Rev B User Manual

18 Stadium Circle
Oneonta, NY 13820

TABLE OF CONTENTS
Model.........................................................................................................................................................................1

Safety........................................................................................................................................................................1

Description
Feature Identification............................................................................................................................................2

Unpacking.................................................................................................................................................................2

Installation
Maintenance Mode.................................................................................................................................................3
Mounting Location................................................................................................................................................3
Pre-Installation Checks.........................................................................................................................................3
Installation.........................................................................................................................................................3-4
Mechanical......................................................................................................................................................4
Electrical.........................................................................................................................................................4
Wiring Diagrams...................................................................................................................................................5

Operation
Status.....................................................................................................................................................................6
Maintenance Mode......................................................................................................................... ....................6
Run Mode............................................................................................................................................................6
Standby Mode......................................................................................................................................................6
Jump Start Charge Mode.....................................................................................................................................7
Fault Mode...........................................................................................................................................................7
Bluetooth Connection...........................................................................................................................................7
Flow Charts.....................................................................................................................................................7-10
Installation and Startup...................................................................................................................................8
Disconnecting uSTART for Service.................................................................................................................9
Using uSTART to Jump Start Your Vehicle(after a failed start).....................................................................10

Troubleshooting................................................................................................................................................11-12

Maintenance..............................................................................................................................................................12

Storage....................................................................................................................................................................12

Disposal...................................................................................................................................................................12

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 Document ID: 1-0004, Rev B

MODEL
- Model uST12V0375G31-MDA
uSTART® Medium Duty Vehicle Class 3 - 6 with 12V Operating System

SAFETY
uSTART® is not a battery, so it must be treated differently than a battery. Please review this important safety information to
prevent personal injury or equipment damage. Please note, you must read and comply with all directions and warnings
in this manual. Any questions should be discussed with Ioxus prior to starting the installation or service related to the
uSTART® module. You can contact IOXUS® at ioxus.com for any updates or additional information.

WARNING!
DO NOT SHORT TERMINALS
Spark will occur when connected to a battery.

DO NOT CONNECT IN REVERSE

POLARITY
Do not connect the terminals in
reverse(+ to - and/or - to +).

Do not connect in reverse polarity. uSTART® is protected from up to 28 VDC reverse polarity in Maintenance Mode,
but sparks and arcing will occur if a reverse polarity connection is attempted in Run Mode leading to possible injury
or equipment damage

Do not connect to an energy source at 48 VDC or above. Do not connect to an energy source capable of constant
≥48 VDC or damage to uSTART® and equipment can occur.

Do not operate in environments where temperatures can exceed +149°F (+65°C). Operation above +149°F (+65°C)
will accelerate product wear and will void any warranties.

Failure to install uSTART® properly can lead to damage of the module, which can cause the failure of the unit. This
can cause the unit to stop working, or lead to equipment damage or fire. Improper installation voids the warranty,
and all risks are assumed by the installer.

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 Document ID: 042922, Rev B

DESCRIPTION
uSTART® is an ultracapacitor based device that enhances vehicle performance. uSTART® improves battery life by
maintaining a vehicle’s voltage under a wide range of load conditions. It supplies nearly all of the cranking current
during engine starts. uSTART® stores a relatively small amount of energy compared with a battery, but it can deliver
engine cranking current for a few seconds or power auxiliary loads for a few minutes.

Feature Identification
Status

Negative Terminal (-) Positive Terminal (+)

Figure 1 - uSTART® Feature Identification

UNPACKING
Please inspect the shipping carton for signs of damage prior to unpacking. Report any damage to the carton, or the
contents, to the carrier immediately. Retain all shipping materials until uSTART® is fully inspected and determined to
be operational.

uSTART® should be lifted by the module body. The terminals should not be used for hoisting.

If any parts are determined to be missing or defective an RMA number must be issued prior to returning the unit for
repair or replacement. Please contact your salesperson or distributor to request an RMA number.

uSTART® is designed for years of maintenance free operation if handled, installed, and used properly. These
handling precautions should be observed:
- uSTART® should not be stacked.
- The only tools to be used on a uSTART® should be properly sized wrenches for the terminals and mounting
bolts(hammers, chisels, files or power tools should not be used).
- High Voltage X-Series Module: iMOD102V083ACX-XXB

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 Document ID: 1-0004, Rev B

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.

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 Document ID: 1-0004, Rev B

INSTALLATION(cont’d)
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. Refer to the
Wiring Diagrams section for typical vehicle wiring before and after uSTART® installation.

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.

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 Document ID: 1-0004, Rev B

Wiring Diagrams

Alternator Vehicle Load Starter Batteries

Figure 2 - Typical wiring diagram before uSTART® install.

Alternator Vehicle Load Starter uSTART® + Battery

-40oC to 65oC

Figure 3 - Typical wiring diagram after uSTART® install.

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 Document ID: 1-0004, Rev B

OPERATION
Status
The Status LEDs indicate uSTART® operation mode. The green and yellow LEDs indicate the mode. The red LED indicates
there is an error. The blue LED indicates a Bluetooth connection to the module. Refer to Figure 4 for Status LED states.

MODE GREEN YELLOW RED DESCRIPTION

UltraSTART® is connected.
Maintenance OFF SOLID OFF
There is no energy at the terminals.
Jump Start Charge SOLID *FLASH* OFF UltraSTART® is charging for the first time.
Run SOLID OFF OFF UltraSTART® is active.
Standby OFF OFF OFF UltraSTART® is asleep.
UltraSTART® is experiencing a fault.
Fault OFF OFF SOLID
Please see user manual for instructions.
Figure 4 - uSTART® Staus LED States

Maintenance Mode
In Maintenance Mode, uSTART® terminals are not energized. It is safe to handle and work on when it is in this mode.
uSTART® should always be in Maintenance Mode prior to any maintenance.

If uSTART® is connected to a battery, the solid yellow LED indicates that it is in Maintenance Mode. If uSTART® is not
connected to a battery it will still have the protections of Maintenance Mode, even when the LEDs are off.

If uSTART® is not in Maintenance Mode when it is disconnected from a battery, it will automatically switch to Maintenance
Mode within 7 seconds.

Run Mode
uSTART® is on and actively maintaining the vehicle’s voltage while in Run Mode. It can support engine cranking currents for
a few seconds or support vehicle loads for many seconds to several minutes. It is not safe to handle or work on uSTART®
when it is in Run Mode.

Run Mode is indicated by a solid green LED.

Standby Mode
If uSTART® is in Run Mode and a vehicle’s battery charging system has been inactive for more than 1 hour, uSTART® will
automatically enter Standby Mode in order to reduce energy consumption. If at any time uSTART® detects a significant,
rapid change in the voltage level (as will occur during engine start), uSTART® will automatically return to Run Mode and
support the engine cranking event. It is not safe to handle or work on uSTART® when it is in Sta

Standby Mode is indicated by all LED’s being off while connected to battery power. uSTART® operation can be confirmed
by noting the change to a solid green LED upon engine start, indicating a return to Run Mode.

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 Document ID: 1-0004, Rev B

Jump Start Charge Mode

uSTART® will automatically switch from Maintenance Mode to Jump Start Charge Mode if a vehicle’s battery
charging system is active for more than 10 seconds.

Jump Start Charge Mode also allows uSTART® to charge up its ultracapacitors from a weak vehicle battery and
provide power to jump start the vehicle.

Jump Start Charge Mode can be accessed through the uSTART® App. The green LED will be solid and the yellow
LED will flash as uSTART® charges its ultracapacitors. After the charging period finishes, the green LED will be
solid, indicating that the vehicle is ready to be started. Start the vehicle immediately for best results. See the
uSTART® App User Manual for additional details.

Fault Mode

uSTART® has experienced an abnormal condition, indicated by a solid red LED. See the Troubleshooting section
for more information.

Bluetooth Connection

uSTART® is connected via Bluetooth when the blue LED is lit solid. See the uSTART® App User Manual for more
details (note that the blue LED may be difficult to see in bright locations, shading the status LED area may help
with seeing it).

FLOW CHARTS
The below flow charts can be utilized for the most common scenarios of use: Installation, preparation for service and use
during a jump start attempt.

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 Document ID: 1-0004, Rev B

Installation and Startup

uSTART® Installed and Connected to Battery

Maintenance Mode
Solid Yellow LED

Start Vehicle and Wait 10 Seconds

-or-
Switch to Run Mode with uSTART® App

Jump Start Charge Mode

Solid Geen LED

Flashing Yellow LED

Ultracapacitors Fully Charged

Run Mode
Ready to Support Vehicle
Solid Geen LED

Figure 5 - Installation Flow Chart

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 Document ID: 1-0004, Rev B

Disconnecting uSTART® for Service

uSTART® Previously Installed

With App Solid Green LED(Run Mode)
-or-
All LEDs Off(Standby Mode)

Switch to
Maintenance Mode
With uSTART® App

Without App

Maintenance Mode
Solid Yellow LED

Disconnect uSTART®
Positive Terminal,
Wait 7 Seconds

uSTART® is Safe to Handle

All LEDs Are Off

Figure 6 - Service Flow Chart

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 Document ID: 1-0004, Rev B

Using uSTART® to Jump Start a Vehicle(after failed start)

uSTART® Previously Installed

but Vehicle Failed Start Attempt

All LEDs Off Yellow LED On

uSTART® LED Status

Load may be pulling

down vehicle voltage. Maintenance Mode
Shut off ll loads and wait Solid Yellow LED
for voltage > ~10V.

Using uSTART® App

Put Into uSTART®
Jump Start Charge Mode

Jump Start Charge Mode

Solid Geen LED

Flashing Yellow LED

Ultracapacitors Fully Charged

May take up to 15 minutes.

Run Mode
Start vehicle as soon as the
yellow LED stops flashing.
Solid Green LED

Figure 6 - Service Flow Chart

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TROUBLESHOOTING
Items To
Condition Possible Cause Remedy
Check

Over Temperature Protection

An environmental condition above 65°C Remove uSTART® from the high temperature condition. Allow
(149°F) will cause uSTART® to enter Fault uSTART® to cool. The fault will clear as soon as uSTART® returns to
1 Mode in order to protect the product. an internal temperature below 60°C (149°F). If this condition is
Prolonged operation above 65°C (149°F) will noted as occurring more than once on a particular vehicle a
cause reduced lifetime and void the warranty. reflective heat shield may be worth installing between a heat source
and the uSTART®.

Over Current Protection

High current for extended periods (beyond The fault condition will clear within 30 seconds and uSTART® will
normal engine cranking times) will cause return to Run Mode. Check for loose electrical connections and
uSTART® to enter fault mode in order to battery condition.
Red LED ensure long term product lifetime is not
2 reduced. Infrequent activation of Over Current Protection does not pose any
On concern for uSTART® and can be expected under conditions of very
high load, or if uSTART® terminals experience a short circuit (ex.
wrench contacts both terminals during installation).

If fault mode continues to occur after the steps above, contact

IOXUS®® Customer Service.
IOXUS

Malfunction Protection
uSTART® has detected an abnormal internal The fault condition will not automatically clear and the RED LED will
condition causing it to enter fault mode. remain on. This condition can occur if uSTART® internal measure-
ments are outside of reasonable values or if uSTART® detects
malfunctions transferring energy. This could be caused by an
internal uSTART® fault or by a poor electrical connection.
3
Check for loose electrical connections and battery condition.

Reset power by removing the Negative lead from uSTART® for 30

seconds and then reattaching. uSTART® will enter Maintenance
mode. Start the vehicle and observe uSTART® for 1 minute. If the
fault persists, contact IOXUS®® Customer Service.

Energy Storage Protection

Abnormality detected with ultracapacitor cell This condition will clear as soon as ultracapacitor cell voltage
voltage management. management returns to normal parameters. uSTART® will reduce
Red LED ultracapacitor charge voltage maximum limit as long as the
1 condition persists which will result in less energy storage, but this
Blink will not impact engine cranking performance.

If the condition persists for more than 24 hours, uSTART®may

enter ERROR Mode.

Energy Storage Protection

1 uSTART® will enter Standby Mode after 1 This is a normal condition. uSTART® will enter Run Mode automatically
hour without vehicle operation in order to when the vehicle is started or a high load is applied
conserve electrical energy.

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 Document ID: 1-0004, Rev B

TROUBLESHOOTING(cont’d)
Items To
Condition Possible Cause Remedy
Check

uSTART® Problem
uSTART® has stopped functioning. Check for loose electrical connections and battery condition.

Turn off the vehicle and ensure the battery and uSTART® are
connected in parallel as shown in Figure 3. Measure the voltage at
the battery terminals. If the voltage is less than 11.5V, the battery
should be charged.
No LED
2 Measure the voltage at the uSTART® terminals. Confirm the voltage
On measurements at the battery terminals and uSTART® terminals are
similar (within 0.2V). If the battery terminal voltage is not similar to
the uSTART® terminal voltage there is a problem in the wiring
between the battery and uSTART®.

Disconnect the uSTART® Negative lead for 30 seconds and then

reconnect. If the Yellow LED does not light, contact IOXUS®®
Customer Service.

MAINTENANCE
Terminals should be periodically checked for oxidation or loose connections and cleaned or tightened as necessary. No
other maintenance is required. Poor electrical connections can cause performance problems with uSTART®. Prior to
removal or system maintenance, ensure that uSTART® is in Maintenance Mode. uSTART® can be cleaned while in
Maintenance Mode by use of a cloth and simple soap and water solution. Avoid the use of hoses or pressurized sprays.

STORAGE
uSTART® can be stored in its original packaging, in a dry place for up to four (4) years. Observe the maximum storage
temperature as stated in the product specifications.

DISPOSAL
Do not incinerate, crush, or dispose of in trash. Do not recycle with lead-acid batteries. Please recycle according to local
codes and regulations for electronic waste.

Specifications
Please see data sheet for specifications.

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