IOXUS uSTART uST12D1100G31-ISA Assembly instructions

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [email protected] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 1
Installation Guide and User Manual
Model uST12D1100G31-ISA
uSTART
®
Medium Duty Vehicles Class 3 – 6 with
12V Operating System
Table of Contents
Model uST12D1100G31-ISA..................................................................................................... 1
Safety........................................................................................................................................... 2
Description ................................................................................................................................. 3
Feature Identification...........................................................................................................................................................3
Unpacking ................................................................................................................................... 3
Installation .................................................................................................................................. 4
Maintenance Mode...............................................................................................................................................................4
Mounting Location ...............................................................................................................................................................4
Pre-Installation Checks .......................................................................................................................................................4
Installation..............................................................................................................................................................................5
Wiring Diagrams ..................................................................................................................................................................6
Operation.................................................................................................................................... 7
Status....................................................................................................................................................7
Maintenance Mode..............................................................................................................................7
Run Mode .............................................................................................................................................7
Standby Mode......................................................................................................................................8
Jump Start Mode .................................................................................................................................8
Fault Mode ...........................................................................................................................................8
Bluetooth Connection ........................................................................................................................8
Flow Charts .........................................................................................................................................8
Run Mode...............................................................................................................................................................................9
Maintenance Mode............................................................................................................................................................ 10
Jump Start Mode................................................................................................................................................................ 11
Maintenance ............................................................................................................................. 12
Troubleshooting....................................................................................................................... 12

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 2
Storage...................................................................................................................................... 13
Disposal ..................................................................................................................................... 13
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 www.ioxus.com for any
updates or additional information.






Do not connect in reverse polarity. uSTART®is protected from 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 36 VDC or above. Do not connect to an energy source
capable of constant ≥36 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.

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [email protected] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 3
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

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 uSTART
®
should be properly sized wrenches for the terminal and
mounting bolts (hammers, chisels, files or power tools in general should not be used)
Do not drop uSTART
®
; internal damage may occur
Positive Terminal
(
+
)
Ne
g
ative Terminal
(
-
)
Status LEDs

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 4
Installation
Maintenance Mode
WARNING!CONNECTIONOFuSTART®TOANENERGYSOURCEWHENLIVEVOLTAGEISPRESENT
ONuSTART®TERMINALSCOULDCAUSEPERSONALINJURYOREQUIPMENTDAMAGE!
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.

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 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.

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [email protected] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 6
Wiring Diagrams

Figure2:TypicalwiringdiagrambeforeuSTART®install

Figure3:TypicalwiringdiagramafteruSTART®install

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 7
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.

Figure4:uSTART®Status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 be in Maintenance Mode, but the LEDs will be 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.On the first start after installation, Run Mode is indicated by
a solid green LED and a flashing yellow LED while uSTART®charges its ultracapacitors for the first time.
uSTART®will automatically switch from Maintenance Mode to Run Mode if a vehicle’s battery charging
system is active for more than 10 seconds.

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 8
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 Standby Mode.
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.
Jump Start Mode
Jump Start Mode allows uSTART®to charge up its ultracapacitors from a weak vehicle battery and provide
power to jump start the vehicle.
Jump Start Mode can be accessed through the uSTART App. The green LED will flash and the yellow
LED will flash as uSTART®charges its ultracapacitors. After the charging period finishes, the green LED will
flash and the yellow LED will light 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 or fault, 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 to move through the different modes of uSTART®The flow charts are
separated by mode and navigate through each mode separately. For example, if Run Mode is desired, use the
Run Mode flow chart.

IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 9
Run Mode

Figure5:RunModeFlowChart


IOXUS, INC.
18 Stadium Circle
Oneonta, NY 13820


Toll Free: [phone] Fax: [phone] http://www.ioxus.com [e-mail] 2/21/2019
DOC 1-0004 Rev A
© 2017 Ioxus, Inc. All rights reserved. 10
Maintenance Mode

Figure6:MaintenanceModeFlowChart