'%()$)-&./ TI4676 !"#$%&'%()$&*+", Tesla Industries Inc. 109 CenterPoint Blvd. New Castle, DE 19720 (302)324-8910 Phone (302) 324-8912 Fax www.TESLAind.
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 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.(302)324-8910 FAX (302)324-8912 www.teslaind.
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 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.
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 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.
WARNING 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. Ὢ ὸὤή ὧὃ Ὡ ήὲὰ ὃ Ὤ ά ὦὲή ήὨ ὦί έ ὲὺὨ ήὃ ὶ ὲὸ ήὦὨ 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.
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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.
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 result of design analysis, testing, and operating experience.
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.
AC Line Cords North American Old British U.K Cont. Europe (more examples in appendix or call factory for information) 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.
3-8. 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 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) 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 120240 50/60 Hz AC 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 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 suspected. DO NOT USE until unit’s exterior and receptacles are dried. Operation shall be restricted to use without 120 or 240 power cord.
CAUTION Unit damage may occur if inlet and outlet vent ports are obstructed and/or cooling airflow is restricted. Back Vent 3-13. Side Vents Cooling Fan 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.
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 (ensure that the DC receptacle is oriented in the same position as the original battery). 3.
SECTION II. OPERATING PROCEDURES (cont.) 4-5. OPERATING PROCEDURES This section deals with normal procedures, and includes all steps necessary to ensure safe and efficient operation of the TI4676. As experience 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.
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.
CAUTION Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. 2. CHECK FOR FULL CHARGE INDICATION - After 1 HR 15 minutes, LED charge indicator should show a single steady 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 exhibit ratcheting but will not come on.
SECTION III. FUNCTIONAL CHECK PROCEDURES AND TROUBLE SHOOTING 4-8. FUNCTIONAL CHECK PROCEDURES This section deals with normal functional check procedures, and includes all steps necessary to ensure the TI4676 is functioning within specific operational parameters prior to operational use. As users gain experience with the TI4676, they will incorporate these functional checks as a routine practice. 4-9. REQUIRED EQUIPMENT FOR FUNCTIONAL CHECK. FLUKE OR EQUIVALENT TYPE DIGITAL MULTIMETER. 4-10.
7. CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS. cells are fully charged (see step 6.) Ensure power 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.
CHAPTER 5 PERFORMANCE DATA SECTION 1. INTRODUCTION 5-1. PURPOSE This chapter provides performance data for the TI4676. Continual reference to this information will enable the user to obtain maximum performance, utilization and service life from the TI4676. 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
TI4676MPU-24 OUTPUT VOLTAGE 24 OUTPUT VOLTAGE 20 16 12 8 4 0 0 10 30 20 40 MINUTES 23 AMP CONSTANT CURRENT LOAD FIGURE 5-2 5-4 50 60
MAXIMUM OUTPUT CURRENT 1500 * * ** 1350 **** 1200 * * ** * (+25 C Temp) 1050 * ** * * * **** * AMPS 900 * * * * ** 750 * ******* * 600 * * * * * ** * * * * (-29 C Temp) 450 * * * * * ** * * * 300 150 0 0 5 10 15 SECONDS Calculation based on actual test data at Pratt-Whitmey on 30 March 1992 FIGURE 5-3 5-5 20 25 30
CHAPTER 6 CARE AND MAINTENANCE SECTION I. 6-1. UNIT CARE GENERAL Although the TI4676 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 the aircraft or hanger.
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 50/60 Hz Abbreviations, VAC Charger and AC to DC Converter Limits, 3-4 1-5 AC Power Cord Limits, After Use, 3-5 6-2 Appendix A Line Cord Table Before Operation Check, 4-6 Continuous Output Rate, 28.
PARAGRAPH INDEX Index, 1-4 Installation, 4-1 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, 4-3 4-5 3-12 4-4 Power Cell Recharge, 4-7 Power Cell Recharge Limits, Purpose, Chapter 3, 3-1 Purpose, Chapter 5, 5-1 Push to test modification, 3-3 7-1 Rated Peak Output (Engine Starting), 3-7 Required Equipment for Functional Check, Specific Condi
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.
