%+)&-.,+]%Z+
,%+[%>>/M&-+DEJa;b+=EdE9RD2+\<-*-W-.+]%Z+>--+,<->-+>]OM%&>X++
+
%.++ <--'+,<-/.+/*>,.ZN,/%*>e+
+
DEJa;b+E\E9aSaDD+DbQ"c1D+ESR+QaES#SfDX++
;=#D+\E9S#Sf+DbQ"c1+#RaS;#J#aD+D7aY#E1+
#SD;9CY;#cSD+c9+79cYaRC9aD0+\=#Y=0+#J+Sc;+
Yc99aY;1b+Jc11c\aR0+YcC1R+9aDC1;+#S+7a9DcSE1+
#SgC9b2
+
+
;=#D+YEC;#cS+DbQ"c1+#RaS;#J#aD+D7aY#E1+#SD;9CY;#cSD+c9+
79cYaRC9aD0+\=#Y=0+#J+Sc;+D;9#Y;1b+c"Da9PaR0+YcC1R+9aDC1;+#S+
REQEfa+;c+c9+RaD;9CY;#cS+cJ+ahC#7QaS;2
+
+
+
!E7%L-.+O%'Z&-+/>+)+[.%'ZN,+%^+</8<+-&-N,./N+[%L-.2
S-W-.+ ><%.,+ N/.NZ/,+ !E7%L-.+ O%'Z&-+ ,-.O/*)&>e+ "Z.*/*8+ %.+ /8*/,/*8+ %^+
N%OMZ>,/M&-+O),-./)&>+)'i)N-*,+,%+,<-+[%/*,+%^+><%.,+N/.NZ/,+O)]+^%&&%L+/,2+
#*+ N)>-+ %^+ )NN/'-*,)&+ ><%.,(N/.NZ/,(/*8+ %^+ ,<-+ !E7%L-.+ O%'Z&-+ %.+
/*'/W/'Z)&+ N)[)N/,%.>+ /,+ />+ *-N->>).]+ ,%+ '/>N%**-N,+,<-+ !E7%L-.+O%'Z&-+
/OO-'/),-&]+^.%O+,<-+-&-N,./N+N/.NZ/,+,):/*8+.-&-W)*,+>)^-,]+O-)>Z.->2+
+
+
+
+
S%*N%O[&/)*N-+L/,<+,<-+.-_Z/.-O-*,>+>-,+^%.,<+/*+,</>+Q)*Z)&+O)]+.->Z&,+/*+!E7%L-.+O%'Z&-+^)/&Z.-2+DZN<+
.-_Z/.-O-*,>+><)&&+M-+.-W/-L-'+[./%.+,%+)*'+%M>-.W-'+/*+,<-+N%Z.>-+%^+!E7%L-.+O%'Z&-+%[-.),/%*+)*'+/*>,)&&),/%*2
;<-+!E7%L-.+O%'Z&-+/>+[%&)./,]+>-*>/,/W-2+7%&)./,]+><)&&+M-+>,./N,&]+%M>-.W-'+L<-*+N%**-N,/*8+,<-+!E7%L-.+O%'Z&-e
WARNING
CAUTION
WARNING
CAUTION
WARNING
Note:&&KAPower&is#not#a"high(voltage(device.((It(simply(supplies'the'
same%voltage%that%it%was%charged%up%to.%%Treat%it%with%the%same%
respect'you'would'give'to'a'fully'charged'battery.
CAUTION

+
I+
TABLE OF CONTENTS:
+
7).,>+&/>,+)*'+.-_Z/.-'+/,-O>22222222222222222222222222222222222222222222222222H+
#*,.%'ZN,/%*22222222222222222222222222222222222222222222222222222222222222222222222222222222222A
#*>,)&&),/%*2222222222222222222222222222222222222222222222222222222222222222222222222222222222222?+
R/O-*>/%*>jjjjjjjjjjjjjjjjjjjjj3+k+5+
\/./*8+R/)8.)Ojjjjjjjjjjjjj2jjjj@6+k+@4
c[-.),/%*22222222222222222222222222222222222222222222222222222222222222222222222222222222222222@I
;.%ZM&-><%%,/*8222222222222222222222222222222222222222222222222222222222222222222222222@A
Q)/*,-*)*N-22222222222222222222222222222222222222222222222222222222222222222222222222222222@A
D,%.)8-2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222@?
;.)*>[%.,),/%*222222222222222222222222222222222222222222222222222222222222222222222222222@?
S%,->X
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
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+
+
+

+
A+
INTRODUCTION:
!DQ+/>+)+[.-[)N:)8-'+!E7%L-.+)>>-OM&]+)&&%L/*8+^%.+,<-+-)>-+%^+/*>,)&&),/%*+)*'+%[-.),/%*+
%^+]%Z.+!E7%L-.+>]>,-O2++;<-+!DQ+-*N&%>Z.-+N%*>/>,>+%^+)+!E7%L-.+O%'Z&-0+)+N%*,)N,%.0+)+
71Y+ Q%'Z&-0+ )+ N/.NZ/,+ M.-):-.0+ N)M&->0+ N%*'ZN,%.>+ )*'+ N%**-N,%.>2+ ;<-+ N%W-.+ %^+ ,<-+ !DQ+
-*N&%>Z.-+N)*+M-+.-O%W-'+M]+Z*>N.-L/*8+)*'+.-O%W/*8+,<-+,-*+F@6G+^)>,-*-.>+^%Z*'+%*+,<-+
,%[+ )*'+ >/'->+ %^+ ,<-+ -*N&%>Z.-2+ + ;<-+ N%W-.+ ><%Z&'+ %*&]+ M-+ .-O%W-'+ ^%.+ >-.W/N/*8+ %.+
,.%ZM&-><%%,/*82+
!E7%L-.+ />+ '->/8*-'+ )>+ )*+ )ZK/&/).]+ [%L-.+ >%Z.N-+ ,%+ M-+ /*>,)&&-'+ /*+ [).)&&-&+ L/,<+ ]%Z.+
N.)*:/*8+M),,-./->2+#,+'-./W->+/,>+[%L-.+^.%O+]%Z.+M),,-./->+%.+-*8/*-+N<).8/*8+>]>,-O+)*'+
'/>N<).8->+,</>+[%L-.+L<-*+*--'-'2+!E7%L-.+/>+/*,-*'-'+^%.+>Z[[&]/*8+-&-N,./N+[%L-.+,%+
W)./%Z>+ &%)'>+ %[-.),-'+ /*+ </8<+ [Z&>-+ [%L-.+ F-*8/*-+ N.)*:/*8G+ O%'->2+ !E7%L-.+ L/&&+
-*<)*N-+)*'+[.%W/'-+^%.+.-&/)M&-+N.)*:/*8+)*'+>,).,/*8+%^+/*,-.*)&+N%OMZ>,/%*+-*8/*->2++
KAPowerX+
mD,%.->+Y.)*:/*8+P%&,)8-+C*,/&+S--'-'+m1%*8+D-.W/N-+1/^-+n+C[L).'>+%^+)+Q/&&/%*+Y]N&->+
m7-.^%.O)*N-+P/.,Z)&&]+C*)^^-N,-'+M]+;-O[-.),Z.->+m#*N.-)>->+,<-+1/^-+%^+"),,-./->+
m9-_Z/.->+Sc+Q)/*,-*)*N-+mD)^-+k+a)>]+,%+#*>,)&&
+
KAPower$Basic$Description:$
$
;<-+!E7%L-.+O%'Z&-+/>+)*+-*-.8]+>,%.)8-+'-W/N-2++!E7%L-.+/>+)+=/8<+7%L-.+'-W/N-+L/,<+
1%L+ a*-.8]+ '-*>/,]2+ + ;<-+ N.)*:/*8+ %.+ '/>N<).8-+ [-./%'>+ L/&&+ M-+ ><%.,+ MZ,+ [%L-.^Z&+
F,][/N)&&]+ &->>+ ,<)*+ 46+ >-N%*'>G+ L/,<+ ,<-+ ,/O-+ ,%+ ^Z&&+ .-N<).8-+ .),-'+ /*+ ,-*>+ %^+ >-N%*'>2+
9-N<).8/*8+ N)*+ M-+ )NN%O[&/><-'+ ^.%O+ W/.,Z)&&]+ )*]+ -&-N,./N)&+ [%L-.+ >%Z.N-2+ + Y]N&/*80+
N<).8-+ )*'+ '/>N<).8-+ -W-*,>+ L/&&+ *%,+ L-).+ %Z,+ ,<-+ '-W/N-2+ + ;<-+ Y]N&-+ RZ,]+ />+ .),-'+ /*+
<Z*'.-'>+%^+,<%Z>)*'>+%^+N]N&->+)[[.%)N</*8+%*-+O/&&/%*+N]N&->2+
+
The$KAPower$Module:$
$
;<-+ !E7%L-.+ O%'Z&-+ .-[.->-*,>+ )*+ /*,-.*)&+ M)*:+ %^+?0+@6+ %.+ @H+N)[)N/,%.+ N-&&>+>-./->(
N%**-N,-'+,%+-)N<+%,<-.2++
An$Electrochemical$Capacitor$(EDLC):$
$
E*+ a&-N,.%N<-O/N)&+ R%ZM&-+ &)]-.+ Y)[)N/,%.+ .-[.->-*,>+ )+ '-W/N-+ N)[)M&-+ %^+ >,%./*8+ )*'+
'-&/W-./*8+ -&-N,./N+ [%L-.+ 'Z-+ O)/*&]+ ,%+ ,<-+ -K/>,/*8+ N)[)N/,)*N-+ %^+ ,<-+ '%ZM&-+ -&-N,./N+
&)]-.0+L</N<+/>+^%.O-'+M]+,<-+N)[)N/,%.o>+-&-N,.%'->+M-/*8+/*+N%*,)N,+L/,<+-&-N,.%&],-2+;<-+
N)[)N/,%.+ N%*>/>,>+ %^+ *-8),/W-+ )*'+ [%>/,/W-+ -&-N,.%'->+ L/,<+ ,-.O/*)&>0+ >-[).),%.0+
-&-N,.%&],-0+)*'+)+><-&&2+
+

+
?+
INSTALLATION:$
+
;<-+ !E7%L-.+ !DQ+ />+ )+ [.%'ZN,+ %^+ </8<+ -&-N,./N+ [%L-.2+ EW%/'+ ><%.,/*8+
O%'Z&-+,-.O/*)&>e+E+M./-^0+><%.,+N/.NZ/,+L/&&+*%,+N)Z>-+[.%'ZN,+^)/&Z.-0+<%L(
-W-.0+/,+O)]+.->Z&,+/*+MZ.*/*8+%.+/8*/,/*8+%^+N%OMZ>,/M&-+O),-./)&>+)'i)N-*,+,%+,<-+[%/*,+%^+
><%.,+N/.NZ/,2+
IMPORTANT!
9-O-OM-.+,<),+a&-N,./N)&+9->/>,)*N-+/*+,<-+N/.NZ/,+N.-),-'+/>+,<-+N%*>ZO-.+%^+,<-+-&-N,./N)&+
-*-.8]+ /*+ ]%Z.+ !E7%L-.+ Q%'Z&-2+ !--[+ ,<-+ .->/>,)*N-+ ,%+ )*+ )M>%&Z,-+ O/*/OZO2+ D<%.,0+
<-)W]+N)M&->+)*'+8%%'0+N&-)*+N)M&-+N%**-N,/%*>+).-+->>-*,/)&e+
\<-*+>-&-N,/*8+)+&%N),/%*+^%.+/*>,)&&),/%*0+O):-+>Z.-+,<),+,<-+!E7%L-.+!DQ+
O%'Z&-+L/&&+N&-).+)*]+&/'>+)*'+%,<-.+O%W)M&-+[).,>2+#*>,)&&+,<-+!E7%L-.+!DQ+
O%'Z&-+)>+N&%>-+,%+,<-+-*8/*-o>+N.)*:/*8+O%,%.+)>+[%>>/M&-2+EW%/'+&%N),/%*>+
,<),+).-+>ZMi-N,+,%+-K,.-O-+<-),0+<ZO/'/,]0+.%)'+'/.,0+/N-+)*'+>*%L2+7.-W-*,+,<-+-K,-.*)&+
N)>-+%^+,<-+!E7%L-.+!DQ+O%'Z&-+^.%O+[<]>/N)&+/O[)N,>2+
P/>Z)&&]+/*>[-N,+,<-+-K,-.*)&+N)>-+[./%.+,%+O%Z*,/*8+,<-+O%'Z&-2++Q):-+>Z.-+,<),+*%+,.)N->+
%^+[<]>/N)&+/O[)N,>+).-+[.->-*,+%*+,<-+-K,-.*)&+N)>-+%^+,<-+!E7%L-.+!DQ+O%'Z&-2+
Rc+ Sc;+ .-O%W-+,<-+ -K,-.*)&+ [&)>,/N+ N)>-+ N%W-.+ %^+ ,<-+ !E7%L-.+ O%'Z&-+
&%N),-'+L/,</*+,<-+!DQ+-*N&%>Z.-2+Rc+Sc;+><%.,+N/.NZ/,+,-.O/*)&>2+
"-^%.-+ /*>,)&&),/%*0+ ^)O/&/)./p-+ ]%Z.>-&^+ L/,<+ ,<-+ >[-N/^/N),/%*>+ %^+ ]%Z.+ !E7%L-.+ !DQ+
O%'Z&-2+#*>Z.-+,<),+]%Z+<)W-+,<-+[.%[-.+'-W/N-+^%.+]%Z.+)[[&/N),/%*2+
+++++++++++++++++++
++++++++++++++++++++++++ +
CAUTION
WARNING
WARNING

+
B+
ELECTRICAL CABLE SELECTION:$
$
$
$
@2 a&-N,./N)&+.->/>,)*N-+/*+,<-+N/.NZ/,+]%Z+N.-),-+/>+)+>/8*/^/N)*,+N%*>ZO-.+%^+,<-+[%L-.+
)W)/&)M&-+ /*+ ,<-+ !E7%L-.+ '-W/N-2+ J%.+ %[,/O)&+ [-.^%.O)*N-+ ,<-+ &%)'+ .->/>,)*N-+
F-*,/.-+&%)'G+)*'+,<-+/*,-.*)&+.->/>,)*N-+%^+,<-+N)[)N/,%.+O%'Z&-+><%Z&'+M-+O),N<-'+
)>+N&%>-&]+)>+[%>>/M&-2+
H2 C>-+,<-+<-)W/->,+8)Z8-+N)M&-+)W)/&)M&-2+#,+/>+.-N%OO-*'-'+,<),+I$6+N)M&-+M-+Z>-'2++
42 !--[+ N)M&-+ &-*8,<+ ,%+ )*+ )M>%&Z,-+ O/*/OZO2+ ;<-+ N/.NZ/,+ .->/>,)*N-+ /*N.-)>->+ L/,<+
N)M&-+&-*8,<2++
I2 #*>Z.-+ ,<),+ ,<-+ N)M&-+ ,-.O/*),/%*+ N%**-N,/%*>+ F,-.O/*)&>G+ ).-+ [.%[-.&]+ N./O[-'+
)*'$%.+>%&'-.-'+,%+,<-+N)M&->2+
A2 ;<-+ _Z)&/,]+ %^+ ,<-+ N)M&-+ N%**-N,/%*>+ ^.%O+ ,<-+ !DQ+ ,%+ ,<-+ W-</N&-+ %.+ -_Z/[O-*,+ />+
N./,/N)&2++Q):-+>Z.-+,%+[.%W/'-+8%%'0+N&-)*0+.%MZ>,+N)M&-+/*,-.^)N-+N%**-N,/%*>2+
?2 ;<-+N&%>-.+,<-+!DQ+/>+&%N),-'+,%+,<-+-*8/*-q>+N.)*:/*8+O%,%.0+,<-+><%.,-.+,<-+N)M&-+
&-*8,<>+).-0+,<-+><%.,->,+%W-.)&&+&-*8,<+%^+,<-+-*,/.-+<-)W]+NZ..-*,+N/.NZ/,0+,<-+M-,,-.+
,<-+[-.^%.O)*N-+L/&&+M-+L/,<+]%Z.+!DQ2+
B2 ;<-+I+7/*+R-Z,>N<+N%**-N,%.+<)>+M--*+>Z[[&/-'+L/,<+)+O),/*8+N%**-N,%.2++"-+>Z.-+,%+
^%&&%L+[.%[-.+L/.-+>N<-O->+)>+/'-*,/^/-'+/*+,<-+'/)8.)O>2+
32 ;<-+>Z[[&/-'+R7D;+>L/,N<+L/&&+-/,<-.+M-+.-[&)N/*8+)*+-K/>,/*8+[Z><(MZ,,%*+-*8/*-(
>,).,+>L/,N<+%.+L/&&+M-+/*+)''/,/%*+,%+,<-+-K/>,/*8+:-](>,).,+>L/,N<0+'-[-*'/*8+%*+<%L+
]%Z.+W-</N&-+%.+-_Z/[O-*,+/>+NZ..-*,&]+>-,Z[0+>,).,-'2++1%N),-+)*'+/*>,)&&+,<-+R7D;+
>L/,N<+/*+)+N%*W-*/-*,+&%N),/%*+.-&),/W-+,%+,<-+:-]+>L/,N<+/^+,<-.-+/>+*%+-K/>,/*8+[Z><(
MZ,,%*+>,).,+>L/,N<+,%+.-[&)N-2+
$
$
$
$

+
3+
$
MOUNTING THE KSM UNIT:$
$
C>/*8+,<-+'/O-*>/%*>+><%L*+M-&%L0+Z>-+^%Z.+FIG++rs+M%&,>0+*Z,>+k+&%N:+L)><-.>+F*%,+
>Z[[&/-'G+,%+O%Z*,+,<-+!DQ+Z*/,+,%+W-</N&-+%.+-_Z/[O-*,+N<)>>/>.$$
$
+
\<-*+ >-&-N,/*8+ )+ &%N),/%*+ ^%.+ /*>,)&&),/%*0+ O):-+ >Z.-+ ,<),+ ,<-+ !DQ+ O%'Z&-+ )*'+
N)M&->+ L/&&+ N&-).+ )*]+ <%%'>0+ &/'>0+ N%W-.>+)*'+ %,<-.+ O%W)M&-+ W-</N&-+ %.+ -_Z/[O-*,+
[).,>2+ #*>,)&&+ ,<-+ !DQ+ O%'Z&-+ )>+ N&%>-+ ,%+ ,<-+ -*8/*-o>+ N.)*:/*8+ O%,%.+ )>+ [%>>/M&-2+
EW%/'+&%N),/%*>+,<),+).-+>ZMi-N,+,%+-K,.-O-+<-),0+<ZO/'/,]0+.%)'+'/.,0+/N-+)*'+>*%L2+
;<-+!DQ+Z*/,+ O)]+M-+O%Z*,-'+/*+)*]+ [%>/,/%*2++;):-+N).-+,%+[.-W-*,+,<-+-K,-.*)&+
N)>-+%^+,<-+!DQ+O%'Z&-+^.%O+.-N-/W/*8+)*]+[<]>/N)&+/O[)N,>2+
+
+
+
+
+
+
+
+
+
+
+
+
CAUTION
6"cell"KSM"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"details."
+

+
5+
+
+
+
+
+
+
+
10"&"12"cell"KSM"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"details."
+

+
@6+
+
!"#$%&'($
)*+%#,$-%&'($.$/0+1,$
2*34*'$)3*45"*$678$
9:4#;<'($=*1$
>4?'$)*#'?@/;'$A"**';#"?$B4*C=%#$ DEFGF$A"**';#"?$B4*C=%#$
H'%#&;<$A"**';#"?$
HIJKCGB$
GENERAL WIRING INSTALLATION PROCEDURE:
CAUTION!KSM$Power$Stud$Nuts$should$be$torqued$to$180$Inch$Pounds.$
CONNECTORS$LOCATED$ON$THE$END-FACEPLATE$OF$THE$KSM$ENCLOSURE.$
END-FACEPLATE!OF!THE!
KSM!ENCLOSURE.!
The$J1939$connector$is$used$for$KBI$Factory$
programing$only.$$$Contact$KBI$for$details.!
Discrete Signal
See schematic, page 13