INSTALLATION - OPERATION MANUAL. Revision of 01/2012

Transcription

1 KAPower INSTALLATION - OPERATION MANUAL Revision of 01/2012 KBi/Kold-Ban International, Ltd Pingree Road, Lake In The Hills, Illinois U.S.A. (800) , (847) , Fax (847) , ATA VMRS - T44 KLDBN

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3 SAFETY AWARENESS SAFETY AWARENESS SYMBOLS are inserted in this manual to alert you to possible SAFETY HAZARDS. Whenever you see these symbols: WARNING or heed their instructions! SAFETY AWARENESS SYMBOLS AND MEANINGS: WARNING THIS WARNING SYMBOL IDENTIFIES SPECIAL INSTRUCTIONS OR PROCEDURES WHICH, IF NOT CORRECTLY FOLLOWED, COULD RESULT IN PERSONAL INJURY. THIS SYMBOL IDENTIFIES SPECIAL INSTRUCTIONS OR PROCEDURES WHICH, IF NOT STRICTLY OBSERVED, COULD RESULT IN DAMAGE TO, OR DESTRUCTION OF EQUIPMENT. WARNING Capacitors assembled into the KAPower module contain an electrolyte which represents a potassium hydroxide solution. Requirements to the KAPower modules operation shall be observed to avoid electrolyte leakage! Electrolyte may cause chemical burn if spilled onto unprotected skin. If the KAPower module or individual capacitors are destroyed due to accidental physical impact, it is necessary to take actions preventing electrolyte from spilling onto unprotected skin of attending personnel. KAPower module is a product of high electric power. Never short circuit KAPower module terminals! It may be followed by burning or igniting of combustible materials adjacent to the point of short circuit. In case of accidental short circuiting of the KAPower module or individual capacitors it is necessary to disconnect the KAPower module immediately from the electric circuit taking relevant safety measures. Noncompliance with the requirements set forth in this Manual may result in KAPower module failure. Such requirements shall be reviewed prior to and observed in the course of KAPower module operation and installation. The KAPower module is polarity sensitive. Polarity shall be strictly observed when connecting the KAPower module! Page 3

4 TABLE OF CONTENTS Introduction... 5 Installation... 7 Operation Troubleshooting Maintenance Storage Transportation Notes: Page 4

5 INTRODUCTION KAPower is designed as an auxiliary power source to be installed in parallel with your cranking batteries. It derives its power from your batteries or vehicle charging system and discharges this power when needed. KAPower is intended for supplying electric power to various loads operated in high pulse power (engine cranking) modes. KAPower will enhance and provide for reliable cranking and starting of internal combustion engines. KAPower: Stores Cranking Voltage Until Needed. Long Service Life - 500,000 + Cycles. Performance Virtually Unaffected by Cold Temperatures. Increases the Life of Batteries. Requires NO Maintenance. Safe & Easy to Install. KAPower Description The KAPower module is a polarity sensitive device. Polarity should be strictly observed when connecting the KAPower module into any circuit. KAPower Module The KAPower module represents an internal bank of 10 or 20 capacitors series-connected to each other. External Positive (+) and negative (-) terminals with threaded connections are located on the plastic cover of the module. Electrochemical Capacitor Electrochemical capacitor represents a device capable of storing and delivering electric power due mainly to the existing capacitance of the double electric layer which is formed by the capacitor's negative electrodes being in contact with electrolyte. The capacitor consists of negative and positive electrodes with terminals, separator, electrolyte, shell and a valve. Electrodes Negative electrodes are made of activated carbon material, positive ones are nickel hydroxide electrodes. The design of the electrodes provides for a high charge/discharge rate. Electrolyte Aqueous solution of potassium hydroxide having a density of ounces per cubic inch ( grams per cubic centimeter), is used as the electrolyte. The concentration of the potassium hydroxide is 30% (30 grams per 100 grams of electrolyte solution). KAPower design Provides for a slight Faradaic process that creates high power and high-energy performance characteristics virtually unaffected by cold temperatures. Provides for extremely low self-discharge rates which enable extended periods of storage or nonuse while providing sufficient power for engine starting. Allows for a self-balancing effect of the voltage between the individual cells within the device without using electronic circuitry. Provides safe, efficient and effective operation without elaborate internal controls. Leakage Currents are diminished as voltage declines, eventually becoming almost nonexistent. Leakage Current declines as the temperature declines and rises as the temperature rises. Page 5

6 * Module can be kept at this voltage for a short period. Short-Term discharge of the module down to zero voltage is possible; however, it should be stored at a voltage not less than the Minimum Voltage specified in the table. ** Operating temperature is dependent not only on the ambient temperature, but also on the module operating mode. High charge/discharge cycle frequency and high charge/discharge currents produce higher internal temperatures. To insure guaranteed cycle life of the capacitor module, internal cell temperatures should not exceed 131 F (55 C). Module operation at temperatures above 131 F (55 C) may result in a reduction of the module's capacitance and delivered energy. See Temperature vs. Voltage, Table 2 below. Table 1 KAPower Operating Voltages 12 Volt 24 Volt Operating Voltage Window Volts 8-29 Volts Minimum Voltage* 4 Volts 8 Volts Maximum Voltage* 16 Volts 32 Volts Operating Temperature Range** -40 to 122 F (-40 to 50 C) Storage Temperature -76 to 158 F (-60 to 70 C) Note: Additional specifications for the module(s) that you will be using are identified on the engineering drawing supplied with the module(s) in the original packaging. Table 2 Temperature vs. Voltage This chart identifies the maximum voltage the capacitor can be operated at with respect to capacitor internal temperature. Page 6

7 INSTALLATION The KAPower Module is a product of high electric power. Avoid shorting module terminals! A brief, short circuit will not cause product failure, however, it may result in burning or igniting of combustible materials adjacent to the point of short circuit. Before installation, familiarize yourself with the specifications of your KAPower module. Insure that you have the proper device for your application. IMPORTANT! Remember that Electrical Resistance in the circuit created is the consumer of the electrical energy in your KAPower Module. Keep the resistance to an absolute minimum. Short, heavy cables and good, clean cable connections are essential! When selecting a location for installation, make sure that the KAPower module will clear the vehicle hood or compartment door and other movable parts. Install the KAPower module as close to the engine's cranking motor as possible. Avoid locations that are subject to extreme heat, humidity, road dirt, ice and snow. The KAPower module must be mounted in an upright position (with its cover up). Prevent the external case of the KAPower module from physical impacts to avoid damaging the plastic shells of the individual capacitors. WARNING The KAPower module must be installed with the terminals up ( ). Visually inspect the external case prior to installing the module. Make sure that no traces of physical impacts or electrolyte leaks are present on the external case of the KAPower module. DO NOT open the external case cover of the KAPower Module. DO NOT short circuit terminals. Capacitor and Relay contact studs are copper/nickel plated, torque specifications are to be STRICTLY adhered to: Capacitor Studs, 122 in lbs.; Relay Studs, in. lbs. Electrical Cable Selection 1. Electrical resistance in the circuit you create is a significant consumer of the power available in the KAPower device. For optimal performance, the load resistance (entire load), and the internal resistance of the capacitor module should be matched as closely as possible. 2. Use the heaviest gauge cable available. It is recommended that 4/0 cable is used in many cases. 3. Keep cable length to an absolute minimum. The circuit resistance increases with cable length. 4. Insure that the cable termination connections (terminals) are properly crimped and/or soldered to the cables. 5. For optimal performance, the capacitor module should be completely isolated from the electrical circuit when the engine is not running (See Figure 2, 3, or 4). Page 7

8 Typical Group 31 Type Batteries KAPower Module Cranking Motor Battery 1 Battery 2 Battery 3 Battery 4 You may be able to remove half of the Batteries when using a KAPower Module. Replacing existing lead acid batteries with deep cycle batteries will enhance your system. Figure 1 Connecting the KAPower Module to a Standard Battery(s) A. Connecting the KAPower Module to a Standard Battery (see Figure 1) 1. It is recommended that the KAPower Module be charged to a voltage that will be within 2 volts of the fully charged battery (circuit) voltage; this is to prevent harm to the battery or terminal connections during the initial high current draw from the battery to the KAPower module. A standard heavy duty commercial battery charger can be used for this initial charge. It is important to MONITOR the voltage when charging the KAPower module to its Maximum Voltage listed in Table 1. Failure to do so may result in module failure. KAPower modules should not be used on continuous load(s) that bring the module below the Minimum Voltage before recharging or the module will be damaged. Capacitor and Relay contact studs are copper/nickel plated, torque specifications are to be STRICTLY adhered to: Capacitor Studs, 122 in lbs.; Relay Studs, in. lbs. 2. Remove the protective caps from the KAPower module terminals. 3. Check the KAPower module voltage. 4. Check the battery voltage. 5. If the difference between the KAPower module and the battery voltages is within 2 volts, then the KAPower module terminals may be connected as follows: a. One of the cables shall first be connected to the + clamp or terminal of the battery and then connected to the + terminal of the KAPower module. b. The second cable shall be connected to the - clamp or terminal of the battery first and then connected to the - terminal of the KAPower module. 6. If the difference between the charged KAPower module and the charged battery voltage is more than 2 volts, it is necessary to charge the KAPower module by a charger or discharge it with the use of a resistor. 7. System Installation is now complete. Page 8

9 B. Connecting the KAPower Module with Engine Oil Pressure Switch and DPST Switch (see Figures 2 & 3) This system will consist of one KAPower module, one Normally Open oil pressure switch, one Double Pole Single Throw (DPST) momentary push button switch, and one Relay. 1. It is recommended that the KAPower Module be charged to a voltage that will be within 2 volts of the fully charged battery (circuit) voltage; this is to prevent harm to the battery or terminal connections during the initial high current draw from the battery to the KAPower module. A standard heavy-duty commercial battery charger can be used for this initial charge. It is important to MONITOR the voltage when charging the KAPower module to its Maximum Voltage listed in Table 1. Failure to do so may result in module failure. KAPower modules should not be used on continuous load(s) that bring the module below the Minimum Voltage before recharging or the module will be damaged. 2. Remove the protective caps from the KAPower module terminals. 3. Check the KAPower module voltage. 4. Check the battery voltage. 5. If the difference between the KAPower module and the battery voltages is within 2 volts, then the KAPower module terminals may be connected as follows: a. One of the cables shall first be connected to the + (Positive) clamp or terminal of the battery and then connected to the + (Positive) terminal of the KAPower module. b. The second cable shall be connected to the - (Negative) clamp or terminal of the battery first and then connected to one of the posts on the relay. c. The third cable shall be connected to the other post on the relay, the other end of this cable will be connected to the - (Negative) terminal of the KAPower module. 6. If the difference between the charged KAPower module and the charged battery volt age is more than 2 volts, it is necessary to charge the KAPower module by a charger or discharge it with the use of a resistor. 7. When installing this system you will be adding a Normally Open oil pressure switch into a 1/8 NPT engine oil passage port or an oil pressure manifold if available. NOTE: Some Heavy Duty Truck Manufacturers have installed an Original Equipment Manufacture (OEM) oil pressure manifold behind the vehicle dash board which may be utilized for the Normally Open oil pressure switch by removing one of the pressure switches from the block, installing a 1/8 NPT street tee than reinstalling the pressure switch as well as the KBi pressure switch. 8. The DPST switch, which should be mounted in the cab of the vehicle within access of the operators reach. 9. For wiring of the Oil Pressure switch, Relay and DPST switch follow the diagram for your particular application. 10. To test the system leave the ignition key in the off position and push the push button, you should hear the relay close. 11. System Installation is now complete. Page 9

10 Cranking Motor Battery 1 Battery 2 Capacitor and Relay contact studs are copper/nickel plated, torque specifications are to be STRICTLY adhered to: Capacitor Studs, 122 in lbs.; Relay Studs, in. lbs. Figure 2 Connecting the KAPower Module with Engine Oil Pressure Switch and DPST Switch Required 10 psi N/O (close on rise) Oil Pressure Switch Ignition Crank Circuit Required DPST Push Button Crank Switch KAPower Module Fuse 5 amp Fuse 5 amp Required Relay For use under one or more US Patent Numbers: 6,242,887-6,362,595-6,819,010-6,871,625-6,888,266-6,988,475-6,988,476-7,131,415 and 7,198,016 Page 10

11 Note 1 The optional method opposed to the oil pressure switch is to interface with the vehicle multiplex system to activate the capacitor contactor once the engine is running. Leaving the KAPower capacitor in the recharge mode for a period of 2-3 minutes. Double Pole Start Switch Cranking Motor On Off On Off Mulit-Plex Control Confirmed Engine, Run Activate Capacitor Relay 2-3 Minutes Time Engine Cranking Event Capacitor Recharge Event Engine In Operation Until Shut-Down Figure 3 Vehicle Installation with Rear Start Capabilities Rear Push Button DSPT Start Switch (Optional) Existing Start Switch Connections Master Disconnect KAPower Module Proprietary Poles On Start Switch Front Push Button DPST Start Switch Existing Start Switch Connections Battery 3 Proprietary Poles On Start Switch 10 psi Normally Open Oil Pressure Switch (see Note 1) Fuse 5 amp Fuse 5 amp Batteries Battery 2 Battery Box Components Required Relay Capacitor and Relay contact studs are copper/nickel plated, torque specifications are to be STRICTLY adhered to: Capacitor Studs, 122 in lbs.; Relay Studs, in. lbs. For use under one or more US Patent Numbers: 6,242,887-6,362,595-6,819,010-6,871,625-6,888,266-6,988,475-6,988,476-7,131,415 and 7,198,016 Page 11

12 C. Connecting the KAPower Module with Timer Switch and DPST Switch (see Figure 4) This system will consist of one KAPower module, one Timer switch, one Double Pole Single Throw (DPST) momentary push button switch, a diode assembly, and one Relay. 1. It is recommended that the KAPower Module be charged to a voltage that will be within 2 volts of the fully charged battery (circuit) voltage; this is to prevent harm to the battery or terminal connections during the initial high current draw from the battery to the KAPower module. A standard heavy-duty commercial battery charger can be used for this initial charge. It is important to MONITOR the voltage when charging the KAPower module to its Maximum Voltage listed in Table 1. Failure to do so may result in module failure. KAPower modules should not be used on continuous load(s) that bring the module below the Minimum Voltage before recharging or the module will be damaged. Capacitor and Relay contact studs are copper/nickel plated; torque specs are to be STRICTLY adhered to: Capacitor Studs, 122 in. lbs.; Relay Studs, in. lbs. 2. Remove the protective caps from the KAPower module terminals. 3. Check the KAPower module voltage. 4. Check the battery voltage. 5. If the difference between the KAPower module and the battery voltages is within 2 volts, then the KAPower module terminals may be connected as follows: a. One of the cables shall first be connected to the - (Negative) clamp or terminal of the battery and then connected to the - (Negative) terminal of the KAPower module. b. The second cable shall be connected to the + (Positive) clamp or terminal of the battery first and then connected to one of the posts on the relay. c. The third cable shall be connected to the other post on the relay, the other end of this cable will be connected to the + (Positive) terminal of the KAPower module. 6. If the difference between the charged KAPower module and the charged battery volt age is more than 2 volts, it is necessary to charge the KAPower module by a charger or discharge it with the use of a resistor. 7. The DPST switch, which should be mounted in the cab of the vehicle within access of the operators reach. 8. For wiring of the Timer switch, Relay and DPST switch follow the diagram in figure To test the system leave the ignition key in the off position and push the push button, you should hear the relay close. 10. System Installation is now complete. Page 12

13 Capacitor Enclosure Diode Assembly Required Relay Fuse 5 amp 30 Load Capacitor and Relay contact studs are copper/nickel plated, torque specifications are to be STRICTLY adhered to: Capacitor Studs, 122 in lbs.; Relay Studs, in. lbs. Fuse 5 amp 85 Ground 87A Input Their Relay 86 Power Required DPST Push Button Crank Switch Ignition Crank Circuit Connect to Ground Bus KAPower Module Patent Pending Figure 4 Connecting the KAPower Module with Timer Switch and DPST Switch Cranking Motor Battery Enclosure Battery Bank Page 13

14 OPERATION Charge voltage shall not exceed the Maximum Voltage as specified in Table 1. It is important to MONITOR the voltage when charging the KAPower module to its Maximum Voltage. Failure to do so may result in module failure. KAPower modules should not be used on a continuous load to bring the module below Minimum Voltage before recharging. Operating the KAPower Module in the Buffer Mode Operating the KAPower module together with a power source in the buffer (floating), mode provides for the KAPower module to be parallel connected to a power source (for instance, to a standard battery), for a long time. If the KAPower module is operated in the buffer mode, it is necessary to remember that the module voltage shall not exceed 14.5 volts (for modules having a 4/14.5 volt voltage window) or 29 volts (for modules having a 8/29 volts voltage window). Stand-Alone KAPower Module Operation Stand-alone KAPower module operation provides for occasional charge/discharge of the KAPower module within its Operating Voltage Window, at the same time: 1. The KAPower module shall be connected to a power source (charging device), during charge. 2. The KAPower module shall be disconnected from the charging device and be connected to a load during discharge. Cranking Instructions with DPST Switch and Oil Pressure Switch: If a second starting attempt is required, activate the DPST switch for about seconds (without cranking the engine), key in the off position. This will recharge the KAPower capacitor provided the battery/batteries have at least a 10 Volt charge (12 v system). After recharging the KAPower, repeat the above cranking instructions. Page 14

15 TROUBLESHOOTING Table 3 specifies a list of possible troubles and recommendations on how to eliminate them. Table 3 Possible Troubles and Remedies Trouble and its' Signs Reduction of capacitance Heating of module terminals above 158 F (70 C). Possible Cause Possible undercharge. Insufficient electrolyte quantity. Charging mode voltage is not observed. Poor contact in capacitors connections. MAINTENANCE Remedy Check the charging mode. Contact KBi. Check the charging mode. Contact KBi. Maintenance of the KAPower modules shall not be required provided that the operating conditions are proper and that the requirements specified in this Manual are observed. STORAGE The KAPower modules shall be charged up to the Maximum Voltage per Engineering Drawing prior to storage. The total duration of the KAPower modules storage time shall not exceed five years during it's service life. The KAPower modules shall be stored within enclosed heated or unheated premises outfitted with a natural ventilation system in regions having moderate or cold weather conditions. Climate control systems are not required. The required storage temperature range is -76 to 158 F (-60 to 70 C) TRANSPORTATION The KAPower modules may be transported by any transportation mean at any distance. The KAPower modules shall be wrapped into polyethylene covers and transported in special wooden, cardboard or plastic cases. The modules shall be placed into the cases with no spaces left between them to avoid displacement. KAPower modules shall be transported in normal working position (with their covers up) and cases shall bear relevant marking specifying this requirement. Page 15

16 LIMITED WARRANTY All products are guaranteed against defects in material and workmanship for three (3) years from date of purchase. The KAPower is a sealed unit. If the KAPower does not operate properly, it must be returned to the factory, prepaid, for replacement. If factory inspection determines 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 be liable for loss of use of the KAPower or other incidental or consequential costs, expenses or damages incurred by the purchaser or user. This warranty does not include labor for repair or replacement. Kold-Ban International, Ltd Pingree Road Lake In The Hills, IL (847) (800) KBi KAPower 2012 KBi Form # Rev. 02/12