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TI5400A 400Hz Manual - Tesla™ Industries Inc

1. Figure 4 17 1 Location of the Inverter On Off Figure 4 17 2 Inverter On Off Switch Switch outlined in blue 4 18 60 Hz 120 Vac Power Outlet and Circuit Breaker The 60Hz 120 Vac Power Outlet and Circuit Breaker are located on the top right of the GPU s side panel next to the Inverter Display Panel see figures 4 18 1 and 4 18 2 When the Inverter is active the Power Outlet will provide 120 Vac at 16 66 A continuous and up to 20 A peak for the 2 kW unit If the load exceeds 20 A the Inverter Output Circuit Breaker will trip Figure 4 18 1 Location of the 60 2 120 Vac Figure 4 18 2 60Hz 120 Vac Output Output and Circuit Breaker outlined in blue and Circuit Breaker TI5400A 400Hz GPU 24 UAV ACDC 21 4 Features Overview 4 19 Telescopic Handle The Telescopic Handle located on the bottom front of the GPU see figures 4 19 1 and 4 19 2 makes maneuvering the 115400A 400Hz GPU 24 UAV ACDC easy and a rubber grip allows the user to firmly grip the handle When the unit has been positioned the handle can be retracted to reduce the unit footprint Figure 4 19 1 Location of the Figure 4 19 2 Retractable Telescopic Telescopic Handle outlined in blue Handle 4 20 Run Flat Removable Tires The Run Flat Removable Tires located on the bottom rear of the 115400A 400Hz GPU 24 UAV ACDC see figure 4 20 1 and 4 20 2 make it easy to move the GPU When the unit has been positioned the tires can be quickly detached by
2. AA BERS ES UNS RRA RA NN ti Lj DIS eH a uS Lnd 10 m vec A WO Figure 4 5 1 Location of DVAM Figure 4 5 2 TI3100A DVAM 3100A outlined in blue 14 TI5400A 400Hz GPU 24 UAV ACDC Features Overview 4 4 6 DC Output ON and OFF Buttons The DC Output ON and OFF buttons are located directly above the 60 Hz AC Input Circuit Breaker see Figures 4 6 1 and 4 6 2 below To prevent arcing while connecting or disconnecting dc power plugs the 115400 400Hz GPU 24 UAV ACDC has been equipped with an internal contactor The ON button engages this contactor for safe transfer of power up to 3000 amps E m emm dee Figure 4 6 1 Location of the Figure 4 6 2 DC Output On and Off Buttons DC Output On and Off Buttons outlined in blue 4 7 DC Output Receptacle The DC Output Receptacle shown in Figures 4 7 1 and 4 7 2 will provide regulated 28 5 Vdc up to 400 amps when the unit is plugged into 3 phase power Up to 3000 peak amps are available via the internal cells Newer Units will be equipped with a Protective Cover When the Output Connector is not in use cover the receptacle with the Protective Cover This will protect the Output Connector from dust and foreign matter Woon NNN N VN WS 9 0 M4 NNN AAA NAN NN A RRR V VN at zz e 200046 th NV 0202022 Gm HH AG HH m N WO PEgeeegh
3. Power Anytime Anywhere Tesla TIS400A 400Hz GPU 24 UAV ACDC Ground Power Unit User Manual Built Smart Proven Tough Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www teslaind com NOTE All users must read this entire manual prior to operating the TIS400A 400Hz GPU 24 UAV ACDC The 15400 400Hz GPU 24 UAV ACDC is a maintenance free and sealed unit No internal repairs are authorized Warranty will be voided if any internal components are tampered with or if unauthorized repairs are made For technical support please contact TESLA INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 WEBSITE www teslaind com EMAIL tesla1 teslaind com WARNING Improper use or failure to follow instructions in this user manual can result in unit damage and or injury or death by electrical shock Any attempts to open or examine the inside of this unit via a tool or device borescope probe etc can result in unit failure and or injury by electrical shock This unit is maintenance free and should not be opened or disassembled for any reason Always protect the unit from short circuit Shipping Hazards NONE The 15400 400Hz GPU 24 UAV ACDC contains sealed dry cell rechargeable batteries There is no potential for toxic liquid or gas leakage No part of this manual may be
4. 1 1 Transient 1 l Surge I Protection I Soft Start i Circuit 60Hz AC 1 1 1 1 1 1 1 1 1 I 1 I 1 60 Amp Breaker 1 I 1 1 208 Vac 3 Phase e a 60Hz Input PFC Filter DC Filter 115400 400Hz GPU 24 UAV ACDC Filtered 3 Phase 400Hz Out to Aircraft Mii a ee LV MEL I Transient Surge 1 1 and Fuse l 1 Protection l 1 l Converter Boards O O 400 Amps Continuous 30 25 Vdc ie 115400 400Hz GPU 24 UAV ACDC J DVAM Digital Volt Amp Meter DC On Off Buttons Contactor DC Out to Aircraft Push To Test Button l I Batteries 46 Amp Hours 3000 Amps Peak 100 Amp I DC Circuit Breaker on Front Panel 1 Inverter 2kw Inverter Display Panel 20 Amp 1 Circuit Breaker 1 I 120 Vac 1 Outlet om m mi _3 Unit Specifications 000878 70 3 3 Physical Dimensions Imm 24 625 625 47 mm 21 533 40 mm 22 75 577 85 mm 50 1270 mm Figure 3 3 1 5400 400Hz GPU 24 UAV ACDC physical dimensions 3 4 Airflow Ports CAUTION When the T15400A 400Hz GPU 24 UAV ACDC is plugged into ac power the internal cooling system will efficiently regulate unit temperature regardless of load At room temperature 77 F the exhaust air will not exceed the ambient temperature by more than 5 F In more extreme temperatures greater than 90 F the exhaust air will not exceed the a
5. 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 Website www teslaind com Email Tesla1Oteslaind com CAUTION CAUTION Unplug both the 60Hz and 400hz AC Input Cables from power Additionally disconnect all output connections 400 2 AV Output DC Output 60Hz Inverter Outlet etc Checking Unit Internal Resistance Testing for Shorts It is essential to test for shorts to detect any problems with the GPU First set the digital multimeter to measure Q or resistance Next test to see if both terminals are isolated from the chassis ground and the line ground using the steps in Figure 8 2 2 In each case a reading of greater than 10 MO will assure no short exists 115400 400Hz GPU 24 UAV ACDC Unit Care and Maintenance 8 Testing the 400Hz AC Input Receptacle Touch the black lead of the multimeter to an exposed metal area on the chassis e g the telescopic handle frame Next touch the red lead of the multimeter to the neutral pin of the 400Hz AC Input Receptacle see figure 8 2 2 The multimeter should read zero less than 1 Q If this is not the case please contact Tesla for further instruction Figure 8 2 2 400Hz AC Input Receptacle Figure 8 2 3 Multimeter Reading Neutral pin under test Continuity good connection Testing between the 400Hz Neutral Pin and the DC Output Receptacle Keep the Red lead of the multimeter on the 400H
6. Push to Test button to verify that the power cells are fully charged see figure 8 2 4 Under a full charge the Capacity Meter will show a single green LED See Section 4 7 for more details TI5400A 400Hz GPU 24 UAV ACDC 39 amp Unit Care and Maintenance Checking DC Voltage at DC Output Receptacle Pins These tests are only necessary if the DVAM Digital Volt Amp Meter is not operational NOTE Before making a voltage measurement the DC Output ON Button needs to be turned on This will close the contactor and connect the power cells to the DC Output Receptacle Next set your digital multimeter to measure dc voltage Place the red lead of the multimeter on the positive post of the DC Output Connector marked with the symbol see figure 8 2 16 Next place the black lead on the negative post of the DC Output Connector marked with the symbol The multimeter display should read approximately 28 80 Vdc 0 05 Vdc while running on ac power with power cells fully charged see Figure 8 2 17 The multimeter display should read approximately 23 to 26 Vdc without ac power If unit is left charging after the batteries are fully charged the unit will enter a standby mode The voltage will drop from 28 80 to 28 26 volts When a load greater than 2 amps is applied the unit will return to normal operation Figure 8 2 16 Measuring voltage on DC Figure 8 2 17 Multimeter reading typical Output Receptacle power cell volt
7. or continuously between 0 30 and 0 10 inch per hour Light rain drizzle or sleet OK DC OPERATIONS ONLY Precipitation falling on a continuous basis between 0 10 inch and less than 1 50 inch 0 5 mm per hour Heavy or steady snow OK OPERATION NOT RECOMMENDED Generally meaning an accumulation between 4 inches and less than 1 inch in a 12 hour period Light snow OK DC OPERATIONS ONLY Snow falling intermediately with little or no accumulation Fog OK OK 115400 400Hz GPU 24 UAV ACDC Section 3 Unit Specifications 3 1 General Specifications Electrical DC Output Power e 3000 peak starting amps e 400 amp continuous 28 5 Vdc 11400 Watts when plugged into ac power 400 amp continuous 28 Vdc from end of TI2007 024 Cable 446 amp hours 12 424 watt hours with three phase ac power e 46 amp hours 1 024 watt hours of rechargeable battery power without three phase ac Rechargeable Rate e 12 minutes from full discharge with 208 240 Vac power three phase 25 C AC Input Power Operates and charges from either three phase 200 260 Vac 50 60 Hz or three phase 200 Y 115 Vac 400 Hz e 42 Amps 208 Vac 60 Hz 8 36 Watts e 75 Amps 200 Vac 400 Hz 1500 Watts e Requires 60 amp service for 50 60 Hz contact Tesla for receptacle information e Requires 100 amp service for 400 Hz contact Tesla for receptacle information 2 kW AC Inverter Inverter Operating Temperature e 1800 watts e 20 C t
8. 5 and one fan will activate The unit is now ready for normal operation NOTE If the unit is not fully charged after 30 minutes the power cells may need to be replaced Return the unit to Tesla for evaluation and maintenance 115400 400Hz GPU 24 UAV ACDC Section 6 Operating Procedures 6 1 Operating Overview The T115400A 400Hz GPU 24 UAV ACDC has three primary functions that will be discussed in this section 1 Providing 30 25 Vdc continuous regulated output power 2 powering aircraft systems and 3 power conversion via a convenient 120 Vac power outlet Step by step instructions will be given for performing each function 6 2 Regulated 28 5 Vdc Output Power WARNING WARNING The 400 Hz AC Input Circuit Breaker located on the top box of the GPU s front panel underneath a weatherproof cover see Figure 4 10 1 serves as the On Off Switch for the 400 Hz AC Input When activated it provides power to the GPU but does not have any effect on the 400 Hz 200 Y 115 Vac Output Filter To disconnect power from the 400 Hz AC Output refer to Section 4 15 under 400 Hz AC Output Circuit Breaker Checking Unit Charge State Press the Push to Test button and check the Charge Status Meter see figure 6 2 1 Only the green OK section of the Charge Status Meter should be lit See figure 6 2 2 signifying a minimum of 80 of full charge If the yellow or red sections of the charge status meter are lit the unit wil
9. Cart with a team of customer service professionals and a 2 year warranty The TI2000 155 features Run Flat or Pneumatic all terrain tires manual rear disc brakes tow handle with handle release front wheel steering via tow handle and four stainless steel compression draw latches to secure case to cart Figure 9 4 1 TI2000 155 Tow Cart 115400 400Hz GPU 24 UAV ACDC 43 section 10 Frequently Asked Questions 1 What are the advantages of owning a Tesla Ground Power Unit Tesla Ground Power Units are multi functional systems that are ideal for support of 24 Vdc vehicles and aircraft and their electronics avionics These units are available in different sizes and capacities are man portable maintenance free and provide pure dc power in a completely safe package Tesla GPUs are perfect for maintenance support at a main facility or in remote locations They will also provide 28 5 or 30 25 Vdc when the system is connected to the appropriate ac source Tesla GPUs are remarkably smaller and lighter than most ground power units on the market today They are safe for storage and for transport aboard an aircraft The technology can be upgraded on certain models And as always there are no HAZMAT or disposal issues with any of our GPUs 2 How does a Turbo Start work The Turbo Start combines state of the art power conversion electronics with our proprietary dry cell batteries The system s electronics incorporate an in
10. The multimeter should read nearly zero A broken connection will show an open circuit see Figure 11 1 3 Pins F and E are not in use Figure 11 1 1 400 2 3 Phase AC Plug Figure 11 1 2 400Hz 3 Phase Aviation Plug 46 TI5400A 400Hz GPU 24 UAV ACDC Troubleshooting 11 Continuity good connection Open Circuit bad connection Figure 11 1 3 Multimeter showing continuity and open circuit between connector pins Is the 400Hz 3 Phase AC cable good No Contact Tesla Industries Inc Yes Proceed to the next step Is the 400Hz AC Input Circuit Breaker on No Turn the breaker ON Yes Contact Tesla Industries nc The unit should power up automatically If the GPU is still not charging contact Tesla for further instructions The TI5400 GPU 24 is equipped with a charger temperature sensor that automatically disables AC and charging functions when the internal temperature reaches 150 F 65 C This protects the unit from overheating and damage If the unit shuts down move the unit into a cooler environment such as shade or air conditioning when possible Perform a full function test prior to use after the unit has been allowed to cool 2 When I plug in the GPU the Air Exhaust Fans do not turn on The internal cooling system of the 115400 GPU 24 has been designed to efficiently regulate unit temperature regardless of load If the fans are not on but the Capacity Meter displays a charge this may indicate
11. UAV Output Voltage N N O AR O N LLI x O gt a z O co 20 30 40 46 AMP CONSTANT CURRENT LOAD 12 5 1 Output voltage versus discharge time MAXIMUM OUTPUT CURRENT SECONDS Calculations based on actual test data at Pratt Whitney Canada on 30 March 1992 12 5 2 Maximum output current versus time 115400 400Hz GPU 24 UAV ACDC 12 6 Temperature Conversion Chart o i C 16 4 2 2 4 0 6 68 8 67 0 65 2 63 4 61 6 59 8 58 0 56 2 54 4 52 6 50 8 49 0 47 2 45 4 43 6 15 8 41 8 17 6 40 0 7 0 19 4 38 2 36 4 34 6 32 8 31 0 29 2 27 4 25 6 23 8 22 0 20 2 18 4 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 11 0 10 0 16 6 42 8 14 8 1 0 44 6 13 0 46 4 11 2 48 2 9 4 50 0 7 6 51 8 5 8 53 6 4 0 55 4 2 2 57 2 0 4 59 0 1 4 60 8 Sm 62 6 5 0 64 4 66 2 68 0 69 8 71 6 73 4 m 77 0 78 8 80 6 82 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 39 0 40 0 41 0 42 0 43 0 44 0 45 0 46 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 0 56 0 57 0 58 0 59 0 102 2 104 0 105 8 107 6 109 4 TI 113 0 114 8 116 6 118 4 120 2 122 0 123 8 125 6 127 4 1292 131 0 132 8 134 6 136 4 138 2 140 0 141 8 143 6 145 4 147 2 149 0 150 8 152 6 154 4 156 2 158 0 159 8 5
12. aircraft power cable a 25 ft DC aircraft cable with dc plug a 60 Hz extension cable a TI3100A DVAM a user manual and a limited two year warranty 13 Is the TIS400A 400Hz GPU 24 UAV ACDC waterproof The GPU is water resistant but not waterproof See Section 2 3 for further information 14 Are there any HAZMAT or disposal issues No Tesla will reclaim all battery cells for disposal Contact Tesla for more information 115400 400Hz GPU 24 UAV ACDC section 11 Troubleshooting 1 When I plug the GPU into AC power it does not charge While charging at least one green LED should be illuminated on the Charge Status Meter If this is not the case verify that the outlet has proper line voltage 60 Hz 3 phase AC power Is there ac line voltage at the outlet No Consult an electrician Yes Proceed to the next step Is the 60 Hz AC Input Circuit Breaker on No Turn the breaker ON Yes Contact Tesla Industries Inc The unit should power up automatically If the unit is still not charging contact Tesla Industries for further instructions 400 Hz 3 phase AC power at Filter Is there ac line voltage at the outlet No Consult an electrician Yes Proceed to the next step Verify that the 400 Hz 3 phase ac cable is good Disconnect the cable from both the GPU and ac power Set your multimeter to measure Q resistance and check continuity between the connector pins according to the chart see Figures 11 1 1 and 11 1 2
13. an On Off Switch for the 400 Hz AC Output When activated it provides power to the 400 Hz 200 Y 115 Vac Output up to 30 amps The Power Indicator will illuminate when 400 Hz power is present and the AC Output Circuit Breaker is set to ON Figure 4 15 1 Location of the Figure 4 15 2 400Hz Output Circuit 400Hz Output Circuit Breaker and Breaker and Power Indicator Power Indicator outlined in blue 4 16 Inverter Display Panel The Inverter Display Panel located on the top right of the GPU s side panel underneath a weatherproof cover see Figure 4 16 1 provides information about the DC input voltage and current levels as well as the amount of AC power going out see Figure 4 16 2 If either the 60 Hz AC Inverter Power Switch or the Inverter On Off Switch are switched OFF the Inverter Display Panel LCD will turn off indicating that the inverter is OFF Fe qq F Figure 4 16 1 Location of the Inverter Figure 4 16 2 Inverter Display Panel Display Panel outlined in blue 20 TI5400A 400Hz GPU 24 UAV ACDC Features Overview 4 4 17 Inverter On Off Switch The Inverter On Off Switch located on the top right of the GPU s side panel below the Inverter Display Panel see Figures 4 17 1 and 4 17 2 activates the internal circuitry of the Pure Sine Wave Inverter When switched to the ON position the LCD display will illuminate and the Power Outlet will provide 120 Vac at 15 amps continuous 1800 watts
14. on all sides and return it to Tesla at the address listed below Please contact Tesla Customer Service at 302 324 8910 with any questions or concerns TESLA M INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 Website www teslaind com Email Teslai teslaind com exc E o Tu NH Figure 8 4 1 Tesla TI5400 6 24 400Hz UAV ACDC Shipping Case Optional TI5400A 400Hz GPU 24 UAV ACDC 41 Section 9 Optional Accessories 9 1 Rain Dust Cover TI 000 083 The T15400 400 Hz GPU 24 UAV ACDC has an optional Rain Dust Cover to allow for safe operation in precipitation or in dust prone environments This heavy vinyl cover fastens with Velcro straps for a secure fit To order a Rain Dust Cover or any of the Tesla accessories shown here please contact Tesla Customer Service at 302 324 8910 Figure 9 1 1 Rain Dust Cover 9 2 Shipping Case TI 000 069 An optional shipping and storage case is available for the 115400 400 Hz GPU 24 UAV ACDC It is a reinforced hard case specifically designed to house the unit and unit accessories power cables manual etc The interior of the case and lid is lined with durable foam to protect the unit Additionally the lid is fitted with two locking mechanisms and recessed handles for easy shipping and transport Figure 9 2 1 Shipping Case 42 TI5400A 400Hz GPU
15. state see Figure 4 8 3 below Each LED indicates approximately 1096 of charge Additionally the display will act as a load status indicator under high power demands see Section 6 3 for more information STATUS STATUS STATUS Full Charge Half Charge No Charge Figure 4 8 3 LED Status Meter charge state 115400 400Hz GPU 24 UAV ACDC Features Overview 4 4 9 400 Hz AC Input CAUTION CAUTION The 5400 400Hz GPU 24 UAV ACDC comes equipped with a 3 phase 400 Hz 200 Y 115 Vac Input located above the front faceplate under a transparent weatherproof cover see Figures 4 9 1 and 4 9 2 This input receives a 400 Hz cable assembly that comes standard with the GPU and will connect to any 3 phase 400 Hz 200 Y 115 Vac receptacle Tun Figure 4 9 1 Location of the 400Hz Figure 4 9 2 3 phase 400 Hz AC Input AC Input outlined in blue 4 10 400 Hz AC Input Circuit Breaker The 400 Hz AC Input Circuit Breaker located on the top left of the GPU sfront panel underneath a vveatherproof cover see Figure 4 10 1 serves as the On Off Switch for the 400 Hz AC Input When activated it provides power to the GPU but does not have any effect on the 400 Hz 200 Y 115 Vac Output To disconnect power from the 400 Hz AC Output refer to Section 4 15 under 400 Hz AC Output Circuit Breaker AAA zw N SO Ww EEEE dill Mtm yi 2221 02000 AVIDI N D ACC 240 0006 00802020 4
16. the unit is still not putting out any voltage contact Tesla Industries for further instructions 6 The 400Hz AC Input is connected and the GPU is running but l m not getting any voltage from the 400Hz AC Output Receptacle The 400 Hz AC Output Receptacle is connected directly to the 400 Hz AC Input Receptacle via the 400 Hz Surge EMC Filter and 400 Hz Output Circuit Breaker As a result the user only needs to set the 400 Hz Output Circuit Breaker to transfer power Is the 400Hz Output Circuit Breaker set to the ON position No Turn on the 400Hz Output Circuit Breaker Yes Contact Tesla Industries Inc The 400Hz AC Output Power Indicator should illuminate indicating that the 400Hz AC Output Receptacle is live If the GPU is still not putting out any voltage and the Output Power Indicator is not lit contact Tesla Industries for further instructions 115400 400Hz GPU 24 UAV ACDC Troubleshooting 11 7 When I plug my device into the 60Hz 120 Vac Power Outlet don t get any power The 60Hz 120 Vac Power Outlet produces voltage directly from the power cells Therefore the 120Vac Outlet should function regardless of whether the GPU is plugged in Before proceeding make sure the batteries have a sufficient charge If the Power Outlet is not on verify that the 60Hz AC Inverter Power Switch is in the ON position The red LED next to the Inverter Power Switch should be on see figure 11 1 4 Is the 60Hz AC Inverter Pow
17. 24 UAV ACDC Optional Accessories 9 9 3 Customized Cables Tesla Industries can customize cables to cater to our customers specific needs Our connectors and cable assemblies are warranted for 2 years Custom cables and cable assemblies can be ordered through the Tesla Customer Service 9 4 Cobra DC Aviation Plug Replacement Contacts and Tools Cobra DC Plugs provide reliable high power connections up to 3000 amps even in the harshest conditions A rugged combination of advanced composite materials and corrosion resistant alloys make each plug maximized for durability and connectivity To extend the life of the Cobra connectors included with your unit replacement contacts posts noses and tools can be ordered through the Tesla Customer Service Figure 9 4 1 Cobra Aviation Figure 9 4 2 Cobra 400 Hz Figure 9 4 3 Cobra Aviation Plug Aviation Plug Plug Contact Replacement and Tools 9 5 Tow Cart The Tesla TI2000 155 is a custom stainless steel cart designed especially to hold Tesla s M TI5400 Series Storage Cases The cases can be secured directly to the cart making the TI2000 155 the safest way to support and transport any 115400 model out in the field and through hangars and flight lines You can operate the 115400 GPU without ever removing it from the cart simply remove the lid of the Storage Case for access to the entire unit And you can rest assured that Tesla stands behind the Tow
18. 400A 400Hz GPU 24 UAV ACDC is at least 20 feet 6 meters away from the nearest fueling source before connecting either the ac or dc plugs 115400 400Hz GPU 24 UAV ACDC _1 Safety Review 606060 09070 0 2 5 Extreme Environments CAUTION The TI5400A 400Hz GPU 24 UAV ACDC is equipped with a charger temperature switch that automatically disables ac and charging functions when the internal temperature reaches above 150 F 65 C This protects the unit from overheating and damage If the unit shuts down move the unit into a cooler climate such as shade or air conditioning when possible Perform a full function test prior to use after the unit has been allowed to cool See Section 3 5 for further information WARNING If the unit is exposed to moisture preventive measures and precautions shall be taken to A Prevent accumulation of moisture on ac and dc connectors receptacles B Minimize moisture entering forward inlet and aft outlet cooling fan vent ports Unit inlet and outlet vent ports shall be covered from exposure Unit shall be kept horizontal Recommendations include a Protective Rain Cover to guard the unit from moisture see Section 8 The limits and operational constraints listed below shall apply for the following environmental weather conditions Conditions VVithout Raincover Raincover Heavy or steady rain OK OPERATION NOT RECOMMENDED Precipitation falling vvith an intensity in excess of 0 30 inch 0 76 cm
19. 8 2 10 Multimeter Reading Open Circuit Dad connection 38 TI5400A 400Hz GPU 24 UAV ACDC Unit Care and Maintenance 8 Testing between the Chassis and the DC Output Receptacle Place the red lead of the multimeter on one of the DC Output Receptacle screws as shown in figures 8 2 11 and 8 2 13 Next touch the black lead of the multimeter to the negative pin of the DC Output Receptacle see figure 8 2 11 The meter should read about 2 0 MO see figure 8 2 11 Do the same for the positive pin see figure 8 2 13 The meter should read open circuit Shown in figure 8 2 10 Figure 8 2 11 DC Output Figure 8 2 12 Multimeter Reading Figure 8 2 13 DC Output Receptacle Negative Pin Nearly 2 0 MO good connection Receptacle Positive Pin Plugging in the Power Cable Be sure to use only Tesla approved power cables when connecting the GPU to an ac power source The 115400A 400Hz GPU 24 UAV ACDC comes with a built in 6 Hz AC Power Cable and detachable 400Hz AC Power Cable Before plugging in either cable set both AC Input Circuit Breakers to the OFF position Shown in figures 8 2 14 an 8 2 15 z r 4 aba REM S LY kt 4 r i d ue i Figure 8 2 14 400Hz AC Input Circuit Figure 8 2 15 60Hz AC Input Circuit Breaker Breaker set to OFF position set to OFF position Checking the Unit for Charge State After the unit has charged for at least 12 minutes the user should check the charge state Press the
20. 9 0 58 0 57 0 56 0 590 54 0 530 52 0 51 0 50 0 49 0 48 0 47 0 46 0 45 0 44 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 25 0 32 0 31 0 30 0 29 0 28 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 10 4 12 2 14 0 o i 5 0 4 0 3 0 2 0 1 0 23 0 24 8 26 6 28 4 30 2 32 0 33 8 35 6 37 4 39 2 41 0 61 0 62 0 63 0 64 0 65 0 1 0 2 0 3 0 4 0 67 0 68 0 x NO TI 70 0 71 0 Ol O o TI o Tl TRENT 600 760 59 0 7422 58 0 724 570 306 56 0 688 55 0 6670 54 0 652 53 0 634 52 0 616 510 59 8 50 0 58 0 _ 49 0 56 2 _ 480 544 470 526 460 50 8 45 0 490 440 47 2 43 0 454 42 0 43 6 410 418 40 0 400 39 0 382 38 0 364 370 34 6 _ 36 0 32 8 35 0 3310 34 0 292 33 0 274 32 0 25 6 _ 31 0 23 8 30 0 22 0 _ 29 0 20 2 _ 280 4184 Figure 12 6 1 Temperature conversion from Celsius to Fahrenheit 115400 400Hz GPU 24 UAV ACDC 53 Avionics Digital Multimeter Ground Fault Intelligent Recharging Memory Effect Monolithic Dry Cell Single Phase Power Lead Acid Battery UAV Glossary A combination of the words aviation and electronics avionics comprises electronic s
21. D Indicates unit is connected to 400 Hz power 3 400 Hz Interlock Fuse Protects internal Interlock circuitry from potential shorts in the 400 Hz Cable or external equipment 4 400 Hz AC Input Receptacle for 400 Hz 200 Y 115Vac 3 phase input power 5 400 Hz Input Circuit Breaker Protects the GPU from any power surges 6 Inverter Fan Provides active cooling for Inverter 7 Push to Test Button Displays current battery charge state when pressed 8 LED Charge Status Meter Indicates battery charge state power output status VANS KK NN 9 Air Inlet Fan Provides active cooling for internal components 10 60 Hz 3 phase AC Input Cable Used for 60 Hz 3 phase 208 240 Vac input power 11 DC Output Receptacle Provides output of 28 5 Vdc 400 A 3000 A peak 12 DC Output ON Button Engages the DC Output Receptacle 13 DC Output OFF Button Disengages the DC Output Receptacle 14 60 Hz AC Inverter Power Switch Enables Disables 120 Vac Inverter 15 DVAM Interface Receptacle Allows direct connection of Tesla DVAM 16 60 Hz Input Circuit Breaker Provides 60 Hz power to GPU 115400 400Hz GPU 24 UAV ACDC 1 3 TI5400A 400Hz GPU 24 UAV ACDC Side View 400 Hz Surge EMC Filter Filters 400 Hz input and ports to 400 Hz Output 400 Hz 200 Y 115 AC Output Provides output of 200 Y 115 Vac 30 A when active 400 Hz Output Circuit Breaker Enables disabl
22. Dau 294 ESEE VB L 028502020 0009 GE u ee m5 2 9 2 7 E G g gg G QQQ 220098 I A hOoOd a 8 Figure 4 10 1 Location of the 400 Hz AC Figure 4 10 2 400 Hz AC Input Circuit Input Circuit Breaker outlined in blue Breaker 115400 400Hz GPU 24 UAV ACDC 1 4 Features Overview Figure 4 10 3 Breaker Set to OFF Figure 4 10 4 Breaker Set to ON position position 4 11 400Hz Input Interlock Lamp The 400 Hz Input Interlock LED located on the top left of the GPU s front panel above the 400 Hz Input Circuit Breaker see Figures 4 11 1 and 4 11 2 illuminates when the 400 Hz AC Input Circuit Breaker is set to the ON position ul RERE 002090 2002904 2020209202 Figure 4 11 1 Location of 400 2 Input Figure 4 11 2 400Hz Input Interlock Lamp Interlock Lamp outlined in blue 4 12 400Hz Interlock Fuse The 400 Hz Interlock Fuse located on the top left of the GPU s front panel above the 400 Hz Input Circuit Breaker See Figures 4 12 1 and 4 12 2 protects the internal interlock circuitry from potential shorts in the 400 Hz cable or external equipment Lag RA ORAS Ne dilda i Kew X x It ym ORB 1122221 0020220 0006 2020202020 Su 77 W 2 77 1 22222 G 0 G Gg g og UQQOQQ Q QQ IIIEXxxXBZUI a 8 00000 Figure 4 12 1 Location of the 400Hz Figure 4 12 2 400 2 Interlock
23. Fuse Interlock Fuse outlined in blue 18 TI5400A 400Hz GPU 24 UAV ACDC Features Overview 4 4 13 400 Hz Surge EMC Filter The 400 Hz Surge EMC Filter located on the top center of the GPU s side panel see Figures 4 13 1 and 4 13 2 provides filtering for the 400 Hz Vac Output Connected directly to the 400 Hz ac Input the filter eliminates potentially harmful surges and high frequency noise and harmonics Figure 4 13 1 Location of the 400Hz Figure 4 13 2 400Hz Surge EMC Filter Surge EMC Filter outlined in blue 4 14 400 Hz 200 Y 115 Vac Output NOTE The 400 Hz AC Input must be connected to a power source to use the Output The 400 Hz 200 Y 115 Vac Output located on the top left of the GPU s side panel See Figures 4 14 1 and 4 14 2 provides filtered 400 Hz 200 Y 115 Vac at 30 amps Connected directly to the 400 Hz AC Input through a filtering circuit the output is not affected by the state of the 400 Hz AC Input Circuit Breaker Only the 400 Hz AC Output Circuit Breaker controls this output zz T ce l f ex Figure 4 14 1 Location of the 400Hz 200 Y Figure 4 14 2 400Hz 200 Y 115 Output 115 Vac Output outlined in blue 115400 400Hz GPU 24 UAV ACDC 19 4 Features Overview 4 15 400 Hz AC Output Circuit Breaker and Power Indicator The 400 Hz AC Output Circuit Breaker located on the top center of the GPU s side panel underneath a weatherproof cover see Figures 4 15 1 and 4 15 2 serves as
24. PU s life Therefore protect the unit from the elements and man made hazards whenever possible The TI 000 083 Rain Dust Cover is recommended in wet and dust prone environments and will add a level of protection to the internal circuitry See Section 9 under Optional Accessories Figure 7 1 1 115400A 400Hz GPU 24 UAV ACDC Figure 7 1 2 400Hz 3 Phase 200 Y 115 attached to a 3 Phase 60Hz 208 Vac outlet Vac 7 2 Power Cell Recharging The GPU has an intelligent recharging system that will enable it to rapidly recharge when connected to an ac power source If the unit s power cells become fully discharged the unit should be recharged within 24 hours to ensure maximum life and performance Under normal circumstances a minimum of 12 minutes will be required to fully recharge the unit Please refer to Section 5 1 under Unit Charging for more information 34 TI5400A 400Hz GPU 24 UAV ACDC Section 8 Unit Care and Maintenance 8 1 Unit Care WARNING CAUTION Avoid Prolonged Exposure to Extremely Damp Environments Be sure to disconnect ac power from ac source if the 115400A 400Hz GPU 24 UAV ACDC has come into contact with water If the AC Input Circuit Breaker has tripped due to water infiltration allow the unit to dry out before attempting to reset the circuit breaker Cover the unit to prevent water infiltration If the unit is operated in extremely damp condition it should be stored in an environmentally controlled building wh
25. Wie Je hM MW 82522222 000200208 foe e d A 18 4 4 4 5595 4 8 CS D gt BOGS 21 Pppp n 99 115 4520 OEE 2222BH OO0OQ0N g 22227 0 8x 09 X 55 5 55 54 2202000 222020 2222 Figure 4 7 1 Location of the DC Figure 4 7 2 DC Output Receptacle Output Receptacle outlined in blue 115400 400Hz GPU 24 UAV ACDC 15 4 8 Push to Test Button and LED Charge Status Meter The Push to Test Button see Figures 4 8 1 and 4 8 2 determines the load capacity of the power cells This allows the user to determine if there is enough power to perform an engine start or if the GPU needs to be recharged see GPU Charging under Section 5 1 Do not press the Push to Test button when either the ac or dc connections are made Wait 2 minutes after disconnecting both plugs to CAUTION ensure an accurate reading Do not hold the Push to Test button for more than 5 seconds This will trip a temperature sensor and disable the Push to Test function If this occurs allow 5 minutes for cooling before pushing the button again R 75 5 E AGE SS nm 4 x A LI m Figure 4 8 1 Location of the Push to Test Figure 4 8 2 Push to Test and LED and LED Status Meter outlined in blue Status Meter When attached to ac line voltage the Charge Status Meter gives a visual indication of the power cells charge
26. age with AC power Function Test Complete Once the 15400 400 HZ GPU 24 UAV ACDC has fully passed function test procedures the GPU should be plugged into ac power and remain plugged in until required for use 40 TI5400A 400Hz GPU 24 UAV ACDC Unit Care and Maintenance 8 8 3 Unit Servicing The 115400 400 HZ GPU 24 UAV ACDC is a maintenance free sealed unit No repairs except those found in section 8 5 are authorized outside of Tesla Warranty will be voided if unit is tampered with in any way including any damage to the WARRANTY VOID stickers located on the case see Figure 8 3 1 below If the unit requires maintenance other than those found in section 8 5 please contact Tesla Customer Service at 302 324 8910 A Repair Request Form can be found on the last page of this manual Figure 8 3 1 Warranty Void stickers on the front and back of unit 8 4 Packaging and Shipping Ensure proper packaging when returning the GPU The best method for transport is to utilize the optional 115400A 400 HZ GPU 24 UAV ACDC Shipping Case see Section 9 2 If the Shipping Case is not available pack the GPU in a box with at least 6 inches of clearance on all sides be sure to enclose the Repair Request Form To guarantee that the unit remains centered within the box do not use loose packing materials such as packing peanuts Instead wrap the unit tightly in foam or other dense material until it fits snugly in the box Seal the box
27. d with in any way including any damage to the WARRANTY VOID stickers located on the case Regardless we strongly recommend allowing Tesla to repair any unit as we will analyze the complete system and re calibrate it 9 How do I get my TI5400A 400Hz GPU 24 UAV ACDC serviced If the unit needs to be returned for repairs please contact Tesla Customer Service by phone at 302 324 8910 or by email at tesla1Gteslaind com and a representative will explain the return process For your convenience a Repair Request Form can be found at the back of this manual The form can also be found online at www teslaind com 10 What type of maintenance does the TI5400A 400Hz GPU 24 UAV ACDC require Although the unit is maintenance free it is recommended to keep the GPU plugged in when not in use This will greatly extend the life of the cells Keep unit in a well ventilated climate controlled environment while charging Always keep the vent areas clean and free of debris 50 TI5400A 400Hz GPU 24 UAV ACDC Section 12 Performance Data 12 1 Purpose This chapter provides performance data for the TIb400A 400Hz GPU 24 UAV ACDC This information will allow the user to obtain maximum performance and life from the unit Regular referral to this chapter is recommended to A Gain knowledge of the unit s performance characteristics to anticipate unexpected conditions or extreme operational requirements B Readily identify situations requiring maximum per
28. e The unit will not overcharge or overheat 5 2 Unit Charging Attaching AC Input Power Before operating the T15400A 400Hz GPU 24 UAV ACDC it is recommended to fully charge the unit The GPU can be plugged into either a 50 60 Hz 3 phase 208 240 Vac outlet see figures 5 2 1 or a 400Hz 3 phase 200 Y 115 Vac outlet see figure 5 2 2 as Figure 5 2 1 Hard wired AC Input cable Figure 5 2 2 400Hz 3 Phase 200 Y and 3 phase 60Hz AC input plug 115 Vac Turning on AC Power If the 3 Phase 60Hz AC Input is used the 60Hz 3 Phase AC Input Circuit Breaker must be set to the ON position see figure 5 2 3 Otherwise if the 400Hz AC Input is used the 400 2 AC Input Circuit Breaker must be set to the ON position see figure 5 2 4 Figure 5 2 3 60Hz AC Input Circuit Figure 5 2 4 400 2 AC Input Circuit Breaker set to the ON position Breaker set to the ON position TI5400A 400Hz GPU 24 UAV ACDC 25 Charging the Power Cells The Charge Status Meter will immediately show the current charge state of the power cells Make sure there are at least 2 to 3 inches of clearance in front of the Air Exhaust Fans to provide for sufficient ventilation If the GPU is completely discharged a minimum of 12 minutes will be required to fully charge the GPU LED and Fan Activity Initially several LEDs will be illuminated on the Status Meter see left image in figure 5 2 5 As the unit charges the LEDs will go out one b
29. e 400Hz AC Input Receptacle by lifting the protective cover and pushing the connector firmly into place see figure 6 3 3 Next connect the 400Hz Aircraft Plug from the aircraft to the 400Hz ac power source making sure that it is fully seated into the ac receptacle see figure 6 3 4 Figure 6 3 3 Connecting 400Hz power cable to Figure 6 3 4 Connecting 400Hz power 400Hz AC Input Receptacle cable to Aircraft 115400 400Hz GPU 24 UAV ACDC 29 Operating Procedures Attaching 400Hz AC Output Cable Attach the aircraft s ac input power cable to the 400Hz 200 Y 115 Vac Output Receptacle figure 6 3 5 by turning the circular cover counterclockwise and lifting it up Insert the ac input plug and push firmly into place Then lock the connector collar The cover will stay open once plug is in place Figure 6 3 5 400Hz AC Output Power Cable Figure 6 3 6 400 2 Output Power Indicator connected Connect the ac output power cable to the aircraft making sure that it is fully seated into the ac receptacle The unit is now ready to safely transfer power and will provide a clean source of 400Hz power via the 400Hz Surge EMC Filter Regardless of whether the 400 Hz input is being used to power the GPU the 400 Hz power is routed to the 400 Hz AC Filter Input to take advantage of the 115400A 400Hz GPU 24 UAV ACDC s advanced filtering technology Activating Deactivating the 400Hz AC Output When ready set the 400Hz Output Circuit Breaker to t
30. en not in use Keep Unit Plugged into AC Power Source When Not in Use To maximize the life of the power cells and to ensure that the unit is always ready for use periodically plug the unit into ac power There is no risk of damage from overheating or overcharging See Section 5 1 for more information Protect Cables from Damage Do not cut crush or drag the input or output power cables when handling the unit Always inspect cables prior to use If no damage is evident proceed to the next step If damage is evident contact Tesla Customer Service Do not attempt to use any other type of power cables other then the cables supplied with your unit 115400 400Hz GPU 24 UAV ACDC 8 2 Normal Function Test Procedures This section deals with normal function test procedures and includes all steps necessary to ensure that the 115400A 400Hz GPU 24 UAV ACDC is operating within specified parameters prior to every use A digital multimeter an example is shown in Figure 8 2 1 capable of measuring dc and ac voltage and resistance will be required to perform some of the tests These functional test procedures should become routine Check Unit for Evidence of Damage Check for dents punctures case distortion or misalignment and cracked or loose connectors If no damage is evident proceed to the next step If damage is evident contact Tesla Industries Inc Figure 8 2 1 Digital Multimeter TESLA INDUSTRIES INCORPORATED
31. er Switch On LED illuminated No Turn on the 60Hz AC Inverter Power Switch Yes Proceed to the next step Figure 11 1 4 60Hz AC Inverter Power Figure 11 1 5 Inverter Display Panel and On set to ON position LED illuminated Off Switch turned on and active Is the Inverter On Off Switch in the I position see figure 11 1 5 No Turn on the Inverter On Off Switch Yes Proceed to the next step Is the Inverter Display Panel LCD on see figure 11 1 5 No Contact Tesla Industries Inc Yes Proceed to the next step Is the Inverter Output Circuit Breaker tripped see figure 11 1 6 No Proceed to the next step Yes Push the breaker in to reset Is the 60Hz AC Power Outlet LED illuminated see figure 11 1 7 No Press the Reset button on the Outlet Yes Proceed to the next step 115400 400Hz GPU 24 UAV ACDC 49 11 Troubleshooting Figure 11 1 6 60Hz AC Output Circuit Figure 11 1 7 60Hz AC Power Outlet ON Breaker push to reset green LED illuminated If the green LED on the front of the 60Hz AC Power Outlet is illuminated the Outlet should be live If the LED does not light after pressing the Reset button contact Tesla Industries for further instructions 8 Can I make repairs to the unit During the warranty period the unit can only be repaired by Tesla Industries for the warranty to remain n effect No other repairs outside of Tesla are authorized Warranty will be voided if unit is tampere
32. es 400 Hz output 400 Hz Output Power Indicator Indicates that power is present at 400 Hz output 60 Hz 120 Vac Power Outlet Provides output of 120 Vac 15 A when active 115400 400Hz GPU 24 UAV ACDC Inverter Output Circuit Breaker Trips if Inverter output exceeds 20A Inverter Display Panel Indicates input voltage and current and output power Inverter On Off Switch Enables disables Inverter Output Telescopic Handle Allows easy transport and maneuvering of unit 10 Removable Run Flat Tires Solid foam rubber tire easily removable for replacement section 2 Safety Review 2 1 Safety Notices Safety notices appear throughout this manual to alert the user to important information regarding proper installation operation maintenance and storage of the unit These notices as illustrated below contain a key word that indicates the level of hazard and a triangular icon that indicates the specific type of hazard Indicates a condition operating procedure or practice which if not WARNING adhered to could result in serious injury or death Indicates a condition or operating procedure which if not strictl CAUTION y adhered to could result in damage or destruction of equipment Indicates a condition operating procedure or practice which is essential to highlight 2 2 Symbols The following symbols will appear within the warning triangles to alert the user to the speci
33. fic type of danger or hazard General Warning Electrical Hazard Explosion Hazard Fire Hazard Battery Warning Guard from Moisture Figure 2 2 1 Different types of hazard and caution symbols 115400 400Hz GPU 24 UAV ACDC 2 3 Hazards WARNING Severe injury or death from electrical shock may occur if either user or the unit is wet while the unit is connected to a power source If the unit has come into contact with water disconnect ac power from the ac source If AC Input Circuit Breaker has tripped due to water infiltration DO NOT try to reset it with the ac line voltage attached WARNING Severe injury or death from electrical shock can occur when damp electrical plugs are connected to the unit Before making any connections turn off unit Failure to use proper grounding can cause potential shock hazard In different countries the power cord may require the use of a plug adapter to achieve plug style compatibility for operation Use only adapters with proper grounding mechanism Figure 2 3 1 Proper plug for 60 Hz three phase 2 4 Important Safety Precautions WARNING Severe injury or death from fire or explosion can occur if electrical sparks are produced near fuel vapors DO NOT CONNECT TO A POWER SUPPLY WHILE FUELING 120 240 Vac Power charger or inverter functions of unit shall not be operated during any fuel handling operation Power output is restricted to 24 Vdc power only Make sure the TI5
34. formance The information provided in this chapter is most useful when anticipating operations under unknown conditions or environmental extremes The data can also be used to establish local operating procedures and to maximize the unit s life 12 2 Explanation of Data The data presented covers the full range of operating conditions and expected performance In each area of performance temperature effects and dc electrical load demands in relation to ground power support requirements are presented In some cases data is presented conservatively In all cases performance data presented is within the applicable limits of the T15400A 400Hz GPU 24 UAV ACDC Any attempt to exceed maximum recommended limits may cause the unit to malfunction and may cause permanent damage 12 3 General Conditions In addition to the specific conditions the following general condition is applicable to the performance data Variations in Aircraft Power demand differences between individual aircraft of the same make and model are known to exist due to variations in dc electrical system efficiency These differences however are considered insignificant and are not accounted for individually 12 4 Definition of Abbreviations Unless otherwise indicated the abbreviations defined in the beginning of this manual will be applicable to all charts and graphs in this chapter 115400 400Hz GPU 24 UAV ACDC 12 5 Performance Graphs TI5400A 400Hz GPU 24
35. he ON position The 400Hz Output Power Indicator Lamp should illuminate as illustrated in figure 6 3 6 If the user only needs 400 2 power out through the filter it is not necessary to activate the 400Hz Input Circuit Breaker The Filter works independently of the Main input Circuit Breaker Setting this breaker to the ON position will provide power to the GPU but it does not affect the transfer of power to the 400Hz AC Output Receptacle Disconnecting the 400Hz AC Input and Output When power is no longer needed make sure to set the 400Hz Input and Output Circuit Breakers to the OFF position before disconnecting any plugs refer to figures 6 3 1 and 6 3 2 The 400Hz AC Output Power Indicator should turn off After confirming that the 400 2 AC Output is OFF the user can safely proceed to disconnect the cables 30 TI5400A 400Hz GPU 24 UAV ACDC Operating Procedures 6 6 4 60Hz 120 Vac Power Outlet Enabling the 60Hz 120 Vac Power Outlet To activate the 60Hz 120 Vac Power Outlet first set the 60Hz AC Inverter Power Switch to the ON position see figure 6 4 1 This provides power directly from the internal cells to the Pure Sine Wave Inverter If the batteries are charged the LED next to the 60Hz AC Inverter Power Switch LED will illuminate as shown in figure 6 4 1 Next set the Inverter On Off switch to the I position Initially the screen on the LCD Display will indicate the input voltage outp
36. input plug shown in Figure 4 1 1 and a 25 foot 60 Hz 3 phase ac extension cable see Figure 4 1 2 This cable is used to plug the GPU into 3 phase 208 240 Vac 50 60 Hz power Only the Tesla ac cables and plugs provided should be used to plug the unit into ac power When the plug is not in use it can be secured by a Velcro strap located at the back of the GPU see Figure 4 1 3 To order a replacement ac input cable or plug please contact the Tesla Customer Service at 302 324 8910 Figure 4 1 2 3 phase ac cable extension Figure 4 1 3 AC plug Velcro strap standard with unit 12 TI5400A 400Hz GPU 24 UAV ACDC Features Overview 4 4 2 60 Hz 3 Phase AC Input Circuit Breaker The 3 phase 60Hz ac input circuit breaker is located at the center bottom of the GPU s front panel See Figures 4 2 1 and 4 2 2 It is also used as an On Off Switch for powering the GPU S AAA AAA NA mm SX Ite El c ui s My we LI ds vx x i s xt ea Figure 4 2 1 Location of the 60Hz Figure 4 2 2 3 phase 60 Hz Input Circuit 3 Phase AC Input Circuit Breaker Breaker outlined in blue 4 3 Inverter Input Power Switch The 60 Hz AC Inverter Power Switch located at the bottom center of the T15400A 400Hz GPU 24 UAV ACDC s front panel see Figures 4 3 1 and 4 3 2 connects the ac inverter directly to the internal cells providing 120 Vac 60 Hz power The LED next to the switch illuminates when the swi
37. ire Special Fire Fighting Procedures If batteries are on charge shut off power Use positive pressure self contained breathing apparatus Water applied to electrolyte generates heat and causes it to spatter Wear acid resistant clothing gloves face and eye protection Note that strings of series connected batteries may still pose risk of electric shock even when charging equipment is shut down Unusual Fire and Explosion Hazards Highly flammable hydrogen gas is generated during charging and operation of batteries To avoid risk of fire or explosion keep sparks or other sources of ignition away from batteries Do not allow metallic materials to simultaneously contact negative and positive terminals of cells and batteries Follow manufacturer s instructions for installation and service VI PRECAUTIONS FOR SAFE HANDLING AND USE Spill or Leak Procedures Stop flow of material contain absorb small spills with dry sand earth and vermiculite Do not use combustible materials If possible carefully neutralize spilled electrolyte with soda ash sodium bicarbonate lime etc Wear acid resistant clothing boots gloves and face shield Do not allow discharge of unneutralized acid to sewer Acid must be managed in accordance with local state and federal requirements Consult state environmental agency and or federal EPA Handling Unless involved in recycling operations do not breach the casing or empty the contents of the batter
38. l not provide the maximum rated output current Each LED indicates approximately 1096 of charge See Section 3 5 for further information regarding minimum charge times versus output current capability STATUS STATUS 2 Full Charge No Charge Figure 6 2 1 Push to Test and Status Meter Figure 6 2 2 Charge Status Meter Do not press the Push to Test button when either the ac or dc connections are made Wait 2 minutes after disconnecting both plugs to ensure an accurate reading Do not hold the Push to Test button for more than 5 seconds This will trip a temperature sensor and disable the Push to Test function If this occurs allow 5 minutes for cooling before pushing the button again 115400 400Hz GPU 24 UAV ACDC 6 Operating Procedures Disabling DC Output Receptacle To prevent potential arcing and connector damage press the DC Output OFF button to ensure that the DC Output Receptacle is disabled The ON button should not be illuminated see figures 6 2 3 and 6 2 4 Figure 6 2 3 DC Output OFF Figure 6 2 4 DC Output ON and Switch is Illuminated Attaching DC Plug Cable Assembly Attach the DC Output Connector to the DC Output Receptacle by pushing the connector into place and turning the T handle on the connector clockwise until it locks See figure 6 2 5 Next attach the DC Aviation Plug to the aircraft making sure that it is properly seated in the DC Receptacle Consult the aircraft s operator manual fo
39. mately 6 to 8 starts before it needs to be plugged in to an ac power source for recharging 115400 400Hz GPU 24 UAV ACDC 7 How long does this unit stay charged When not plugged into an AC power source the GPU will retain 8096 of its capacity after one year of storage However the GPU should never be allowed to fully discharge 8 How do I check the status of the charge Press the Push To Test button on the unit s faceplate A fully charged unit will have one green LED light showing See Section 5 3 for further information 9 Why does my LED flicker when the unit is plugged in Under a full charge some units will show a single pulsating green LED See Section 6 2 under GPU Charging for more information 10 Why does the cooling fan run continuously when the TI5400A 400Hz GPU 24 UAV ACDC is connected to ac power Why does the cooling fan slow down The cooling fan speed varies to regulate the temperature of the internal circuitry when plugged into an ac power source 11 How do you prolong the life of the TIS400A 400Hz GPU 24 UAV ACDC s power cells Plug the GPU into an ac power outlet when not in use Users who periodically plug the unit into ac power can expect to get approximately 5 to 7 years from their cells before replacement See Section 7 1 for more information about general care and maintenance 12 What is included with my TI5400A 400Hz GPU 24 UAV ACDC The GPU comes with a Tesla approved 400 Hz
40. mbient temperature by more than 10 F Figure 3 4 1 Air intake and exhaust ports and internal air circulation 115400 400Hz GPU 24 UAV ACDC 3 5 Engine Starting Power The user should always ensure that the unit has been charged to at least 80 of full charge see Section 5 2 under Unit Charging prior to ground support engine starting However in certain circumstances a full unit recharge may not be possible and immediate external engine starting power is required The following chart provides minimum states of charge necessary to provide ample power for an efficient engine start under specific current load demands Each LED on the Charge Status Meter indicates approximately 1096 of charge Of Full Charge 40 5096 6096 80 100 Charge Time min 5 1 3 9 25 11 5 12 Peak Current amps 1300 1300 1700 1 00 2000 2400 3000 3000 Figure 3 5 1 Engine starting power in amps versus percentage of battery charge 27 25 23 21 Output Voltage 19 17 15 0 5 10 15 20 25 30 35 40 45 50 55 60 Discharge time minutes as 5Min Charge 7 5 min charge 9 25 min charge 11 5 min charge 12 min charge Figure 3 5 2 Discharge time versus charge time 115400 400Hz GPU 24 UAV ACDC Section 4 Features Overview 4 1 3 Phase 60 Hz AC Input Cable Assembly and Cable Extension CAUTION CAUTION The 115400 400 Hz GPU 24 UAV ACDC is outfitted with a hard wired 7 foot ac input cable with a 60 Hz 3 phase ac
41. mperature above 20 C 68 F for 2 hours For HOT SOAKED temperature stabilization the unit must be placed in an environment with a temperature below 38 C 100 F for 1 hour Ambient Percentage of Temperature Cell Capacity Figure 5 1 1 Cell storage capacity versus ambient temperature Hot Soaked or Cold Soaked Definition Simple terms When a material is exposed to a change in temperature its temperature will also change Some material changes temperature quickly others slowly If the ambient temperature changes and is then held constant the materials temperature will also change until its temperature stabilizes Once the material temperature has stabilized it is considered soaked Example A unit is moved from the cool shade into the hot sun That unit s temperature will increase until it stabilizes Once stabilized the unit would be considered hot soaked The unit s temperature switch automatically disables ac power functions when the internal temperature is above 150 F 65 C This protects the unit from overheating and damage If the unit shuts down move the unit into a cooler climate such as shade or air conditioning when possible Perform a full function test prior to use after the unit has been allowed to cool 115400 400Hz GPU 24 UAV ACDC Pre Operation Procedures 5 Plug the TI5400A 400Hz GPU 24 UAV ACDC into ac power to keep the cells charged whenever it is not in use even if it is at Full Charg
42. nd sulfuric acid electrolyte are the primary components of every battery manufactured by Tesla Products There are no mercury or cadmium containing products present in batteries manufactured by Tesla Products Form SDS 853027 Revised 05 14 15 Supersedes NEW ECO 1001584 SAFETY DATA SHEET IV FIRST AID MEASURES Sulfuric Acid Remove to fresh air immediately If breathing is difficult give oxygen Consult a physician Lead Remove from exposure gargle wash nose and lips consult physician Ingestion Sulfuric Acid Give large quantities of water do not induce vomiting or aspiration into the lungs may occur and can cause permanent injury or death consult a physician Lead Consult physician immediately Sulfuric Acid Flush with large amounts of water for at least 15 minutes remove contaminated clothing completely including shoes If symptoms persist seek medical attention Wash contaminated clothing before reuse Discard contaminated shoes Lead Wash immediately with soap and water Sulfuric Acid and Lead Flush immediately with large amounts of water for at least 15 minutes while lifting lids Seek immediate medical attention if eyes have been exposed directly to acid V FIRE FIGHTING MEASURES Flash Point N A Flammable Limits LEL 4 1 Hydrogen Gas UEL 74 2 Hydrogen Gas Extinguishing Media Carbon dioxide foam dry chemical Avoid breathing vapors Use appropriate media for surrounding f
43. o 65 C 4 F to 150 F e 120 Vac 60 Hz Pure Sine Wave e 15 amps output Inverter Storage Temperature e Surge 2900 watts e 40 C to 65 C 40 F to 150 F e 396 THD e Dual GFI receptacle Power Cell Dry High Rate Discharge Rechargeable Maintenance free Physical Properties e Size 50 L x 22 75 W x 21 H 24 655 H with DVAM attached e 1270mm x 577 85mm x 533 40mm 625 47mm with DVAM attached e Weight 292 Ibs 132 4 kg GPU Operating Temperature e 40 C to 60 C 40 F to 140 F without ac power e 40 C to 55 C 40 F to 131 F with ac power GPU Storage Temperature e 65 C to 105 C 85 F to 221 F Cell Capacity e 40 C 110 05 425 C 100 05 00 C 80 05 20 C 65 1096 40 C 50 10 115400 400Hz GPU 24 UAV ACDC 3 2 Block Diagram Input Transient Output Transient 1 Surge Protection Surge Protection 1 1 OA OA 1 3 Phase 400Hz 1 Filter ee ED 1 3 Phase l l 400Hz AC i 30 Amp Breaker i B B 1 1 I I i i ELI a 1 I 1 1 OC OC 1 1 I qu e mmo mo mis m I 1 3 Phase 1 1 400 2 1 l 1 60 Amp Breaker 200 115 Wye l l 400Hz Input mE Q 28Vdc 1Amp Transformer and 1 Interlock Fuse Bridge Circuit for 1 P I 28 Vdc Interlock 1 1 for Aircraft l l Lo mi Interlock Common Mode EMI Filter 3 Phase Bridge quomm mr mms mm NEL mo SUE MCN Lm mil
44. oid creation of flames and sparks nearby Wear face and eye protection when near batteries being charged For expanded detailed info download the PDF online at http www teslaind com PDF chart Tesla Safety Data Sheet pdf or go to http www teslaind com support manuals php and click on Battery Safety Data Sheet link under Battery Info heading or use the QR Code to the right Table of Contents Section 1 Product Overview 1 1 Introduction 1 2 TI5400A 400Hz GPU 24 UAV ACDC Front View 1 3 15400 400Hz GPU 24 UAV ACDC Side View Section 2 Safety Review 2 1 Safety Notices 2 2 Symbols 2 3 Hazards 2 4 Important Safety Precautions 2 5 Extreme Environments Section 3 Unit Specifications 3 1 General Specifications 3 2 Block Diagram 3 3 Physical Dimensions 3 4 Airflow Ports 3 5 Engine Starting Power Section 4 Features Overview 4 1 3 Phase 60Hz AC Input Cable Assembly and Cable Extension 4 2 60Hz 3 Phase AC Input Circuit Breaker 4 3 Inverter Input Power Switch 4 4 DVAM Interface Receptacle 4 5 Digital Volt Amp Meter DVAM 4 6 DC Output ON and OFF buttons 4 7 DC Output Receptacle 4 8 Push to Test Button and LED Charge Status Meter 4 9 400Hz AC Input 4 10 400Hz AC Input Circuit Breaker 4 11 400 2 AC Input Interlock Lamp 4 12 400Hz Interlock Fuse 4 13 400Hz Surge EMC Filter 4 14 400Hz 200 Y 115 Vac Outp
45. or the fan to be off Once an ac Load is applied to the Inverter the fan will turn on The fan will continue to run until the AC Load is disconnected Once the AC Load is disconnected the fan will decrease in RPM and eventually turn off depending on how hot the temperature of the Inverter is to conserve power Figure 6 4 3 Inverter Fan Sine Wave Powersave Mode The Sine Wave Inverter has a built in Povversave mode to reduce the drain on the power cells when no load is present This mode when enabled checks the output for a load every 2 5 seconds and will automatically power up with a load of at least 10 watts To enable disable this feature set the Inverter Power Switch to O and then I When the PWR SAVE screen comes up quickly set the power switch to O wait three seconds and set the switch to I This will toggle the Powersave function on and off GFCI Outlet Test and Reset Buttons The inverter output is equipped with a GFCI outlet that will protect the user from potentially dangerous shocks due to faulty grounding see figure 6 4 4 Pressing the Test button will trip the outlet and break the circuit Pressing Reset will restore the circuit assuming no ground fault is present The green LED will illuminate when the receptacle is live In the event that the outlet does not work after resetting both the Inverter Output Circuit Breaker see figure 6 4 5 and the GFCI receptacle contact Tesla for further in
46. phs 52 12 6 Temperature Conversion Chart 53 Glossary 54 Repair Request Form 55 115400 400Hz GPU 24 UAV ACDC Abbreviations and Symbols Abbreviations that may be used within the text headings and titles of this manual LIST OF ABBREVIATIONS Abbreviation Definition ac AFT AWG amp or A cont C F dc EFF ft FWD GPU Hr Hz kg kHz kW LED max MQ min MPU NEMA PF PFC rms THD TMDE UAV Vac Vdc Alternating Current Airflow Technology American Wire Gauge Ampere Continuous Degree Celsius Degree Fahrenheit Direct Current Efficiency Feet Forward Ground Power Unit Hour Hertz Kilograms Kilohertz Kilowatts Light Emitting Diode Maximum megaohm Minimum Micro Power Unit National Electrical Manufacturers Association ohm power factor power factor correction root mean square Total Harmonic Distortion Test Measurement amp Diagnostic Equipment Unmanned aerial vehicle Volts Alternating Current Volts Direct Current watts 115400 400Hz GPU 24 UAV ACDC Section 1 Product Overview 1 1 Introduction This manual contains the complete operating instructions and procedures for the TIS400A 400Hz GPU 24 UAV ACDC The Tesla TI5400 series GPU has been designed to serve as a single source of power for the Global Hawk UAV as well as other UAV systems Using a 30 kVA 3 phase 400 Hz Generator the 115400A 400Hz GPU 24 UAV ACDC provides a protected and filtered 400 Hz 3 phase outp
47. r receptacle location The 115400A 400Hz GPU 24 UAV ACDC is now ready to safely transfer up to 3000 amps When ready press the unit s DC Output ON button The button should illuminate green see figure 6 2 4 DC power should be on and the aircraft s voltmeter should read between 23 and 26 Vdc without ac power To transfer power internally to the aircraft the user should follow system operating procedures as specified in the aircraft s operator manual When power is no longer needed make sure to press the DC Output OFF button before disconnecting any plugs see figure 6 2 3 Once confirming that the DC Output is OFF the user can safely proceed to disconnect the cable Figure 6 2 5 Connect DC cable to GPU 28 TI5400A 400Hz GPU 24 UAV ACDC Operating Procedures 6 6 3 400Hz 200 Y 115 3 Phase 30 Amp Vac Disabling the 400Hz AC Input and 400 Hz AC Output To prevent potential arcing or connector damage place the 400Hz 3 Phase Vac AC Input Circuit Breaker to the OFF position figure 6 3 1 before connecting either end of the 400 Hz aircraft power cable Next place the 400Hz 3 Phase Vac Output Circuit Breaker to the OFF position figure 6 3 2 Figure 6 3 1 400Hz AC Input Circuit Figure 6 3 2 400Hz Output Circuit Breaker set to the OFF position Breaker set to the OFF position Attaching 400 2 AC Input Cable and 400Hz Aircraft Power Cable Attach the 400Hz power cable from any compatible power source to th
48. removing the two cotter pins making it easy for replacement The tires feature sealed bearings in the wheel hub to keep out dust and moisture Figure 4 20 1 Location of the Figure 4 20 2 Removable Tires Removable Tires outlined in blue 22 TI5400A 400Hz GPU 24 UAV ACDC Overview 4 Feature D 60 4 21 Air Exhaust Fans CAUTION There are four intake fans on the front and five cooling exhaust fans mounted on the back of the TID400A 400 2 GPU 24 UAV ACDC see figure 4 21 1 and 4 21 2 The internal cooling system of the T15400A 400Hz GPU 24 UAV ACDC has been designed to efficiently regulate unit temperature regardless of load see figure 4 21 3 See Section 3 3 for more information Figure 4 21 1 Location of the Air Figure 4 21 2 Air Exhaust Fans Exhaust Fans outlined in blue Figure 4 21 3 Air intake and exhaust ports and internal air circulation 115400 400Hz GPU 24 UAV ACDC 23 Section 5 Pre Operation Procedures 5 1 Temperature Specifications Cold Hot Soaked Temperature Exposing the unit for one 1 hour or more to the ambient temperature establishes the unit s cold hot soaked stabilization temperature If the unit s cold hot soaked temperature is outside the normal operating temperature range the unit must be stabilized priorto operation For COLD SOAKED temperature stabilization the unit must be placed in an environment with a temperature above 10 C 41 F for 3 hours or a te
49. reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or any information storage and retrieval system without prior written permission from Tesla Industries Inc Copyright 2014 by Tesla Industries Incorporated All rights reserved TI5400A 400Hz GPU 24 UAV ACDC Form SDS 853027 Revised 05 14 15 Supersedes NEW ECO 1001584 SAFETY DATA SHEET I PRODUCT IDENTIFICATION Chemical Trade Name as used on label Chemical Family Classification Tesla Industries Inc Sealed Lead Battery Synonyms Sealed Lead Acid Battery VRLA Battery Telephone For information contact Tesla Industries Inc Manufacturer s Name Address Customer Service Dept at 302 324 8910 Tesla Industries Inc 101 Centerpoint Blvd 24 Hour Emergency Response Contact New Castle DE 19720 4180 CHEMTREC DOMESTIC 800 424 9300 CHEMTREC INT L 703 527 3877 II GHS HAZRDS IDENTFICATION Acute Toxicity Aquatic Chronic 1 Explosive Chemical Division 1 3 Oral Dermal Inhalation Category 4 Aquatic Acute 1 Skin Corrosion Irritation Category 1A Eye Damage Category 1 Reproductive Category 1A Carcinogenicity lead compounds Category 1B Carcinogenicity acid mist Category 1A Specific Target Organ Toxicity repeated exposure Category 2 GHS LABEL HEALTH ENVIRONMENTAL PHYSICAL Hazard Statements Precautionary Statements DANGER Wash thoroughly after handling Causes se
50. roduce a voltage e g a car battery A UAV unmanned aerial vehicle is an unpiloted aircraft either controlled from a re mote location or flying autonomously based on pre programmed flight plans using more complex and dynamic automation systems 115400 400Hz GPU 24 UAV ACDC Repair Request Form Please complete the information below to ensure prompt and accurate service Include this form with the unit you are returning Thank you Date of return Company name amp Billing address Contact person Phone Fax Email Purchase Order Model Serial Model Serial Shipping method to Tesla Description of shipping package Description of problem Return to Tesla Industries Inc 101 Centerpoint Boulevard New Castle DE 19720 Attention Repair Department WE GET THE MILITARY STARTED Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 USA Tel 302 324 8910 Fax 302 324 8912 9475 Double R Blvd Suite 2 Reno NV 89521 Tel 775 622 8801 Fax 775 622 8810 www teslaind com
51. structions Figure 6 4 4 60 2 120 Volt AC Outlet Figure 6 4 5 Inverter Output Circuit Breaker with GFCI receptacle for 60Hz 120 Vac Output 115400 400Hz GPU 24 UAV ACDC N LLL erating Procedures 6 Inverter Output Circuit Breaker The AC input circuit breaker is located to the left of the AC Inverter Display When the circuit breaker has been tripped the button will pop out In the event the breaker trips 1 2 3 4 Disconnect any ac plugs Wait for a minimum of 60 seconds Reset breaker by pressing the button Reconnect the ac plugs The Inverter Output should power up If the breaker continues to trip turn off the 60Hz AC Inverter Power switch and contact Tesla for further instructions Disabling the 60Hz 120 Vac Power Outlet When power is no longer needed make sure to turn off both the Inverter On Off switch and the 60Hz AC Inverter Power switch This will ensure that the power cells are not drained unnecessarily 115400 400Hz GPU 24 UAV ACDC Section Post Operation 7 1 After Operating When not in use the TI5400A 400Hz GPU 24 UAV ACDC should be covered and stored in a dry temperature controlled area To preserve cell life the GPU should be periodically plugged into an ac power source as shown in figure 7 1 1 Either 60Hz or 400 2 power see figure 7 1 2 may be used Although the GPU is rugged and weather resistant good general care should be taken to maximize the G
52. tch is on IRR UNS AAA NN GS b Ss O OG G 7 B 2 D 7 4 2251 C3 H CUM 2221 ad Z QOQUd ANS P 2002060 0080010 65222 o S z 232735 ggg TT SF O II 6 65 5L 3 OU 0 0 f 0000 229098298 I 4 A44 ETT BEYTY T ERRER Figure 4 3 1 Location of the GOHz Figure 4 3 2 60 Hz Inverter Power Switch Inverter Power Switch outlined in blue 115400 400Hz GPU 24 UAV ACDC 13 4 Features Overview 4 4 DVAM Interface Receptacle The DVAM Digital Volt Amp Meter Interface Receptacle located at the center bottom of the 115400A 400Hz GPU 24 UAV ACDC s front panel See Figures 4 4 1 and 4 4 2 allows the user to measure the voltage and current at the DC Output Receptacle using the Tesla TI3100A DVAM Digital Volt Amp Meter Plug the 113100A 0010 Power Cord into the Interface Receptacle and the back of the TI3100A DVAM to provide measurements for dc voltage E 1 Figure 4 4 1 Location of DVAM Interface Figure 4 4 2 DVAM Interface Receptacle Receptacle outlined in blue 4 5 Digital Volt Amp Meter TI3100A DVAM The Tesla Digital Volt Amp Meter is a high powered measuring solution The TI3100A DVAM provides measurements for dc voltage from 1 to 200 V and dc current up to 2000 amps for Aircraft and vehicle Integrated with the Tesla Turbo Start GPU power supply DVAM is a valuable tool for troubleshooting and conducting systems checks
53. telligent charging system for the cells as well as an ac to dc converter The cells are ideal for this application as they are non spillable lead dry cells that are sealed maintenance free and safe for air transport 3 Do the cells have memory No The user can plug the 15400 400 Hz GPU 24 UAV ACDC into either a 60 Hz or 400 Hz ac power source for charging regardless of the unit s state of charge The intelligent charging system will rapidly recharge the cells and then switch to trickle mode to maintain a full charge 4 How are Ground Power Units used in aviation support A Tesla GPU can be used to start any aircraft that uses a 24 volt system and can provide reliable ground power GPUs can be connected to a 60 Hz or 400 Hz ac power source to produce 28 5 or 30 25 Vdc for testing and troubleshooting avionics and communications systems without depleting the charged cells 5 How much dc power will the TI5400 400 Hz GPU 24 UAV ACDC provide The 15400 400Hz GPU 24 UAV ACDC will provide regulated 30 25 Vdc Output Ground Power up to 400 continuous amps with an ac power source and 3000 peak starting amps directly from the internal cells The 400 Hz Output will provide up to 30 amps of filtered power and the Inverter will provide 120 Vac 60Hz at up to 20 amps 6 How many engine starts will the TIS400A 400Hz GPU 24 UAV ACDC provide until depleted If the GPU is not allowed time to back charge after an engine start it should provide approxi
54. that the Air Exhaust Fans have failed Disconnect power immediately and contact Tesla for further instructions 3 The GPU has power but the cells are not charging Under normal circumstances the unit requires 12 minutes to fully recharge after a complete discharge If the unit is not fully charged after 12 minutes the power cells may need to be replaced Return the unit to Tesla for evaluation and maintenance 115400 400Hz GPU 24 UAV ACDC 4T 11 4 The unit is charged but the Push to Test button does not seem to work If the unit is fully charged the internal temperature sensor may have tripped This happens any time the Push to Test button has been pressed for more than 5 seconds Allow 5 minutes for cooling before pushing the button again If the Push to Test button still fails to activate the Capacity Meter return the unit to Tesla for evaluation and maintenance 5 The unit is charged but I m not getting any voltage from the DC Output Receptacle The power cells on the TI5400 GPU require a minimum charge level to function properly If one or more red LEDs are illuminated on the Capacity Meter the GPU may need recharging If this is not the case verify that the green DC Output ON button is illuminated Is the DC Output ON Button active button illuminated No Press the DC Output ON Button Yes Contact Tesla Industries Inc The DC Output Receptacle should read between 24 0 V and 27 6V If
55. ut 4 15 400Hz AC Output Circuit Breaker and Power Indicator 4 16 Inverter Display Panel 4 17 Inverter On Off Switch 4 18 60Hz 120 Vac Power Outlet and Circuit Breaker 4 19 Telescopic Handle 4 20 Removable Tires 4 21 Air Exhaust Fans WNP O 0 OARA D 12 12 13 13 14 14 15 15 16 17 17 18 18 18 19 19 20 20 21 21 22 22 23 115400 400Hz GPU 24 UAV ACDC Section 5 Pre Operation Procedures 24 5 1 Temperature Specifications 24 5 2 Unit Charging 25 26 5 3 Maintenance Check 26 5 4 Checking Cell Capacity 26 Section 6 Operating Procedures 2 6 1 Operating Overview 2 6 2 Regulated 30 25 Vdc Output Ground Power 27 28 6 3 400Hz 200 Y 115 3 Phase 30 Amp Vac 29 30 6 4 60Hz 120 Vac Power Outlet 31 33 Section 7 Post Operation 34 7 1 After Operating 34 1 2 Power Cell Recharging 34 Section 8 Unit Care and Maintenance 35 8 1 Unit Care 35 8 2 Normal Function Test Procedures 36 40 8 3 Unit Servicing 41 8 4 Packaging and Shipping 41 Section 9 Optional Accessories 42 9 1 Rain Dust Cover 42 9 2 Shipping Case 42 9 3 Customized Cables 43 9 4 Cobra DC Aviation Plug Replacement Contacts and Tools 43 9 5 Tow Cart 43 Section 10 Frequently Asked Questions 44 45 Section 11 Troubleshooting 46 50 Section 12 Performance Data 51 12 1 Purpose 51 12 2 Explanation of Data 51 12 3 General Conditions 51 12 4 Definitions of Abbreviations 51 12 5 Performance Gra
56. ut power up to 30 amps for aircraft systems b 30 25 Vdc 400 amp continuous regulated dc output voltage and c a convenient ac power outlet that can be used to plug in a laptop computer test equipment and other electronic devices The unit s high capacity power cells and circuitry are encased in a rugged enclosure This internal circuitry incorporates an intelligent recharging system that allows the GPU to rapidly recharge from either a 3 phase 208 Vac 50 60 Hz or 3 phase 200 Y 115 Vac 400 Hz power source The unit also comes equipped with independent controls for each output Circuit Breakers ON OFF Buttons an LCD readout for Inverter function and a built in Charge Status Meter via the Push to Test button that also serves as a recharge state indicator for the dc output Additionally the GPU includes a 25 DC Aviation Cable Assembly TI2007 425 or a 15 DC Aviation Cable Assembly T12007 415 a 3 Phase Extension Cable with 460 POW TI2000 O70 a 400 Hz Interface Cable TI2006 309 and a TI3100A DVAM Digital Volt Amp Meter with a TI2006 001 DVAM Interface Line Cord Figure 1 1 1 115400A 400Hz GPU 24 UAV ACDC 115400 400Hz GPU 24 UAV ACDC 1 1 2 5400 400Hz GPU 24 UAV ACDC Front View ARA ed s MM NA NUNN UN 1 TI3100A DVAM Digital Volt Amp Meter Provides measurements for DC voltage from 1 to 100 V and dc current up to 2000 amps for Aircraft and vehicle 2 400 Hz Input Interlock LE
57. ut voltage and frequency configuration Then the screen will display input voltage input current and output power see figure 6 4 2 The 60 2 120 Vac Power Outlet is now active JD Figure 6 4 1 60 2 AC Inverter Power Switch Figure 6 4 2 Inverter Display Panel ON with Switch set to I ON position Control Panel and LCD Display The Pure Sine Wave Inverter is equipped with a Control Panel that displays operational information so you can monitor the status of the inverter and the GPU s power cells A backlit LCD display shows both input voltage and current from the power cells Actual output power in watts from the inverter will be displayed when equipment is plugged into the power outlet In figure 6 4 2 the inverter has an input voltage of 24 4V with a current draw of 27A The resulting output power is displayed on an analog bar and reads 400W NOTE When activated the power outlet will operate with or without ac power attached 115400 400Hz GPU 24 UAV ACDC 31 Operating Procedures Operating the Pure Sine Wave Inverter Once the standard display screen is shown any type of 120 Vac load can be attached to the 60Hz 120 Volt AC Outlet see figure 6 4 4 including cell phone chargers laptops and any other electronic devices When equipment is plugged in the output power is displayed in watts on an analog bar graph at the bottom of the LCD display Inverter Fan When the Inverter is initially powered on it is normal f
58. vere skin burns and eye damage Do not eat drink or smoke when using this product Causes serious eye damage Wear protective gloves protective clothing eye protection face protection May damage fertility or the unborn child if ingested or Avoid breathing dust fume gas mist vapors spray inhaled Use only outdoors or in a well ventilated area May cause cancer if ingested or inhaled Causes skin irritation serious eye damage Causes damage to central nervous system blood and Contact with internal components may cause irritation or severe burns Avoid contact with internal acid kidneys through prolonged or repeated exposure Irritating to eyes respiratory system and skin May form explosive air gas mixture during charging Extremely flammable gas hydrogen Explosive fire blast or projection hazard HAZARDOUS INGREDIENTS IDENTIFY INFORMATION Components CAS Number Approximate by Weight Inorganic Lead Compound Lead 7439 92 1 Lead Dioxide 1309 60 0 Ti 7440 31 5 in Sulfuric Acid Electrolyte Sulfuric Acid Water 7664 93 9 15 20 Case Material 5 10 Polypropylene 9003 07 0 Polystyrene 9003 53 6 Styrene Acrylonitrile 9003 54 7 Acrylonitrile Butadiene Styrene 9003 56 9 Styrene Butadiene 9003 55 8 Polyvinylchloride 9002 86 2 Polycarbonate Hard Rubber Polyethylene 9002 88 4 Polyphenylene Oxide 25134 01 4 Polycarbonate Polyester Alloy Other Absorbent Glass Mat 1 2 Inorganic lead a
59. y There may be increasing risk of electric shock from strings of connected batteries Keep containers tightly closed when not in use If battery case is broken avoid contact with internal components Keep vent caps on and cover terminals to prevent short circuits Place cardboard between layers of stacked automotive batteries to avoid damage and short circuits Keep away from combustible materials organic chemicals reducing substances metals strong oxidizers and water Use banding or stretch wrap to secure items for shipping Storage Store batteries in cool dry well ventilated areas with impervious surfaces and adequate containment in the event of spills Batteries should also be stored under roof for protection against adverse weather conditions Separate from incompatible materials Store and handle only in areas with adequate water supply and spill control Avoid damage to containers Keep away from fire sparks and heat Keep away from metallic objects which could bridge the terminals on a battery and create a dangerous short circuit Charging There is a possible risk of electric shock from charging equipment and from strings of series connected batteries whether or not being charged Shut off power to chargers whenever not in use and before detachment of any circuit connections Batteries being charged will generate and release flammable hydrogen gas Charging space should be ventilated Keep battery vent caps in position Prohibit smoking and av
60. y one Under a full charge the Meter will show a single solid green LED In addition the fan will be running at reduced RPM This indicates that the unit is in standby mode and ready for use STATUS STATUS STATUS Full Charge Half Charge No Charge Figure 5 2 5 Charge Status Meter If unit is left charging after the batteries are fully charged the unit will enter a standby mode The voltage will drop from 28 80 to 28 26 volts When a load greater than 2 amps is applied the unit will return to normal operation 5 3 Maintenance Check Check the GPU for dents punctures case distortion or misalignment and cracked or loose connectors Check cables for cuts chafing or evidence of crushing Check connectors for cracks cuts distortion excessive wear broken loose fasteners and cables or strain reliefs Also be sure to check the tires The GPU comes equipped with solid run flat tires No air is required but if the tires are damaged they can easily be replaced If no external damage is evident proceed to the next step Otherwise contact Tesla for further instructions 5 4 Checking Cell Capacity To check the Cell Capacity set the appropriate AC Input Circuit Breaker to the OFF position and wait for approximately two minutes Then press the Push to Test button to verify that the power cells are fully charged Under a full charge the Charge Status Meter will show a single green LED as shown in figure 5 2
61. ystems for use on aircraft such as communications navigation and the display and management of multiple systems A digital multimeter DMM DVAM DVOM displays the measured value in numerals and may also display a bar of a length proportional to the quantity being measured It is an electronic measurement device that combines several functions into one unit A standard multimeter may include features such as the ability to measure voltage current and resistance A condition in which an imbalance in electrical current occurs due to a faulty connection path such as a current leakage through the body of a person who is grounded and accidentally touching the energized part of the circuit A system which continuously monitors the cell s charge state and automatically adjusts the recharge rate to maximum performance and minimize cell degradation If a NiCd battery is only partially discharged then recharged many times it will be gin to remember the level it was discharged to and will no longer fully recharge The 115400 GPU s internal cells do not have a memory effect A one piece battery that is hermetically sealed and designed for maintenance free operation In electrical engineering single phase electric power refers to the distribution of alternating current electric power using a system in which all the voltages of the supply vary in unison A battery that uses the reaction of lead and lead oxide with sulfuric acid electrolytes to p
62. z AC Input Receptacle as shown in figure 8 2 2 Next touch the Black lead of the multimeter to the negative pin of the DC Output Receptacle as seen in figure 8 2 4 The meter should read about 2 0 MO Do the same for the positive pin as seen in figure 8 2 5 The meter should read open circuit Figure 8 2 4 DC Output Receptacle Figure 8 2 5 DC Output Receptacle Negative Pin Positive Pin 115400 400Hz GPU 24 UAV ACDC 37 8 Unit Care and Maintenance 60Hz AC Input Receptacle Verifying Connection between the Chassis and 60Hz Neutral Connection Touch the black lead of the multimeter to an exposed metal area on the chassis Next touch the Red lead of the multimeter to the neutral pin of the GOHz AC Input Receptacle Shown in figure 8 2 7 The multimeter should read nearly zero ohms Figure 8 2 6 Multimeter Reading Continuity Figure 8 2 7 400Hz AC Input Receptacle good connection Ground pin under test Testing between the 60Hz Neutral Connection and the DC Output Receptacle Keep the Red lead of the multimeter on the 60Hz AC Input Receptacle as shown in figure 8 2 7 Next touch the Black lead of the multimeter to the negative pin of the DC Output Receptacle as seen in figure 8 2 8 Do the same for the positive pin as seen in figure 8 2 9 In both cases the meter should read open circuit shown in figure 8 2 10 EE Figure 8 2 8 DC Output Receptacle Negative Pin Figure 8 2 9 DC Output Receptacle Positive Pin Figure

TI5400A 400Hz Manual - Tesla™ Industries Inc

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TI5400A 400Hz Manual - Tesla&trade; Industries Inc

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TI5400A 400Hz Manual - Tesla™ Industries Inc