RustStop RS-5 electronic rust proofing 5-Step Installation Instructions

RustStop® RS-5 (formerly Rust Stop RS2000 and RS-4) is simple to install without any special equipment.

Step 1. Mount the Command Module
Step 2. Mount the Rust Magnets™ (anodes) (read all of Step 2 below)
Step 3. Run and Connect the Rust Magnet™ Wires
Step 4. Run and Connect the Power Wires
Step 5. Tests to Ensure Correct Installation
The simple detailed instructions are below. It’s recommended that you read all the instructions before you begin, especially #2. MOUNT THE RUST MAGNETS™ (anodes).

1 x Command Module with 2 x adhesive mounting strips on back.
1 x Warranty and Maintenance Record Card.
1 x Rust Magnet™ Wire Loom with 8m and 4m black leads.
4 x Rust Magnets™ with special adhesive mounting strips.
4 x Rust Magnet™ Screws with Locking Washers.
4 x 3mm (1/8 inch) crimp type ring terminal wire connectors (for the Rust Magnets™).
2 x 8mm (5/16 inch) crimp type ring terminal wire connectors (for the battery).

1. MOUNT THE COMMAND MODULE: Find a suitable flat surface inside engine compartment on the battery side of the vehicle (if possible) where it’s easily visible (See figure 1). Remove dirt, grease etc. with alcohol or a suitable safe non-oil-based cleaner and wipe dry. Remove the protective backing from the two adhesive strips and, carefully, mount the Command Module in place, pressing firmly to seat the adhesive.
DO NOT MAKE BATTERY CONNECTIONS AT THIS TIME.

Figure 1. Mount the Command Module on

the firewall (A), fender (B) or any surface (C), where it can be easily seen.

2. MOUNT THE RUST MAGNETS™ (anodes): Start by identifying Rust Magnet™ locations (do not fit yet) for all of the Rust Magnets™, making sure that you attempt to have one on each corner of the vehicle, i.e. two in the front and two in the rear (see Figure 10 for a simple wiring diagram). Choose locations that allow as much unobstructed room around each side of the Rust Magnet™ as possible.

IMPORTANT: : Ideally, all Rust Magnets™ should be placed in areas of the vehicle where they will get wet anytime the vehicle gets wet. Try to choose locations where water runs off. Avoid mounting the Rust Magnets™ where water stays pooled. Suggested mounting locations for the front Rust Magnets™ are the hood (bonnet) recess channels used for water run-off (see Figure 2). The rear Rust Magnets™ can similarly be mounted in the trunk (boot) recess channel (see Figure 3). For all Rust Magnets™ make sure that the Rust Magnet™ does not make contact with the hood (bonnet) or trunk (boot) when closed. See Figures 4, 5 and 6 for other rear locations. Choose Rust Magnet™ locations, which are convenient to run wires to. Make sure the surface is flat and the Rust Magnets™ do not obstruct any moving parts.

IMPORTANT: It is not recommend that you mount the Rust Magnets™ in areas where mud, snow, slush and etc. will accumulate on them; for example, not in the fender wells (wheel wells).

Figure 2. Locate the Front

Rust Magnets™ in the hood recesses. One on each side.

Figure 3. Inside trunk lid in recesses similar to the hood recesses. Be sure the Rust Magnets™ are located outside of the weather seal so rain flows over it.		Figure 4. The best locations for pickup/utility type vehicles, find flat areas underneath the tailgate or on a support member etc.

Figure 5. Another option for pickup/utility type vehicles, find flat areas such as on the box beside the tailgate.		Figure 6. For Vans, SUVs and other vehicles with similar rear ends, mount the Rust Magnets™ in the recesses outside the weather seal so rain flows over it. Place Rust Magnets™ where they won’t get damaged by in and out traffic and where it is easy for wiring.

Clean areas well with rubbing alcohol, or a suitable safe non-oil-based cleaner, ensuring all dirt, grease and grime are removed, and then dry thoroughly. Remove the protective backing from the adhesive strip. Carefully position the Rust Magnet™ and set it in place, then press firmly and square to seat the adhesive. Only mount each Rust Magnet™ at this stage, do not wire them.

IMPORTANT: The specially designed adhesive tape must be kept dry for a minimum of 24 hours after placement, to allow a proper bond. It is also advisable, that once the installation is complete, to again press firmly on the Rust Magnets™ to ensure that they are securely adhered.

3. RUN AND CONNECT THE RUST MAGNET™ WIRES: The Command Module (module) has two Rust Magnet™ outputs connected to a loom-plug. Use the Rust Magnet™ wire-loom to wire the Rust Magnets™. Usually, the 4m lead is for the front Rust Magnets™ and the 8m lead is for the rear Rust Magnets™. (See figure 7) Plug the loom-plug into the output plug from the module. Start by wiring the front Rust Magnet™ closest to the module. Thread the wire from the module through any convenient hole or crevice towards the closest front Rust Magnet™, securing occasionally to other wiring, fixtures, etc. with electrical tape or plastic cable ties, or under existing rubbers and covers.

Figure 7.

Rust Magnet™ Wire Loom-Plug.

IMPORTANT: Keep wire away from moving parts and hot or abrasive surfaces. At any point where wire goes through a hole, or over some sharp edge, protection is advisable. Electrical tape wrapped around wire, or a wire sleeve can be used to protect the wire in these areas

Cut the wire, leaving ample length to make connection to the Rust Magnet™, strip the end exposing about 10mm (3/8 inch) of bare copper. Now strip one end of the remaining cut-off Rust Magnet™ wire in the same way and twist the two stripped ends together. Insert this into a small 3mm (1/8 inch) ring terminal (See Figure 8). Using a crimping tool or pliers, crimp the wire in place and test by pulling firmly to ensure that it is securely crimped. Insert a screw and locking washer through the ring terminal and screw into the Rust Magnet™ hole tightly.

Figure 8.

Two wire crimping.

IMPORTANT: It is essential that the lock washers are used and under no circumstances should they be left out.

Now run the wire from this Rust Magnet™ to the other front Rust Magnet™, cut the wire, leaving ample length to make connection to the Rust Magnet™. Strip the end exposing 10mm (3/8 inch) bare copper. Twist the exposed copper and insert the exposed copper into a small 3mm (1/8 inch) ring terminal (See figure 9). Run the rear Rust Magnets™ in the same way, starting with the closest Rust Magnet™ from the Command Module, linking each Rust Magnet™ toward the furthest Rust Magnet™. Note: If the vehicle is continually exposed to extremely harsh conditions, you should first “tin” the wires with rosin-core solder and then solder the wires to the connectors.

Figure 9.

One wire crimping.

(3mm ring terminal)

Figure 10.

Simple wiring diagram.

4. RUN AND CONNECT THE POWER WIRES: Thread the black wire from the Command Module through the engine compartment to the vehicle’s battery, securing it occasionally, and leaving ample length to connect it to the negative battery terminal. (If the wires provided are too short due to relative locations of the Command Module and Battery they may be lengthened accordingly. Be sure to insulate connections well using tape or connectors.) Strip the end by removing about 20mm (3/4 inch) of insulation, twist the exposed copper, bend it back over itself (doubling the copper width) and insert the exposed copper into a large 8mm (5/16 inch) ring terminal (see Figure 11) and crimp firmly. Fasten this to the negative battery terminal connection.

Figure 11.

One wire crimping.

(8mm ring terminal)

Thread the red wire from the Command Module through the engine compartment to the vehicle’s battery, securing it occasionally, and leaving ample length to connect it to the positive battery terminal. (If the wires provided are too short due to relative locations of Command Module and Battery they may be lengthened accordingly. Be sure to insulate connections well using tape or connectors.) Strip the end by removing about 20mm (3/4 inch) of insulation, twist the exposed copper, bend it back over itself (doubling the copper width) and insert the exposed copper into a large 8mm (5/16 inch) ring terminal (see Figure 11) and crimp firmly. IMPORTANT: Do this last, fasten this to the positive battery terminal connection.

5. TESTS TO ENSURE CORRECT INSTALLATION: The best way to test the system is by using a voltmeter set to measure 50 volts DC. Place the red (positive) lead on the metal of one of the Rust Magnets™ and the black (negative) lead on any earthed (grounded) part of the vehicle. Your reading should be between 35 and 50 volts DC. The other Rust Magnets™ should read about the same. If you do not have access to a voltmeter, an alternative test can be done by placing one end of a piece of wire (you could use an off-cut from the left over Rust Magnet™ wire) to one of the Rust Magnets™ and the other to a suitable earth (ground). If the installation has been done correctly, the “Inspection Light” should come on, do this to check each Rust Magnet™.

NOTE: The Command Module is ALWAYS on so that the vehicle is constantly protected. The power draw is minimal and special circuitry shuts unit off in the event of a weak battery, lights left on etc. It comes back on automatically when power is restored. The electrical current operating the RustStop® RS-5 system will not interfere with any of the vehicles functions or other electrical accessories and is absolutely safe.

RustStop® RS-5 electronic rust prevention system and other rust control products - Serving the Americas, Europe and Russia