Tesla TI4100 GPU-24 User's Manual
Contents
1. S PROTECT DC POWER CABLE AND AC POWER CORD FROM DAMAGE Prevent from being cut gouged crushed dragged or otherwise abused SECTION MAINTENANCE 6 3 MAINTENANCE OF UNIT The Turbo Start 4100 is a maintenance free unit no repairs are authorized Warranty will be void if unit is tampered with If unit fails to operate contact Manufactures War ranty Claim see unit warranty Warranty Void Sticker Do not Remove Warranty Void Sticker Do not Remove Chapter 7 Push To Test Modification General Information And Operation 7 1 General THIS MODIFICATION HAS BECOME STANDARD EQUIPMENT FOR EACH OF OUR UNITS BOTH MILITARY AND CIVILIAN CLIENTS HAVE FOUND THIS MODIFICA TION TO BE CRITICAL TO THEIR OPERATION THE PUSH TO TEST BUTTON IS USED TO INDICATE THE CAPACITY OF THE POWER CELLS WITHOUT APPLYING AC INPUT POWER IT ALLOWS THE END USER TO CHECK THE STATUS OF THE POWER CELLS THIS LETS THE OPERATOR KNOW IF THERE IS ENOUGH POWER TO PER FORM ANOTHER ENGINE START OR IF THE UNIT HAS TO BE RETURNED TO AC POWER TO ALLOW IT TO RECHARGE 722 OPERATION 1 MAKE SURE THAT YOU WAIT AT LEAST 2 MINUTES AFTER AC POWER IS APPLIED OR DC POWER IS EXTRACTED FROM THE UNIT BEF2. Chapter 8 ON OFF SWITCH General Information And Operation 7 1 General The TI4100GPU 24 comes equipped with an On Off switch on the face plate This switch controls AC power input only It does not control the DC output power to the aircraft Whenever the unit is plugged into an aircraft it is supplying DC power The ON OFF switch located on the face plate does not have any control on the DC output power funtion 8 2 OPERATION 1 Place the On Off switch in the Off position 2 Plug the unit into 208 240 single phase 30 AMP AC power 3 Connect the DC cord to the Aircraft or vehicle At this time the unit will be providing 24 VDC Power 4 Place the On Off switch to the on position After 2 3 seconds The led bar graph should light and the fans should begin to operate 5 If the fans and led bar graph do not operate than check the AC outlet for power NOTE The power cells will only recharge while the On Off switch is in the on position The On Off switch does not control the DC output power PARAGRAPH INDEX 208 240 VAC Charger and AC to DC Converter Limits 24 VDC Ground Power NO 208 240 VAC Power Supply DC system Power 4 6 3 4 Engine Starting or 24 VDC Ground Power With 208 240 VAC Power System High Power Demand 21 1500 Amps or Engine Starting 4 7 28 5 VDC Ground Power with 208 240 VAC Power System Low Power De mand 100 Am
3. 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 WARNING Ax SHOCK HAZARD POTENTIAL x xxx x MR 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 pamage 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
4. 13 Use of Word Shall Should and May 1 7 Warning Caution and Notes Defined 1 2
5. 86 Kg AC POWER CORD 0 4 lbs 0 18 Kg INPUT POWER AC TI4100GPU 24 208 240 Single Phase VAC 50 60 Hz 30 0 amps max OUTPUT POWER DC CONVERTER 28 5 VDC TO 100 AMPS 24 VDC 121 AMPS AND ABOVE POWER CELLS 24 VDC PEAK OUTPUT 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 DISCRIPTION AND DEMENTIONS UNIT 122 32 mm AQ 250 Back Rest 35 250 882 50 mm AIR FLOW Handle 5851 unu coopt Telescopic Handle Front Wheels Sticker Copacity Indicator Charge Indicator 19 25 468 95 mm ID A As l0 mm Dc Connector C Warrants Wedel Sticker 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 fro
6. connected to an approved AC power supply After approximately 5 8 seconds ensure unit s LED status indicator illuminates indicating power cell state of charge and cool ing fan is operating 4 5 CAUTION Unit may overheat if cooling fan fails Do not operate if cooling fan fails Front Vent Cooling Fan Back Vent Cooling Fan 2 CHECK FOR FULL CHARGE NDICATION After 30 minutes LED charge indicator should show singl le steady or flashing green LED bar when fully charged the last LED bar AC power may be left connected to unit when power cells are fully charged NOTE Under a full charge two things will be observable with the unit A non blinking lighted green bar or a blinking green bar at the bottom of the bar graph both indicate a full charge Also the fan will dis play ratcheting but not come on when the unit is fully charged SECTION Ill FUNCTIONAL CHECK PROCEDURES 4 10 FUNCTIONAL CHECK PROCEDURES This section deals with normal functional check procedures and in cludes all steps necessary to ensure the Turbo Start 4100 is func tioning within specific operational parameters prior to operational use As users gain experience with the Turbo Start 4100 they will incorporate these functional checks as a routine practice 4 11 REQUIRED EQUIPMENT FOR FUNCTIONAL CHECK FLUKE OR EQUIVALENT TYPE DIGITAL MULTIMETER 4 12 DC FUNCTI
7. 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 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 PTRE EXPLOSION HAZARD Severe injury or Death may occur from fire or explosion as a result of electrical sparks produced near fuel vapors 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 Th
8. 500 peak amps at 2590 71 5 See Figure 5 3 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 NIMUM CHARGE 0 charged ENGINE START CURRENT LOAD DEMAND Under 650 peak starting amps 650 850 peak startin 0 charged amps 0 charged amps 0 charged 1000 1200 peak startin o u oO eJZ g 850 1000 peak starting amps g g 0 charged 1200 1500 peak startin amps 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
9. Celsius cont Continuous DC Direct Current Fahrenheit Feet FWD Forward GPU Ground Power Unit Hr Hour Hz Hertz Kg Kilograms Kw Kilowatts Degree LED Light Emitting Diode MAX Maximum MIN Minimum VAC Volts Alternating Current VDC Volts Direct Current Explosion Hazard Potential Shock Hazard Potential Guard from moisture CNN Guard from incorrect power source 1 2 1 6 FORMS AND RECORDS NONE REQUIRED 1 7 USE OF WORDS SHALL SHOULD AND MAY Within this technical manual the word shall is used to indicate a mandatory requirement for proper operation and warranty purposes The word should is used to indicate a non mandatory but preferred method of accomplishment The word may is used to indicate an ceptable method of accomplishment CHAPTER 2 UNIT DESCRIPTION AND OPERATION SECTION I UNIT 2 1 GENERAL The TI4100GPU 24 Turbo Start 4100 Figure 2 1 and 2 2 is a compact 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 pow
10. E 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 x CHECK UNIT FOR EVIDENCE OF DAMAGE Check for dents punctures case distortion or misalignment cracked or loose connectors and that cooling fan is functioning 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 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 15 TRANSPORT UNIT The Turbo Start 4100 is easily transported using the wheels that are incorporated into the unit Th
11. LS 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 THE 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 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 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 9 POWER CELL RECHARGE 2 CONNECT POWER CORD TO UNIT Unit shall be in horizontal po sition to ensure unit s vent ports are free from blockage Ensure 208 240 VAC power cord is properly
12. ONAL CHECK 1 CHECK UNIT FOR EVIDENCE OF DAMAGE Check for dents punctures case distortion or misalignment cracked or loose connectors If no damage is evident proceed to step two IF DAMAGE S EVIDENT contact distributor or manufacturer 2 ENSURE UNIT IS NOT PLUGGED INTO 208 240 VDC Unplug AC power if plugged in 3 CHECK UNIT INTERNAL RESISTANCE TEST FOR SHORTS Better than 10 Megohms Ensure no short exists Negative DC receptacle terminal and unit case Positive DC receptacle terminal and unit case 4 CHECK DC VOLTAGE READING DC RECEPTACLE TERMINALS 24 to 25 5 VDC depending on state of charge 54 PLUG IN 208 240 POWER CORD Ensure power unit is connected to a suitable AC power source 208 240 Single Phase 50 60 Hz 6 CHECK UNIT FOR STATE OF CHARGE Unit shall be in horizontal position to ensure unit s vent ports are free from blockage After approximately 5 8 seconds unit LED status indicator shall illuminate indicating power cell state of charge Ensure LED status indicator and cooling fan are operational Prior to continuing to step 7 the LED status indicator should show a single green bar last LED bar to indicate the unit s power cells are fully charged Also under full charge the fan will ratchet but not enable Under a full charge i
13. ORE YOU DEPRESS THE PUSH TO TEST BUTTON THIS WILL ENSURE A CORRECT READING I 2 WITHOUT AC POWER INPUT OR DC POWER OUTPUT SIMPLY DEPRESS THE PUSH TO TEST BUTTON ON THE FACE PLATE AND HOLD FOR APPROXIMATELY 15 SECONDS 3 AT THIS TIME THE LED BAR GRAPH SHOULD LIGHT UP INDICATING THE STATUS OF IHE POWER CELLS 4 THE FAN SHOULD ALSO OPERATE AT THIS TIME IF YOU DO NOT HEAR THE FAN RUNNING STOP DEPRESSING THE BUTTON AND CHECK FOR OBSTRUCTIONS TO THI FAN 5 NEVER DEPRESS THE PUSH TEST BUTTON WHILE THE UNIT IS PLUGGED INTO POWER FOR RECHARGE OR PLUGGED INTO AIRCRAFT FOR DC POWER OUTPUT Lr 6 NEVER DEPRESS THE PUSH TO TEST BUTTON FOR MORE THAN 30 SECONDS THIS MAY CAUSE A TEMPERATURE SENSOR TO TEMPORARILY DISRUPT PUSH TO TEST FUNCTION IF THIS SENSOR IS TRIPPED ALLOW TEN MINUTES FOR UNIT TO COOL BEFORE OPERATING PUSH TO TEST BUTTON STATUS I I
14. POWERED BY 114100 GPU 24 GROUND POWER UNIT 109 CenterPoint New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www TESLAind com WARNING 65 SHOCK HAZARD POTENTIAL IMPROPER USE FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN SULT IN UNIT FAILURE AND OR POSSIBLE INJURY OR DEATH BY ELECTRICAL SHOCK THE TI4100GPU 24 IS A MAINTENANCE FREE SEALED UNIT NO REPAIRS ARE AUTHORIZED WARRANTY WILL BE VOID IF UNIT S TAMPERED WITH FOR TECHNICAL SUPPORT CONTACT TESLA INDUSTRIES INC 109 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PH 302 324 8910 FAX 302 324 8912 WARNING A SHOCK HAZARD POTENTIAL lp ATTEMPTS TO OPEN OR ENTER THE INSIDE OF THIS UNIT BY USING ANY TOOL OR DEVICE i e PROBE BORESCOPE etc CAN RESULT IN UNIT FAILURE AND OR POSSIBLE INJURY BY ELECTRICAL SHOCK THIS UNIT IS MAINTENANCE FREE AND SHALL NOT BE OPENED OR DISASSEMBLED FOR ANY REASON SHIPPING HAZARDS NONE DRY Non spillable POWER CELL battery No Free liquids to leak or toxic gases Always protect unit from short circuit Return Power cells to Tesla for Recycling TITLE CHAPTER CHAPTER Section Section CHAPTER Section Section CHAPTER Section Section Sect
15. Whitney Canada on 30 March 1992 FIGURE 5 3 CHAPTER 6 CARE AND MAINTENANCE SECTION UNIT CARE 6 1 GENERAL Although the TI4100GPU 24 Turbo Start 4100 has been ruggedized and made weather resistant within the scope of unit s intended use it is essential that good general care be taken to maintain unit in good operating condition and to maximize unit s operational life 6 2 AFTER USE Unit should be protected from the environmental elements and man made hazards Ideally unit should be secured in a building or shed Most importantly unit shall be fully covered if stored exposed to environmental elements l KEEP UNIT RECEPTACLES AND OUTER CASE CLEAN wipe with dry cloth KEEP FOREIGN OBJECTS OUT OF UNIT Cover unit to prevent foreign objects water and dirt from entering vent ports and recep tacles 3 KEEP FROM PROLONGED EXPOSURE TO EXTREMELY DAMP ENVIRONMENTS Cover unit to prevent migration of moisture If unit is operated in extremely damp environments unit should be kept in an environmentally controlled building 4 KEEP UNIT PLUGGED INTO AC POWER SUPPLY WHEN NOT IN USE To maximize life of power cells and to ensure unit is always ready for use unit should remained plugged in to AC power when not in use NEVER LET DISCHARGED UNIT SIT FOR MORE THAN 24 HOURS WITHOUT FULLY RECHARGING POWER CELLS
16. al 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 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 amp Ampere AC Alternating Current C
17. 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 41 F or 2 hours above 20C9 68 F WARMED SOAKED cooled for 1 hour below 38C 100 F Operating range without AC power 40C 40 F 60C9 1409 with AC Power 30C9 23 TO 50C 1249 Storage range 60C9 76 R TO 60C9 5140972 CONTINUED ON NEXT PAGE 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
18. e 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 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 SECTION Il 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 STAT
19. e 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 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 7 24 VDC GROUND POWER WITH 208 240 VAC POWER SYSTEM HIGH POWER DE MAND 101 amps and above OR ENGINE STARTING 15 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 po
20. er 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 SECTION II DESCRIPTION 2 2 GENERAL SPECIFICATIONS WEIGHT UNIT 100 lbs 50 39 Eg DC POWER CABLE 8 5 lbs 3
21. erified by tests 5 4 SPECIFIC CONDITIONS The data presented are accurate only for specific conditions listed under the title of each chart or graph Variables for which data are not presented but which may affect that phase of performance are discussed in associated text Where data are available or reasonable estimates can be made the amount that each variable affects perfor mance will be given 5 5 GENERAL CONDITIONS In addition to the specific conditions the following general condi tions are applicable to the performance data a Variation in Aircraft Power demand differences between indi vidual aircraft of th same make and model are known to exist due to variations in DC electrical system efficiency These differ ences however are considered insignificant and are not individu ally accounted for Ground Support Aircraft Instrument Variations The data shown in the performance charts do not account for instrument tol erance differences or inaccuracies 5 6 DEFINITIONS OF ABBREVIATIONS Unless otherwise indicated the abbreviations defined in Chapter 1 will be applicable to all charts and graphs in this chapter TEMPERATUE CONVERSION CHART T Z 5 a 20 20 DEGREES CELSILIS FIGURE 5 1 FIGURE 5 2 MAXIMUM OUTPUT CURRENT Pee AMPS Calculations based on actual test data at Pratt
22. expected perfor mance NOTE The information provided in this chapter is primarily intended for operational planning and is most useful when planning operations under unfamiliar conditions or environmental extremes The data may also be used to establish local operating procedures and to ensure unit s operational life is maximized 5 2 GENERAL The data presented covers the maximum range of conditions and perfor mance that can reasonably be expected In each area of performance the effects of temperature and DC electrical load demand relating to the ground power support requirements are presented Wherever practi cal data is presented conservatively However NO GENERAL CONSERVA TISM HAS BEEN APPLIED All performance data presented is within the applicable limits of the Turbo Start SECTION DATA CRITERIA 5 3 DATA BASIS The type of data used is indicated at the bottom of each performance chart under DATA BASIS The applicable report and date of the data are also given The data provided generally are based on one of three categories a Derived From Actual Controlled Testing Controlled test data obtained a similar unit type b Calculated Data Data based on tests but not on a similar unit type placed under a controlled test Cx Estimated Data Data based on estimates using rules of phys ics mathematics and electrical engineering principles and con cepts but not v
23. ion TABLE OF CONTENTS INTRODUCTION Unit Description UNIT DESCRIPTION AND OPERATION OPERATING LIMITS AND RESTRICTIONS General Operational Restrictions and Safety Limits OPERATING PROCEDURES Unit Operation Operating Procedures CHAPTER Section Section CHAPTER Section Section CHAPTER Section Section CHAPTER Section Section 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 2 2 5 1 52 5 3 Title Dimensions General Details Temperature Conversion Discharge Load Curve Maximum Output Current Functional Check Procedures Chart Page 2 2 2 4 5 3 5 4 95 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 person
24. m 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 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 monito
25. ndicate a malfunction NOTE the last green LED bar may blink This does not A non blinking lighted green bar or blink ing green bar at the bottom of the LED column both indicate a full 7 power cells are fully charged s step 6 28 5 8 DC with power cells at full 0 57 V ONAL CHECK COMPLETE Unit should remain plugged in to AC charge DC VOLTAGE READING AT DC RECEPTACLE TERMINALS Ensure power until required for use state of charge CHAPTER 5 PERFORMANCE DATA SECTION 1 INTRODUCTION 5 1 PURPOSE This chapter provides performance data for the TI4100GPU 24 Turbo Start 4100 Continual reference to this information will enable the user to obtain maximum performance utilization and service life from the Turbo Start Although maximum performance is not always required regular referral to this chapter is recommended for the following rea sons a To generate knowledge of unit s performance margins to enable the operator to make sound judgment when unexpected conditions or alternat operational requirements are encountered enable the user to readily recognize situations requiring maximum performance Que To gain experience in accurately estimating the effects of variables for which data is not presented d To help the operator determine if an aircraft system malfunc tion exists by comparing actual performance with
26. plying 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 nsure 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 8 28 5 VDC GROUND POWER WITH 208 240 VAC POWER SYSTEM LOW POWER DEMAND 100 amps or less ie 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 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 CONTRO
27. ps or less 4 8 Abbreviations 1 5 AC Power Cord Limits 9 5 After Use 6 2 Appendix A Line Cord Table Before Operation Check 4 5 Continuous Output Rate 28 5 VDC Constant Output Data Basis 5 3 DC Functional Check 4 12 Definitions of Abbreviations 5 6 Dimensions Figure 2 1 Discharge Load Curve Figure 552 Description Engine Starting Power 3 9 Environmental 3 11 Functional Check Procedures 4 10 Forms and Records 1 6 General Chapter 1 1 2 1 3 2 General Chapter General Chapter 2 6 1 2 5 General Chapter General Chapter 1 2 3 General Chapter 4 4 1 5 6 5 General Condition General Details Figure 2 2 General Specifications 2 2 3 8 PARAGRAPH INDEX Index 1 4 Maintenance of Unit 6 3 Maximum Output Current Figure 5 8 On Off Switch General 8 1 On Off Switch Operation 8 2 One 1 Hour Rate 24 VDC Constant Output 3 6 Operating Limits and Restrictions 4 2 Operating Procedures 4 4 Operating Position 3 12 Performance 4 3 Power Cell Recharge 4 9 Power Cell Recharge Limits 3 3 Purpose Chapter 3 3 1 Purpose Chapter 5 5 1 Rated Peak Output Engine Starting 3e Required Equipment for Functional Check 4 11 Specific Conditions 5 4 Temperature 3 10 Temperature Conversion Chart Figure Oc Unit Operation During Aircraft Fueling Defueling 3
28. r 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 nsure power cells are charged to maximum capacity CAUTION Unit will be damaged if unapproved 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 WARNING xxxxxx x SHOCK HAZARD POTENTIAL xx S 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 1
29. sition 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 ue 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 Dus 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 sup
Download Pdf Manuals
Related Search