KAPower Starting Module (KSM)
With
Programmable Logic Controller (PLC)
INSTALLATION – OPERATION MANUAL
Gen 3. Rev D
!"#$!%&'(")*+#*,-.*),/%*)&0+1,'2
3456+7/*8.--+9%)'0+1):-+#*+;<-+=/&&>0+#&&/*%/>+?6@A?(5?4B+C2D2E2
F366G+AHB(3HB30+F3IBG+?A3(3A?@0+J)K+F3IBG+?A3(5H360+LLL2:%&'M)*2N%O
E;E+PQ9D+(+;II+!1R"S+
+
+
+
!"#T !E7%L-.T U+H6@B+!"#+J%.O+V@4@I66 9-W2+R
Gen$3
$
12$&$24$Volt
$
+
H+
+
+
+
PARTS$LISTX+
+
@2 !DQ+71Y+O%'Z&-2++
H2 R%ZM&-+7%&-+D/*8&-+;<.%L+FR7D;G+[Z><+MZ,,%*+>L/,N<2+
42 \/./*8+<).*->>2+FS%,+D<%L*G+
I2 ;-.O/*)&+8.-)>-2+FS%,+D<%L*G++
A2 7.%,-N,/W-+M%%,>2+FS%,+D<%L*G+
ITEMS$NEEDED$FOR$INSTALLATIONX+
+
@2 "),,-.]+N)M&->0+I$6+N)M&-+/>+.-N%OO-*'-'2++
H2 ;-.O/*)&>+^%.+M),,-.]+N)M&-2+
42 ;%._Z-+L.-*N<+L/,<+`+/*N<+>%N:-,2++
I2 @?+8)Z8-+L/.-+^%.+<).*->>->2++
+
+++++++++++++++++++++++++++++++++++++ ++++++++++++++++++++++++++++++++++++ +
+ + + + +
+++++++++++++++++++++++@2++ + + + + ++++++++++++++H2+++++++++++++++++++++++++++
+
++
+
4+
SAFETY AWARENESS
+
DEJa;b+E\E9aSaDD+ DbQ"c1D+).-+ /*>-.,-'+ /*+ ,</>+O)*Z)&+ ,%+ )&-.,+]%Z+
,%+[%>>/M&-+DEJa;b+=EdE9RD 2+\ <-* -W- .+]%Z +>--+,<- >-+>]OM%&>X++
+
%.++ <--'+,<-/.+/*>,.ZN,/%*>e+
+
DEJa;b+E\E9aSaDD+DbQ"c1D+ESR+QaES#SfDX++
;=#D+\E9S#Sf+DbQ"c1+#RaS;#J#aD+D7aY#E1+
#SD;9CY;#cSD+c9+79cYaRC 9aD0+\=#Y=0+#J+Sc;+
Yc99aY;1b+Jc11c\aR0+YcC1R+9aDC1;+#S+7a9DcSE1+
#SgC9b2
+
+
;=#D+YEC;#cS+DbQ"c1+#RaS;#J#aD+D7aY#E1+#SD;9CY;#cSD+c9+
79cYaRC9aD0+\=#Y=0+#J+Sc;+D;9#Y;1b+c"Da9PaR0+YcC1R+9aDC1;+#S+
REQEfa+;c+c9+RaD;9CY;#cS+cJ+ahC#7QaS;2
+
+
+
!E7%L-.+O%'Z&-+/>+)+[.%'ZN,+%^+</8<+-&-N,./N+[%L-.2
S-W-.+ ><%.,+ N/.NZ/,+ !E7%L-.+ O%'Z&-+ ,-.O/*)&>e+ "Z.*/*8+ %.+ /8*/,/*8+ %^+
N%OMZ>,/M&-+O),-./)&>+)'i)N-*,+,%+,<-+[%/*,+%^+><%.,+N/.NZ/,+O)]+^%&&%L+/,2+
#*+ N)>-+ %^+ )NN/'-*,)&+ ><%.,(N/.NZ/,(/*8+ %^+ ,<-+ !E7%L-.+ O%'Z&-+ %.+
/*'/W/'Z)&+ N)[)N/,%.>+ /,+/>+ *-N->>).]+ ,%+'/>N%**-N,+ ,<-+!E7%L-.+ O%'Z&-+
/OO-'/),-&]+^.%O+,< - +-& -N ,./N +N/. NZ /,+, ): /* 8 +.-& -W ) *, +>) ^-, ]+O-)>Z.->2+
+
+
+
+
S%*N%O[&/)*N-+L/,<+,<-+.-_Z/.-O-*,>+>-,+^%.,<+/*+,</>+Q)*Z)&+O)]+.->Z&,+/*+!E7%L-.+O%'Z&-+^)/&Z.-2+DZN<+
.-_Z/.-O-*,>+><)&&+M-+.-W/-L-'+[./%.+,%+)*'+%M>-.W-'+/*+,<-+N%Z.>-+%^+!E7%L-.+O%'Z&-+%[-.),/%*+)*'+/*>,)&&),/%*2
;<-+!E7%L-.+O%'Z&-+/>+[%&)./,]+>-*>/,/W-2+7%&)./,]+><)&&+M-+>,./N,&]+%M>-.W-'+L<-*+N%**-N,/*8+,<-+!E7%L-.+O%'Z&-e
WARNING
CAUTION
WARNING
CAUTION
WARNING
Note:&&KAPower&is#not#a"high(voltage(device.((It(simply(supplies'the'
same%voltage%that%it%was%charged%up%to.%%Treat%it%with%the%same%
respect'you'would'g ive'to'a'fully'charged'battery.
CAUTION
+
I+
TABLE OF CONTENTS:
+
7).,>+&/>,+)*'+.-_Z/.-'+/,-O>22222222222222222222222222222222222222222222222222H+
#*,.%'ZN,/%*22222222222222222222222222222222222222222222222222222222222222222222222222222222222A
#*>,)&&),/%*2222222222222222222222222222222222222222222222222222222222222222222222222222222222222?+
R/O-*>/%*>jjjjjjjjjjjjjjjjjjjjj3+k+5+
\/./*8+R/)8.)Ojjjjjjjjjjjjj2jjjj@6+k+@4
c[-.),/%*22222222222222222222222222222222222222222222222222222222222222222222222222222222222222@I
;.%ZM&-><%%,/*8222222222222222222222222222222222222222222222222222222222222222222222222@A
Q)/*,-*)*N-22222222222222222222222222222222222222222222222222222222222222222222222222222222@A
D,%.)8-2222222222222222222222222222222222222222222222222222222222222222222222222222222222222222222@?
;.)*>[%.,),/%*222222222222222222222222222222222222222222222222222222222222222222222222222@?
S%,->X
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
lllllllllllllllllllllllllllllllllllllllllllllllllllllllll
+
+
+
+
A+
INTRODUCTION:
!DQ+/>+)+[.-[)N:)8-'+!E7%L-.+)>>-OM&]+)&&%L/*8+^%.+,<-+-)>-+%^+/*>,)&&),/%*+)*'+%[-.),/%*+
%^+]%Z.+!E7%L-.+>]>,-O2++;<-+!DQ+-*N&%>Z.-+N%*>/>,>+%^+)+!E7%L-.+O%'Z&-0+)+N%*,)N,%.0+)+
71Y+ Q%'Z&-0+ )+ N/.NZ/,+ M.-):-.0+ N)M&->0+ N%*'ZN,%.>+ )*'+ N%**-N,%.>2+ ;<-+ N%W-.+ %^+ ,<-+ !DQ+
-*N&%>Z.-+N)*+ M-+.-O%W-'+M]+Z*>N.-L/*8+)*'+.-O%W/*8+,<-+,-*+F@6G+^)>,-*-.>+^%Z*'+%*+,<-+
,%[+ )*'+ >/'->+ %^+ ,<-+ -*N&%>Z.-2+ + ;<-+ N%W-.+ ><%Z&'+ %*&]+ M-+ .-O%W-'+ ^%.+ >-.W/N/*8+ %.+
,.%ZM&-><%%,/*82+
!E7%L-.+ />+ '->/8*-'+ )>+ )*+ )ZK/&/).]+ [%L-.+ >%Z.N-+ ,%+ M-+ /*>,)&&-'+ /*+ [).)&&-&+ L/,<+ ]%Z.+
N.)*:/*8+M),,-./->2+#,+'-./W->+/,>+[%L-.+^.%O+]%Z.+M),,-./->+%.+-*8/*-+ N<).8/*8+>]>,-O+)*'+
'/>N<).8->+,</>+ [%L-.+L<-*+ *--'-'2+!E7%L-.+/>+ /*,-*'-'+^%.+ >Z[[&]/*8+-&-N,./N+ [%L-.+,%+
W)./%Z>+ &%)'>+ %[-.),-'+ /*+ </8<+ [Z&>-+ [%L-.+ F-*8/*-+ N.)*:/*8G+ O%'->2+ !E7%L-.+ L/&&+
-*<)*N-+)*'+[.%W/'-+^%.+.-&/)M&-+N.)*:/*8+)*'+>,).,/*8+%^+/*,-.*)&+N%OMZ>,/%*+-*8/*->2++
KAPowerX+
mD,%.->+Y.)*:/*8+P%&,)8-+C*,/&+S--'-'+m1%*8+D-.W/N-+1/^-+n+C[L).'>+%^+)+Q/&&/%*+Y]N&->+
m7-.^%.O)*N-+P/.,Z)&&]+C*)^^-N,-'+M]+;-O[-.),Z.->+m#*N.-)>->+,<-+1/^-+%^+"),,-./->+
m9-_Z/.->+Sc+Q)/*,-*)*N-+mD)^-+k+a)>]+,%+#*>,)&&
+
KAPower$Basic$Description:$
$
;<-+!E7%L-.+O%'Z&-+/>+ )*+-*-.8]+>,%.)8- +'-W/N-2++!E7%L-.+/>+)+=/8<+7%L-.+'-W/N-+L/,<+
1%L+ a*-.8]+ '-*>/,]2+ + ;<-+ N.)*:/*8+ %.+ '/>N<).8-+ [-./%'>+ L/&&+ M-+ ><%.,+ MZ,+ [%L-.^Z&+
F,][/N)&&]+ &->>+ ,<)*+ 46+ >-N%*'>G+ L/,<+ ,<-+ ,/O-+ ,%+ ^Z&&+ .-N<).8-+ .),-'+ /*+ ,-*>+ %^+ >-N%*'>2+
9-N<).8/*8+ N)*+ M-+ )NN%O[&/><-'+ ^.%O+ W/.,Z)&&]+ )*]+ -&-N,./N)&+ [%L-.+ >%Z.N-2+ + Y]N&/*80+
N<).8-+ )*'+ '/>N<).8-+ -W-*,>+ L/&&+ *%,+ L-).+ %Z,+ ,<-+ '-W/N-2+ + ;<-+ Y]N&-+ RZ,]+ />+ .),-'+ /*+
<Z*'.-'>+%^+,<%Z>)*'>+%^+N]N&->+)[[.%)N</*8+%*-+O/&&/%*+N]N&->2+
+
The$KAPower$Module:$
$
;<-+ !E7%L-.+ O%'Z&-+ .-[.->-*,>+ )*+ /*,-.*)&+ M)*:+ %^+ ?0+ @6+ %.+ @H+ N)[)N/,%.+ N-&&>+ >-./->(
N%**-N,-'+,%+-)N<+%,<-.2++
An$Electrochemical$Capacitor$(EDLC):$
$
E*+ a&-N,.%N<-O/N)&+ R%ZM&-+ &)]-.+ Y)[)N/,%.+ .-[.->-*,>+ )+ '-W/N-+ N)[)M&-+ %^+ >,%./*8+ )*'+
'-&/W-./*8+ -&-N,./N+ [%L-.+ 'Z-+ O)/*&]+ ,%+ ,<-+ -K/>,/*8+ N)[)N/,)*N-+ %^+ ,<-+ '%ZM&-+ -&-N,./N+
&)]-.0+L</N<+/>+^%.O-'+M]+,<-+N)[)N/,%.o>+-&-N,.%' -> +M -/* 8 +/* +N%*,)N,+L /, < +-& -N ,.%&],-2+;<-+
N)[)N/,%.+ N%*>/>,>+ %^+ *-8),/W-+ )*'+ [%>/,/W-+ -&-N,.%'->+ L/,<+ ,-.O/*)&>0+ >-[).),%.0+
-&-N,.%&],-0+)*'+)+><-&&2+
+
+
?+
INSTALLATION:$
+
;<-+ !E7%L-.+ !DQ+ />+ )+ [.%'ZN,+ %^+ </8<+ -&-N,./N+ [%L-.2+ EW%/'+ ><%.,/*8+
O%'Z&-+,-.O/*)&>e+E+ M./-^0+><%.,+N/.NZ/,+L/&&+*%,+ N)Z>-+[.%'ZN,+^)/&Z.-0+<%L(
-W-.0+/,+O)]+.->Z&,+/*+MZ.*/*8+%.+ /8*/,/*8+%^+N%OMZ>,/M&-+O),-./)&>+)'i)N-*,+,%+,<-+[ %/*,+%^+
><%.,+N/.NZ/,2+
IMPORTANT!
9-O-OM-.+,<),+a&-N,./N)&+9->/>,)*N-+/*+,<-+N/.NZ/,+N.-),-'+/>+,<-+N%*>ZO-.+%^+,<-+-&-N,./N)&+
-*-.8]+ /*+ ]%Z.+ !E7%L-.+ Q%'Z&-2+ !--[+ ,<-+ .->/>,)*N-+ ,%+ )*+ )M>%&Z,-+ O/*/OZO2+ D<%.,0+
<-)W]+N)M&->+)*'+8%%'0+N&-)*+N)M&-+N%**-N,/%*>+).-+->>-*,/)&e+
\<-*+>-&-N,/*8+)+&%N),/%*+^%.+/*>,)&&),/%*0+O):-+>Z.-+,<),+,<-+!E7%L-.+!DQ+
O%'Z&-+L/&&+N&-).+ )*]+&/'>+)*'+%,<-.+O%W)M&-+[).,>2+#*>,)&&+,<-+!E7%L-.+!DQ+
O%'Z&-+)>+ N&%>-+,%+,<-+ -*8/*-o>+N.)*:/*8+O%,%.+)>+ [%>>/M&-2+EW%/'+ &%N),/%*>+
,<),+) .-+ >ZMi-N,+ ,%+-K,.-O-+<-),0+ <ZO/'/,]0+ .%)'+'/.,0+/N-+ )*'+>*%L2+7.-W-*,+ ,<-+ -K,-.*)&+
N)>-+%^+,<-+!E7%L-.+!DQ+O%'Z&-+^.%O+[<]>/N)&+/O[)N,>2+
P/>Z)&&]+/*>[-N,+,<-+-K,-.*)&+N)>-+[./%.+,%+O%Z*,/*8+,<-+ O%'Z&-2++Q):-+>Z.-+,<),+*%+,.)N->+
%^+[<]>/N)&+/O[)N,>+).-+[.->-*,+%*+,<-+-K,-.*)&+N)>-+%^+,<-+!E7%L-.+!DQ+O%'Z&-2+
Rc+ Sc;+ .-O%W-+ ,<-+ -K,-.* )&+ [&)>,/N+ N)>-+ N%W-.+ %^+ ,<-+ !E7%L-.+ O%'Z&-+
&%N),-'+L/,</*+,<-+!DQ+-*N&%>Z.-2+Rc+Sc;+><%.,+N/.NZ/,+,-.O/*)&>2+
"-^%.-+ /*>,)&&),/%*0+ ^)O/&/)./p-+ ]%Z.>-&^+ L/,<+ ,<-+ >[-N/^/N),/%*>+ %^+ ]%Z.+ !E7%L-.+ !DQ+
O%'Z&-2+#*>Z.-+,<),+]%Z+<)W-+,<-+[.%[-.+'-W/N-+^%.+]%Z.+)[[&/N),/%*2+
+++++++++++++++++++
++++++++++++++++++++++++ +
CAUTION
WARNING
WARNING
+
B+
ELECTRICAL CABLE SELECTION:$
$
$
$
@2 a&-N,./N)&+.->/>,)*N-+/*+,<-+N/.NZ/,+]%Z+N.-),-+/>+)+>/8*/^/N)*,+N%*>ZO-.+%^+,<-+[%L-.+
)W)/&)M&-+ /*+ ,<-+ !E7%L-.+ '-W/N-2+ J%.+ %[,/O)&+ [-.^%.O)*N-+ ,<-+ &%)'+ .->/>,)*N-+
F-*,/.-+&%)'G+)*'+,<-+/*,-.*)&+.->/>,)*N-+%^+,<- +N)[)N/,%.+O%'Z&-+><%Z&'+M-+O),N<-'+
)>+N&%>-&]+)>+[%>>/M&-2+
H2 C>-+,<-+<-)W/->,+8)Z8-+N)M&-+)W)/&)M&-2+#,+/>+.-N%OO-*'-'+,<),+I$6+N)M&-+M-+Z>-'2++
42 !--[+ N)M&-+ &-*8,<+ ,%+ )*+ )M>%&Z,-+ O/*/OZO2+ ;<-+ N/.NZ/,+ .->/>,)*N-+ /*N.-)>->+ L/,<+
N)M&-+&-*8,<2++
I2 #*>Z.-+ ,<),+ ,<-+ N)M&-+ ,-.O/*),/%*+ N%**-N,/%*>+ F,-.O/*)&>G+ ).-+ [.%[- .&]+ N./O[-'+
)*'$%.+>%&'-.-'+,%+,<-+N)M&->2+
A2 ;<-+ _Z)&/,]+ %^+ ,<-+ N)M&-+ N%**-N,/%*>+ ^.%O+ ,<-+ !DQ+ ,%+ ,<-+ W-</N&-+ %.+ -_Z/[O-*,+ />+
N./,/N)&2++Q):-+>Z.-+,%+[.%W/'-+8%%'0+N&-)*0+.%MZ>,+N)M&-+/*,-.^)N-+N%**-N,/%*>2+
?2 ;<-+N&%>-.+,<-+!DQ+/>+&%N),-'+,%+,<-+-*8/*-q>+N.)*:/*8+O%,%.0+,<-+><%.,-.+,<-+N)M&-+
&-*8,<>+).-0+,<-+><%.,->,+%W-.)&&+&-*8,<+%^+,<-+-*,/.-+<-)W]+NZ..-*,+N/.NZ/,0+,<-+M-,,-.+
,<-+[-.^%.O)*N-+L/&&+M-+L/,<+]%Z.+!DQ2+
B2 ;<-+I+7/*+R-Z,>N<+N%**-N,%.+<)>+M--*+>Z[[&/-'+ L /,<+)+O),/*8+N%**-N,%.2++"-+>Z.-+,%+
^%&&%L+[.%[-.+L/.-+>N<-O->+)>+/'-*,/^/-'+/*+,<-+'/)8 .) O > 2+
32 ;<-+>Z[[&/-'+ R7D;+>L/,N<+L/&&+ -/,<-.+M-+ .-[&)N/*8+)*+-K/>,/*8+ [Z><(MZ,,%*+-*8/*-(
>,).,+>L/,N<+%.+L/&&+ M -+/*+)''/,/%*+,%+,<-+-K/>,/*8+:-](>,).,+>L/,N<0+'-[-*'/*8+%*+<%L+
]%Z.+W-</N&-+ %.+-_Z/[O-*,+/>+ NZ..-*,&]+>-,Z[0+>,).,-'2+ +1%N),-+ )*'+ /*>,)&&+,<-+ R7D;+
>L/,N<+/*+)+N%*W-*/-*,+&%N),/%*+.-&),/W-+,%+,<-+:-]+>L/,N<+/^+,<-.-+/>+*%+-K/>,/*8+[Z><(
MZ,,%*+>,).,+>L/,N<+,%+.-[&)N-2+
$
$
$
$
+
3+
$
MOUNTING THE KSM UNIT:$
$
C>/*8+,<-+'/O-*>/%*>+><%L*+M-&%L0+Z>-+^%Z.+FIG++rs+M%&,>0+*Z,>+k+&%N:+L)><-.>+F*%,+
>Z[[&/-'G+,%+O%Z*,+,<-+!DQ+Z*/,+,%+W-</N&-+%.+-_Z/[O-*,+N<)>>/>.$$
$
+
\<-*+ >-&-N,/*8+ )+ &%N),/%*+ ^%.+ /*>,)&&),/%*0+ O):-+ >Z.-+ ,<),+ ,<-+ !DQ+ O%'Z&-+ )*'+
N)M&->+ L/&&+ N&-).+ )*]+ <%%'>0+ &/'>0+ N%W-.>+ )*'+ %,<-.+ O%W)M&-+ W-</N&-+ %.+ -_Z/[O-*,+
[).,>2+#*>,)&&+,<-+!DQ+O%'Z&-+)>+N&%>-+ ,%+ ,<-+ -*8/*-o>+ N.)*:/*8+ O%,%.+ )>+ [%>>/M&-2+
EW%/'+&%N),/%*>+,<),+).-+>ZMi-N,+,%+-K,.-O-+<-),0+<ZO/'/,]0+.%)'+'/.,0+/N-+)*'+>*%L2+
;<-+!DQ + Z*/,+ O)]+M-+O%Z*,-'+ /*+ )*]+[%>/,/%*2+ + ;):-+N).-+,%+ [.-W-*,+ ,<-+-K,-.*)&+
N)>-+%^+,<-+!DQ+O%'Z&-+^.%O+.-N-/W/*8+)*]+[<]>/N)&+/O[)N,>2+
+
+
+
+
+
+
+
+
+
+
+
+
CAUTION
6"cell"KSM"
The"J1939"connector"is"used"f or"KBI "Factory"programing"only."""Contact"KBI"for"details."
+
5+
+
+
+
+
+
+
+
10"&"12"cell"KSM"
The"J1939"connector"is"used"f or"KBI "Factory"programing"only."""Contact"KBI"for"details."
+
@6+
+
!"#$%&'($
)*+%#,$-%&'($.$/0+1,$
2*34*'$)3*45"*$678$
9:4#;<'($=*1$
>4?'$)*#'?@/;'$A"**';#"?$B4*C=%#$
DEFGF$A"**';#"?$B4*C=%#$
H'%#&;<$A"**';#"?$
HIJKCGB$
GENERAL WIRING INSTALLATION PROCEDURE:
CAUTION!
KSM$Power$Stud$Nuts$should$be$torqued$to$180$Inch$Pounds.$
CONNECTORS$LOCATED$ON$THE$END-FACEPLATE$OF$THE$KSM$ENCLOSURE.$
END-FACEPLATE!OF!THE!
KSM!ENCLOSURE.!
The$J1939$connector$is$used$for$KBI$Factory$
programing$only.$$$Contact$KBI$for$details.!
Discrete Signal
See schematic, page 13
+
@@+
+
GENERAL WIRING INSTALLATION PROCEDURE:$
(CONTINUED)$
$
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
Theory'of'Operation,'explaining'ho w'the'KSM'module'works:'
'
Once"installed"and"wired"properly,"the"LED"on"the"End-Faceplate"of"the"KSM"will"
be"illuminated"whenever"the"KSM"contactor"relay"is"closed.""When"the"LED"is"
illuminated,"the"contactor"is"closed;"the"KAPower"Module"is"running"parallel"with"
the"vehicle"or"equipment"batteries"and"electrical"system."
"
When"the"DPST"switch"is"depressed"you"are"closing"th e"contactor"inside"the"KSM"
enclosure,"using"power"from"the"KAPower"module,"regardless"of"the"state"of"
charge"of"the"vehicle"or"equipment’s"batteries.""When"depressing"the"DPST"switch"
you"are"also"engaging"the"cranking"motor"cir cuit.""This"is"done"by"wiring"and"
using"the"recommended"electrical"circuit,"displayed"on"the"schematic"(page"13).""
By"doing"so,"you"have"tapped"into"the"OEM"(Original"Equipment"Manufacture)"
electrical"circuit"allowing"both"the"KSM"and"the"OEM"cranking"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"c lose"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"next"engine-starting"event,"the"pressing"down"of"the"
DPST"switch."""
The'PLC'preprogrammed'functions:'
The"PLC"has"been"preprogrammed"to"monitor"and"control"the"state-of-charge"of"
the"KAPower"capacitor"module"based"on"temperature,"voltage"&"time.""Once"a"
voltage"signal"is"received"at"pin"four"(4)"of"the"Wiring"Interface"Connector"the"
PLC"“wakes-up”"and"will"determine"when"and"how"long"to"keep"the"contactor"
closed.""Remember,"anytime"the"LED"Status"Indicator"is"illuminated"the"contactor"
is"closed."In"a"typical"engine-starting"event"you"will"see"the"LED"illuminate"during"
engine"cranking"and"then"go"out"for"several"seconds"after"the"engine"has"started.""
The"LED"will"then"illuminate"again"and"could"remain"illuminated"for"several"
seconds"based"on"the"condition"of"the"KAPower"module.""The"LED"may"even"begin"
to"“cycle”"depending"on"the"vehicle"or"system"voltage"during"the"recharging"
events."
"
The"J1939"connector"is"used"for"KBI"Factory"programing"only."""Contact"KBI"for"
details."
+
"
+
@H+
+
+
+
GENERAL WIRING INSTALLATION PROCEDURE:$
(CONTINUED)$
+
+
+
1. "-^%.-+ ),,)N</*8+ )*]+ N)M&->0+ >&/'-+ /*N&Z'-'+ >Z[[&/-'+ [.%,-N,/W-+ M%%,>+ %*,%+ ,<-+
N)M&->2 ;<-+ ^/.>,+ N)M&-+ ><)&&+ M-+ N%**-N,-'+ ,%+ ,<-+ tut+ ,-.O/*)&+ %^+ ,<-+!DQ+)*'+,<-*+
N%**-N,-'+,%+,<-+tut+,-.O/*)&+%^+,<-+M),,-.]2+
2. D&/'-+ /*N&Z'-'+ [ .%,-N,/W-+ M%%,+ %*,%+ ,<-+ t(t+ N)M&-2 ;</>+ >-N%*'+ N)M&-+ ><)&&+ M-+
N%**-N,-'+,%+,<-+t(t+N&)O[+%.+,-.O/*)&+%^+,<-+M),,-.]+)*'+,<-*+N%**-N,-'+,%+,<-+t(t+
,-.O/*)&+%^+,<-+!DQ+O%'Z&-2+
3. E>+M)>-'+%*+[)8-+@6+k+@4+N.-),-+)*'+L/.-+,<-+<).*->>->+,%+,<-+R-Z,>N<+N%**-N,%.2++
;<-+ !DQ+ R-Z,>N<+ N%**-N,%.+ <)>+ M--*+ [.%W/'-'+ L/,<+ O),/*8+ N%**-N,%.+ ,<),+ <)>+
[/8,)/&+L/.-+&-)'>+,)88-'+k+/'-*,/^/-'+/*+%.'-.+,%+^)N/&/,),-+/*>,)&&),/%*2
4. J%.+ ,<-+ 71Y+ /*[Z,0+ [/*+ ^%Z.+ FIG+ %^+ ,<-+ L/.-+ /*,-.^)N-+ N%** -N,%.0+ ]%Z+ OZ>,+ ^/*'+ )+ A+
EO[2+ [%L-.+ >%Z.N-+ ^.%O+ ,<-+ W-</N&-0+v:-](%*s+/8*/,/%*+>%Z.N-+,<),+/>+ &/W-+ FuG+ %*&]+
L<-*+,<-+-*8/*-+/>+N.)*:/*8+)*'+.Z**/*82++#*>,)&&+)+^/W-+FAG()O[+^Z>-+/*+,</>+N/.NZ/,+)>+
N&%>-+,%+,<-+[%L-.+>%Z.N-+)>+[%>>/M&-2
5. \/.-+R7D;+)*'+^/*'+k+L/.-+,<-+)[[.%[. /), -+71Y+/*[Z,+F[/*+IG+)>+M)>-'+)*'+'-[/N,-'+
%*+,<-+'/)8.)O+k+>N<-O),/N+[)8->+@6+k+@42++b%Z+ L/&&+*%,+M-+N%* *-N,/*8+ ) *]+ L/./*8+,%+
,<-+g@545+Y%**-N,%.2++The"J1939"CAN-Bus"is"used"for"KBI"Factory"programming"only.""
Contact"KBI"for"details.
6. E[[&]+[.%W/'-'+[.%,-N,/W-+8.-)>-+%*+!DQ+++k+-+,-.O/*)&>2
7. E,,)N<+[.%W/'-'+[.%,-N,/W-+M%%,>+,%+,-.O/*)&>+%*+!DQ+O%'Z&-2++
8. \/./*8+/>+N%O[&-,-+)*'+,<-+Z*/,+/>+*%L+.-)']+,%+%[-.),-2
+
+
+
+
CAUTION
E^,-.+,<-+/*>,)&&),/%*+)*'+L/./*8+).-+N%O[&-,-0+L<-*-W-.+,<-+R7D;+
>L/,N<+/>+'-[.->>-'+,<-+!DQ+[%>/,/W-++$)*'+*-8),/W-+n+,-.O/*)&>+
L/&&+M-+&/W-2++R%+*%,+><%.,(N/.NZ/,+,<-+,-.O/*)&>2+
+
@4+
+
NOTE: In Transit bus applications
where the rear-start feature is desired,
a second DPST Switch can be installed
in the rear-start location, wired in
parallel with the front-start DPST
switch.
OEM$
Push$Bu*on$or$
Key$Switch$$
Cranking$/$Start$
Switch'
+
@I+
+
+
OPERATION:
+
+
R%+*%,+M][)>>+,<-+ 71Y+ ^Z*N,/%*)&/,]2+ +Y<).8-+W%&,)8-+)*'+,-O[-.),Z.-+ ><)&&+
*%,+-KN--'+,<-+Q)K/OZO+P%&,)8-+)*'+;-O[-.),Z.-+)>+ >[-N/^/-'+/*+,<-+;)M&->+
%*+ [)8-+ ?2+ + #,+ />+ /O[%.,)*,+ ,%+ QcS#;c9+ ,<-+ W%&,)8-+ L<-*+ N<).8/*8+ ,<-+
!E7%L-.+ O%'Z&-+ ,%+ /,>+ Q)K/OZO+ P%&,)8-2+ + J)/&Z.-+ ,%+ '%+ >%+ O)]+ .->Z&,+ /*+ [.-O),Z.-+
O%'Z&-+^)/&Z.-2+
Using$the$systemX+
• Q):-+>Z.-+]%Z+<)W-+[.%[-.&]+/*>,)&&-'+,<-+!DQ+O%'Z&-+M-^%.-+)N,/W),/%*2+
• D/O[&]+ [Z>< + )*'+ <%&'+ '%L*+ ,<-+ R7D;+ >L/,N<+ ,%+ -*8)8-+ ,<-+ !E7%L-.+ !DQ+
>]>,-O+Z*,/&+,<-+-*8/*-+>,).,>2+
• "]+Z>/*8+ [%L-.+^.%O+,<-+!E7%L-.+N)[)N/,%.0+,<-+!DQ+ N%*,)N,%.+L/&&+N&%>-+)*'+
>,)]+ N&%>-'+L<-*-W-.+,<-+R7D;+>L/,N<+/>+'-[.->>-'2++;<-+R7D;+ >L /,N<+><%Z&'+
)&>%+M-+-*8)8/*8+,<-+W-</N&-+%.+-_Z/[O-*,q>+caQ+N.)*:/*8+O%,%.+N/.NZ/,2+
• \<-*-W-.+ ,<-+ !DQ+ !E7%L-.+ N%*,)N,%.+ />+ N&%>-'0+ ,<-+ 1aR+ %*+ ,<-+ a*'(
J)N-[&),-+><%Z&'+M-+/&&ZO/*),-'2+
• ;<-+-*8/*-+><%Z&'+M-8/*+,%+N.)*:(%W-.+L/,<+ [%L-.+M-/*8+>Z[[&/-'+^.%O+M%,<+
,<-+!DQ+N)[)N/,%.+O%'Z&-+)*'+,<-+>,)*').'+M),,-./->2++
• c*N-+,<-+-*8/*-+>,).,>+ )*'+,<-+R7D;+>L/,N<+/>+.-&-)>-'0+,<-+!DQ+/*,-.*)&+71Y+
O%'Z&-+ ><%Z&'+ M-+ )N,/W-0+ :--[/*8+ ,<-+ N%*,)N,%.+ N&%>-'+ L<-*+ .-_Z/.-'0+
)&&%L/*8+,<-+!E7%L-.+O%'Z&-+,%+.-N<).8-2++
• NOTE:$ If$ the$ vehicle$ or$ equipment’s$ batteries$ where$ completely$
discharged$ (“dead”)$ you$ may$ need $ to$ keep$ the$ DPST$ switch$ depressed$
until$ the$ vehicle’s$ electrical$ (charging)$ system$ has$ becom e$ active.$ $ The$
“dead”$ batteries,$ on$ their$ own,$ may$ not$ support$ all$ of$ the$ engine’s$
electrical$power$requirements$to$keep$it$runn ing.$$ In $this$case,$keep$the$
DPST$switch$depressed$ until$you$are$sure$the$ vehicle’s$charging$system$
is$ active.$ $ The$ KAPower$ module$ will$ have$ enough$ power$ to$ keep$ the$
engine$running$until$the$engine’s$charging$system$becomes$active.$
• \<-*+ ,<-+ -*8/*-+ >,%[>+ )*'+ ,<-+ W-</N&-+ %.+ -_Z/[O-*,+ />+ ,Z.*-'+ %^^+ ,<-+ !DQ+
N%*,)N,%.+><%Z&'+%[-*0+ : --[/*8+,<-+^Z&&]+N<).8-'+!E7%L-.+O%'Z&-+/*+.->-.W-+
^%.+,<-+*-K,+-*8/*-(>,).,/*8+-W-*,2++
+
+
+
CAUTION
+
@A+
TROUBLESHOOTING
AND
MAINTENANCE:
Q)/*,-*)*N-+ %^+ ,<-+ !E7%L-.+ O%'Z&-+ L /,< /* + ,<-+ !DQ+ -*N&%>Z.-+ ><) &&+ *%,+ M-+ .-_Z/.-'+
[.%W/'-'+,<),+,<-+%[-.),/*8+N%*'/,/%*>+).-+[.%[-.+)*'+,<),+ ,<-+.-_Z/.-O-*,>+ >[-N/^/-'+/*+
,</>+Q)*Z)&+).-+%M>-.W-'2++
• ;<-+ 1aR+&%N),-'+ %*+,<-+ a*'(J)N-[&),-+%^+,<-+ !DQ+/*'/N),->+,<-+)N,/W-+N%*'/,/%*+%^+
,<-+!DQ+O%'Z&-2++D--+[)8-+@62++#^+,<-+1aR+/>+*%,+/&&ZO/*),-'+L<-*+,<-+-K[-N,-'0+F>--+
;<-%.]+ %^+ c[-.),/%*0+ [)8-+ @@G+ ,<-*+ /*>Z.-+ ,<),+ )&&+ L/./*8+ )*'+ N%**-N,/%*>+ ).-+ /*+
)NN%.')*N-+ L/,<+ ,<-+ /*>,.ZN,/%*>+ L/,</*+ ,</>+ O)*Z)&2+ + Q):-+ >Z.-+ ,%+ N<-N:+ ,<-+
/*,-8./,]+%^+,<-+R7D;+)*'+,<-+71Y+)N,/W-+</8<+Fa*8/*-+#8*/,/%*++$ DL/,N<-'+c*G+/*[Z,+
L/./*8+<).*->>+]%Z+N.-),-'2+
• #^+ ,<-+ L/./*8+ )*'+ <).*->>->+ ).-+ /*+ 8%%'+ %.'-.+ N%*,/*Z-+ ,.%ZM&-><%%,/*8+ M]+
Z*[&Z88/*8+ ,<-+ R-Z,>N<+ N%**-N,%.+ %*+ ,<-+ a*'(J)N-[&),-+ %^+ ,<-+ !DQ0+ 8/W/*8+ ]%Z+
)NN->>+,%+,<-+[/*+,-.O/*)&>+%*+,<-+!DQ+N%**-N,%.2++9-^-.+,%+[)8->+@6+k+@42+
• Y<-N:+ ,<-+ N/.NZ/,+ M.-):-.+ )*'+ N%*,)N,%.+ .-&)]+ L/,</*+ ,<-+ !DQ+ O%'Z&-2+#*+%.'-.+,%+
>-.W/N-+%.+.-[&)N-+)*]+%^+,<->-+N%O[%*-*,>+]%Z+L/&&+<) W-+,%+.-O%W-+,<-+N%W-.+%^+,<-+
!DQ+-*N&%>Z.-2++9-^-.-*N-+[)8-+A2+
• ;<-+M/(N%&%.+F.-'$8.--*G+1aR+/>+)*+/*'/N),%.+^%.+<%L+,<-+!DQ+/>+^Z*N,/%*/*82++;<-+
8.--*+>/'-+%^+,<-+1aR+/>+N%**-N,-'+[).)&&-&+L/,<+,<-+N%*,)N,%.2++;<-+.-'+>/'-+/>+
N%**-N,-'+,%+)*+%Z,[Z,+%*+,<-+71Y+)>+><%L*+/*+,<-+>N<-O),/N+'-[/N,-'+%*+[)8-+@42+
;<-+71Y+O%*/,%.>+,<-+N)[)N/,%.+W%&,)8-+'Z./*8+)*'+)^,-.+,<-+.-N<).8-+N]N&-2++#^+,<-+
Y)[+W%&,)8-+'.%[>+,%+M-&%L+)*+)NN-[,)M&-+&-W-&+/*+,<-+^/.>,+A+O/*Z,->+)^,-.+,<-+
.-N<).8-0+,<-+.-'+1aR+L/&&+^&)><0+/*'/N),/*8+)+^)Z&,2++#^+),+)*]+,/O-+L</&-+,<-+71Y+/>+
[%L-.-'+Z[+)*'+,<-+!DQ+Y/.NZ/,+".-):-.+,./[>+%.+,<-+N)[+W%&,)8-+&-W-&+'.%[>+M-&%L+
I+W%&,>+,<-+.-'+1aR+L/&&+^&)><2+
+
++++++++++++++++++++++++++++++++++++++++++++++++++ +
+
Priority' Name' Flash'Rate'
!" #$%$&'()*"+,-*".-/%-*$(0*-" 1"
2" .-/%-*$(0*-"3-45)*"6**)*" 7"
8"
#)4($&()*"+,-*"#0**-4("
6**)*"
8"
9"
#)4($&()*"#)':"+%-4"#'*&0'("
6**)*"
9"
1" ;)<"#$%$&'()*"=):($>-"6**)*" 2"
7"
?$%'@"=):($>-"A-&$B"$C-*"
?-&D$*>-"
E"
+
@?+
+
+
+
+
+
+
TO$CHECK$KSM$INTERNAL$CIRCUIT:$
$
• \/,<+,<-+N/.NZ/,+M.-):-.+.->-,0+Z>/*8+)+W%&,O-,-.+N<-N:+W%&,)8-+),+7/*+V@+%^+,<-+
R-Z,>N<+^%Z.([/*+N%**-N,%.+)*'+,<-+!DQ+*-8),/W-+F-)+8.%Z*'+7%L-.+D,Z'+,-.O/*)&2+#^+
W%&,)8-+/>+[.->-*,+,<-+N/.NZ/,+/>+v8%%'s2++;<-+W%&,)8-+.-)'/*8+/>+,<-+)N,Z)&+!E7%L-.+
O%'Z&-+W%&,)8-+)*'+><%Z&'+M-+),+&-)>,+@6+W%&,>+/*+%.'-.+,%+)N,/W),-+,<-+N%*,)N,%.2++
• gZO[+[/*>+@+) * ' +H +%* +,< -+^% Z .([/*+N%**-N,%.0+,<-+N%*,)N,%.+><%Z&'+)N,/W),-2+#^+*%,+
.-O%W-+N%W-.+)*'+N<-N:+^%.+^)Z&,]+N%*,)N,%.+%.+/*,-.*)&+L/./*82+
• #^+,<-+N/.NZ/,+M.-):-.+N%*,/*Z->+,%+,./[+N<-N:+,<-+/*,-8./,]+%^+,<-+W-</N&-+>/'-+%^+,<-+
L/./*8+<).*->>+^%.+/>>Z->+>ZN<+)>+><%.,>0+N<)^/*8+%.+M)'+N%**-N,/%*>+)*'+
N%O[%*-*,>2+
• ;<-+71Y+Q%'Z&-+/>+)+>-)&-'+Z*/,2++#,+N)**%,+M-+>-.W/N-'2++#^+)''/,/%*)&+,.%ZM&-><%%,/*8+
/>+.-_Z/.-'+N%*,)N,+!"#2+
+
$
$
$
STORAGE:+
;<-+! E7%L-.+O%'Z&-+><%Z&'+M-+'/>N<).8-'+'%L*+,%+)+A6w+>,),-(%^(N<).8-+
[./%.+,%+>,%.)8-+ )*'+^%.+[.%&%*8-'+ [-./%'>+Fx@+]-).G+ ><%Z&'+M-+>,% .-'+ /*+)+
N%O[&-,-&]+'/>N<).8-'+>,),-2+
;<-+ !E7%L-.+ O%'Z&->+ ><)&&+ M-+ >,%.-'+ L/,</*+ -*N&%>-'+ <-),-'+ %.+ Z*<-),-'+ [.-O/>->+
%Z,^/,,-'+ L/,<+ )+ *),Z.)&+ W-*,/&),/%*+ >]>,-O+ /*+ .-8/%*>+ <)W/*8+ O%'-.),-+ %.+ N%&'+ L-),<-.+
N%*'/,/%*>2+ Y&/O),-+N%*,.%&+>]>,-O>+).-+*%,+.-_Z/.-'2+;<-+ .-_Z/.-'+ >,%.)8-+ ,-O[-.),Z.-+
.)*8-+/>+(B?y+,%+@3AyJ+F(?6y+,%+3AyYG2+
TRANSPORTATION:+
;<-+!E7%L-.+ !DQ+O%'Z&->+N)*+M-+ ></[[-'+/*+)[[.%W-'+N%..Z8),-'+N).'M%).'0+L%%'-*0+
%.+[&)>,/N+N%*,)/*-.>2+J%.+O%.-+/*^%.O),/%*+%*+,.)*>[%.,),/%*+N%*,)N,+!"#2++
+
+
+
+
+
+
CAUTION
+
@B+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
LIMITED WARRANTY
;<-+!E7%L-.+O%'Z&-+/,>-&^+/>+8Z).)*,--'+)8)/*>,+'-^-N,>+/*+
O),-./)&+)*'+L%.:O)*></[+^%.+,<.--+F4G+]-).>+^.%O+'),-+%^+
[Z.N<)>-2+;<-+!E7%L-.+/>+)+>-)&-'+Z*/,2+#^+,<-+!E7%L-.+'%->+
*%,+%[-.),-+[.%[-.&]0+/,+OZ>,+M-+.-,Z.*-'+,%+,<-+^)N,%.]0+
[.-[)/'0+^%.+.-[&)N-O-*,2+#^+^)N,%.]+/*>[-N,/%*+'-,-.O/*->+,<-+
[.%'ZN,+,%+M-+'-^-N,/W-+Z*'-.+,<-+,-.O>+%^+,</>+L)..)*,]0+/,+L/&&+
M-+.-[&)N-'+L/,<%Z,+N<).8-2++E&&+%,<-.+!DQ+N%O[%*-*,>+).-+
8Z).)*,--'+)8)/*>,+'-^-N,>+/*+O),-./)&+)*'+L%.:O)*></[+^%.+
%*-+F@G+]-).+^.%O+,<-+'),-+%^+[Z.N<)>-2+
J)/&Z.-+'Z-+,%+)NN/'-*,0+)MZ>-0+*-8&-N,0+Z>-+%,<-.+,<)*+/*+,<-+
/*,-*'-'+)[[&/N),/%*+>[-N/^/-'+/*+,</>+O)*Z)&0+/O[.%[-.+
/*>,)&&),/%*+%.+O)/*,-*)*N-0+O/><)*'&/*80+)*'+.-[)/.>+%.+
),,-O[,-'+.-[)/.>+L</N<+<)W-+M--*+O)'-+M]+%,<-.>0+).-+*%,+
N%W-.-'+Z*'-.+,<-+,-.O>+%^+,</>+L)..)*,]2
!%&'(")*+#*,-.*),/%*)&0+1,'2+><)&&+*%,+M-+&/)M&-+^%.+&%>>+%^+Z>-+%^+
,<-+!E7%L-.+!DQ+%.+%,<-.+/*N/'-*,)&+%.+N%*>-_Z-*,/)&+N%>,>0+
-K[-*>->+%.+')O)8->+/*NZ..-'+M]+,<-+[Z.N<)>-.+%.+Z>-.2
;</>+L)..)*,]+'%->+*%,+/*N&Z'-+&)M%.+^%.+.-[)/.+%.+.-[&)N-O-*,2
!%&'(")*+#*,-.*),/%*)&0+1,'2
3456+7/*8.--+9%)'
1):-+#*+;<-+=/&&>0+#1+?6@A?(5?4B
F3IBG+?A3(3A?@+F366G+AHB(3HB3
+
@3+
Loading...