XS Power / IOXUS UC-31 Ultracapacitor Instructions / ManualUpdated 2 months ago

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INSTALLATION

Maintenance Mode:

uSTART® will be shipped in Maintenance Mode. The solid yellow LED will light while uSTART® is first connected to a battery to show it is in Maintenance Mode. uSTART® is now ready to support the vehicle and will automatically enter Run Mode when the vehicle starts.

Mounting Location:

uSTART® is designed to mount in the same space as a group 31 battery. The typical installation location is in the battery box of a Class 3 – 6 truck. uSTART® must be installed in parallel with at least one battery in order to function and provide energy. If there are two or more batteries in a battery box, one can be removed to make room for uSTART® . On some truck models the Diesel Particulate Filter After-Treatment System or other exhaust components may be located near the battery box. These systems can generate very high temperatures during operation which may cause uSTART® to exceed +149°F (+65°C). If the vehicle battery box is near the Diesel Particulate Filter After-Treatment System or any part of the exhaust, mount uSTART® in a location far away from it or install heat shielding capable of preventing uSTART® from experiencing +149°F (+65°C) temperatures under worst case conditions. 

Pre-Installation Checks:

1. Test the vehicle starting and charging system prior to installing uSTART® to isolate any pre-existing problems. Refer to Recommended Practice 129A (RP 129A) of the American Trucking Association (ATA) Technology and Maintenance Council (TMC) for procedures to test cable connections between all starting and charging system components for maximum voltage drop. Repair any issues found before proceeding.
2. Remove the cables from the negative (-) terminal(s) of the vehicle battery(s).
3. Remove the cables from the positive (+) terminal(s) of the vehicle battery(s).
4.  All cable terminations and battery terminals should be cleaned thoroughly to remove all oxidation and grease.
5. Test the vehicle battery(s) individually to ensure that they are properly charged. Remove and replace any batteries that are discharged below their specified voltage or failed to meet their CCA rating.
6. If there is no additional space in a vehicle’s battery box, remove a battery to make room for uSTART®.
7. Place uSTART® in the desired mounting location.
8. Check that uSTART® positive (+) and negative (-) terminals line up with positive (+) and negative (-) terminals on remaining battery(s) and vehicle positive (+) and negative (-) battery cables.

Installation:

In most instances, it is desirable to use existing vehicle cables to connect uSTART® to the vehicle starting and charging systems. If new cables need to be made, the insulation should meet the requirements of SAE J1127, SAE J259, and TMC RP 166. Recommended cable insulations are 125°C rated Cross-Linked Polyethylene (SAE J1127 type SGX) and 125°C rated Thermoset Elastomer (SAE J1127 type SGR where flexibility is required). Selection of cable size is based on voltage drop requirements for a vehicle’s starting and charging systems. Refer to TMC RP 105C to determine minimum cable size requirements.

Mechanical:

It is desirable to install uSTART® electrically closest to the starter or in the location where the starter cable is designed to terminate. However, the unit will perform well even installed remotely. Regardless, it must be installed electrically in parallel with at least one 12V battery using appropriately sized cables and hardware. Start from a point that all the cables both positive (+) and negative (-) are disconnected and fastened out of the way for installation or not installed in the vehicle yet. Install the battery(ies) and uSTART® in their appropriate locations.

When installing uSTART® it is important to consider the battery hold down being used and how uSTART® relates to any batteries being mounted with it.

uSTART® is designed to be installed using the existing Group 31 battery hardware. Install uSTART® using the existing Group 31 battery hardware and torque specifications. For custom installations please contact IOXUS® Customer Service for additional support.

Electrical:

1. Connect the vehicle positive (+) battery cable and Starter Solenoid positive (+) cable to the positive (+) terminal of uSTART®.
2. Connect the vehicle positive (+) battery cable to the positive (+) terminal(s) of the battery(s).
3. Connect the vehicle negative (-) battery cable and Starter Solenoid negative (-) cable to the negative (-) terminal of uSTART®.
4. Connect the vehicle negative (-) battery cable to the negative (-) terminal(s) of the battery(s).
5. The solid yellow LED indicates that uSTART® is in Maintenance Mode and connected to a battery.
6. uSTART® is now ready to support the vehicle. uSTART® will automatically enter Run Mode when the vehicle starts. The yellow LED flashes in Run Mode after a new uSTART® installation while uSTART® ultracapacitors are initially charged. Once the ultracapacitors are charged, Run Mode is denoted by a solid green LED.