Tesla TI4676 User Manual Download Page 1

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Tesla Industries Inc.

109 CenterPoint Blvd.
New Castle, DE 19720
(302)324-8910 Phone

(302) 324-8912 Fax

www.TESLAind.com

4676

Summary of Contents for TI4676

Page 1: ... Tesla Industries Inc 109 CenterPoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www TESLAind com TI4676 ...

Page 2: ...TERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PH 302 324 8910 FAX 302 324 8912 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 HA...

Page 3: ...ation 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 D...

Page 4: ...perating 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 troubl...

Page 5: ...is 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 Potent...

Page 6: ... 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 ...

Page 7: ...20 240 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 ...

Page 8: ...ng 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 RECH...

Page 9: ... ...

Page 10: ...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...

Page 11: ... 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 o...

Page 12: ...n 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 a...

Page 13: ...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 an...

Page 14: ...r 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 ...

Page 15: ...de 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...

Page 16: ...e 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 ...

Page 17: ... 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 ...

Page 18: ...o 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 str...

Page 19: ...lugged 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 com...

Page 20: ... 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 acco...

Page 21: ...dy or flickering LED bar when fully charged AC power may be left connected to unit when power cells are fully charged 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 4 4 ...

Page 22: ...ptacle terminal and unit case Positive DC receptacle terminal and unit case 4 CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS 24 to 25 5 VDC depending on state of charge 5 PLUG IN 120 OR 240 POWER CORD CHECK FUSE WINDOW FOR PROPER SET TING Ensure power unit is connected to a suitable AC power source 120 USA or 240 European 6 CHECK UNIT FOR STATE OF CHARGE Unit shall be in a position to en sure...

Page 23: ...ECEPTACLE TERMINALS Ensure power cells are fully charged see step 6 28 5 0 57 VDC with power cells at full state of charge 8 FUNCTIONAL CHECK COMPLETE Unit should remain plugged in to AC power until ready for installtion in aircraft 4 6 ...

Page 24: ...which data is not presented d To help the operator determine if an aircraft system malfunction exists by comparing actual performance with expected performance NOTE The information provided in this chapter is primarily intended for op erational planning and is most useful when planning operations under unfamiliar conditions or environmental extremes The data may also be used to establish local ope...

Page 25: ...r which data are not presented but which may affect that phase of performance are dis cussed in associated text Where data is available or reasonable esti mates can be made the amount that each variable affect performance will be given 5 5 GENERAL CONDITIONS In addition to the specific conditions the following general condi tions are applicable to the performance data a Variation in Aircraft Power...

Page 26: ...FIGURE 5 1 5 3 ...

Page 27: ...FIGURE 5 2 5 4 TI4676MPU 24 OUTPUT VOLTAGE OUTPUT VOLTAGE MINUTES 23 AMP CONSTANT CURRENT LOAD 24 20 16 12 8 4 0 0 10 20 30 40 50 60 ...

Page 28: ...IMUM OUTPUT CURRENT AMPS Calculation based on actual test data at Pratt Whitmey on 30 March 1992 SECONDS 1500 1350 1200 1050 900 750 600 450 150 300 0 0 5 10 15 20 25 30 29 C Temp 25 C Temp FIGURE 5 3 5 5 ...

Page 29: ...OUT OF UNIT Cover unit to prevent foreign objects water and dirt from entering vent ports and recep tacles Keep a c compartment closed when not in use 3 AFTER USE PLUG UNIT INTO AC POWER SUPPLY WHEN NOT IN USE CHECK FUSE WINDOW FOR PROPER SETTING To maximize life of power cells and to ensure unit is always ready for use unit should remain plugged in to AC power when not installed in aircraft NEVER...

Page 30: ...RE A CORRECT READ ING 2 WITHOUT AC POWER INPUT OR DC POWER OUTPUT SIMPLY DEPRESS THE PUSH TO TEST BUTTON ON THE FACE PLATE AND HOLD FOR APPROXIMATELY 10 15 SECONDS 3 AT THIS TIME THE LED BAR GRAPH SHOULD LIGHT UP INDICATING THE STATUS OF THE POWER CELLS 4 THE FAN SHOULD ALSO OPERATE AT THIS TIME IF YOU DO NOT HEAR THE FAN RUNNING STOP DEPRESSING THE BUTTON AND CHECK FOR ANY OBSTRUCTIONS TO THE FAN...

Page 31: ...a Basis 5 3 DC Functional Check 4 10 Definitions of Abbreviations 5 6 Dimensions Figure 2 1 Discharge Load Curve Figure 5 2 Description 1 3 Engine Starting Power 3 9 Environmental 3 11 Functional Check Procedures 4 8 Forms and Records 1 6 General Chapter 1 1 1 General Chapter 2 2 1 General Chapter 3 3 2 General Chapter 4 4 2 General Chapter 5 5 2 General Chapter 6 6 1 General Conditions 5 5 Genera...

Page 32: ...rformance 4 4 Power Cell Recharge 4 7 Power Cell Recharge Limits 3 3 Purpose Chapter 3 3 1 Purpose Chapter 5 5 1 Push to test modification 7 1 Rated Peak Output Engine Starting 3 7 Required Equipment for Functional Check 4 9 Specific Conditions 5 4 Temperature 3 10 Temperature Conversion Chart Figure 5 1 Unit Operation During Aircraft Fueling De fueling 3 13 Use of Word Shall Should and May 1 7 Wa...

Page 33: ...roplug Line Cord Set Burma Now Myanmar 230 50 TI25000 005 United Kingdom Line Cord Set Burundi 220 50 TI25000 003 Cont European Line Cord Set Cambodia 220 50 TI25000 100 Europlug Line Cord Set Cameroon 230 50 TI25000 003 Cont European Line Cord Set Canada 120 60 TI25000 001 North American Line Cord Set Canary Islands Spain 220 b TI25000 003 Cont European Line Cord Set Cape Verde Rep of 220 50 TI25...

Page 34: ...ont European Line Cord Set Guam 110 120 60 TI25000 001 North American Line Cord Set Guatemala 120 60 TI25000 001 North American Line Cord Set Guinea 220 50 TI25000 003 Cont European Line Cord Set Guinea Bissau 220 50 TI25000 003 Cont European Line Cord Set Guyana 110 50 60 TI25000 001 North American Line Cord Set Haiti 110 120 50 60 TI25000 001 North American Line Cord Set Honduras 110 60 TI25000 ...

Page 35: ...gdom Line Cord Set Morocco 220 50 TI25000 003 Cont European Line Cord Set Mozambique 220 50 TI25000 003 Cont European Line Cord Set Namibia W S Africa 220 250 50 TI25000 004 Old British Line Cord Set Nepal 220 50 TI25000 004 Old British Line Cord Set Neth Antilles 220 50 60 TI25000 003 Cont European Line Cord Set Netherlands 220 50 TI25000 003 Cont European Line Cord Set New Caledonia 220 50 TI250...

Page 36: ... Line Cord Set Sweden 220 50 TI25000 003 Cont European Line Cord Set Switzerland 220 50 TI25000 006 Switzerland Line Cord Set Syria 220 50 TI25000 100 Europlug Line Cord Set Tahiti 220 50 TI25000 003 Cont European Line Cord Set Taiwan 110 60 TI25000 001 North American Line Cord Set Tanzania 230 50 TI25000 005 United Kingdom Line Cord Set Thailand 220 50 TI25000 100 Europlug Line Cord Set Togo 220 ...

Page 37: ...MAY BE RETURNED TO TESLA INDUSTRIES FOR A NOMINAL COST AND MODIFIED TO ALLOW OPERATION WITH THE UNIVERSAL AC LINE CORD KIT TESLA UNIVERSAL AC LINE CORD KIT P N TI25000 U00 IS COMPRISED OF THE FOLLOWING FOUR PART NUMBERS TI25000 U01 NORTH AMERICAN LINE CORD TI25000 U04 OLD BRITISH LINE CORD TI25000 U03 EUROPEAN 10A 250V TI25000 U05 ENGLAND 10A 250V TESLA REPLACEMENT 8 FOOT DC POWER CORD P N TI2006 ...

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