Enercraft Ultra-Starter UST-2030 User manual

April 2020
Ultra-Starter 28V ENERCRAFT UST-2030 & UST-4030 USER MANUAL
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Ultra-Starter 28V
Energy that makes you fly
UST-2030 UST-4030
IMPORTANT NOTE
All users must read this entire guide prior to initiate
operations of the UST-2030 or the UST-4030

April 2020
Ultra-Starter 28V ENERCRAFT UST-2030 & UST-4030 USER MANUAL
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Thank you and congratulations for the purchase of your new Ultra-Starter.
This User Guide contains the operating instructions and procedures for the UST-
2030 & UST-4030, needed to safely and efficiently operate these units.
These Ultra-Starter units provide 30 ± 0.5 Volt DC electrical ground power for
aircraft engine starts. Following the right procedures, and being aware of the
limitations and best practices will ensure peak operating efficiency and will
maximize operational capabilities and the final life cycle of the unit.
1. INTRODUCTION
The UST-2030 & UST-4030 are limited maintenance-free and sealed units. No
repairs by the User are authorized. Warranty will be voided if the units are
tampered in any way, or if unauthorized repairs are made. For technical support
please contact:
[e-mail]
Cell –Eduardo (Spanish): [phone]
Argentina
[email protected]m
Cell –Fred (Spanish/English/Portuguese): [phone]
Canada
[e-mail]
Cell –Alberto (Spanish/English/Portuguese): [phone]
Europe
CAUTION SHOCK HAZARD POTENTIAL
Improper use or failure to follow instructions contained in this User Guide can
result in unit damage and/or injury or death by electrical shock.
Any attempts to open or examine the inside of the UST-2030 or the UST-4030
via any tool or any device (borescope, probe, etc...) can result in the unit failure
and/or injury by electrical shock. This Ultra-Starters are maintenance free and
should not be opened or disassembled for any reason.
Always protect the units from short circuit.
Shipping Hazards: The UST-2030 & UST-4030 contain LiFePO4 cell batteries.
These batteries must be shipped according to directive UN38.3.

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2. BASIC PRODUCT DESCRIPTION
Ultra-Starters 28V UST-2030 & UST-4030 are devices developed by ENERCRAFT
to improve the engine start of airplanes or helicopters, providing clean energy
and extending the life of the engines, being capable of operating in any weather
and environmental condition.
The equipment must be connected through the external power connector to the
aircraft. The ENERCRAFT Ultra-Starter units were developed to offer the latest
technology in energy storage, with a unique configuration, by combining the
best of Lithium batteries and the best of Ultracapacitors.
3. MAIN FEATURES
Incorporates the latest technology
✓ENERCRAFT patented design
✓First to incorporate Lithium & Ultracapacitor technology
✓Full operation in any weather and environmental condition
✓Peak current is ensured, even in non-ideal charge conditions
✓Extend & preserve the aircraft main battery useful life
✓Supports more engine starts without recharge
✓Provides clean energy and a more efficient engine start
Full data display
✓Voltage and Battery load %
✓+ USB connector
Protective Case
✓Reliable waterproofing
✓NANUK®'s patented latching system
✓Robust and Impact resistant
✓Lightweight and modern design
Portable equipment
✓Light weight
✓All in one unit (Starter + GPU)
✓One-handed operation
✓Two stage retractable handle (UST-4030 only)
✓Polyurethane wheels and stainless steel bearings (UST-4030 only)

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Ultra-Starter 28V ENERCRAFT UST-2030 & UST-4030 USER MANUAL
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4. SPECIFICATIONS AND PERFORMANCE
4.1 Ultra-Starter UST-2030
UST-2030 (20 Ah unit)
AC INPUT
Charges from Single Phase
90-240 Vac, Freq. 50/60 Hz
2 amps
DC OUTPUT
28.5 VDC. (30@full charge)
Peak start: 1500 amp (Standard PHCA 5sec)
GPU: 10 Amps (connected to a power source)
RECHARGING RATE
45 minutes
from full discharge @ 25° C
TEMPERATURE RANGE
- 40° C ↔ 70° C (in operation)
- 50° C ↔ 85° C (in storage)
DIMENSIONS
426 mm x 327 mm x 236 mm
WEIGHT
13 kg (including cable and AN2551)
CABLE
1.5 mts Standard 3 PINS NATO AN2551 (50mm²)
PROTECTION
Electronic sensors & Internal fuses
COOLING
Integrated design system
UST-2030

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Ultra-Starter 28V ENERCRAFT UST-2030 & UST-4030 USER MANUAL
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4.2 Ultra-Starter UST-4030
UST-4030 (40 Ah unit)
AC INPUT
Charges from Single Phase
90-240 Vac, Freq. 50/60 Hz
2 amps
DC OUTPUT
28.5 VDC. (30@full charge)
Peak start: 2600 amp (Standard PHCA 5sec)
GPU: 10 Amps (connected to a power source)
RECHARGING RATE
90 minutes
from full discharge @ 25° C
TEMPERATURE RANGE
- 40° C ↔ 70° C (in operation)
- 50° C ↔ 85° C (in storage)
DIMENSIONS
558 mm x 355 mm x 228 mm
WEIGHT
25 kg (including cable and AN2551)
CABLE
1.5 mts Standard 3 PINS NATO AN2551 (50mm²)
PROTECTION
Electronic sensors & Internal fuses
COOLING
Integrated design system
UST-4030

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5. PANEL OVERVIEW
5.1 Ultra-Starter UST-2030
1. AC power switch
2. USB charger connector
3. AC input and fuse w/holder
4. Charger output DC fuse
5. DISPLAY: Battery load level and output voltage indicator
6. DC output
7. DC power switch
8. Air inlets
5
6
7
8
2
1
3
4
8

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5.2 Ultra-Starter UST-4030
1. AC power switch
2. USB charger connector
3. AC input and fuse w/holder
4. Charger output DC fuse
5. DISPLAY: Battery load level and output voltage indicator
6. DC output
7. DC power switch
8. Air inlets
6
5
2
3
1
4
8
7

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6. OPERATING PROCEDURE
6.1 Receiving your Ultra-Starter
Please check the overall status of the unit to make sure that it hasn’t been
tampered in any way during the Shipment and/or potential Customs
inspections. If you detect anything, please contact us immediately.
Due to the time needed to pack and deliver your Ultra-Starter from our factory
in Canada to your hangar or operational base, and due to the existent
regulations for shipping Lithium batteries (we must keep the cells under its 30%
of charge), your unit won’t be ready to be used once you receive it.
To be completely sure, please check first the battery status. The voltage may be
below 28V, which means that you must proceed to its first full charge. For this
first charge, we recommend you to charge the equipment for, at least, three (3)
hours. The unit can reach a maximum voltage of 30.6V before that time, but
please keep it charging for this first full charge only, in order to stabilize the
batteries.
After three (3) hours, your new Ultra-Starter will be ready to be used! Please
check the voltage again to confirm that it has reached more than 30V, and you
can initiate normal operations to start the engines of all your aircraft.
6.2 Normal operations. DISPLAY reading and understanding
Once you start using the unit you will see that the discharge voltage will remain
almost constant for quite a while. This is an advantage and a characteristic of
the Lithium cells, which will improve the energy delivery efficiency of the Ultra-
Stater. But, at some point after some engine starts (amount depending on type
of engine/s or environmental factors), the display will show changes, according
to the sequence below. Please follow the indications shown:
….… Several engine starts are performed…….
The output voltage will gradually drop from 30.6V initially down to 26.8V and all
the battery load level LEDs (2 red and 6 green LEDs) will remain ON during this
process.

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At 26.7V, the first green LED will fade out. But the unit can still be used.
At 26.4V, the second green LED will fade out too. But the unit can still be used.
At 26.2V, the third green LED will fade out too. We strongly recommend you to
recharge the unit when reaching this voltage level. If you keep on using the unit
beyond this point, the discharge sequence would continue as shown below,
moving to critical voltage levels.
6.3 Check battery status
•Switch DC Output to ON position.
•Check display. If voltage is less than 26.2, please re-charge the unit.
6.4 Check Cables status
•Always check the cables to visually detect any possible cuts or damages.
6.5 Engine Starting procedure
•Unplug AC Cord (if the unit is plugged in).
•Plug DC connector to the aircraft.
•Turn DC power switch to ON position.
6.6 Battery charge procedure
•Turn DC power switch to OFF position.
•Plug AC Cord to a properly grounded outlet.
•Switch charger (AC power switch) to ON position.
•The unit will charge in 45 minutes (UST-2030) or 90 minutes (UST-4030)
from full discharge. When the voltage is higher than 30V, then the unit is
fully charged again.

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•During the charging process, it is normal to feel an electrolyte smell. The
3.2v LiFePo4 batteries of the equipment, are prismatic cells prepared for
high currents, and have ventilation that can result in the User perceiving
that smell.
•Always charge the Ultra-Starter units on a well ventilated area.
•NOTE: If the units are not in use, they do not have to be charging if the
voltage is still above 26.2V. The configuration of these units and the
Lithium batteries will avoid strong discharges if the units are stored or not
in operation for short periods of time.
6.7 Use of the units as GPU
You have two options to use the Ultra-Starter as a GPU:
OPTION 1 - PLUGGED IN - Power coming from the Switching Power Supply
All of the ENERCRAFT Ultra-Starter units have an internal Switching Power
Supply and can work as well as GPUs, delivering up to 10 Amps continuously (no
time limit) if they are plugged in. For that use:
•Plug AC Cord to a properly grounded outlet.
•Plug DC connector to the aircraft.
•Switch charger (AC power switch) to ON position.
•Turn DC power switch to ON position.
OPTION 2 - NOT PLUGGED IN - Power coming from the Lithium Batteries
For those situations when you are working outside the hangar, you have landed
in a remote location, you may need to power the aircraft with higher currents
(more than the 10 Amps provided by the Switching Power Supply) for a short
period of time, etc…our Ultra-Starters are fully ready to deliver that power too.
Due to the energy stored in its High Quality Prismatic Lithium Batteries, the units
can be used remotely (without being plugged in) and can deliver the power
needed to switch on the avionics, to power other electronic equipment, or to
recharge the aircraft batteries, for example...
For that use, with the AC Cord unplugged:
•Plug DC connector to the aircraft.
•Turn DC power switch to ON position.

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Ultra-Starter 28V ENERCRAFT UST-2030 & UST-4030 USER MANUAL
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In the case of the UST-2030, with 20Ah batteries, the unit would deliver 20 Amp
for 1 hour, or 10 Amp for 2 hours in a row.
In the case of the UST-4030, with 40Ah batteries, the unit would deliver 40 Amp
for 1 hour, 20 Amp for 2 hours, or 10 Amp for 4 hours in a row.
The time estimates above are considering taking the equipment almost to its
total discharge, which is not advised. Please remember the critical voltage levels
indicated in 6.2 above. When the voltage reaches 26.2V, we recommend you to
recharge the unit.
7. STORAGE
IMPORTANT NOTE: The Ultra-Starter units cannot be stored for long periods of
time, without any use. It is highly recommended to check the batteries often
and charge the units every 15-30 days if the Ultra-Starters are not being used,
to avoid full battery discharge. Be aware that battery life may be compromised,
and the Lithium cells can lose their properties. A full repair service and
replacement of the cells may be needed if the units are left unattended and
discharged for more than 30 days.
©ENERCRAFT CANADA Inc. Barrie, Ontario –Canada ALL RIGHTS RESERVED
More information: https://www.enercraft.ca/