KBi KAPower Starting Module Installation & Operation Manual Download Page 1

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KAPower Starting Module (KSM)

INSTALLATION – OPERATION MANUAL

Gen 3. Rev E

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®

Rev. E

n 3

& 2

4 V

olt

Summary of Contents for KAPower Starting Module

Page 1: ...ION MANUAL Gen 3 Rev E 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 2018 KBI Form 131400 Rev E Gen 3 12 24 Volt ...

Page 2: ...3 Wiring harness Not Shown 4 Terminal grease Not Shown 5 Protective boots Not Shown ITEMS NEEDED FOR INSTALLATION 1 Battery cables 4 0 cable is recommended 2 Terminals for battery cable 3 Torque wrench with inch socket 4 Minimum 16 gauge wire for harnesses KSM Enclosure DPST Switch ...

Page 3: ...circuit may follow such a short circuit In case of accidental short circuit ing of the KAPower module or individual capacitors immediately disconnect the KAPower module from the electric circuit Use caution when doing so as short circuited cables can become very hot while spewing melting insulation and copper Noncompliance with the requirements set forth in this Manual may result in KAPower module...

Page 4: ...__________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ _________...

Page 5: ...lly Unaffected by Temperatures Increases the Life of Batteries Requires NO Maintenance Safe Easy to Install KAPower Basic Description The KAPower module is an energy storage device KAPower is a High Power device with Low 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 b...

Page 6: ...ovable parts Install the KAPower KSM module as close to the engine s starting batteries or starter as possible Avoid locations that are subject to extreme heat humidity dripping water under deck ventilation systems aboard boats for instance road dirt ice and snow Prevent the external case of the KAPower KSM module from physical impacts Visually inspect the external case prior to mounting the modul...

Page 7: ...on connections is recommended 5 The quality of the cable connections from the KSM to the vehicle or equipment is critical Make sure to provide good clean robust cable interface connections The cables between the KSM module and the battery do not benefit from over current protection i e they have no fuse or circuit breaker If a short circuit occurs the cable will overheat and it may catch fire or i...

Page 8: ...s Avoid locations that are subject to extreme heat dripping water humidity road dirt ice and snow While the KSM unit may be mounted in any position or orientation do not mount it directly over batteries or under ventilation systems through which water might drip The internal components of the KSM are IP67 rated but the KSM itself is not IP rated Take care to prevent the external case of the KSM mo...

Page 9: ...9 10 12 cell KSM The J1939 connector is used for KBI Factory programing only Contact KBI for details ...

Page 10: ...LLATION 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 Note DPST is wired parallel with OEM start switch connecCons ...

Page 11: ... 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 waiting for the...

Page 12: ...urced at the engine Install a 5 amp fuse in this circuit within seven 7 inches of the power source Use care not to disturb or compromise the engine s own wiring harness or connections 5 Wire the DPST switch and find and wire the appropriate PLC input pin 4 as based and depicted on the diagram schematic pages 10 13 You will not be connecting any wiring to the J1939 Connector The J1939 CAN Bus is us...

Page 13: ...us 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 OEM Push Bu on or Key Switch Cranking Start Switch ...

Page 14: ...power being supplied from both the KSM capacitor module and the standard batteries Once the engine starts and the DPST switch is released the KSM internal PLC module will be active keeping the contactor closed when required allowing the KAPower module to recharge NOTE If the vehicle vessel or equipment s batteries are completely discharged if the battery is dead it may be necessary to keep the DPS...

Page 15: ...al Check the integrity of the DPST switch and the power supply to the PLC sourced from the engine ignition switched when on wiring harness you created This bi color red green LED is also an indicator for how the KSM is functioning The green side of the LED is connected parallel with the contactor The red side is connected to an output on the PLC as shown in the schematic depicted on page 13 The PL...

Page 16: ...ker and contactor relay connections within the KSM module In order to service or replace any of these components you will have to remove the cover of the KSM enclosure Reference page 5 INTRODUCTION Again contact KBI for assistance The PLC Module is a sealed unit It cannot be serviced If additional troubleshooting is required contact KBI STORAGE The KAPower module should be discharged prior to stor...

Page 17: ...the product to be defective under the terms of this warranty it will be replaced without 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...

Page 18: ...18 Appendix A ...

Page 19: ...19 TM R R TM R R R TM R R R R M J Burke D R Solberg Appendix B ...

Page 20: ...20 ...

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