IOXUS, INC.
18
Stadium
Circle
Oneonta, NY 13820
Toll Free: +1 877-751-4222
Fax: 607-433-9014
http://www.ioxus.com
2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved.
5
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
Refer to the Wiring Diagrams section for typical vehicle wiring before and after uSTART
®
installation.
1.
Apply a thin coat of Noalox
®
or similar anti-oxidizing compound for aluminum to the terminal pads of
uSTART
®
before installing any cables
2.
Connect the vehicle positive (+) battery cable and Starter Solenoid positive (+) cable to the positive
(+) terminal of uSTART
®
.
3.
Connect the vehicle positive (+) battery cable to the positive (+) terminal(s) of the battery(s).
4.
Connect the vehicle negative (-) battery cable and Starter Solenoid negative (-) cable to the negative
(-) terminal of uSTART
®
.
5.
Connect the vehicle negative (-) battery cable to the negative (-) terminal(s) of the battery(s).
6.
The
solid
yellow LED
indicates that uSTART® is in
Maintenance Mode
and connected to a
battery.
7.
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
.
