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Sirius Capacitor Module – User Manual 1 Model Number -3550-48-B-1.7C-TM-SD-A-G

This manual is subject to change without notice and at the sole discretion of Kilowatt Labs, Inc. Kilowatt Labs, Inc. | www.kilowattlabs.com

SIRIUS CAPACITOR MODULE User Manual

Model number: 3550-48-B-1.7C-TM-SD-A-G Version 3.0; Release Date: January 2019

Copyright©2019 Kilowattlabs Inc. All rights reserved

http://www.kilowattlabs.com/



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.

Safety

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. Please follow the instructions in this Manual carefully to prevent accidents. The Sirius module must be installed by trained personnel.

Symbol Convention

Symbol Indication

Caution Used as a warning of potential dangers. Ignoring this information may result in serious personal injury and other unpredictable result

Warning

Selling and installation of this product is only through the Company’s Resellers who are trained on installation, operation and maintenance of the Sirius modules.




Table of Contents

S. No Contents Page No

1 Unpacking and Handling 4

1.1 Unpacking 4

1.2 Handling 5

1.3 Installation 5

2 Product part number 5

3 Product Overview 6

4 Mechanical Drawings 7

5 Front Panel Description 8

6 Module to module connections 11

6.1 Parallel connection of Sirius modules 11

6.2 Series connection of Sirius modules 11

7 Operation procedure 12

7.1 Connection of cables to Anderson connector 14

8 Safety Features 15

9 Recovery Procedure 17

10 Trouble Shooting: Faults and Solutions 18

11 Maintenance 19

12 Storage 19

13 Disposal 19




1.Unpacking and Handling 1.1. Unpacking Inspect the shipping carton for damage prior to unpacking the module. Document (photograph) any damage and report this to the Company or the Company’s authorized representative and 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. Sirius Capacitor Modules are shipped out via air and sea. If the modules are shipped via air, please follow the below instructions:

• 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 the modules are shipped via sea, please follow the below instructions:

• 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 NOTE: The weight of the module is approx. 75kg

The module must be removed from the carton by lifting the module from base.

The following items are included in the package:

Sirius Capacitor Module: 3.55kWh48VDC

USB cable A-B

Cable tie

Cable tie support




Anderson connector with lugs

NOTE: The original shipping materials are approved for both air and ground shipment. 1.2. Handling The Sirius Capacitor modules are designed to provide years of trouble-free operation. Proper handling is required to avoid damage to the module. In particular, the following handling precautions should be observed:

• Do not stack modules once they have been removed from the packaging, instead the module should be placed on shelving.

• Do not drop the module. Internal damage may occur that will not be visible from the exterior.

• Only mount the module horizontally.

• Do not step on the module.

• Protect the module from impact.

1.3. Installation 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.

2.Product part number The explanation of the product part number is as follows:

① Capacity of the module in Wh

② Nominal voltage of the module

③ Terminals are on the front side

④Charge rate of the module




⑤With total monitoring and no individual cell monitoring

⑥With safety

⑦With alarm

⑧General module

3.Product Overview The appearance of the Sirius Capacitor Module is shown in the figure below:




4.Mechanical Drawings Below are the mechanical drawings of the Sirius module




5.Front Panel Description The figure below describes the front panel components of the module:

1 Auxiliary USB 2 COMM Connector USB

3 Comm Status LED 4 Terminal Status LED

5 Fault Reset 6 LCD

7 Circuit Breaker 8 Protected terminal

9 Unprotected terminal

Auxiliary USB This is an auxiliary connector for wireless monitoring, module combiner and future purposes.




COMM Connector USB This is a COMM connector to monitor the module using the sirius software COMM Status LED COMM Status LED indicates the communication status. LED has the following status:

• If the LED is blinking red, this indicates that the control module is communicating with the sirius software.

• If the LED is steady(red), this indicates that the control module is not communicating with the sirius software.

• If the LED is dimming, this indicates that the module has reached to power down state. Terminal Status LED Terminal status LED indicates the protected terminal status.

• If the LED is ON(Green), this indicates that the protected terminal is active and if the LED is OFF, this indicates that the protected terminal is not working.

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:

• Hold fault reset for 5 seconds to toggle the protected terminal.

• Hold fault reset for 3 seconds to reset fault if there is/are any.

• Press fault reset button to check the state of charge and instantaneous power.

• We can set the current reading to zero. LCD Once the power is switched ON from the circuit breaker, the module gets power and the LCD shows the below message after 3seconds under normal operation:




After 1 second, the following two LCD screens gets switched between each other.

Circuit Breaker This act as a second line of protection. If the circuit fails to protect the module from over current, the circuit breaker will trip. Protected Terminal This is the output terminal of the module which has electronic switch protection which is limited to 100VDC only. Note: Do not use this terminal when connecting the module is series. 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 from short circuit.




6.Module to module connections This section explains the possible module to module connections. 6.1. Parallel Connection of Sirius Modules The parallel combination of the Sirius modules is as shown below. Any number of modules can be connected in parallel.

To do the parallel connection, the positive of the protected terminal of all the modules should be connected together and negative of the protected terminal of all the modules should be connected together and the output positive and output negative should be taken from the respective common point. Note: Use only the protected terminal when connecting in parallel. Caution: Charge all the modules to 100% SOC or same voltage level before connecting them to parallel. 6.2. Series Connection of Sirius Modules The series combination of the Sirius modules is as shown below. Only 8 modules can be connected in series with module combiner and please make sure that all the modules are balanced and charged to same SOC level. The advised way is to charge them to 100% SOC level and then put them in series. Note: Use only the unprotected terminal when connecting in series.




To connect the modules in series, the negative of the unprotected terminal of the first module should be connected with the positive of the unprotected terminal of the next module and the output negative should be taken from the last module and the output positive should be taken from the first module.

7.Operation Procedures The module should only be operated within the specified voltage and temperature ratings. Observe polarity indicated on module. Do not reverse polarity.

Follow the steps below (in sequence) to operate the module:

• Turn ON the circuit breaker by pushing the encircled button upwards as shown in the below picture




The below picture indicates that the module is turned ON.

• Use the protected terminal for the output of the module

• Use the unprotected terminal for connecting the modules in series with different modules and for recovery purpose

Follow the steps below (in sequence) to operate the software:

• Connect the USB cable to the COMM connector USB slot to start communication and monitoring.

• The LCD will display data.

• Click on the software icon (Ref to the Sirius View monitoring software manual)

• Install the monitoring software application in the monitoring device

• The module can be shut down by the circuit breaker (As shown in the pic below, push the encircled button to turn the module OFF)




NOTE: Switch OFF the module when not in use as the module is self-powered or else it can result in faster self-discharge of the module. 7.1. Connection of cables to Anderson connectors Follow the below steps to connect the Anderson connector (shown below) provided to the cables of your system:

Strip the insulation of the cable and gently twist the wire strands to keep them contained in the contact (as shown in pic below)

Put the wire strand into the Anderson connector and crimp tightly down. Below pic shows how connector looks like after crimping. Once crimped, pull on the connector to make sure it is firmly attached to the wires.




Hold the housing and take the connector and place it into the back of the housing and push until fully engaged

8.Safety Features Sirius Capacitor Module has the following safety features: Overcurrent (OCD) When the module has an overcurrent fault (OCD),the counter counts for 5 sec and if the current did not drop lower than cut-off and count down reach zero,the buzzer alarms and the protected terminal will shut down and the LCD shows the following warning message:

This means the current has reached the cut-off current of 125A (in the illustration, the LCD shows that the module current has reached the cut -off 125A).




Module Charge Full When the module has reached the maximum voltage, the protected terminal will shut down and the LCD shows the following warning message:

This means that each cell from the module reached maximum rated charge. The event can be repeated if the charger is still ON and operating in the same condition and the buzzer alarms and LCD will display the following:

Low charge module When the module has reached the minimum voltage and its in standby mode, the LCD will display the following message every 30 seconds.

When the module has reached the minimum voltage and the module is loaded, the buzzer alarms, protected terminal will shut down and the LCD will display following message




Overtemperature (OT) When the module has an overtemperature fault (OT), the buzzer alarms, the protected terminal will shut down and the LCD shows the following warning message:

This means that the temperature of the module has reached the cut-off value of 80°C. The LCD shows the temperature at that time as well (in the illustration, the LCD shows that the module temperature has reached to 80°C). Terminal Overtemperature When the module has a terminal overtemperature fault, the buzzer alarms, the protected terminal will shut down and the LCD shows the following warning message:

This means that the electronic switch has reached 80°C.

9.Recovery Procedure When the module voltage goes down too low that the control electronics is turned OFF, use the unprotected terminal to turn it ON. For this process, a 44VDC to 54VDC, 1A to 10A power supply is required to recover the unit. The positive terminal of the supply should be connected to the positive terminal of the unprotected terminal and negative terminal of the supply should be connected to the negative terminal of the unprotected terminal using the lead provided. Once the connection is done, turn ON the circuit breaker, the unit can recharge and recover to a voltage where the control electronics can be turned ON. This may take several minutes depending on the power supply used. At this stage, the recovery power supply can be removed and the module can recharge normally.

Do not use current more than 10A to recover the module




Specification of the recommended charger

Maximum current 10A

Recommended voltage 44V-54V

10.Trouble shooting: Faults and Solutions Over-Current (OC) OC occurs when the current goes above 125A or when the module is short-circuited. In this event, the protected terminal will shut down. Troubleshooting: Switch off the circuit breaker and check the continuity across the module terminals to find whether there is a short circuit. In case of a short circuit, check the operating circuitry and clear the short circuit. Over-Temperature (OT) OT occurs when the module temperature goes above 80°C. In this event, the protected terminal turns off Troubleshooting: Shut down the module and check the surrounding temperature and ensure the ambient temperature is less than 60°C. If not leave the module to cool till the module temperature comes below 60°C. Now, turn ON the circuit breaker. Multiple Errors The above-mentioned errors can occur simultaneously and will be shown on the LCD. To clear these, follow the steps explained in the above sections.




11.MaintenanceThe Sirius Capacitor Module does not require periodic maintenance.

Safety

Strictly observe the safety instructions listed below to ensure safe handling, injury prevention and trouble-free operation of the module.

• Ensure precautions to prevent short-circuit under all circumstances.

• Do not operate the module above the specified voltage.

• Do not operate the module above the specified temperature rating.

• Do not touch the terminals with conductors while the module is charged. Serious burns,shock, or material fusing may occur.

• Wear protective equipment when handling the modules including electrical gloves,protective eyewear and rubber shoes.

• Protect surrounding electrical components from incidental contact.

• Do not use the module in an open environment, in rain or in a place exposed to waterand other liquids.

• In case the module is physically damaged due to any event, do not install and energizethe module under any circumstances and contact your Reseller.

• When connecting to external devices ensure that galvanic isolation does not exceed1000V.

• Under no circumstances must the charge / discharge current exceed 125A.

• Under no circumstances must the charging voltage exceed 55VDC for more than 60seconds.

• During charge cycle ensure never to exceed constant voltage of 54VDC and constantcurrent of 125A.

• All modules must be at 100% SOC before connecting in series or parallel.

• The maximum number of modules that can be connected in series is 8 with a ModuleCombiner. Under no circumstances should you connect more than 8 modules in series.

• If you want to connect more than 8 modules in series, please contact your Reseller.

• Modules cannot be connected in a series – parallel combination under anycircumstances.

12.StorageThe Sirius modules can be stored at any SOC (State of Charge) without affecting the projected supercap cell cycle life.

Shelf life (the life of the module (in years) from the date it is manufactured to the time it is first operated) is 10 years.

13.DisposalDispose according to local regulations.


sirius capacitor module - greenfox.co.nz€¦ · to parallel. 6.2. series connection of sirius...

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