KAPower Starting Module (KSM)

With Programmable Logic Controller (PLC)

INSTALLATION – OPERATION MANUAL

Gen 3. Rev D

KBI/Kold-BanInternational,Ltd. 8390PingreeRoad,LakeInTheHills,Illinois60156-9637U.S.A.

(800)527-8278,(847)658-8561,Fax(847)658-9280,www.koldban.com ATAVMRS-T44KLDBN

KBI® KAPower® ©2017KBIForm#131400 Rev.D

Gen312&24Volt

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PARTSLIST:1. KSMPLCmodule.2. DoublePoleSingleThrow(DPST)pushbuttonswitch.3. Wiringharness.(NotShown)4. Terminalgrease.(NotShown)5. Protectiveboots.(NotShown) ITEMSNEEDEDFORINSTALLATION:1. Batterycables,4/0cableisrecommended.2. Terminalsforbatterycable.3. Torquewrenchwith¾inchsocket.4. 16gaugewireforharnesses.

1. 2.

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SAFETY AWARENESS

SAFETYAWARENESSSYMBOLSare inserted in thismanual toalertyoutopossibleSAFETYHAZARDS.Wheneveryouseethesesymbols:

or heedtheirinstructions!

SAFETYAWARENESSSYMBOLSANDMEANINGS:

THISWARNINGSYMBOLIDENTIFIESSPECIALINSTRUCTIONSORPROCEDURES,WHICH,IFNOTCORRECTLYFOLLOWED,COULDRESULTINPERSONALINJURY.

THISCAUTIONSYMBOLIDENTIFIESSPECIALINSTRUCTIONSORPROCEDURES,WHICH,IFNOTSTRICTLYOBSERVED,COULDRESULTINDAMAGETOORDESTRUCTIONOFEQUIPMENT.

KAPowermoduleisaproductofhighelectricpower.

Never short circuit KAPower module terminals! Burning or igniting ofcombustiblematerialsadjacenttothepointofshortcircuitmayfollowit.In case of accidental short-circuit-ing of the KAPower module orindividual capacitors it isnecessary todisconnect theKAPowermoduleimmediatelyfromtheelectriccircuittakingrelevantsafetymeasures.

NoncompliancewiththerequirementssetforthinthisManualmayresultinKAPowermodulefailure.SuchrequirementsshallbereviewedpriortoandobservedinthecourseofKAPowermoduleoperationandinstallation.

TheKAPowermoduleispolaritysensitive.PolarityshallbestrictlyobservedwhenconnectingtheKAPowermodule!

WARNING CAUTION

WARNING

CAUTION

WARNING

Note:KAPowerisnotahigh-voltagedevice.Itsimplysuppliesthesamevoltagethatitwaschargedupto.Treatitwiththesame

respectyouwouldgivetoafullychargedbattery.

CAUTION

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TABLE OF CONTENTS:

Partslistandrequireditems..................................................2Introduction...................................................................................5 Installation.....................................................................................6Dimensions………………………………………………………8&9WiringDiagram………………………………….…………10&13 Operation......................................................................................14 Troubleshooting........................................................................15 Maintenance................................................................................15 Storage...........................................................................................16 Transportation...........................................................................16

Notes: _________________________________________________________

_________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________

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INTRODUCTION: KSMisaprepackagedKAPowerassemblyallowingfortheeaseofinstallationandoperationofyourKAPowersystem.TheKSMenclosureconsistsofaKAPowermodule,acontactor,aPLCModule, a circuit breaker, cables, conductors and connectors. The cover of the KSMenclosurecanberemovedbyunscrewingandremovingtheten(10)fastenersfoundonthetop and sides of the enclosure. The cover should only be removed for servicing ortroubleshooting.KAPower is designed as an auxiliary power source to be installed in parallel with yourcrankingbatteries.Itderivesitspowerfromyourbatteriesorenginechargingsystemanddischargesthispowerwhenneeded.KAPower is intendedforsupplyingelectricpowertovarious loads operated in high pulse power (engine cranking) modes. KAPower willenhanceandprovideforreliablecrankingandstartingofinternalcombustionengines.

KAPower:•StoresCrankingVoltageUntilNeeded•LongServiceLife–UpwardsofaMillionCycles•PerformanceVirtuallyUnaffectedbyTemperatures•IncreasestheLifeofBatteries

•RequiresNOMaintenance•Safe&EasytoInstall

KAPowerBasicDescription:

TheKAPowermoduleisanenergystoragedevice.KAPowerisaHighPowerdevicewithLow Energy density. The cranking or discharge periods will be short but powerful(typically less than 30 seconds)with the time to full recharge rated in tens of seconds.Recharging can be accomplished from virtually any electrical power source. Cycling,charge and discharge events will not wear out the device. The Cycle Duty is rated inhundredsofthousandsofcyclesapproachingonemillioncycles.

TheKAPowerModule:

TheKAPowermodule represents an internal bank of 6, 10 or 12 capacitor cells series-connectedtoeachother.

AnElectrochemicalCapacitor(EDLC):

An Electrochemical Double layer Capacitor represents a device capable of storing anddelivering electric power due mainly to the existing capacitance of the double electriclayer,whichisformedbythecapacitor'selectrodesbeingincontactwithelectrolyte.Thecapacitor consists of negative and positive electrodes with terminals, separator,electrolyte,andashell.

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INSTALLATION:

The KAPower KSM is a product of high electric power. Avoid shortingmoduleterminals!Abrief,shortcircuitwillnotcauseproduct failure,how-

ever,itmayresultinburningorignitingofcombustiblematerialsadjacenttothepointofshortcircuit.

IMPORTANT! RememberthatElectricalResistanceinthecircuitcreatedistheconsumeroftheelectricalenergy in your KAPower Module. Keep the resistance to an absolute minimum. Short,heavycablesandgood,cleancableconnectionsareessential!

Whenselectingalocationforinstallation,makesurethattheKAPowerKSMmodulewillclearanylidsandothermovableparts.InstalltheKAPowerKSMmoduleasclose to theengine'scrankingmotoraspossible.Avoid locations

thataresubject toextremeheat,humidity,roaddirt, iceandsnow.Prevent theexternalcaseoftheKAPowerKSMmodulefromphysicalimpacts.Visuallyinspecttheexternalcasepriortomountingthemodule.MakesurethatnotracesofphysicalimpactsarepresentontheexternalcaseoftheKAPowerKSMmodule.

DO NOT remove the external plastic case cover of the KAPower modulelocatedwithintheKSMenclosure.DONOTshortcircuitterminals.

Before installation, familiarize yourself with the specifications of your KAPower KSMmodule.Insurethatyouhavetheproperdeviceforyourapplication.

CAUTION

WARNING

WARNING

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ELECTRICAL CABLE SELECTION:

1. Electricalresistanceinthecircuityoucreateisasignificantconsumerofthepower

available in the KAPower device. For optimal performance the load resistance(entireload)andtheinternalresistanceofthecapacitormoduleshouldbematchedascloselyaspossible.

2. Usetheheaviestgaugecableavailable.Itisrecommendedthat4/0cablebeused.3. Keep cable length to an absoluteminimum. The circuit resistance increases with

cablelength.4. Insure that the cable termination connections (terminals) are properly crimped

and/orsolderedtothecables.5. Thequalityof the cable connections from theKSM to the vehicleor equipment is

critical.Makesuretoprovidegood,clean,robustcableinterfaceconnections.6. TheclosertheKSMislocatedtotheengine’scrankingmotor,theshorterthecable

lengthsare,theshortestoveralllengthoftheentireheavycurrentcircuit,thebettertheperformancewillbewithyourKSM.

7. The4PinDeutschconnectorhasbeensuppliedwithamatingconnector.Besuretofollowproperwireschemesasidentifiedinthediagrams.

8. ThesuppliedDPSTswitchwilleitherbereplacinganexistingpush-buttonengine-startswitchorwillbeinadditiontotheexistingkey-startswitch,dependingonhowyourvehicleorequipment iscurrentlysetup,started. Locateand install theDPSTswitchinaconvenientlocationrelativetothekeyswitchifthereisnoexistingpush-buttonstartswitchtoreplace.

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MOUNTING THE KSM UNIT:

Usingthedimensionsshownbelow,usefour(4)¼”bolts,nuts&lockwashers(notsupplied)tomounttheKSMunittovehicleorequipmentchassis.

When selecting a location for installation, make sure that the KSM module andcableswill clear any hoods, lids, covers and othermovable vehicle or equipmentparts. Install theKSMmoduleas close to theengine's crankingmotoraspossible.Avoidlocationsthataresubjecttoextremeheat,humidity,roaddirt,iceandsnow.TheKSMunitmaybemounted inanyposition. Takecare toprevent theexternalcaseoftheKSMmodulefromreceivinganyphysicalimpacts.

CAUTION

6cellKSM

TheJ1939connectorisusedforKBIFactoryprogramingonly.ContactKBIfordetails.

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10&12cellKSM

TheJ1939connectorisusedforKBIFactoryprogramingonly.ContactKBIfordetails.

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Not$used$

Input,$Fused$5$amp.,$Engine$Igni5on$(+)$Switched$On.$

Wire$Interface$Connector$PinCOut$ J1939$Connector$PinCOut$

Deutsch$Connector$DT04C3P$

GENERAL WIRING INSTALLATION PROCEDURE:

CAUTION KSMPowerStudNutsshouldbetorquedto180InchPounds.

CONNECTORSLOCATEDONTHEEND-FACEPLATEOFTHEKSMENCLOSURE.

END-FACEPLATEOFTHEKSMENCLOSURE.

TheJ1939connectorisusedforKBIFactoryprogramingonly.ContactKBIfordetails.

Discrete SignalSee schematic, page 13

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GENERAL WIRING INSTALLATION PROCEDURE:

(CONTINUED)

TheoryofOperation,explaininghowtheKSMmoduleworks:

Onceinstalledandwiredproperly,theLEDontheEnd-FaceplateoftheKSMwillbeilluminatedwhenevertheKSMcontactorrelayisclosed.WhentheLEDisilluminated,thecontactorisclosed;theKAPowerModuleisrunningparallelwiththevehicleorequipmentbatteriesandelectricalsystem.

WhentheDPSTswitchisdepressedyouareclosingthecontactorinsidetheKSMenclosure,usingpowerfromtheKAPowermodule,regardlessofthestateofchargeofthevehicleorequipment’sbatteries.WhendepressingtheDPSTswitchyouarealsoengagingthecrankingmotorcircuit.Thisisdonebywiringandusingtherecommendedelectricalcircuit,displayedontheschematic(page13).Bydoingso,youhavetappedintotheOEM(OriginalEquipmentManufacture)electricalcircuitallowingboththeKSMandtheOEMcrankingmotorcircuittobeengaged,simultaneously.Oncetheenginestarts,theProgrammableLogicController(PLC)insidetheKSMmonitorstheconditionoftheKAPowerModuleandwillcloseoropentheContactorRelayinsidetheKSM,basedonthepreprogrammedparametersinsidethePLC.Whentheengineisstopped,theequipmentisturnedoff,thecontactoropensandtheKAPowermoduleremainsisolated,waitingforthenextengine-startingevent,thepressingdownoftheDPSTswitch.

ThePLCpreprogrammedfunctions:ThePLChasbeenpreprogrammedtomonitorandcontrolthestate-of-chargeoftheKAPowercapacitormodulebasedontemperature,voltage&time.Onceavoltagesignalisreceivedatpinfour(4)oftheWiringInterfaceConnectorthePLC“wakes-up”andwilldeterminewhenandhowlongtokeepthecontactorclosed.Remember,anytimetheLEDStatusIndicatorisilluminatedthecontactorisclosed.Inatypicalengine-startingeventyouwillseetheLEDilluminateduringenginecrankingandthengooutforseveralsecondsaftertheenginehasstarted.TheLEDwillthenilluminateagainandcouldremainilluminatedforseveralsecondsbasedontheconditionoftheKAPowermodule.TheLEDmayevenbeginto“cycle”dependingonthevehicleorsystemvoltageduringtherechargingevents.TheJ1939connectorisusedforKBIFactoryprogramingonly.ContactKBIfordetails.

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GENERAL WIRING INSTALLATION PROCEDURE:

(CONTINUED)1. Before attaching any cables, slide included supplied protective boots onto the

cables. The first cable shallbe connected to the "+" terminalof theKSMand thenconnectedtothe"+"terminalofthebattery.

2. Slide included protective boot onto the "-" cable. This second cable shall beconnectedtothe"-"clamporterminalofthebatteryandthenconnectedtothe"-"terminaloftheKSMmodule.

3. Asbasedonpage10&13createandwiretheharnessestotheDeutschconnector.The KSM Deutsch connector has been provided with mating connector that haspigtailwireleadstagged&identifiedinordertofacilitateinstallation.

4. For thePLC input, pin four (4) of thewire interface connector, youmust find a5Amp.power source from thevehicle, “key-on” ignition source that is live (+)onlywhentheengineiscrankingandrunning.Installafive(5)-ampfuseinthiscircuitasclosetothepowersourceaspossible.

5. WireDPSTandfind&wiretheappropriatePLCinput(pin4)asbasedanddepictedonthediagram&schematicpages10&13.YouwillnotbeconnectinganywiringtotheJ1939Connector. TheJ1939CAN-BusisusedforKBIFactoryprogrammingonly.ContactKBIfordetails.

6. ApplyprovidedprotectivegreaseonKSM+&-terminals. 7. AttachprovidedprotectivebootstoterminalsonKSMmodule. 8. Wiringiscompleteandtheunitisnowreadytooperate.

CAUTION Aftertheinstallationandwiringarecomplete,whenevertheDPSTswitchisdepressedtheKSMpositive+andnegative–terminalswillbelive.Donotshort-circuittheterminals.

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NOTE: In Transit bus applications where the rear-start feature is desired, a second DPST Switch can be installed in the rear-start location, wired in parallel with the front-start DPST switch.

OEMPushBu*onorKeySwitch

Cranking/Start

Switch

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OPERATION:

Donotbypass thePLC functionality. Chargevoltageand temperature shallnotexceedtheMaximumVoltageandTemperatureasspecifiedintheTableson page 6. It is important to MONITOR the voltage when charging the

KAPower module to its Maximum Voltage. Failure to do so may result in prematuremodulefailure.

Usingthesystem:

• MakesureyouhaveproperlyinstalledtheKSMmodulebeforeactivation.• Simply push and hold down the DPST switch to engage the KAPower KSMsystemuntiltheenginestarts.

• ByusingpowerfromtheKAPowercapacitor,theKSMcontactorwillcloseandstayclosedwhenevertheDPSTswitchisdepressed.TheDPSTswitchshouldalsobeengagingthevehicleorequipment’sOEMcrankingmotorcircuit.

• Whenever the KSM KAPower contactor is closed, the LED on the End-Faceplateshouldbeilluminated.

• Theengineshouldbegintocrank-overwithpowerbeingsuppliedfromboththeKSMcapacitormoduleandthestandardbatteries.

• OncetheenginestartsandtheDPSTswitchisreleased,theKSMinternalPLCmodule should be active, keeping the contactor closed when required,allowingtheKAPowermoduletorecharge.

• NOTE: If the vehicle or equipment’s batteries where completelydischarged (“dead”) youmayneed to keep theDPST switch depresseduntil thevehicle’s electrical (charging) systemhasbecomeactive. The“dead” batteries, on their own, may not support all of the engine’selectricalpowerrequirementstokeepitrunning.Inthiscase,keeptheDPSTswitchdepresseduntilyouaresurethevehicle’schargingsystemis active. The KAPower modulewill have enough power to keep theenginerunninguntiltheengine’schargingsystembecomesactive.

• When the engine stops and the vehicle or equipment is turned off the KSMcontactorshouldopen,keepingthefullychargedKAPowermoduleinreserveforthenextengine-startingevent.

CAUTION

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TROUBLESHOOTING

AND MAINTENANCE:

Maintenance of the KAPower module within the KSM enclosure shall not be requiredprovidedthattheoperatingconditionsareproperandthattherequirementsspecifiedinthisManualareobserved.

• TheLEDlocatedontheEnd-Faceplateof theKSMindicatestheactiveconditionoftheKSMmodule.Seepage10.IftheLEDisnotilluminatedwhentheexpected,(seeTheory of Operation, page 11) then insure that all wiring and connections are inaccordance with the instructions within this manual. Make sure to check theintegrityoftheDPSTandthePLCactivehigh(EngineIgnition+SwitchedOn)inputwiringharnessyoucreated.

• If the wiring and harnesses are in good order continue troubleshooting byunplugging the Deutsch connector on the End-Faceplate of the KSM, giving youaccesstothepinterminalsontheKSMconnector.Refertopages10&13.

• Check the circuitbreakerand contactor relaywithin theKSMmodule. Inorder toserviceorreplaceanyofthesecomponentsyouwillhavetoremovethecoveroftheKSMenclosure.Referencepage5.

• Thebi-color(red/green)LEDisanindicatorforhowtheKSMisfunctioning.ThegreensideoftheLEDisconnectedparallelwiththecontactor.TheredsideisconnectedtoanoutputonthePLCasshownintheschematicdepictedonpage13.ThePLCmonitorsthecapacitorvoltageduringandaftertherechargecycle.IftheCapvoltagedropstobelowanacceptablelevelinthefirst5minutesaftertherecharge,theredLEDwillflash,indicatingafault.IfatanytimewhilethePLCispoweredupandtheKSMCircuitBreakertripsorthecapvoltageleveldropsbelow4voltstheredLEDwillflash.

Priority Name FlashRate

1 CapacitorOverTemperature 2

6 TemperatureSensorError 3

4 ContactorOverCurrentError 4

5 ContactorCoilOpenCircuitError 5

2 LowCapacitorVoltageError 6

3 RapidVoltageDecayaCerRecharge 7

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TOCHECKKSMINTERNALCIRCUIT:

• Withthecircuitbreakerreset,usingavoltmetercheckvoltageatPin#1oftheDeutschfour-pinconnectorandtheKSMnegative(-)groundPowerStudterminal.Ifvoltageispresentthecircuitis“good”.ThevoltagereadingistheactualKAPowermodulevoltageandshouldbeatleast10voltsinordertoactivatethecontactor.

• Jumppins1and2onthefour-pinconnector,thecontactorshouldactivate.Ifnotremovecoverandcheckforfaultycontactororinternalwiring.

• Ifthecircuitbreakercontinuestotripchecktheintegrityofthevehiclesideofthewiringharnessforissuessuchasshorts,chafingorbadconnectionsandcomponents.

• ThePLCModuleisasealedunit.Itcannotbeserviced.IfadditionaltroubleshootingisrequiredcontactKBI.

STORAGE:TheKAPowermoduleshouldbedischargeddowntoa50%state-of-chargepriortostorageandforprolongedperiods(>1year)shouldbestoredina

completelydischargedstate.The KAPower modules shall be stored within enclosed heated or unheated premisesoutfittedwith a natural ventilation system in regions havingmoderate or coldweatherconditions.Climate control systemsarenot required.The required storage temperaturerangeis-76ºto185ºF(-60ºto85ºC).

TRANSPORTATION:TheKAPowerKSMmodulescanbeshippedinapprovedcorrugatedcardboard,wooden,orplasticcontainers.FormoreinformationontransportationcontactKBI.

CAUTION

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LIMITED WARRANTY TheKAPowermoduleitselfisguaranteedagainstdefectsinmaterialandworkmanshipforthree(3)yearsfromdateofpurchase.TheKAPowerisasealedunit.IftheKAPowerdoesnotoperateproperly,itmustbereturnedtothefactory,

prepaid,forreplacement.Iffactoryinspectiondeterminestheproducttobedefectiveunderthetermsofthiswarranty,itwillbereplacedwithoutcharge.AllotherKSMcomponentsareguaranteedagainstdefectsinmaterialandworkmanshipfor

one(1)yearfromthedateofpurchase. Failureduetoaccident,abuse,neglect,useotherthanintheintendedapplicationspecifiedinthismanual,improperinstallationormaintenance,mishandling,andrepairsor

attemptedrepairswhichhavebeenmadebyothers,arenotcoveredunderthetermsofthiswarranty.

Kold-BanInternational,Ltd.shallnotbeliableforlossofuseoftheKAPowerKSMorotherincidentalorconsequentialcosts,expensesordamagesincurredbythepurchaseroruser.

Thiswarrantydoesnotincludelaborforrepairorreplacement. Kold-BanInternational,Ltd.

8390PingreeRoad LakeInTheHills,IL60156-9637 (847)658-8561(800)527-8278

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