Tesla TI4676 User manual

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Tesla Industries Inc.
109 CenterPoint Blvd.
New Castle, DE 19720
[phone] Phone
[phone] Fax
www.TESLAind.com
TI4676

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 TI4676 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]
www.teslaind.com
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 AND INSTALLATION PROCEDURES 4-1
Section I Installation Procedures 4-1
Section II Unit Operation 4-1
Section III Operating Procedures 4-2
Section IV 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 Operation 7-1
INDEX Index 1
LIST OF ILLUSTRATIONS
Figure Title Page
2-1 Dimensions 2-3
2-2 Fuse Setting Procedures 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 TI4676 Micro Power Unit (MPU).
1-2. WARNING, CAUTION, AND NOTE DEFINED
A warning, caution, or note is used to emphasize important and critical
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 procedures
for the TI4676 MPU. The TI4676 is intended to provide an on-board bat-
tery along with DC electrical ground power for aircraft systems 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 support for ground maintenance, avionics/
electrical trouble shooting and testing. The unit also has a built in
capacity tester (push to test button), and recharge rate indicator. The
TI4676 MPU has a internal, independent, intelligent recharger that will
enable the MPU to be rapidly recharged from either the aircraft genera-
tor or any 120-240 50/60 Hz VAC common power source. The observance
of procedures, limitations and performance criteria is essential to
ensure peak operating efficiency and to maximize operational capabili-
ties and life of the TI4676 MPU.
1-1

1-4. INDEX
The index lists, in alphabetical order, every titled paragraph and fig-
ure 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
MPU Micro 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
ᮂᮐ᭼ᮍ᭿᭛ᮁᮍᮊᮈ᭛ᮄᮉ᭾ᮊᮍᮍᮀ
᭾ᮏ
ᮋᮊᮒᮀᮍ᭛ᮎᮊᮐᮍ᭾ᮀ
Guard from incorrect power source
1-2

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 acceptable
method of accomplishment.
1-3

CHAPTER 2
UNIT DESCRIPTION AND OPERATION
SECTION I. UNIT
2-1. GENERAL
The TI4676 (Figure 2-1) is a compact, portable and highly versatile 24/
28.5 VDC electrical MPU. The unit incorporates a 120-240 50/60 Hz to
28.5 VDC converter, a 24 volt unique (dry) power cell and an internal
intelligent 120-240 50/60 Hz VAC charger to recharge the power cells.
In addition the MPU incorporates a push to test button which gives the
user the ability to test the capacity of the power cells These built-
in features give the TI4676 self-sufficiency in an aircraft battery,
and long term ground operations with AC electrical power. Aircraft bat-
tery operations rely on the unique dry-cell batteries that can be rap-
idly recharged from the aircraft generator or any common 120-240 50/60
Hz VAC source. Ground operations incorporate the continuous 12 Amp
output of the 120-240 50/60 Hz VAC to 28.5 VDC converter, or a combi-
nation of converter and power cell output to provide 24 VDC output.
The following are the unit’s five (5) main operational support capa-
bilities:
a. 24 VDC 1500 amp peak power output for engine starting or constant
(one hour) rated power output (without a 120-240 50/60 Hz VAC power
source) for short-term trouble shooting.
b. 24 VDC constant (one hour) rated power output or variable high
load demand output (less than one hour) with a 120-240 50/60 Hz 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 120-240 50/60 Hz VAC power source for hangar and routine flight
line maintenance support.
d. Rapid recharge of the unit’s power cells from aircraft generator
or any 120-240 50/60 Hz VAC common power source. This feature elimi-
nates the need for special recharge equipment and dedicated mainte-
nance support man-hours.
e. Built in Capacity tester and state of recharge indicator.
2-1

WARNING
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έὲὺὨήὃὶὲὸήὦὨ
Check fuse holder window to ensure the fuse setting reads either
120 or 240 prior to connecting recharge cord to AC power source. Fuse
setting (120/240) must match AC power source (hangar wall, flight line
AC power) prior to connecting MPU for recharging.
120 VAC Setting 240 VAC Setting
(SEE PAGE 2-4 FOR DETAILS ON FUSE SETTING PROCEDURES)
SECTION II DESCRIPTION
2.2. GENERAL SPECIFICATIONS
WEIGHT
UNIT: 48.2 lbs. (21.8 Kg)
AC POWER CORD: 0.4 lbs. (0.18 Kg)
INPUT POWER AC
TI4676: 110-240 VAC 50/60 Hz 6.50 amps max.
OUTPUT POWER DC
CONVERTER: 28.5 VDC TO 12 AMPS, 24 VDC 15 AMPS AND ABOVE.
POWER CELLS: 24 VDC 23 AMP Hour
PEAK OUTPUT: 1500 AMPS
POWER CELL
DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE
OPTIONAL ACCESORIES
SHIPPING CASES
Used for shipping and storage.
Part # TI7000-023
2-2

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2-4
7) Replace the
white clip back into
the fuse clip. Take
care not to damage
the tabs.
8) Completely insert
white clip in to fuse
clip (GENTLY) until
it snaps into place.
9) Insert fuse clip
back into fuse housing
EVENLY on both sides.
DO NOT FORCE, if fuse
clip does not go in easy,
it means fuses are mis-
aligned, realign fuses and
insert again.
10) Snap fuse clip
back into the housing
(GENTLY). DOUBLE
CHECK VOLTAGE
WINDOW PRIOR
TO PLUGGING UNIT
INTO AC POWER
5) Completely remove
the white clip from the
fuse clip.
6) Ensure that the
proper voltage is selected
on the white clip. (See
Enlargement 2 & 3)
1) Grab both tabs
on left and right side
of the fuse clip. Press
tabs inward and pull
fuse clip out of housing
GENTLY.
2) Completely pull
fuse clip from housing,
being careful not to
drop the fuses from
the fuse clip.
3) Note: The fuses
are not fastened into
the fuse clip, they are
lose. Take care to ensure
fuses are not dropped or
lost.
4) GENTLY pull the
white clip from the
fuse clip, taking care
not to bend any of
the tabs. (See
enlargement 1)
Fuse Setting Procedures
for Switching Voltages or Changing Blown Fuses
ENLARGEMENT 1
TABS
ENLARGEMENT 2 120 VAC SETTING
ENLARGEMENT 3 240 VAC SETTING

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 TI4676 micro
power unit.
3-2. GENERAL
The operating limitations set forth in this chapter are the direct re-
sult of design analysis, testing, and operating experience. Compliance
with these limitations and restrictions will ensure that owners/opera-
tors obtain maximum continued capability from the TI4676 ground power
unit.
SECTION II. OPERATIONAL RESTRICTIONS AND SAFETY LIMITS
3-3. POWER CELL RECHARGE LIMITS
Any time the unit’s power cells are fully discharged the unit shall be
recharged within 24 hours to prevent performance degradation and ensure
maximum life.
CAUTION
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 TI4676 MPU internal charger and the AC power cord furnished with
the equipment, or off the aircraft generator when installed on the air-
craft.
3-1

3-4. 120-240 50/60 Hz VAC CHARGER AND AC TO DC CONVERTER LIMITS
The unit is designed with a single point AC receptacle for external
power to operate both the internal charger and converter. The unit’s
AC voltage range can be factory set from 105 to 250 VAC at 50 to 60 Hz
depending upon customer requirements. The AC power cord provided with
the unit is the mechanism that ensures the specified AC power source
is properly supplied to the unit (see paragraph 3-5). Use no others.
INTERNAL CHARGER: NO LIMIT AC power cord can remain connected when
power cells are fully charged. When the power cells are fully
charged the unit’s intelligent charger will go to a stand-by mode,
LED will stay green or flicker, monitor the power cells state of
charge and only charge the power cells to ensure they stay at maxi-
mum capacity.
INTERNAL AC TO DC CONVERTER: LIMITED (see paragraph 3-6, 3-8 and 3-
10). AC power cord does not have to be disconnected when converter
power output is no longer required. Once DC power demand is termi-
nated the unit’s intelligent charger will remain on line to ensure
power cells are charged to maximum capacity.
CAUTION
*8 $5’ )52 0 ,1&255( &7
32: (5 6285&( Unit will be damaged if unapproved AC power is applied.
3-5 AC POWER CORD LIMITS
The AC power cord governs which AC power source the unit is set to
operate from. The TI4676 is supplied with a single customer specified
AC power cord. Some customers may specify a non North American AC
option (for worldwide mobility see appendix A). Each power cord is
marked accordingly.
FOR MORE INFORMATION ON POWER CORDS SEE APPENDIX A
3-2

AC Line Cords
North American Old British U.K Cont. Europe
(more examples in appendix or call factory for information)
CAUTION
*8 $5’ )52 0 ,1&255( &7
32: (5 6285&( Unit will be damaged if unapproved AC power is applied by fitting
120 or 240 VAC power cord with any kind of unapproved modification or
adapter that changes the specified input power characteristics.
WARNING
********SHOCK HAZARD POTENTIAL*********
Failure to use proper grounding can cause a potential shock hazard!
In different countries, the 240 VAC 50 Hz power cord may require the
use of a plug adapter to achieve plug style compatibility for 240
VAC 50 Hz operation. Use only adapters with proper grounding mecha-
nism.
3-6. ONE (1) HOUR RATE, 24 VDC CONSTANT OUTPUT
23 amp hour (without AC power connected), power cell output.
(see Figure 5-2)
35 amp hours (with AC power connected), both power cell and AC to DC
converter output.
NOTE
If power output is greater than rated amp hour rate, power cell dis-
charge rate will increase correspondingly.
3-7. RATED PEAK OUTPUT (ENGINE STARTING)
1500 peak amps at 25oC (77oF) (See Figure 5-3).
3-3

3-8. CONTINUOUS OUTPUT RATE, 28.5 VDC CONSTANT OUTPUT
35 Amps at 1 hour (with AC power connected)
NOTE
If current demand exceeds 12 amps, converter output voltage will drop
below 28.5 VDC and two or more LED status indicator bars will illumi-
nate. If all LED status indicator bars illuminate, both the converter
and power cells are supplying 24 VDC power output (see paragraph 3-4
and 4-7)
3-9. ENGINE STARTING POWER
Operators should always ensure the unit is charged above 80% prior to
ground support engine starting. However, circumstances may exist dur-
ing use where unit recharge is not readily available and immediate ex-
ternal engine starting power is required. The following provides mini-
mum states of charge necessary to provide ample power for an efficient
engine start under specific current load demands.
ENGINE START CURRENT LOAD DEMAND MINIMUM CHARGE
Under 650 peak starting amps 40% charged
650 - 850 peak starting amps 50% charged
850 - 1000 peak starting amps 60% charged
1000 - 1200 peak starting amps 70% charged
1200 - 1500 peak starting amps 80% charged
3-10. TEMPERATURE
Temperatures refer to the unit’s cold/heat soaked temperature. The
ambient temperature that a unit is exposed to for one (1) hour or more
shall establish a unit’s cold/heat soaked temperature. If unit’s cold/
heat soaked temperature exceeds operating temperature range, unit shall
be stabilized prior to operation as follows: COLD SOAKED, warmed for a
minimum of 3 hours above +10Co(+41oF) or 2 hours above +20Co(+68oF);
WARMED SOAKED, cooled for 1 hour below +38Co(+100oF).
Operating range:
without AC power -40Co(-40oF) TO +60Co(+140oF)
with AC Power -30Co(-22oF) TO +50Co(+124oF)
Storage range:
60Co(-76oF) TO +60Co(+140oF)
(C0NTINUED ON NEXT PAGE)
3-4

CAUTION
Unit may be damaged if operated when unit’s cold or heat soaked tem-
perature exceed the specified limit. If unit is operated when cold or
heat soaked temperature limit is exceeded; a full functional check
should be accomplished prior to continued use.
NOTE
If unit should overheat, an over-temperature sensor will shut down 120-
240 50/60 Hz AC functions (charger and converter) until unit cools to
normal operating temperatures.
3-11. ENVIRONMENTAL
Operating any electrical equipment in the presence of moisture creates
possible safety hazards and/or potential for equipment damage. Every
effort has been made, within the scope of existing technology to pre-
vent foreseeable safety hazards and make the TI4676 moisture resistant
to prevent damage or failure. If the TI4676 is exposed to moisture,
preventive measures and precautions shall be taken to:
a. Prevent accumulation of moisture on AC and DC con-
nectors/receptacles
b. Minimize moisture entering FWD inlet and AFT outlet
cooling fan vent ports
The limits and operational constraints listed below shall apply for the
following environmental (weather) conditions during recharging process:
Heavy or steady rain: OPERATION NOT RECOMMENDED DURING RECHARG-
ING PROCESS
Light rain, drizzle: NO CONVERTER OR CHARGER 120-240 50/60 Hz
VAC
Fog, snow or sleet: POWER SHALL BE APPLIED.
Unit inlet and outlet vent ports shall be covered from exposure. Unit
shall be kept horizontal.
3-5

WARNING
********SHOCK HAZARD POTENTIAL*********
Severe injury, or Death, from electrical shock is possible when person-
nel and/or TI4676 are wet during use and when 120-240 50/60 Hz VAC
power is being supplied to unit.
CAUTION
Damage may occur if unit is operated after exposure to moisture
(rain, drizzle, fog, sleet or snow) or moisture contamination is sus-
pected. DO NOT USE until unit’s exterior and receptacles are dried.
Operation shall be restricted to use without 120 or 240 power cord . DO
NOT CONNECT 120 or 240 VAC power cord until unit has been dried for a
MINIMUM of one (1) hour, prior to use.
Blowing sand or dust: Minimize exposure to sand and dust
when 120-240 50/60 Hz AC power is used. Unit shall be kept hori-
zontal during use.
3-6

CAUTION
Unit damage may occur if inlet and outlet vent ports are obstructed
and/or cooling airflow is restricted.
Back Vent Side Vents Cooling Fan
3-13. UNIT OPERATION DURING AIRCRAFT FUELING/DEFUELING
Power output is restricted to 24 VDC power cell output only. DO NOT
CONNECT 120 or 240 VAC POWER SUPPLY. 120-240 50/60 Hz VAC power
(charger or AC-DC converter) functions of unit shall not be operated
during any aircraft fuel handling operation.
WARNING
*******FIRE/EXPLOSION HAZARD POTENTIAL********
Severe injury, or Death, may occur from fire or explosion, as a re-
sult of electrical sparks produced near fuel vapors.
3-7

CHAPTER 4
OPERATING AND INSTALLATION PROCEDURES
SECTION I. UNIT INSTALLATION
4-1. INSTALLATION
1. Remove original aircraft battery and dispose of properly (follow
your aircraft’s manual for proper removal and disposal of aircraft
battery).
2. Ensure that the TI4676 MPU is fully charged. Remove AC cord and
place the TI4676 MPU in the same position of the original battery (en-
sure that the DC receptacle is oriented in the same position as the
original battery).
3. Position the TI4676 MPU so that the aircraft battery tie-down bolts
are aligned with the bracket on the MPU. Secure the aircraft tie-down
bolts so that the MPU is securely fastened.
4. Attach the aircraft DC plug so that it is fully seated into the MPU
receptacle.
5. Because the TI4676 MPU uses monolithic dry-cell batteries, there is
no need to attach the ventilation tubes to the MPU.
6. Because there is no hazardous materials or liquids in the cells,
there is no risk of thermal runaway, and therefore no need to hook up
temperature sensors.
SECTION II. OPERATING PROCEDURES
4-2. GENERAL
Correct operation of the TI4676 includes both pre-use and operational
checks of the unit. Knowledge of the operating limits, restrictions,
performance, unit capabilities and functions is fundamental to correct
and safe operation. The operator shall ensure compliance with the in-
structions in this manual that affect operational safety and the war-
ranty of the unit.
4-3. OPERATING LIMITS AND RESTRICTIONS
The minimum, maximum and normal operating ranges result from careful
engineering and evaluation of test data. These limitations must be
adhered to during all phases of operation. Refer to Chapter 3, Section
II, OPERATING LIMITS AND RESTRICTIONS, for detailed information.
4-4. PERFORMANCE
Refer to Chapter 5, PERFORMANCE DATA to determine the capability of the
TI4676. Consideration must be given to changes in performance result-
ing from variations in ambient temperature, mode of operation, state of
charge (with or without 120 or 240 VAC power), and aircraft DC bus sys-
tem inefficiency (voltage drops).
4-1

SECTION II. OPERATING PROCEDURES (cont.)
4-5. OPERATING PROCEDURES
This section deals with normal procedures, and includes all steps nec-
essary to ensure safe and efficient operation of the TI4676. As expe-
rience is gained with the TI4676, the user will be able to maximize
the unit’s unique capabilities to enhance the flexibility of aircraft
maintenance and support operations.
NOTE
When the TI4676 is not in use, it should
always remain plugged into a
suitable AC power source to insure operational readiness at all times.
REMEMBER, when the AC line cord is plugged in, the unit must be placed
in
a position to allow the cooling fan to operate unobstructed!
4-6. BEFORE OPERATION CHECK
1. CHECK FUSE WINDOW FOR PROPER SETTING (120/240 ) BEFORE PLUGGING
UNIT INTO THE AC POWER SOURCE TO BE USED .
NOTE:
Under a full charge the LED indicator should show a single steady
green bar or the entire LED will be flickering. The fan will also ex-
hibit ratcheting but will not come on. This is normal operation and
the unit will go into standby mode, the unit is ready for use.
2. CHECK UNIT FOR EVIDENCE OF DAMAGE - Check for dents, punctures,
case distortion or misalignment, cracked or loose connectors, and that
cooling fan is functioning ( cooling fan can be checked by pressing
push to test button ).
4-2
100
90
80
70
60
50
40
30
<20
Capacity %

CAUTION
REMEMBER, when the AC line cord is plugged in, the unit must be placed
in a position to allow the cooling fan to operate properly!
Unit may overheat if cooling fan fails. Do not operate if cooling fan
fails. (More than one green bar is present on bar graph)
Make certian there is at
least 2-3 inches clearence
on the vent fan of the MPU
when connected to AC, to
provide sufficent
ventillation.
3. CHECK AIRCRAFT PLUG AND MPU CONNECTORS FOR DAMAGE - Check cable
for cuts, chafing or evidence of being crushed. Check connectors for
cracks, cuts, distortions, excessive wear, broken/loose fasteners or
loose cable attachment.
4-7 POWER CELL RECHARGE
1. CONNECT AC POWER CORD TO UNIT ( CHECK FUSE WINDOW FOR PROPER SET-
TING ). - Ensure 120 or 240 VAC power cord is properly connected to an
approved AC power supply. Unit shall be in an upright position accord-
ing to aircraft specifacations to ensure unit’s vent ports are free
from blockage. After approximately 5-8 seconds, ensure unit’s LED sta-
tus indicator illuminates indicating power cell state of charge and
cooling fan is operating.
4-3