Tesla Portable Generator TI4100 GPU 24 User Manual

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TABLE OF CONTENTS

TITLE

Page

1-1

2-1

2-2

3-1

4-1

4-2

4-5

5-1

5-2

6-1

6-2

7-1

8-1

Index 1

CHAPTER 1

CHAPTER 2

Section I

Section II

CHAPTER 3

Section I

Section II

CHAPTER 4

Section I

Section II

INTRODUCTION

UNIT DESCRIPTION AND OPERATION

Unit

Description

OPERATING LIMITS AND RESTRICTIONS

General

Operational Restrictions and Safety Limits

OPERATING PROCEDURES

Unit Operation

Operating Procedures

Section III Functional Check Procedures

CHAPTER 5

Section I

Section II

CHAPTER 6

Section I

Section II

CHAPTER 7

Section I

Section II

CHAPTER 8

Section I

Section II

INDEX

PERFORMANCE DATA

Introduction

Data Criteria

CARE AND MAINTENANCE

Unit Care

Maintenance

Push to Test

General

Operation

On/Off Switch

General

Operation

LIST OF ILLUSTRATIONS

Figure

2-1

Title

Page

2-3

2-4

5-3

5-4

5-5

Dimensions

2-2

General Details

5-1

Temperature Conversion Chart

Discharge Load Curve

Maximum Output Current

5-2

5-3

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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 criti-

cal 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 proce-

dures for the TI4100GPU-24 (Turbo Start 4100) ground power unit. The

Turbo Start 4100 is intended to provide DC electrical ground power

for aircraft flight line 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 sup-

port for ground maintenance, avionics/electrical trouble shooting and

testing. The observance of procedures, limitations and performance

criteria is essential to ensure peak operating efficiency and to

maximize operational capabilities and life of the Turbo Start 4100

ground power unit.

1-1

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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.

Unless otherwise indicated, the following list of abbreviations and

symbols are used in this manual:

LIST OF ABBREVIATIONS AND SYMBOLS

Abbreviation

Definition

Ampere

amp

Alternating Current

Celsius

cont

Continuous

Direct Current

Fahrenheit

Feet

FWD

GPU

Forward

Ground Power Unit

Hour

Hertz

Kilograms

Kilowatts

Degree

LED

MAX

MIN

VAC

VDC

Light Emitting Diode

Maximum

Minimum

Volts, Alternating Current

Volts, Direct Current

Explosion Hazard Potential

Shock Hazard Potential

Guard from moisture

Guard from incorrect power source

1-2

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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 ac-

ceptable method of accomplishment.

1-3

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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, por-

table 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. These built-in features give the Turbo

Start 4100 self-sufficiency and mobility for short-term operations without AC

electrical power or long term operations with AC electrical power. Short

term operations rely solely on power cell output and the fast recharge rates

that the unit’s internal charger provides from any standard 208-240 single

phase VAC electrical outlet. Longer term operations incorporate the continu-

ous 100 amp output of the 208-240 VAC to 28.5 VDC converter, or a combination

of converter and power cell output to provide 24 VDC output. The following

are the unit’s four (4) main operational support capabilities:

a. 24 VDC 1500 amp peak power output for engine starting or constant (one

hour) rated power output (without a 208-240 VAC power source) for short term

trouble shooting and flexible flight line support ground power.

b. 24 VDC constant (one hour) rated power output or variable high load de-

mand output (less than one hour) with a 208-240 single phase 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 208-

240 VAC power source for hangar and routine flight line maintenance support,

and avionics bench testing.

d. Rapid recharge of the unit’s power cells from any 208-240 VAC common

power source. This feature eliminates the need for special recharge equip-

ment and dedicated maintenance support man-hours.

2-1

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SECTION II DESCRIPTION

2.2. GENERAL SPECIFICATIONS

WEIGHT

UNIT:

100 lbs (50.39 Kg)

8.5 lbs (3.86 Kg)

0.4 lbs (0.18 Kg)

DC POWER CABLE:

AC POWER CORD:

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.

POWER CELLS:

PEAK OUTPUT:

24 VDC

1500 AMPS

POWER CELL

DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE

DC POWER CABLE

LENGTH: 8 FT

AIRCRAFT CONNECTOR: 3 PIN RECEPTACLE (MS25488)

AC POWER CORD: 8 Ft. 208-240 Single Phase VAC

2-2

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UNIT DISCRIPTION AND DEMENTIONS

2-3

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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 TI4100GPU-

24 (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. Com-

pliance with these limitations and restrictions will ensure that own-

ers/operators obtain maximum continued capability from the Turbo

Start 4100 ground power unit.

SECTION II. OPERATIONAL RESTRICTIONS AND SAFETY LIMITS

3-3. POWER CELL RECHARGE LIMITS

Any time the unit’s power cells are discharged the unit shall be

recharged within 24 hours to prevent performance degradation and en-

sure maximum life.

CAUTION

This unit is set up to recharge off of 208-240 Single Phase 50/60 Hz

VAC Power. Any other type of AC power may cause damage to the unit.

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 TURBO START internal charger and the AC power cord furnished with

the equipment, or when connected aircraft external DC power recep-

tacle.

3-1

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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 para-

graph 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 standby mode,

monitor the power cells state of charge, and only charge the power

cells to ensure they stay at maximum 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 con-

verter power output is no longer required. Once DC power demand

is terminated the unit’s intelligent charger will remain on line to

ensure power cells are charged to maximum capacity.

CAUTION

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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 Turbo Start 4100 is supplied with a single cus-

tomer specified AC power cord.

3-2

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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 ground-

ing mechanism.

3-6. ONE (1) HOUR RATE, 24 VDC CONSTANT OUTPUT

23 amp hour (without AC power connected), power cell output.

(see Figure 5-2)

123 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

discharge rate will increase correspondingly.

3-7. RATED PEAK OUTPUT (ENGINE STARTING)

1500 peak amps at 25 C (77 F) (See Figure 5-3).

3-3

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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. ENGINE STARTING POWER

Operators should always ensure the unit is charged above 80% prior to

ground support engine starting. However, circumstances may exist

during use where unit recharge is not readily available and immediate

external engine starting power is required. The following provides

minimum states of charge necessary to provide ample power for an ef-

ficient engine start under specific current load demands.

ENGINE START CURRENT LOAD DEMAND

Under 650 peak starting amps

MINIMUM CHARGE

40% charged

650-850 peak starting amps

850-1000 peak starting amps

1000-1200 peak starting amps

1200-1500 peak starting amps

50% charged

60% charged

70% charged

80% charged

3-10. TEMPERATURE

Temperatures refer to the unit’s cold/heat soaked temperature. A

unit’s cold/heat soaked temperature shall be established by the ambi-

ent temperature that a unit is exposed to for one (1) hour or more.

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 +10C (+41 F) or 2

hours above +20C (+68 F); WARMED SOAKED, cooled for 1 hour below

+38C (+100 F).

Operating range:

without AC power -40C (-40 F) TO +60C (+140 F)

with AC Power

-30C (-22 F) TO +50C (+124 F)

Storage range:

-60C (-76 F) TO +60C (+140 F)

(C0NTINUED ON NEXT PAGE)

3-4

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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

208-240 VAC functions (charger and converter) until unit cools to

normal operating temperatures.

3-11. ENVIRONMENTAL

Operating any electrical equipment in the presence of moisture cre-

ates possible safety hazards and/or potential for equipment damage.

Every effort has been made, within the scope of existing technology

to prevent foreseeable safety hazards and make the Turbo Start 4100

moisture resistant to prevent damage or failure. If the Turbo Start

4100 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 out-

let cooling fan vent ports

The limits and operational constraints listed below shall apply for

the following environmental (weather) conditions:

Heavy or steady rain: OPERATION NOT RECOMMENDED

Light rain, drizzle: NO CONVERTER OR CHARGER 208-240 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

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WARNING

********SHOCK HAZARD POTENTIAL*********

Severe injury, or Death, from electrical shock is possible when per-

sonnel 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 sus-

pected. DO NOT USE until unit’s exterior and receptacles are dried.

Operation shall be restricted to use without 208-240 power cord. DO

NOT CONNECT 208-240 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

208-240 AC power is used. Unit shall be

kept horizontal during use.

3-12. OPERATING POSITION

Without 208-240 VAC power cord: Horizontal or vertical.

With 208-240 VAC power cord: Horizontal only.

Horizontal only, for proper unit ventilation, when 208-240 VAC line

cord is plugged in and exhaust fan is running.

CAUTION

Unit may be damaged if blown over by propeller, rotor or jet wash, or

accidentally knocked over. Unit should be kept horizontal during

use.

3-6

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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

Back Vent/Cooling Fan

3-13. 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.

WARNING

*******FIRE/EXPLOSION HAZARD POTENTIAL********

Severe injury, or Death, may occur from fire or explosion, as a

result of electrical sparks produced near fuel vapors.

3-7

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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. 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, Sec-

tion II, OPERATING LIMITS AND RESTRICTIONS, for detailed information.

4-3. PERFORMANCE

Refer to Chapter 5, PERFORMANCE DATA to determine the capability of

the Turbo Start. Consideration must be given to changes in perfor-

mance resulting from variations in ambient temperature, mode of op-

eration, state of charge (with or without 208-240 VAC power), and

aircraft DC bus system inefficiency (voltage drops).

4-1

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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 capabili-

ties to enhance the flexibility of aircraft maintenance and support

operations.

NOTE

When the TURBO START 4100 is not in use, it should always remain

plugged into a suitable AC power source to insure operational readi-

ness at all times. 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!

4-5. BEFORE OPERATION CHECK

1. CHECK UNIT FOR STATE OF CHARGE- Ensure power unit is connected to

a suitable AC power source (208-240 Single Phase VAC 30AMP max out-

let). The LED status indicator should show a single green bar ( last

LED bar ) to indicate the unit’s power cells are fully charged.

NOTE:

A full charge is indicated by Either a steady lighted green bar or a

blinking green bar at the bottom of the bar graph column The fan will

also exhibit ratcheting but will not come on when the unit is fully

charged.

STATUS

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.

4-2

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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. Check connectors for

cracks, cuts, distortions, excessive wear, broken/loose fasteners or

loose cable attachment.

4-6. 24 VDC GROUND POWER (NO 208-240 VAC POWER SUPPLY) ENGINE START-

ING OR DC SYSTEM POWER

1. TRANSPORT UNIT - The Turbo Start 4100 is easily transported using

the wheels that are incorporated into the unit. The unit is engi-

neered to be pushed rather than pulled.

2. CONNECT DC POWER CABLE TO UNIT - Ensure power cable connector is

fully seated into unit’s connector. Set the unit down horizontally

ensuring vent ports are unblocked.

3. CONNECT DC POWER CABLE TO AIRCRAFT - Ensure ground power

cable connector is fully seated into aircraft ground power recep-

tacle. DC bus power should come on and aircraft volt meter should

indicate 24 VDC to 23.5 VDC (23 VDC minimum).

4. ENGINE STARTING - Check power cable for security and correct

installation prior to engine start. Follow ground power engine

starting procedure as specified in aircraft operators manual.

5. REMOVING DC POWER SUPPLY FROM AIRCRAFT

a. Switch the ON/OFF switch to the OFF position

b. Remove DC power cable GPU connector from aircraft.

c. Remove DC power cable connector from Turbo Start (if necessary).

4-3

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4-7. 24 VDC GROUND POWER (WITH 208/240 VAC POWER) SYSTEM HIGH POWER DE-

MAND (101 amps and above) OR ENGINE STARTING.

1. TRANSPORT UNIT - The Turbo Start 4100 is easily transported us-

ing the wheels that are incorporate into the unit. The unit is engi-

neered 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. Unit shall

be in Horizontal position to ensure unit’s vent ports are free from

blockage. After approximately 5-8 seconds, unit’s LED status indica-

tor will illuminate indicating power cells state of charge. Cooling

fan will operate. Ensure LED status indicator and cooling fan are

operational prior to continuing to step 3.

NOTE

THE ON/OFF SWITCH CONTROLS THE AC POWER INPUT. IT DOES NOT CONTROL

THE DC POWER OUTPUT. IF YOU PLUG THE UNIT INTO AN AIRCRAFT WITH THE

AC ON/OFF SWITCH IN THE OFF POSITION, THE UNIT WILL STILL PROVIDE

24VDC POWER TO THE AIRCRAFT.

3. CONNECT DC POWER CABLE TO UNIT - Ensure power cable connector is

fully seated into unit’s receptacle.

4. CONNECT DC POWER CABLE TO AIRCRAFT - Connect to aircraft ground

power receptacle. DC bus power should come on and aircraft volt

meter should indicate 27.5 VDC to 23.5 VDC (23 VDC minimum).

5. MOVE THE ON/OFF SWITCH TO THE ON POSITION - After approximately

2-3 seconds, the unit’s LED bar status indicator will illuminate,

indicating the power cells state of charge. The cooling fans will

operate. Ensure the LED status indicator and cooling fans are opera-

tional. At this time the unit can provide 100 amps at 28.5 VDC. If

the current demand is above 100 amps, the output voltage will de-

crease and two or more LED status indicator bars will illuminate.

NOTE

When all LED status indicator bars illuminate, both the converter and

power cells are supplying 24 VDC power output for current demands

above 101 amps (see paragraph 3-4).

6. ENGINE STARTING - UNPLUG AC POWER CORD BEFORE STARTING

ENGINE WITH TURBO START. (see paragraph 4-6.). Prior to engine

start, ensure power cell charge is sufficient to provide an efficient

engine start (see paragraph 3-7).

7. REMOVING DC POWER SUPPLY FROM AIRCRAFT

a. Switch the ON/OFF switch to the OFF position

b. Remove DC power cable GPU connector from aircraft.

c. Remove DC power cable connector from Turbo Start (if neces-

sary).

4-4

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4-8 28.5 VDC GROUND POWER (WITH 208/240 VAC POWER) SYSTEM LOW POWER

DEMAND (100 amps or less).

1. TRANSPORT UNIT - The Turbo Start 4100 is easily transported us-

ing the wheels that are incorporated into the unit. The unit is en-

gineered to be pushed rather than pulled.