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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 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.
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
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 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.
1-4. 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.
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.
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, portable 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.
SECTION II 2.2. DESCRIPTION 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.
UNIT DISCRIPTION AND DEMENTIONS 2-3
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 TI4100GPU24 (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.
3-4. 208-240 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 208 to 240 VAC SINGLE PHASE 30 AMPS MAX at 50/60 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).
WARNING ********SHOCK HAZARD POTENTIAL********* Failure to use proper grounding can cause a potential shock hazard! In different countries, the 240 VAC 50/60 Hz power cord may require the use of a plug adapter to achieve plug style compatibility for 240 VAC 50/60 Hz operation. Use only adapters with proper grounding mechanism. 3-6. ONE (1) HOUR RATE, 24 VDC CONSTANT OUTPUT 23 amp hour (without AC power connected), power cell output.
3-8. CONTINUOUS OUTPUT RATE, 28.5 VDC CONSTANT OUTPUT 100 amp hours (with AC power connected) NOTE If current demand exceeds 100 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.
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 208-240 VAC functions (charger and converter) until unit cools to normal operating temperatures. 3-11.
WARNING ********SHOCK HAZARD POTENTIAL********* Severe injury, or Death, from electrical shock is possible when personnel and/or Turbo Start 4100 are wet during use and when 208-240 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 208-240 power cord.
CAUTION Unit damage may occur if inlet and outlet vent ports are obstructed and/or cooling air flow is restricted. Side Vents Front Vent/Cooling Fan 3-13. Back Vent/Cooling Fan UNIT OPERATION DURING AIRCRAFT FUELING/DEFUELING Power output is restricted to 24 VDC power cell output only. DO NOT CONNECT 208-240 VAC POWER SUPPLY. 208-240 VAC power (charger or AC-DC converter) functions of unit shall not be operated during any aircraft fuel handling operation.
CHAPTER 4 OPERATING PROCEDURES SECTION I. UNIT OPERATION 4-1. GENERAL Correct operation of the TI4100GPU-24 (Turbo Start 4100) 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.
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 TI4100GPU-24 (Turbo Start 4100). As experience is gained with the Turbo Start 4100, the user will be able to maximize the unit’s unique capabilities to enhance the flexibility of aircraft maintenance and support operations.
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) Front Vent/Cooling Fan Back Vent/Cooling Fan 3. CHECK DC POWER CABLE/CONNECTORS FOR DAMAGE - Check cable for cuts, chafing or evidence of being crushed.
4-7. 24 VDC GROUND POWER (WITH 208/240 VAC POWER) SYSTEM HIGH POWER DEMAND (101 amps and above) OR ENGINE STARTING. 1. TRANSPORT UNIT - The Turbo Start 4100 is easily transported using the wheels that are incorporate into the unit. The unit is engineered to be pushed rather than pulled. 2. CONNECT AC POWER CORD TO UNIT - Make sure that the On/Off switch is in the Off position. Ensure 208-240 Single Phase VAC 30AMP power cord is properly connected to an approved AC power supply.
4-8 28.5 VDC GROUND POWER (WITH 208/240 VAC POWER) SYSTEM LOW DEMAND (100 amps or less). POWER 1. TRANSPORT UNIT - The Turbo Start 4100 is easily transported using the wheels that are incorporated into the unit. The unit is engineered to be pushed rather than pulled. 2. CONNECT AC POWER CORD TO UNIT - Make sure that the On/Off switch is in the Off position. Ensure 208-240 Single Phase VAC 30AMP power cord is properly connected to an approved AC power supply.
CAUTION Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. Front Vent/Cooling Fan Back Vent/Cooling Fan 2. CHECK FOR FULL CHARGE INDICATION - After 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.
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 4100 is functioning within specific operational parameters prior to operational use. As users gain experience with the Turbo Start 4100, 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.
NOTE Under a full charge, the last green LED bar may blink. This does not indicate a malfunction. A non-blinking lighted green bar or a blinking green bar at the bottom of the LED column, both indicate a full charge. 7. CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS. power cells are fully charged (see step 6.) Ensure 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 required for use.
CHAPTER 5 PERFORMANCE DATA SECTION 1. INTRODUCTION 5-1. PURPOSE This chapter provides performance data for the TI4100GPU-24 (Turbo Start 4100). 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.
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. Derived From Actual Controlled Testing. obtained on a similar unit type. Controlled test data b. Calculated Data. Data based on tests, but not on a similar unit type placed under a controlled test. c. Estimated Data.
FIGURE 5-1 5-3
TI41000GPU-24 OUTPUT VOLTAGE 24 OUTPUT VOLTAGE 20 16 12 8 4 0 0 10 20 30 40 MINUTES 23 AMP CONSTANT CURRENT LOAD FIGURE 5-2 5-4 50 60
MAXIMUM OUTPUT CURRENT *** 1500 1350 **** 0 ** ** (+25 C Temp) 1200 * *** 1050 ***** ***** AMPS 900 750 * * ***** 600 0 ********* (-29 C Temp) 450 ***** ********** **** 300 150 0 0 5 10 15 20 SECONDS Calculations based on actual test data at Pratt-Whitney Canada on 30 March 1992.
CHAPTER 6 CARE AND MAINTENANCE SECTION I. 6-1. UNIT CARE GENERAL Although the TI4100GPU-24 (Turbo Start 4100) 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.
SECTION II. MAINTENANCE 6-3. MAINTENANCE OF UNIT - The Turbo Start 4100 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.
Chapter 8 ON/OFF SWITCH General Information And Operation 7-1. General The TI4100GPU-24 comes equipped with an On/Off switch on the face plate, This switch controls AC power input only, It does not control the DC output power to the aircraft, Whenever the unit is plugged into an aircraft, it is supplying DC power, The ON/OFF switch located on the face plate does not have any control on the DC output power funtion 8-2. OPERATION 1) Place the On/Off switch in the Off position.
PARAGRAPH INDEX 208-240 VAC Charger and AC to DC Converter Limits, 3-4 24 VDC Ground Power (NO 208-240 VAC Power Supply) Engine Starting or DC system Power, 4-6 24 VDC Ground Power (With 208-240 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 On/Off Switch General, 8-1 On/Off Switch Operation, 8-2 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 Cond
