IOXUS uST12V0375G31-MDA Assembly instructions

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
1
Installation Guide and User Manual
Model uST12V0375G31-MDA
•uSTART®Medium Duty Vehicles Class 3 – 6 with
12V Operating System
Table of Contents
Model uST12V0375G31-MDA .................................................................................................. 1
Safety........................................................................................................................................... 2
Description ................................................................................................................................. 3
Feature Identification...........................................................................................................................................................3
Unpacking ................................................................................................................................... 3
Installation .................................................................................................................................. 4
Maintenance Mode...............................................................................................................................................................4
Mounting Location...............................................................................................................................................................4
Pre-Installation Checks .......................................................................................................................................................4
Installation..............................................................................................................................................................................4
Wiring Diagrams ..................................................................................................................................................................6
Operation.................................................................................................................................... 7
Status ...................................................................................................................................................7
Maintenance Mode..............................................................................................................................7
Run Mode.............................................................................................................................................7
Standby Mode......................................................................................................................................7
Jump Start Charge Mode ...................................................................................................................8
Fault Mode ...........................................................................................................................................8
Bluetooth Connection ........................................................................................................................8
Flow Charts .........................................................................................................................................8
Installation and Startup .......................................................................................................................................................9
Disconnecting uSTART for Service .............................................................................................................................. 10
Using uSTART to Jump Start your vehicle (after a failed start)............................................................................. 11
Troubleshooting....................................................................................................................... 12
Maintenance ............................................................................................................................. 13

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. 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 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.

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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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 (+)
Negative Terminal (-)
Status LEDs

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
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DOC 1-0004 Rev B
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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

IOXUS
18 Stadium Circle
Oneonta, NY 13820
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Fax: [phone]
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DOC 1-0004 Rev B
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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. 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.

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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Wiring Diagrams
Figure 2: Typical wiring diagram before uSTART® install
Figure 3: Typical wiring diagram after uSTART® install

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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Operation
Status
The Status LEDsindicate uSTART®operation mode. The green and yellow LEDsindicate 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 LED
YELLOW LED
RED LED
Description
Maintenance
OFF
SOLID
OFF
uSTART® is connected.
There is no energy at the terminals
Jump Start Charge
SOLID
*FLASH*
OFF
uSTART® is charging for the first time
or charging for a Jump Start
Run
SOLID
OFF
OFF
uSTART® is active
Standby
OFF
OFF
OFF
uSTART® is asleep
Fault
OFF
OFF
SOLID
uSTART® is experiencing a fault.
Please see user manual for instructions
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 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 Standby Mode.

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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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 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 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 for the most common scenarios of use: Installation, preparation for
service and use during a jump start attempt.

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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Installation and Startup
Figure 5: Installation Flow Chart
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
RUN Mode
Ready to support Vehicle
[Solid Green LED]
JUMP START CHARGE Mode
[Solid Green LED]
[Flashing Yellow LED]
Ultracapacitors fully charged

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
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Disconnecting uSTART®for Service
Figure 6: Service Flow Chart
Disconnect uSTART®
Positive Terminal
and wait 7 seconds
uSTART Previously Installed
[Solid Green LED (RUN Mode)]
Or
[All LEDs Off (Standby Mode)]
Switch to
MAINTENANCE mode
with the uSTART App
MAINTENANCE Mode
[Solid Yellow LED]
uSTART® is safe to handle
[LEDs are All Off]
If App is available
Without
App

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
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Using uSTART®to Jump Start your vehicle (after a failed start)
Figure 5: Jump Start Flow Chart
Use uSTART® App
to put uSTART® into
JUMP START
CHARGE Mode
uSTART® Previously Installed
but vehicle failed start attempt
Load may be pulling down
Vehicle voltage. Shut off
All loads and wait for
voltage > ~10V
MAINTENANCE Mode
[Solid Yellow LED]
uSTART® LED
STATUS?
JUMP START CHARGE Mode
[Solid Green LED]
[Flashing Yellow LED]
RUN Mode
START VEHICLE AS SOON AS THE
YELLOW LED STOPS FLASHING
[Solid Green LED]
Ultracapacitors fully charged
May take up to 15 min.
Yellow LED On
All LEDs OFF

IOXUS
18 Stadium Circle
Oneonta, NY 13820
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Fax: [phone]
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Troubleshooting
Condition
Item
To
Check
Possible Cause Remedy
Red LED
On
1
Over Temperature Protection
Remove uSTART® from the high temperature condition.
Allow uSTART® to cool. The fault will clear as soon as
uSTART® returns to an internal temperature below 60°C
(149°F). If this condition is noted as occurring more than
once on a particular vehicle a reflective heat shield may be
worth installing between a heat source and the uSTART®.
An environmental condition above 65°C
(149°F) will cause uSTART® to enter Fault
Mode in order to protect the product.
Prolonged operation above 65°C (149°F) will
cause reduced lifetime and void the warranty
2
Over Current Protection
The fault condition will clear within 30 seconds and uSTART®
will return to Run Mode. Check for loose electrical
connections and battery condition.
Infrequent activation of Over Current Protection does not
pose any 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.
High current for extended periods (beyond
normal engine cranking times) will cause
uSTART® to enter fault mode in order to
ensure long term product lifetime is not
reduced.
3
Malfunction Protection
The fault condition will not automatically clear and the RED
LED will remain on. This condition can occur if uSTART®
internal measurements 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.
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
uSTART® has detected an abnormal internal
condition causing it to enter fault mode.
Red LED
Blink 4
Energy Storage Protection
This condition will clear as soon as ultracapacitor cell voltage
management returns to normal parameters. uSTART® will
reduce ultracapacitor charge voltage maximum limit as long
as the condition persists which will result in less energy
storage, but this will not impact engine cranking
performance.
If the condition persists for more than 24 hours, uSTART®
may enter ERROR Mode.
Abnormality detected with ultracapacitor cell
voltage management.
No LED's
On 1
Standby Mode
This is a normal condition. uSTART® will enter Run Mode
automatically when the vehicle is started or a high load is
applied
uSTART® will enter Standby Mode after 1 hour
without vehicle operation in order to conserve
electrical energy.

IOXUS
18 Stadium Circle
Oneonta, NY 13820
Toll Free: [phone]
Fax: [phone]
http://www.ioxus.com
[e-mail] 2/17/2021
DOC 1-0004 Rev B
© 2021 Ioxus. All rights reserved.
13
Condition
Item
To
Check
Possible Cause Remedy
2
uSTART® Problem
Check for loose electrical connections and battery condition.
Verify the battery voltage with the vehicle off is above 12V.
Confirm uSTART® terminals also have above 12 V.
Disconnect the uSTART® Negative lead for 30 seconds and
then reconnect. If the Yellow LED does not light, contact
Ioxus Customer Service.
uSTART® has stopped functioning.
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.