Tesla TI4100 GPU-24 User manual

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TI4100 GPU-24
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WARNING
*******SHOCK HAZARD POTENTIAL*******
IMPROPER USE/FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN RE-
SULT IN UNIT FAILURE AND/OR POSSIBLE INJURY, OR DEATH, BY ELECTRICAL
SHOCK.
THE TI4100GPU-24 IS A MAINTENANCE FREE, SEALED UNIT
NO REPAIRS ARE AUTHORIZED.
WARRANTY WILL BE VOID IF
UNIT IS TAMPERED WITH.
FOR TECHNICAL SUPPORT CONTACT:
TESLA INDUSTRIES INC.
109 CENTERPOINT BLVD.
CENTERPOINT INDUSTRIAL PARK
NEW CASTLE, DELAWARE 19720
PH.[phone]
FAX [phone]
WARNING
*******SHOCK HAZARD POTENTIAL*******
ATTEMPTS TO OPEN OR ENTER THE INSIDE OF THIS UNIT (BY USING ANY TOOL
OR DEVICE; i.e. PROBE, BORESCOPE, etc.) CAN RESULT IN UNIT FAILURE
AND/OR POSSIBLE INJURY BY ELECTRICAL SHOCK. THIS UNIT IS MAINTENANCE
FREE AND SHALL NOT BE OPENED OR DISASSEMBLED FOR ANY REASON.
***SHIPPING HAZARDS***
“NONE”
“DRY” Non-spillable, POWER CELL (battery),
No Free liquids, to leak or toxic gases.
Always protect unit from short circuit.
Return Power cells to Tesla for Recycling.
i

TABLE OF CONTENTS
TITLE Page
CHAPTER 1 INTRODUCTION 1-1
CHAPTER 2 UNIT DESCRIPTION AND OPERATION 2-1
Section I Unit 2-1
Section II Description 2-2
CHAPTER 3 OPERATING LIMITS AND RESTRICTIONS 3-1
Section I General 3-1
Section II Operational Restrictions and Safety Limits 3-1
CHAPTER 4 OPERATING PROCEDURES 4-1
Section I Unit Operation 4-1
Section II Operating Procedures 4-2
Section III Functional Check Procedures 4-5
CHAPTER 5 PERFORMANCE DATA 5-1
Section I Introduction 5-1
Section II Data Criteria 5-2
CHAPTER 6 CARE AND MAINTENANCE 6-1
Section I Unit Care 6-1
Section II Maintenance 6-2
CHAPTER 7 Push to Test 7-1
Section I General 7-1
Section II Operation 7-1
CHAPTER 8 On/Off Switch 8-1
Section I General 8-1
Section II Operation 8-1
INDEX Index 1
LIST OF ILLUSTRATIONS
Figure Title Page
2-1 Dimensions 2-3
2-2 General Details 2-4
5-1 Temperature Conversion Chart 5-3
5-2 Discharge Load Curve 5-4
5-3 Maximum Output Current 5-5
ii

CHAPTER 1
INTRODUCTION
1-1. GENERAL
These instructions are for use by the owner/operator. They apply to
handling and operation of the TI4100GPU-24 (Turbo Start 4100) ground
power unit.
1-2. WARNING, CAUTION, AND NOTE DEFINED
A warning, caution, or note is used to emphasize important and criti-
cal instructions as defined for the following conditions:
WARNING
An operating procedure, practice, etc., which,
if not correctly followed, could result in
personal injury or loss of life.
CAUTION
An operating procedure, practice, etc., which,
if not strictly observed, could result in
damage to or destruction of equipment.
NOTE
An operating procedure, condition, etc., which
is essential to highlight.
1-3. DESCRIPTION
This manual contains the complete operating instructions and proce-
dures for the TI4100GPU-24 (Turbo Start 4100) ground power unit. The
Turbo Start 4100 is intended to provide DC electrical ground power
for aircraft flight line and maintenance ground support operations.
The unit is designed to provide 24 volt DC electrical power output
for aircraft engine starting and 24 or 28.5 volts DC electrical sup-
port for ground maintenance, avionics/electrical trouble shooting and
testing. The observance of procedures, limitations and performance
criteria is essential to ensure peak operating efficiency and to
maximize operational capabilities and life of the Turbo Start 4100
ground power unit.
1-1

1-4. INDEX
The index lists, in alphabetical order, every titled paragraph and
figure contained in this manual.
1-5. ABBREVIATIONS AND SYMBOLS
Abbreviations and symbols are used within text, headings and titles.
Unless otherwise indicated, the following list of abbreviations and
symbols are used in this manual:
LIST OF ABBREVIATIONS AND SYMBOLS
Abbreviation Definition
amp Ampere
AC Alternating Current
C Celsius
cont Continuous
DC Direct Current
F Fahrenheit
Ft Feet
FWD Forward
GPU Ground Power Unit
Hr Hour
Hz Hertz
Kg Kilograms
Kw Kilowatts
°Degree
LED Light Emitting Diode
MAX Maximum
MIN Minimum
VAC Volts, Alternating Current
VDC Volts, Direct Current
Explosion Hazard Potential
Shock Hazard Potential
Guard from moisture
Guard from incorrect power source
1-2
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1-6. FORMS AND RECORDS
NONE REQUIRED.
1-7. USE OF WORDS SHALL, SHOULD, AND MAY.
Within this technical manual the word “shall” is used to indicate a
mandatory requirement for proper operation and warranty purposes.
The word “should” is used to indicate a non-mandatory but preferred
method of accomplishment. The word “may” is used to indicate an ac-
ceptable method of accomplishment.
1-3

CHAPTER 2
UNIT DESCRIPTION AND OPERATION
SECTION I. UNIT
2-1. GENERAL
The TI4100GPU-24 (Turbo Start 4100) (Figure 2-1 and 2-2) is a compact, por-
table and highly versatile 24/28.5 VDC electrical ground power unit. The
unit incorporates a 208-240 single phase VAC to 28.5 VDC converter, a 24 volt
unique (dry) power cell and an internal intelligent 208 to 240 volt AC
charger to recharge the power cells. These built-in features give the Turbo
Start 4100 self-sufficiency and mobility for short-term operations without AC
electrical power or long term operations with AC electrical power. Short
term operations rely solely on power cell output and the fast recharge rates
that the unit’s internal charger provides from any standard 208-240 single
phase VAC electrical outlet. Longer term operations incorporate the continu-
ous 100 amp output of the 208-240 VAC to 28.5 VDC converter, or a combination
of converter and power cell output to provide 24 VDC output. The following
are the unit’s four (4) main operational support capabilities:
a. 24 VDC 1500 amp peak power output for engine starting or constant (one
hour) rated power output (without a 208-240 VAC power source) for short term
trouble shooting and flexible flight line support ground power.
b. 24 VDC constant (one hour) rated power output or variable high load de-
mand output (less than one hour) with a 208-240 single phase VAC power source
for extended maintenance (hangar) and routine flight line maintenance, ground
support power.
c. 28.5 VDC continuous rated (AC to DC converter) power output with a 208-
240 VAC power source for hangar and routine flight line maintenance support,
and avionics bench testing.
d. Rapid recharge of the unit’s power cells from any 208-240 VAC common
power source. This feature eliminates the need for special recharge equip-
ment and dedicated maintenance support man-hours.
2-1

SECTION II DESCRIPTION
2.2. GENERAL SPECIFICATIONS
WEIGHT
UNIT: 100 lbs (50.39 Kg)
DC POWER CABLE: 8.5 lbs (3.86 Kg)
AC POWER CORD: 0.4 lbs (0.18 Kg)
INPUT POWER AC
TI4100GPU-24: 208-240 Single Phase VAC 50/60 Hz 30.0 amps max.
OUTPUT POWER DC
CONVERTER: 28.5 VDC TO 100 AMPS, 24 VDC 121 AMPS AND
ABOVE.
POWER CELLS: 24 VDC
PEAK OUTPUT: 1500 AMPS
POWER CELL
DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE
DC POWER CABLE
LENGTH: 8 FT
AIRCRAFT CONNECTOR: 3 PIN RECEPTACLE (MS25488)
AC POWER CORD: 8 Ft. 208-240 Single Phase VAC
2-2

2-3
UNIT DISCRIPTION AND DEMENTIONS

CHAPTER 3
OPERATING LIMITS AND RESTRICTIONS
SECTION I. GENERAL
3-1. PURPOSE
Chapter 3 includes all important operating limits and restrictions
that must be observed for proper and safe operation of the TI4100GPU-
24 (Turbo Start 4100) ground power unit.
3-2. GENERAL
The operating limitations set forth in this chapter are the direct
result of design analysis, testing, and operating experience. Com-
pliance with these limitations and restrictions will ensure that own-
ers/operators obtain maximum continued capability from the Turbo
Start 4100 ground power unit.
SECTION II. OPERATIONAL RESTRICTIONS AND SAFETY LIMITS
3-3. POWER CELL RECHARGE LIMITS
Any time the unit’s power cells are discharged the unit shall be
recharged within 24 hours to prevent performance degradation and en-
sure maximum life.
CAUTION
This unit is set up to recharge off of 208-240 Single Phase 50/60 Hz
VAC Power. Any other type of AC power may cause damage to the unit.
Unit’s power cells may be damaged if recharged by NiCad or Lead Acid-
type battery chargers. Power cells should only be charged by either
the TURBO START internal charger and the AC power cord furnished with
the equipment, or when connected aircraft external DC power recep-
tacle.
3-1