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WARNING *******SHOCK HAZARD POTENTIAL******* IMPROPER USE/FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN RESULT IN UNIT FAILURE AND/OR POSSIBLE INJURY, OR DEATH, BY ELECTRICAL SHOCK. THE TI2000GPU-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.
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 Introductio
ii CHAPTER 1 INTRODUCTION 1-1. GENERAL These instructions are for use by the owner/operator. They apply to handling and operation of the TI2000GPU-24 (Turbo Start 2000) ground power unit. 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.
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.
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 TI2000GPU-24 (Turbo Start 2000) (Figure 2-1 and 2-2) is a compact, portable and highly versatile 24/28.5 VDC electrical ground power unit. The unit incorporates a 120-240 VAC to 28.5 VDC converter, a 24 volt unique (dry) power cell and an internal intelligent 120 to 240 volt AC charger to recharge the power cells.
120 VAC Setting 2-1 SECTION II 2.2. 240 VAC Setting DESCRIPTION GENERAL SPECIFICATIONS WEIGHT UNIT: 111 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 TI2000GPU-24: 105-125 VAC 60 Hz 6.50 amps max. TI2000GPU-24-UNV: 210-250 VAC 50/60 Hz 3.25 amps max. TI25000-U01 NORTH AMERICAN LINE CORD 105-125 VAC 60 Hz 6.50 amps max. TI25000-U04 OLD BRITISH LINE CORD 210-250 VAC 50/60 Hz TI25000-U03 EUROPEAN 3.25 amps max.
2-3
Fuse Setting Procedures for Switching Voltages or Changing Blown Fuses 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.
2-2 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 TI2000GPU24 (Turbo Start 2000) 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.
3-1 3-4. 120-240 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 units 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).
3-2 AC Line Cords 乊 乘乄乕 乇丣 义 乕乒 乐 丣 乌 乑 乆乒乕乕么 乆乗 乓 乒乚么 乕丣 乖 乒乘 乕乆么 Cont. Europe U.K. Old British North American CAUTION 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.
3-3 3-8. CONTINUOUS OUTPUT RATE, 28.5 VDC CONSTANT OUTPUT 20 amp hours (with AC power connected) NOTE If current demand exceeds 20 amps, converter output voltage will drop below 28.5 VDC and two or more LED status indicator bars will illuminate. If all LED status indicator bars illuminate, both the converter and power cells are supplying 24 VDC power output (see paragraph 3-4 and 4-7.4.). 3-9.
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 temperature 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 120240 VAC functions (charger and converter) until unit cools to normal operating temperatures. 3-11.
3-5 WARNING ********SHOCK HAZARD POTENTIAL********* Severe injury, or Death, from electrical shock is possible when personnel and/or Turbo Start 2000 are wet during use and when 120-240 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 suspected. DO NOT USE until unit’s exterior and receptacles are dried. Operation shall be restricted to use without 120 or 240 power cord.
3-6 CAUTION Unit damage may occur if inlet and outlet vent ports are obstructed and/or cooling air flow is restricted. 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 VAC power (charger or AC-DC converter) functions of unit shall not be operated during any aircraft fuel handling operation.
3-7 CHAPTER 4 OPERATING PROCEDURES SECTION I. UNIT OPERATION 4-1. GENERAL Correct operation of the TI2000GPU-24 (Turbo Start 2000) 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 instructions in this manual that affect operational safety and the warranty of the unit. 4-2.
4-1 SECTION II. OPERATING PROCEDURES 4-4. OPERATING PROCEDURES This section deals with normal procedures, and includes all steps necessary to ensure safe and efficient operation of the TI2000GPU-24 (Turbo Start 3000). As experience is gained with the Turbo Start 3000, the user will be able to maximize the unit’s unique capabilities to enhance the flexibility of aircraft maintenance and support operations.
that cooling fan is functioning. 4-2 CAUTION REMEMBER,when the AC line cord is plugged in, the unit must be placed in the horizontal 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 present on bar graph) 3. CHECK DC POWER CABLE/CONNECTORS FOR DAMAGE - Check cable for cuts, chafing or evidence of being crushed.
starting procedure as specified in aircraft operators manual. 5. REMOVING DC POWER SUPPLY FROM AIRCRAFT a. Remove DC power cable GPU connector from aircraft. b. Remove DC power cable connector from Turbo Start (if necessary). 4-3 4-7. 24 VDC GROUND POWER (WITH 120/240 VAC POWER) SYSTEM HIGH POWER DEMAND (21 amps and above) OR ENGINE STARTING. 1. TRANSPORT UNIT - The Turbo Start 2000 is easily transported using the wheels that are incorparated into the unit.
(if necessary). 4-4 4-8 28.5 VDC GROUND POWER (WITH 120/240 VAC POWER) SYSTEM LOW DEMAND (20 amps or less). POWER 1. TRANSPORT UNIT - The Turbo Start 2000 is easily transported using the wheels that are incorparated into the unit. The AXEL EXTENTION kit (included with the unit) ensures that the Turbo Start 2000 is stable. The unit is engineered to be pushed rather than pulled. 2. CONNECT AC POWER CORD TO UNIT (CHECK FUSE WINDOW FOR PROPER SETTING).
indicating power cell state of charge and cooling fan is operating. 4-5 CAUTION Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. 2. CHECK FOR FULL CHARGE INDICATION - After 2 HR 30 minutes, LED charge indicator should show a single steady or flashing green LED bar when fully charged, the last LED bar. AC power may be left connected to unit when power cells are fully charged. NOTE Under a full charge, two things will be observable with the unit.
4-6 SECTION III. FUNCTIONAL CHECK PROCEDURES 4-10. FUNCTIONAL CHECK PROCEDURES This section deals with normal functional check procedures, and includes all steps necessary to ensure the Turbo Start 2000 is functioning within specific operational parameters prior to operational use. As users gain experience with the Turbo Start 2000, they will incorporate these functional checks as a routine practice. 4-11. REQUIRED EQUIPMENT FOR FUNCTIONAL CHECK. FLUKE OR EQUIVALENT TYPE DIGITAL MULTIMETER. 4-12.
and cooling fan are operational. Prior to continuing to step 7, the LED status indicator should show a single green bar (last LED bar) to indicate the unit’s power cells are fully charged. Also under full charge the fan will ratchet but not enable. 4−7 NOTE Under a full charge, the last green LED bar may blink. This does not indicate a malfunction. A nonblinking lighted green bar or a blinking green bar at the bottom of the LED column, both indicate a full charge. 7.
4−8 CHAPTER 5 PERFORMANCE DATA SECTION 1. INTRODUCTION 5-1. PURPOSE This chapter provides performance data for the TI2000GPU-24 (Turbo Start 2 000). Continual reference to this information will enable the user to obtain maximum performance, utilization and service life from the Turbo Start. Although maximum performance is not always required, regular referral to this chapter is recommended for the following reasons: a.
the ground power support requirements are presented. Wherever practical, data is presented conservatively. However, NO GENERAL CONSERVATISM HAS BEEN APPLIED. All performance data presented is within the applicable limits of the Turbo Start. 5-1 SECTION II DATA CRITERIA 5-3 DATA BASIS The type of data used is indicated at the bottom of each performance chart under DATA BASIS. The applicable report and date of the data are also given. The data provided generally are based on one of three categories: a.
shown in the performance charts do not account for instrument tolerance differences or inaccuracies. 5-6. DEFINITIONS OF ABBREVIATIONS Unless otherwise indicated, the abbreviations defined in Chapter 1 will be applicable to all charts and graphs in this chapter.
TI2000GPU-24 OUTPUT VOLTAGE 24 OUTPUT VOLTAGE 20 16 5-3 12 8 4 0 0 10 20 30 40 MINUTES 46 AMP CONSTANT CURRENT LOAD FIGURE 5-2 50 60
MAXIMUM OUTPUT CURRENT *** 3000 2700 **** 0 ** ** (+25 C Temp) 2400 * *** 2100 ***** ***** AMPS 1800 1500 * * ***** 1200 0 5-4 ********* (-29 C Temp) 900 ***** ********** **** 600 300 0 0 5 10 15 20 SECONDS Calculations based on actual test data at Pratt-Whitney Canada on 30 March 1992.
5-5 CHAPTER 6 CARE AND MAINTENANCE SECTION I. 6-1. UNIT CARE GENERAL Although the TI2000GPU-24 (Turbo Start 2000) has been ruggedized and made weather resistant within the scope of unit’s intended use, it is essential that good general care be taken to maintain unit in good operating condition and to maximize unit’s operational life. 6-2. AFTER USE - Unit should be protected from the environmental elements and man made hazards. Ideally unit should be secured in a building or shed.
6-1 SECTION II. MAINTENANCE 6-3. MAINTENANCE OF UNIT - The Turbo Start 2000 is a maintenancefree unit, no repairs are authorized. Warranty will be void if unit is tampered with. If unit fails to operate contact Manufactures Warranty Claim (see unit warranty).
Chapter 7 Push To Test Modification General Information And Operation 7-1. General THIS MODIFICATION HAS BECOME STANDARD EQUIPMENT FOR EACH OF OUR UNITS. BOTH MILITARY AND CIVILIAN CLIENTS HAVE FOUND THIS MODIFICATION TO BE CRITICAL TO THEIR OPERATION. THE PUSH TO TEST BUTTON IS USED TO INDICATE THE CAPACITY OF THE POWER CELLS WITHOUT APPLYING AC INPUT POWER. IT ALLOWS THE END USER TO CHECK THE STATUS OF THE POWER CELLS.
PARAGRAPH INDEX 120-240 VAC Charger and AC to DC Converter Limits, 3-4 24 VDC Ground Power (NO 120 or 240 VAC Power Supply) Engine Starting or DC system Power, 4-6 24 VDC Ground Power (With 120/240 VAC Power) System High Power Demand (21-1500 Amps) or Engine Starting, 4-7 28.
PARAGRAPH INDEX Index, 1-4 Maintenance of Unit, 6-3 Maximum Output Current, Figure 5-3 One (1) Hour Rate, 24 VDC Constant Output, Operating Limits and Restrictions, Operating Procedures, Operating Position, Performance, 4-2 4-4 3-12 4-3 Power Cell Recharge, 4-9 Power Cell Recharge Limits, Purpose, Chapter 3, 3-1 Purpose, Chapter 5, 5-1 3-3 Rated Peak Output (Engine Starting), 3-7 Required Equipment for Functional Check, Specific Conditions, Temperature, 3-6 4-11 5-4 3-10 Temperature
APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY HZ TESLA PART # Afganistan Algeria American Samoa Angola Anguilla (U.K.
APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY HZ TESLA PART # Ecuador Egypt El Salvador England Equatorial Guinea Estonia Ethiopia VOLTS 120 220 115 240 220 220 220 60 50 60 50 50 50 50 TI25000-001 TI25000-100 TI25000-001 TI25000-005 TI25000-100 TI25000-003 TI25000-003 North American Line Cord Europlug Line Cord Set North American Line Cord United Kingdom Line Cord Europlug Line Cord Set Cont. European Line Cord Cont.
APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY HZ TESLA PART # Laos Latvia Lebanon Lesotho Liberia Liechtenstein Lithuania Luxembourg Libya VOLTS 220 220 220 240 120 220 220 220 230 50 50 50 50 60 50 50 50 50 TI25000-001 TI25000-003 TI25000-100 TI25000-004 TI25000-005 TI25000-006 TI25000-003 TI25000-003 TI25000-002 North American Line Cord Set Cont.
APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY HZ TESLA PART # Romania Russia Rwanda VOLTS 220 220 220 50 50 50 TI25000-003 Cont. European Line Cord Set TI25000-003 Cont. European Line Cord Set TI25000-100 Europlug Line Cord Set Saudia Arabia Scotland Senegal Seychelles Sierra Leone Singapore Slovakia Somalia South Africa Spain Sri Lanka St. Pierre & Miquelon (France) St. Kitts & Nevis St. Lucia St.
APPENDIX A (Cont.) UNIVERSAL LINE CORD KIT FOR WORLDWIDE OPERATIONS NOTE: TESLA UNIVERSAL AC LINE CORD KIT, P/N: TI25000-U00, IS FOR UNITS ORIGINALLY BUILT WITH THE UNIVERSAL AC LINE CORD OPTION ONLY. THE AC ADAPTER OPTION IS TESLA P/N TI16000-19 AND MUST BE ORDERED WITH THE ORIGINAL PROCUREMENT OF UNIT(S). UNIT(S) MAY BE RETURNED TO TESLA INDUSTRIES, FOR A NOMINAL COST, AND MODIFIED TO ALLOW OPERATION WITH THE UNIVERSAL AC LINE CORD KIT.
