INSTALLATION GUIDE and USER MANUAL · Installation Guide and User Manual ... The 24V ESM works with either 12V or 24V vehicle electrical systems and connects directly to a 24V starter

INSTALLATION GUIDE

and USER MANUAL

Maxwell Technologies®

24V Ultracapacitor Engine Start Module (ESM)

Models:

ESM ULTRA 31/900/24V Engine Start Module ESM ULTRA 31/1100/24V Engine Start Module

Document No. 3000313 Rev. 7

All contents copyright

© 2012, 2013, 2014, 2015 Maxwell Technologies, Inc. All rights reserved. No portion of

these materials may be reproduced in any form, or by any means, without prior written permission from Maxwell Technologies, Inc.

Maxwell Technologies, Inc. Global Headquarters 3888 Calle Fortunada San Diego, CA 92123 USA Phone: +1 858 503 3300 Fax: +1 858 503 3301

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Maxwell Technologies GmbH Leopoldstrasse 244 80807 München Germany Phone: +49 (0)89 4161403 0 Fax: +49 (0)89 4161403 99

Maxwell Technologies Korea Co., Ltd. Room 1524, D-Cube City

Office Tower, 15F #662

Gyeongin-Ro, Guro-Gu,

Seoul, 152-706

South Korea

Phone: +82 10 4518 9829

Maxwell Technologies Shanghai Trading Co., Ltd. Unit A2,C 12th Floor

Huarun Times Square

500 Zhangyang Road,

Pudong New Area

Shanghai 200122,

P.R. China

Phone: +86 21 3852 4000

Fax: +86 21 3852 4099

Maxwell Technologies Shanghai Representative Office Unit B 12th Floor

Huarun Times Square

500 Zhangyang Road,

Pudong New Area

Shanghai 200122,

P.R. China

Phone: +86 21 3852 4000

Fax: +86 21 3852 4099

www.maxwell.com/esm

Contents

1 Safety ........................................................................................................................ 1 2 Introduction ................................................................................................................ 2 3 Unpacking .................................................................................................................. 2 4 Aftermarket Accessories Required for Installation ........................................................... 2 5 Installation .................................................................................................................. 3

5.1 Mounting Location ................................................................................................ 3 5.2 Electrical Installation ............................................................................................. 3

6 Diagnostics ................................................................................................................. 8 7 ESM Discharge ..........................................................................................................11 8 Maintenance ..............................................................................................................11 9 Storage .....................................................................................................................11 10 Disposal .................................................................................................................11 11 ESM Specifications .................................................................................................11 12 Frequently Asked Questions (FAQ) ..........................................................................12 13 Manufacturer Contact Information: ............................................................................12

Installation Guide and User Manual – 24V Engine Start Module (ESM) Page 1 Document No. 3000313.7 © 2012, 2013, 2014, 2015 Maxwell Technologies, Inc.

1 Safety

The Ultracapacitor Engine Start Module is not a battery and must be treated differently than a battery. Please review these important safety warnings.

WARNING

DANGER – HIGH CURRENT HAZARD!

Power terminals pose an extreme arcing hazard when module is charged. Always discharge module prior to removal or handling.

For information about the discharge procedure, refer to Section 7.

Do not operate unit above specified voltage:

INPUT Across Battery Positive (B+) and Battery Negative (B-): 32V max

OUTPUT Across Starter (S+) and Battery Negative (B-): Do not connect to other voltage sources.

Do not operate unit above specified temperature rating of +149⁰F (+65⁰C).

Protect terminals from accidental shorting.

If jump start is required use the external jump post if the vehicle is equipped with one, or jump across any Battery Positive (+) and Battery Negative (-) Terminal.

WARNING

DO NOT CONNECT IN REVERSE POLARITY!

Do not connect the terminals in reverse (+ to – and/or – to +). Sparks and arcing will occur on a charged ESM creating a shock and/or burn hazard. Permanent damage to the ESM will

also occur.

WARNING

DANGER DO NOT CONNECT CABLES FROM THE BATTERY TO THE STARTER (S+) TERMINAL OF THE ESM.

This will short the batteries and cause arcing.

WARNING

WARNING – THIS IS NOT A BATTERY!

DO NOT JUMP START Do not connect battery or Jump Start across the STARTER (S+) and BATTERY (B-)

terminals. Chance of arcing or damage to the battery.

Installation Guide and User Manual – 24V Engine Start Module (ESM) Page 2 Document No.: 3000313.7 © 2012, 2013, 2014, 2015 Maxwell Technologies, Inc.

2 Introduction

The Engine Start Module by Maxwell Technologies, Inc. is intended to provide years of reliable starting for high compression gas or diesel engines up to 15L in displacement. The 24V ESM works with either 12V or 24V vehicle electrical systems and connects directly to a 24V starter solenoid. It is designed to recharge from an existing system battery(s) and provides starting power across a broad temperature range even when batteries would not have sufficient power. There are two products in the 24V ESM family, the ESM ULTRA 31/900/24V, and the ESM ULTRA 31/1100/24V. Please make sure you install the correct ESM product for the engine displacement size shown in the specification table in Section 11.

3 Unpacking

Inspect the shipping box for signs of damage prior to unpacking the ESM. Damage to the shipping box or ESM should be reported to the carrier immediately. Retain the shipping materials until the unit has been inspected and is determined to be operational. Remove the ESM from the shipping box by lifting the ESM straight up. The ESM weighs only 19.2 lbs. (ESM ULTRA 31/900/24V) or 19.6 lbs. (ESM ULTRA 31/1100/24V) and is significantly lighter than a similarly sized lead-acid/AGM battery. DO NOT lift the ESM from the box or carry it using the provided jumper wire from the Starter (+) to the Battery (–) terminals. Discard jumper wire before installation. If the unit is found to be defective or any parts are missing, contact your original Point of Purchase or Maxwell Technologies, Inc. Technical Support toll-free at (888) 890-3337. A Return Material Authorization (RMA) number must be issued prior to returning the unit for repair or replacement.

4 Aftermarket Accessories Required for Installation

Additional materials that may be needed for installation (see step 7 in Section 5.2.2, below) are shown below. These items are not included with ESM, but may be necessary to isolate other vehicle electronic non-starting loads from the starter system. These are not required for new trucks with the ESM factory installed from the Original Equipment Manufacturer (OEM).

Terminal block, Stainless Steel 3/8”–16 thread or equivalent. Examples are shown below:

In place of a terminal block, a simple Stainless Steel 3/8” bolt, washer and nut may be used to connect non-starter vehicle loads to the batteries. Electrical insulation material (Heat Shrink) is also required for proper isolation.

0 AWG – 6 AWG (or appropriately size cable for the load) Cable with 3/8” ring lugs to connect other vehicle electronic non-starting loads to a Positive (+) battery terminal.

Tools Required: (not supplied) • Large Compound-Action Crimp Tool (or similar)

• Standard Shop Tools


5 Installation

5.1 Mounting Location

The 24V ESM is designed to mount in the same space as a BCI Group 31 battery. The typical location is in the battery box of a Class 3-8 truck. If there is adequate space, the ESM should be installed in addition to batteries. If batteries fill the battery box, one battery must be removed (12V systems only) and replaced with the ESM. In 24V systems there is generally no available space to accommodate an extra battery so it may be necessary to fabricate a bracket or shelf along with a hold-down for the ESM in a safe location. However, a 24V ESM can replace one of the 12V batteries for use with a 24V starter motor on a 12V vehicle configuration. An installation video is available at the Maxwell Technologies, Inc. Website for additional installation instructions. Please visit http://www.maxwell.com/esm/video and click on the Maxwell Technologies ESM Installation Video. On some vehicles the Diesel Particulate Filter (DPF) After-Treatment System (ATS) may be located near the vehicle battery box. These systems typically generate very high temperatures during the regeneration process which may cause the Engine Start Module to experience an Over-Temperature Fault (>149⁰ F / 65⁰ C). Mount the ESM far away from the DPF. Refer to Section 6, below for additional diagnostic and trouble-shooting information.

5.2 Electrical Installation

WARNING

DANGER DO NOT CONNECT BATTERY CABLES TO THE STARTER+ TERMINAL OF THE ESM.

This will short the battery and cause arcing.

5.2.1 Electrical Connection Identification

ULTRA 31/1100/24V shown for illustration purposes

Ground

Connection

Battery (+) Terminal

+12V or +24V Input

Starter (+) Terminal

Push-to-Test Button

(Activates Status LEDs)

Status LEDs

Battery (–) Terminal Ground

Connection

Status LEDs

http://www.maxwell.com/esm/video


5.2.2 Cable Selection

Installation of the ESM requires adding new cables from the ESM Starter (+) terminal to the Starter Solenoid positive terminal and the ESM Battery (-) terminal to the Starter Solenoid negative terminal. Typically a smaller diameter wire gauge cable is recommended to meet starter motor life requirements due to the higher current supplied by the ESM. All cabling used to replace the starter cables should have insulation that meets the requirements as per SAE J1127, SAE J2549 and TMC RP 166. Cable insulation recommendations are: a. 125°C Rated Cross-linked polyethylene — SAE J1127 Type SGX. b. 125°C Rated Thermoset Elastomer — SAE J1127 Type SGR where flexibility is required.

Selection of the correct size American Wire Gauge (AWG) of cable depends upon the length of the Positive and Negative cables required to connect the ESM to the Starter. Add both the Positive and Negative cable lengths from the ESM to the Starter for total length and select the cable size from the table below:

RECOMMENDED ESM TO STARTER SOLENOID POSITIVE AND NEGATIVE CABLE SIZE

SELECTION TABLE

Total Cable Length Feet (Length in Meters)

15 - 20 Feet (4.5 - 6.1 m)

20 - 25 Feet (6.1 - 7.6 m)

25 - 30 Feet (7.6 - 9.1 m)

30 - 40 Feet (9.1 - 12.2 m)

Use AWG Cable Size (Metric Cable Size)

2 AWG (35 mm

2)

1 AWG (50 mm

2)

1/0 AWG (50 mm

2)

2/0 AWG (70 mm

2)

Select the proper gauge cable for the total length of the positive and negative cables from the ESM to the Starter Motor. Note: Cable gauges in the table above may seem small. They are correct and must be followed to achieve the maximum life of the starter motor.

5.2.3 Pre-Installation Checks

1. Prior to installing the ESM test the starting and charging system to isolate any pre-existing problems. Refer to the Technology and Maintenance Council (TMC) of the American Trucking Associations (ATA) Recommended Practice 129A (RP 129A) for procedures to test the cable interconnects between all the starting and charging system components for maximum voltage drop. Repair any issues found before proceeding.

2. Remove all cables from the vehicle batteries, noting where they were originally connected. 3. All cable lug terminations and battery terminals should be thoroughly cleaned to remove grease and

oxidation. 4. Test the vehicle batteries individually and ensure they are properly charged to avoid issues later.

Remove and replace any batteries that are discharged below their specified voltage or failed to test to their Cold Crank Amp (CCA) rating.

5. Place the ESM in the desired location being careful to align the (+) and (-) terminals in line with the existing Vehicle Battery(s) (+) and (-) terminals; remove a Battery if needed to install the ESM. DO NOT CONNECT THE ESM UNTIL INSTRUCTED.

5.2.4 Wiring Instructions (refer to the “before and after” installation diagrams below)

1. For aftermarket installations remove all the cables from the Starter Solenoid Positive terminal. Note: If the Starter includes an Integrated Magnetic Switch the short cable from the Magnetic Switch to the Starter Solenoid Positive Terminal can remain connected. All other connections to Starter Solenoid Positive Terminal must be isolated from the ESM.

2. Most vehicle manufacturers connect the Alternator and other vehicle power cables to the Starter Solenoid Positive Terminal. Remove the Alternator, any vehicle power cables and Battery (+) cables from the Starter Solenoid Positive Terminal. Connect these together using a terminal block or a nut and bolt so that they are isolated from the Starter Solenoid Positive Terminal but remain connected to any Battery (+) terminal or most positive Battery (+) terminal in a 24V system.


3. Mount the Terminal Block or other junction point to a secure location and make sure it is properly isolated from all vehicle grounds. Securely insulate, tie wrap and/or bundle all loose cables to minimize damage from vibration, potential grounds, abrasion and corrosion.

4. Remove the Alternator cable connection and other vehicle ground cables from the Starter Negative Terminal. Connect these together using a terminal block or a nut and bolt so that they are isolated from the Starter Negative Terminal but remain connected to any Battery (-) terminal or most negative Battery (-) terminal in a 24V system. If there is another cable from the Starter Negative Terminal to the frame remove and discard that cable.

5. Mount the Terminal Block or other junction point to a secure location and make sure it is properly isolated from all vehicle grounds. Securely insulate, tie wrap and/or bundle all loose cables to minimize damage from vibration, potential grounds, abrasion and corrosion. Note: At this point in the installation the Starter Motor Positive and Negative Terminals should now be completely isolated from the Battery Positive and Negative Terminals. All connections that were previously connected to the Starter Positive and Negative Terminals should be connected to Battery (+) and Battery (-), respectively.

6. Construct two new cables, one positive and one negative to connect the ESM to the Starter Solenoid. The recommended cable size (AWG) can be found in the table above based upon the length of the total cable, positive and negative circuit.

a. The Positive (Red) cable from the ESM Starter (+) terminal should have a 3/8” lug to connect to the ESM Starter (+) terminal, and a ½” lug to connect to the Starter Solenoid Positive terminal.

b. The Negative (Black) cable from the ESM Battery (-) terminal should have a 3/8” lug to connect to the ESM Battery (-) terminal, and a ½” lug to connect to the Starter Solenoid Negative terminal.

c. Wrap both cables with a High Temperature Corrugated Wire Loom to prevent abrasion or heat-related damage.

d. When routing cables avoid placement near sharp frame edges and secure the cables to existing cables with tie wraps every 18 inches.

7. At the batteries, connect the cable from the primary 12V or 24V Battery Negative (-) Terminal to the “BATTERY –” terminal of the ESM.

8. Connect the cable from the primary 12V or 24V Battery Positive (+) Terminal to the “BATTERY (+)” terminal of the ESM. The ESM will now begin its initial charging once connected to the vehicle batteries. Reconnect all previous cables removed from the vehicle batteries.

9. Connect the new Starter Solenoid Negative Terminal cable to the “BATTERY (-)” terminal of the ESM.

10. Before connecting the cable from the Starter Solenoid Positive Terminal to the Starter (+) Terminal of the ESM measure the voltage from the cable lug to both Battery Positive (+) and Battery Negative (-) Terminals. The voltage should read 0 volts for both. A voltage reading on either test indicates the Starter Solenoid may be bad or there is another wiring path from the Starter Solenoid to the batteries. This will result in improper ESM operation and must be corrected before continuing with the installation. See figure below.


11. Connect the ESM Starter (+) Power Cable from the Starter Solenoid Positive Terminal to the “STARTER+” terminal of the ESM.

12. Press the “Push-to-Test Button” on top of the ESM. The status LED’s should display a Flashing Green. This indicates the ESM is charging. Note: The ESM will take up to 20 minutes for an initial charge drawing approximately 20 amps from the batteries. After 20 minutes, press the Push-to-Test button again the light should be Solid Green.

13. Make sure all cables are adequately isolated and secured to original or existing cable bundles to minimize damage from vibration, potential grounds, abrasion and corrosion.

14. The ESM is now ready to start your engine!


Typical 24V System prior to ESM Installation

Typical 24V System after ESM Installation (24V Input)


Split 24V Starter and 12V Vehicle Electronics Installation (12V Input)

A Note about Jumpstarts: Do NOT Jump Start on the ESM Starter + terminal. If required, REMOVE the cable from the ESM “STARTER +” terminal and connect the cable to the jumping battery. If there is no start, there is some other vehicle problem.

6 Diagnostics

The ESM includes two Light Emitting Diodes (LEDs) that display status of the unit when the Push-to-Test button is pressed. To activate the LEDs, simply press and release the Push-to-Test button on the top of the ESM. The red and green LEDs will illuminate and/or flash for 10 seconds as shown in the following diagram to display the status of the ESM. Holding the Push-to-Test button down for 12 seconds will reset the internal computer. Note that the LEDs are only active for 10 seconds when the button is pressed, and then they automatically turn off. The ESM must be connected in parallel to a 12 or 24 Volt power source for the status button and LEDs to function.

Status Lights

Green Light Red Light Meaning

Lit Solid Not Lit Ready to crank

Flashing Not Lit Charging: WAIT 15 minutes

Not Lit Flashing Stuck pushbutton

Not Lit Lit Solid Internal error – push test pushbutton for 10 sec.

Flashing Lit Solid Refer to manual


Fault Class Descriptions: There are six different fault classes incorporated in the ESM. While some may be redundant these diagnostic codes help customer service personnel diagnose any problems with the ESM.

Fault Class

Green LED

Red LED Description / Example Recovery

1 Green Off Red

Flashing Stuck or jammed Push-to-Test Button.

Recovers automatically when fault condition is corrected.

2 Green Off Red On Internal electronics errors and/or internal temperature sensor errors. Not serviceable by user.

Recovers with Manual Reset.

3 Green

Flashing Red On

Internal electronics failure and/or internal temperature sensor failure. Not serviceable by user.

Recovers with Manual Reset.

4 Green

Flashing Red On

Battery under-voltage error, battery over-voltage error, or over-temperature error.

Recovers automatically when fault condition is corrected. Allows continued use with maximum 20V output.

5

Green Flashing

or Green Off

Red On

Internal electronics failure. Not serviceable by user.

Recovers with Manual Reset. Allows continued use with maximum 20V output.

6 Off Off No response from unit and loss of functionality.

Non-recoverable fault.

Normal Operating Conditions: The ESM LEDs will display two types of normal status:

1. A flashing Green LED indicates the ESM is charging, and may or may not have sufficient power to start the vehicle. The initial charge cycle may take up to 30 minutes; subsequent charge cycles may take up to 15 minutes. 2. A solid Green LED indicates the ESM is charged and ready to start the vehicle. Note: The Diagnostic status indicators work ONLY when there is a battery connected to the ESM BATTERY (+) and (-) terminals and the voltage is between 9V to 32V.

Abnormal Fault Conditions: Refer to the ESM Troubleshooting Flow Diagram below.


What do the status lights

show?

Blinking Green only

Green On

only, ESM is ready,

No Faults

Blinking Red and

Green On

Blinking Red only

Red On

only

No lights

Red On and Green Blinking

Disconnect B+ from

Battery(s) Wait 20 sec. and

reconnect B+ to

Battery(s)

Wait 15 sec

Press the Test Button

ESM is charging. Wait 15

min.

No Issue

ESM is OK. If engine still will not start it is due to

some other cause.

Will the engine crank?

Attempt Engine Start

Yes

No

The Push-To-Test

Button is stuck in

the depressed position.

Wiggle the button to clear the

fault. Press the

Test Button

No Yes

Disconnect B+ from

Battery(s) Wait 20 sec.

and reconnect B+ to Battery(s)

Red On & Green Blinking? Red Still

On?




Is Battery Voltage between

9V to 32V?

Is ESM Hot > 149°F?

Yes

Yes

No

No

No

Yes


ESM has an Internal Fault or Failure and should be Replaced

Correct Under or Over Voltage Condition or

Replace Battery(s) and try again.

Disconnect B+ from Battery(s) and allow ESM to Cool Down. Reconnect and try

again.

Press the Test button

Note: Status Lights are active for only 10 seconds, and then the Test Button must be pressed again.

Still No lights?

Ensure the ESM is

properly connected

and battery(s)

are providing 9V to 32V to B+ & B- Terminals.

Engine Start Module Troubleshooting

Flow Diagram (Applies to All ESM Models)


7 ESM Discharge Prior to storing or packing the ESM for return on an authorized RMA please discharge the ESM as follows: 1) If the ESM Starter+ terminal to Battery- terminal voltage is above 2V:

a. Disconnect all cables from the ESM. b. Connect a 24V load, such as a headlight (or two 12V headlights connected in series) or a 24V blower motor, across the “STARTER +” and “BATTERY -” terminals. Leave connected until the light goes out or the blower motor stops running. This will discharge the voltage stored in the ESM. c. Verify voltage is 2V or less. d. DO NOT use a cable, bare wire or low/no resistance conductor to discharge the ESM!

2) Using a voltmeter, measure the voltage between the “STARTER +” and “BATTERY -” terminals. If the voltage is under 2V, the ESM is now considered safe for handling and shipping.

8 Maintenance

Terminals should be periodically checked for oxidation or loose connections and cleaned or tightened as necessary. Prior to removal or system maintenance, ensure that the module is discharged (See section 7). No other regular maintenance is required.

9 Storage

The module can be stored fully discharged in the original package in a dry place for up to four years. Observe the maximum storage temperature as stated in the product specifications below. Discharge the ESM prior to storing or shipment.

10 Disposal

Do not incinerate or recycle with batteries. Do not crush. Do not dispose in trash. Dispose in accordance with local regulations for electronic waste.

11 ESM Specifications

ESM Specifications ULTRA 31/900/24V ULTRA 31/1100/24V

Diesel Engine Size

(Displacement) 12.5 Liter (max.) 15.0 Liter (max.)

Cold Cranking Amps 900 CCA 1 1100 CCA

1

Peak Power 45.5 kW 2 50.7 kW

2

Input voltage 9.5 V to 32 V (on B+ Terminal) 9.5 V to 32 V (on B+ Terminal)

Output voltage Max. 27.0 V (at 0°C or lower) 28.5 V (at 0°C or lower)

Nom. 25.0 V (at 25°C to 65°C) 26.5 V (at 25°C to 65°C)

Extended 20.0 V (at 65°C or higher) 20.0 V (at 65°C or higher)

Recharge Nom. 5 minutes (after one start) 5 minutes (after one start)

Max. 10 minutes (from 14.5V to 25V) 10 minutes (from 14.5V to 25V)

Initial 20 minutes 20 minutes

Current draw Sleep 10 mA (from battery) 10 mA (from battery)

Charge 20 A (max) 20 A (max)

Electrical Cap. 300 F (min, initial) 340 F (min, initial)

ESR 0.004 Ohm (max, initial)

Loss 0.15 volts/day (self-discharge)3

Package Type BCI Group 31

Dim. 13” L x 6-13/16” W x 9-7/16” H

(330mm L x 173mm W x 240mm H)

Weight 19.2 lbs (8.7 kg) 19.6 lbs (8.9 kg)

Terminals Type SAE Type A terminal


ESM Specifications ULTRA 31/900/24V ULTRA 31/1100/24V

Thread 3/8” – 16 UNC

Torque 150 to 200 in-lb (17 to 22.5 N-m)

Temperature Operation -40 to +149 °F (-40 to +65 °C)

Storage -40 to +158 °F (-40 to +70 °C)

Maximum Shelf Life Four Years

Shock and Vibration SAE J1455, Mid-frame

Notes: Ultracapacitor CCA is calculated differently than a battery using a different interval. See footnote

1, below.

1.

ESRCapTime

VVCapCCA MINMAX

2.

ESR

VPeakPower MAX

4

2

Where, Cap = 300F (31/900/24V), or 340F (31/1100/24V) ESR = 0.004 Ohms VMAX = 27V (31/900/24V), or 28.5V (31/1100/24V) VMIN = 14.4V (per SAE) Time = 3 seconds

3. Nominal open circuit self-discharge rate with no power supplied to the B+

terminal. The first day will be a higher discharge rate. Assumes ESM is allowed to charge fully and then connection to lead-acid battery is removed.

12 Frequently Asked Questions (FAQ)

Please visit Maxwell Technologies, Inc. Website for a comprehensive list of FAQ’s at: http://www.maxwell.com/esm/faq.

13 Manufacturer Contact Information:

For Engine Start Module support, contact Maxwell Technologies, Inc. toll-free at:

ESM Technical Support Line: (888) 890-3337

ESM Sales Support Line: (877) 511-4324

Web: www.maxwell.com/esm

Thank you for purchasing the Engine Start Module from Maxwell Technologies, Inc. or Authorized Reseller. We love hearing from our customers! Tell us how the Maxwell ESM helped you stay on the road! Please visit our Website and share your ESM experience at: http://www.maxwell.com/esm/testimonials.

http://www.maxwell.com/esm/faq

http://www.maxwell.com/esm

http://www.maxwell.com/esm/testimonials

Documents

INSTALLATION GUIDE and USER MANUAL · Installation Guide and User Manual ... The 24V ESM works with either 12V or 24V vehicle electrical systems and connects directly to a 24V starter