KBi KSM, Installation & Operation Manual

Page 1: ...ION OPERATION MANUAL Gen 3 12 Volts or 24 Volts KBI Kold Ban International Ltd 8390 Pingree Road Lake In The Hills Illinois 60156 9637 U S A 800 527 8278 847 658 8561 Fax 847 658 9280 www koldban com ATA VMRS T44 KLDBN KBI KAPower 2020 KBI Form 131480 ...

Page 2: ...ult in equipment damage and or equipment failure KBI Kold Ban International Ltd accepts no responsibility or liability for any of its products that are improperly used The safety information in this manual is provided as a guide for the user and is not a substitute for proper training and usage NOTE The information contained in this document is copyright and patent protect This document may not be...

Page 3: ...L VOLTMETER HARNESS 36 10 0 LIMITED WARRANTY 37 Table 1 Specifications 7 Table 2 LED Flash Sequence 20 Figure 1 Parts List Items 4 Figure 2 Typical Cable Installations 10 Figure 3 Six 6 Cell KSM 11 Figure 4 Ten 10 and Twelve 12 Cell KSM 12 Figure 5 General Wiring Installation 14 Figure 6 Standard KSM Schematic 16 Figure 7 Standard MKSM Schematic 17 Appendix A Supplement for Boats using a Key Switc...

Page 4: ...ase Not Shown 5 Protective boots Not Shown 2 0 ITEMS NEEDED FOR INSTALLATION 1 Battery cables See Section 4 1 for cable recommendations 2 Terminals for battery cable 3 Torque wrench with inch socket or 11 16th depending on KSM model 4 Minimum 16 gauge wire for harnesses KSM Enclosure DPST Switch DPST Switch Marine Figure 1 Parts List Items ...

Page 5: ...anking and starting of internal combustion engines This capability may allow for removal of half or most existing starting batteries The KAPower module can produce a significant electric charge KAPower is not a high voltage device It supplies the same amount of voltage as its charge A charged module should be treated as a fully charged battery Do not short circuit KAPower module terminals Burning ...

Page 6: ...g one million cycles 3 3 The KAPower Module The KAPower module which is housed within the KSM enclosure represents an internal bank of 6 10 or 12 capacitor cells series connected to each other 3 4 Electrochemical Double Layer Capacitor EDLC An Electrochemical Double Layer Capacitor represents a device capable of storing and delivering electric power This is due mainly to the existing capacitance o...

Page 7: ... Current at Max Voltage 4 5 mA 4 5 mA 4 5 mA 4 5 mA Operating Conditions Operating Temperature Range 40 185 F 40 85 C 40 185 F 40 85 C 40 185 F 40 85 C 40 185 F 40 85 C Cycle Life 1 000 000 1 000 000 1 000 000 1 000 000 Dimensions and Weight Length x Width x Height 14 79 x 7 75 x 8 19 44 x 7 75 x 8 19 44 x 7 75 x 8 19 44 x 7 75 x 8 Weight 22 lb 32 5 lb 32 5 lb 34 5 lb The KAPower KSM is a product ...

Page 8: ... being recommended A six cell 12 volt unit may use 4 gauge to 2 0 cables 3 Keep cable length to an absolute minimum The circuit resistance increases with cable length 4 Ensure that the cable termination connections terminals are properly crimped and ensure that the holes in ring terminals match the size of the studs over which they are placed Do not use welding cable use high quality fine strand t...

Page 9: ...d bulkhead or other location without backside acsess other fastiners such as suitably sized tapping screws can be used When selecting a location for installation make sure that the KSM module and cables will clear any hoods hatches lids covers and other movable vehicle vessel or equipment parts Avoid locations that are subject to extreme heat dripping water humidity road dirt ice and snow While th...

Page 10: ...10 Figure 2 Typical Cable Installations ...

Page 11: ...11 Figure 3 Six 6 Cell KSM ...

Page 12: ...12 Figure 4 Ten 10 and Twelve 12 Cell KSM ...

Page 13: ...anking motor circuit to be engaged simultaneously Once the engine starts the Programmable Logic Controller PLC inside the KSM monitors the condition of the KAPower Module and will close or open the contactor relay inside the KSM based on the preprogrammed parameters inside the PLC When the engine is stopped the equipment is turned off The contactor opens and the KAPower module remains isolated wai...

Page 14: ...14 NOTE The J1939 connector is used for KBI factory programming only Contact KBI for details Figure 5 General Wiring Installation ...

Page 15: ...n wiring harness or connections NOTE The PLC inside the KSM needs power approximately 2 5 amps from a source such as a key switch that provides power only when the vehicle or boat is in operation Consider this additional 2 5 amps of power and how it may influence the source This new circuit should be protected with a 5 amp fuse or circuit breaker per ABYC standards in marine applications 5 Wire th...

Page 16: ...e 6 Standard KSM Schematic 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 DPST switch ...

Page 17: ...17 Figure 7 Standard MKSM Schematic ...

Page 18: ...ngage the vehicle vessel or equipment s OEM cranking motor circuit 4 Whenever the KSM KAPower contactor is closed the LED on the End Faceplate should be illuminated green 5 The engine should begin to crank over with power being supplied from both the KSM capacitor module and the standard battery ies 6 Once the engine starts and the DPST switch is released the KSM internal PLC module will be active...

Page 19: ...the starting battery to be tested 1 The LED located on the End Faceplate of the KSM indicates the active condition of the KSM module See Figure 5 for location of this light If the LED is not illuminated when expected see Section 4 3 Theory of Operation ensure that all wiring and connections are in accordance with the instructions within this manual Check the integrity of the DPST switch and the po...

Page 20: ...l If voltage is present the circuit is good The voltage reading is the actual KAPower module voltage and should be at least 12 volts for the 24 volt models and 6 volts for the 12 volt models in order to activate the contactor 3 Jump pins 1 and 2 on the four pin connector the contactor should activate and make a clunk sound If not contact KBI for assistance 4 If experiencing problems check the inte...

Page 21: ...on system in regions having moderate or cold weather conditions Climate control systems are not required The required storage temperature range is 76º to 185ºF 60º to 85ºC 8 0 TRANSPORTATION The KAPower KSM modules can be shipped in approved corrugated cardboard wooden or plastic containers For more information on transportation contact KBI CAUTION ...

Page 22: ...ng no rocker switch or push button is required NOTE If the OEM engine manufacturer or the boat builder reviews the KBI KSM Theory of Operation page 13 18 and the requirements for DPST type functionality then incorporating the DPST type function and engineering it into the factory build key switch should be no problem However when installing a KSM on a boat that has already been built with key swit...

Page 23: ...23 Figure A1 Typical Cable Installations ...

Page 24: ...ly when the boat is in operation See Figure A2 Example of existing key switch Figure A2 Typical Boat Key Switch Schematic NOTE S terminal receives power when the key switch initiates an engine starting event The power is also supplied to Pin 3 of the KSM bringing the KSM online to supply engine starting power ...

Page 25: ...25 Figure A3 Schematic Alternate Source for Start Signal ...

Page 26: ...art switch on the vessel There is no change to functionality The other side circuit of the DPST switch turns on the capacitor providing power to the engine s vessel s electrical circuit regardless of lead acid battery condition The capacitor the KSM circuit does not actually engage the starter motor The original OEM circuit does that just as it normally would All the KSM is doing is making sure th...

Page 27: ...27 Figure B1 Typical Cable Installations ...

Page 28: ...arge relay ACR and house battery are shown for reference only Not all installations require or use house batteries but in such a scheme the house battery could also be used for emergency power Figure B2 Multiple Engine Option ...

Page 29: ...29 Figure B3 Simplified Installation Diagram ...

Page 30: ...30 Figure B4 Standard DPST Install ...

Page 31: ...ion KSM activation is not an option If the OEM engine manufacturer or the boat builder reviews the KBI KSM Theory of Operation Pages 13 18 and the requirements for DPST type functionality then incorporating the DPST type function and engineering it into the factory build should be no problem However when installing a KSM on a boat that has already been built with keypad button or digital switch st...

Page 32: ...32 Figure C1 Typical Cable Installation ...

Page 33: ...33 Figure C2 Alternate Method ...

Page 34: ...ch that provides power only when the boat is in operation Consider this additional 2 5 amps of power and how it may influence the source This new circuit should be protected with a 5 amp fuse or circuit breaker per ABYC standards Figure C3 Power Sources for KSM Pin 4 and Emergency Start Switch ...

Page 35: ...35 Figure C4 Multiple Engine MKSM Schematic ...

Page 36: ...s into KSM faceplate The female end will receive the connector from the vehicle or vessel Connect the eyelet over the existing ground connection on the negative post of the KSM A voltmeter can then be installed at the butt splices coming from the Weather Pack connector Note Not all KSM models can use external voltmeter contact KBI for details ...

Page 37: ...ithout charge Failure due to accident abuse neglect use other than in the intended application specified in this manual improper installation or maintenance mishandling and repairs or attempted repairs which have been made by others are not covered under the terms of this warranty Kold Ban International Ltd shall not be liable for loss of use of the KAPower KSM or other incidental or consequential...