Tesla TI4400 GPU-24, User Manual

Page 1: ...a TI4400 GPU 24 User Manual Built Smart Proven Tough Power Anytime Anywhere Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www teslaind com www tesla1 com ...

Page 2: ...ssembled for any reason Always protect the unit from short circuit Shipping Hazards The unit contains sealed dry cell rechargeable batteries that do not pose a shipping hazard 05 04 21 All Ground Power Units Micro Power Units Aviation Batteries and including but not limited to Battery Chargers Conditioners manufactured by Tesla Industries Inc are able to safely and effectively charge any AGM Lead ...

Page 3: ...doors or in a well ventilated area 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 Obtain special instructions before use Explosive fire blast or proj...

Page 4: ... 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 VII HANDLING AND STORAGE Handling Unless involved in recycling operations do not breach the casing or empty the contents of the battery...

Page 5: ...dicator 8 2 9 60 Hz 3 Phase AC Input Circuit Breaker 9 2 10 DVAM Interface Receptacle 9 2 11 DC Output ON and OFF Buttons 10 Section 3 Operating Procedures 11 3 1 Operating Procedures 11 3 2 General 11 3 3 Operating Limits and Restrictions 11 3 4 Performance 11 3 5 Engine Starting Power 11 3 6 Temperature Specifications 12 3 7 Environmental 13 3 8 Operation 14 3 9 Normal Functional Test Procedures...

Page 6: ... 26 6 2 Basic Usage Operation Questions 27 6 3 Basic Troubleshooting 28 29 Section 7 Performance Data 30 7 1 Purpose 30 7 2 General 30 7 3 Data Basis 30 7 4 Specific Conditions 30 7 5 General Conditions 30 7 6 Temperature Conversion Chart 31 7 7 Output Voltage 32 7 8 Maximum Output Current 32 Section 8 Optional Accessories 33 8 1 Shipping Case 33 8 2 GPU Protective Covers 33 8 3 Digital Volt Amp M...

Page 7: ...heit dc Direct Current EFF Efficiency ft Feet FWD Forward GPU Ground Power Unit Hr Hour Hz Hertz kg Kilograms kHz Kilohertz kW Kilowatts LED Light Emitting Diode max Maximum MΩ megaohm min Minimum MPU Micro Power Unit NEMA National Electrical Manufacturers Association Ω ohm PF power factor PFC power factor correction rms root mean square THD Total Harmonic Distortion TMDE Test Measurement Diagnost...

Page 8: ...d WARNING Indicates a condition operating procedure or practice which if not adhered to could result in serious injury or death CAUTION Indicates a condition or operating procedure which if not strictly adhered to could result in damage or destruction of equipment NOTE Indicates a condition operating procedure or practice which is essential to highlight 1 2 Symbols The following symbols will appea...

Page 9: ... restricted to dc power only 1 5 Extreme Environments CAUTION Unit Damage Potential The unit s charger temperature switch automatically disables the unit when the internal temperature exceeds 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 after ...

Page 10: ...I4400 GPU 24 Ground Power Unit The TI4400 GPU 24 provides dc electrical ground power for aircraft flight line maintenance and ground support operations The unit is designed to provide 24 volt dc electrical power output for vehicle and aircraft engine starting and 24 or 28 5 volts dc electrical support for ground maintenance avionics electrical troubleshooting and testing The observance of procedur...

Page 11: ...ngages and Disengages the dc output receptacle 60 Hz Input Circuit Breaker 4 Protects the GPU from any power surges LED Charge Status Meter 5 Displays current battery charge status when pressed Air Intake Fan 6 Provides airflow for cooling internal components 60 Hz 3 Phase AC Input Cable 7 Use for 60 Hz 3 Phase 208 240 Vac Input Power D 8 VAM Interface Receptacle Allows direct connection of Tesla ...

Page 12: ...ps continuous 28 5 Vdc when plugged into ac power 423 amp hours 11 912 watt hours with three phase ac power 23 amp hours 512 watt hours of rechargeable battery power without three phase ac Recharge Rate From Full Discharge 8 minutes 25 C Size 50 23 L x 24 50 W x 16 28 H 1275 80 mm x 622 30 mm x 413 50 mm Weight 205 lbs 93 kg Operating Temperature 40 C to 60 C 40 F to 140 F without ac power 40 C to...

Page 13: ...l 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 ambient temperature by more than 10 F Figure 2 5 1 TI4400 GPU 24 physical dimensions Figure 2 6 1 Air intake exhaust ports and internal air ...

Page 14: ... in both the horizontal Figure 2 7 1 and vertical Figure 2 7 2 positions as shown Make sure that the airflow is not obstructed from air intake figure 2 7 3 and outlet Figure 2 7 4 Figure 2 7 2 Vertical Position Figure 2 7 1 Horizontal Position Figure 2 7 3 Front Inlet Figure 2 7 4 Rear Outlet ...

Page 15: ...and hold for approximately 2 to 3 seconds The LED bar graph should light up indicating the status of the power cells 3 In addition the fan s should start operating when the button is pressed If you do not hear the 4 fan s running stop pressing the button and check for any obstructions CAUTION Never press the Push to Test button while the unit is plugged into aircraft vehicle or ac power CAUTION Ne...

Page 16: ...put Circuit Breaker Figure 2 9 1 Location of the 60Hz 3 Phase AC Input Circuit Breaker outlined in blue 2 10 DVAM Interface Receptacle The DVAM Digital Volt Amp Meter Interface Receptacle located at the center bottom of the TI4400 GPU s front panel see Figures 2 10 1 and 2 10 2 allows the user to measure the voltage and current at the DC Output Receptacle using a Tesla TI3100A Digital Volt Amp Met...

Page 17: ...er see Figures 2 11 1 and 2 11 2 below To prevent arcing while connecting or disconnecting DC power plugs the TI4400 GPU has been equipped with an internal contactor The ON button engages this contactor for safe transfer of power up to 3000 amps Figure 2 11 1 Location of the DC Output On and Off Buttons outlined in blue Figure 2 11 2 DC Output On and Off Buttons ...

Page 18: ...rformance resulting from variations in ambient temperature mode of operation state of charge with or without ac power and aircraft dc bus system inefficiency voltage drops 3 5 Engine Starting Power Theunitshouldalwaysbechargedabove80 priortogroundsupportenginestarting However circumstances may exist during use where unit recharge is not readily available and immediate external engine starting powe...

Page 19: ...ve 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 3 6 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...

Page 20: ...pe of existing technology to prevent foreseeable safety hazards and make the unit moisture resistant to prevent damage or failure Conditions With Raincover Without Raincover Heavy or steady rain Precipitation falling with an intensity in excess of 0 30 inch 0 76 cm or continuously between 0 30 and 0 10 inch per hour OK OPERATION NOT RECOMMENDED Light rain drizzle or sleet Precipitation falling on ...

Page 21: ...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 3 9 1 Digital Multimeter 3 8 Operation 1 Place the On Off Switch in the Off position 2 Plug the unit into three phase 200 260 Vac 50 60 Hz power This unit requires 60 amp service contact Tesla Indu...

Page 22: ...set the digital multimeter to measure dc voltage Turn on the DC Output to ON see page 10 As shown in Figure 3 8 2 place the positive probe red on the positive post of the DC Output Connector and the negative probe on the negative post The multimeter display should read approximately 28 5 Vdc 0 5 Vdc when power cells are fully charged and the unit is plugged into an appropriate ac power source When...

Page 23: ...hat all input and output cables are not damaged See Section 5 1 2 Check unit carefully for any evidence of damage 3 Make sure that airflow is not obstructed from air intake and outlet See Section 2 6 4 Check that all connections are secure and free from water 3 11 Transporting Unit The TI5400 GPU 24 has a telescoping handle that makes rolling the unit easy For transporting on uneven ground axle ex...

Page 24: ...cate 24 Vdc to 23 5 Vdc 23 Vdc minimum Ensure dc power cable plug is fully seated into the vehicle or aircraft s dc receptacle Figure 3 13 2 Attaching NATO DC Power Cable to vehicle Figure 3 13 3 Attaching an Aviation DC Power Cable to aircraft Low Power Demand Low power demand is defined by a requirement of 400 amps or less Connect dc power to aircraft ground power receptacle DC bus power should ...

Page 25: ...bars illuminate both the converter and power cells are supplying 24 Vdc power output for current demands above 60 amps CAUTION Unplug ac power cord before starting engine with unit High Power Demand High power demand is defined by a requirement of greater than 400 amps Connect to aircraft ground power receptacle DC bus power should come on and aircraft voltmeter should indicate 28 5 Vdc to 23 5 Vd...

Page 26: ...hen the Unit is fully charged the LED indicator should show a single steady green bar The fan will also come on at reduced speed This is normal operation indicating the unit is in standby mode and is ready for use If you own an older GPU and this is a replacement manual Under a full charge the LED indicator should show a single steady green bar or the entire LED will be blinking The fan will also ...

Page 27: ...the DVAM is a valuable tool for troubleshooting and system checks The left meter indicates DC voltage output and the right meter indicates amperage draw The meter s range changes from 0 200 AMPS to 0 2 000 AMPS with the flip of a switch The 200 amp setting provides a more detailed reading extending to two decimal places The 2 000 amp setting reads higher currents such as engine starts and in rush ...

Page 28: ...kcharge feature that enables the unit to be recharged from the vehicle once the engine is started and the starter generator is running This feature will enable you to start multiple vehicles without reconnecting to ac power if the GPU is allowed to backcharge for approximately 30 seconds NOTE Plug the TI4400 GPU 24 into ac power to keep the cells charged whenever it is not in use even if it is at ...

Page 29: ...be damaged if recharged by NiCad or Lithium Ion battery chargers Power cells should only be charged by either the TI4400 GPU 24 s internal charger and the ac power cord furnished with the equipment or when connected to aircraft s external dc power receptacle Figure 4 3 3 Proper and Improper Charging Methods OK OK ...

Page 30: ... cloth to remove dust dirt etc 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 than the Tesla cables included with the unit Figure 5 1 1 Damaged ...

Page 31: ...l the crate 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 INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 Website www teslaind com www tesla1 com Email Tesla1 teslaind com Figure 5 3 1 Tesla Shipping Case...

Page 32: ...art aboard your aircraft You may take the Turbo Start anywhere you travel ensuring that you will always have power 4 How much power will my Turbo Start provide Depending on the system the Turbo Start will provide anywhere from 1500 to 3500 peak starting amps 25 to 400 continuous amps dc and 23 to 96 hours of rechargeable power See our website www teslaind com to determine the proper Turbo Start fo...

Page 33: ...get my Turbo Start serviced Contact Tesla We can be reached at 302 324 8910 Ask for customer service You can also email us at tesla1 teslaind com Once we receive the unit at our facility we will examine it Systems that are protected under warranty will be repaired at no charge If the warranty has expired you will receive a quote for necessary repairs prior to work being done Our turnaround time is...

Page 34: ...ways running when I am plugged into ac power Constant cooling fan operation ensures proper and consistent ventilation of the unit 6 Why does the cooling fan slow down Cooling fan rpm varies for better temperature regulation 7 Why does my LED flicker when the unit is plugged in Older Turbo Starts indicated a full charge with a flickering LED readout Newer models feature the illumination of one gree...

Page 35: ...c outlet AC line cord is damaged or bad A Is ac line cord fully plugged into unit B and wall outlet AC circuit breaker has been tripped C No ac power at outlet D Do a continuity test on the ac line cord A Check if line cord is properly secured B Check to make sure ac circuit breaker C is placed in the ON position 4 Unit failed function test Internal failure A Please contact Tesla Customer Service ...

Page 36: ...rvice at 302 324 8910 8 Unit does not put out 28 5 volts dc power Unit is not plugged in A Plug unit into ac power source to A maintain 28 5 Stand alone Vdc is 24 Volts B unplugged 9 Unit stand alone voltage is less than 23 volts Cells discharged A Plug unit into ac power source A Recheck capacity after 25 minutes B Failure to hold above 23 Vdc Please C contact Tesla Customer Service at 302 324 89...

Page 37: ...ce 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 Derived From Actual Controlled Testing Controlled test data obtained on a similar unit type A Calculated Data Data based on tests but not on a similar unit type placed under a controlled test B Estimated Data Data based on estimates using rules of phy...

Page 38: ...14 0 6 8 19 0 66 2 52 0 125 6 46 0 50 8 13 0 8 6 20 0 68 0 53 0 127 4 45 0 49 0 12 0 10 4 21 0 69 8 54 0 129 2 44 0 47 2 11 0 12 2 22 0 71 6 55 0 131 0 43 0 45 4 10 0 14 0 23 0 73 4 56 0 132 8 42 0 43 6 9 0 15 8 24 0 75 2 57 0 134 6 41 0 41 8 8 0 17 6 25 0 77 0 58 0 136 4 40 0 40 0 7 0 19 4 26 0 78 8 59 0 138 2 39 0 38 2 6 0 21 2 27 0 80 6 60 0 140 0 38 0 36 4 5 0 23 0 28 0 82 4 61 0 141 8 37 0 34...

Page 39: ...Calculations based on actual test data at Pratt Whitney Canada on 30 March 1992 SECONDS AMPS MAXIMUM OUTPUT CURRENT 0 0 TI4400 Maximum Output Current OUTPUT VOLTAGE MINUTES 23 AMP CONSTANT CURRENT LOAD 24 20 16 12 8 4 0 0 10 20 30 40 50 60 TI4400 Output Voltage Without AC Power 7 7 Output Voltage 7 8 Maximum Output Current ...

Page 40: ...rotective Covers Protective unit from moisture sand and other damaging elements Custom fit for the TI4400 GPU 24 TI7000 084 8 3 Digital Volt Amp Meter TI3100A TheTesla DigitalVoltAmpMeterisahighpoweredmeasuring solution The DVAM 3100A provides measurements for DC voltage from 12 to 32 V and DC current up to 2000 amps for Aircraft and vehicle Integrated with the Tesla Turbo Start GPU power supply t...

Page 41: ... Customer Service TI2005 238 Cobra Aviation Plug TI2005 078 Cobra NATO Connector NSN 6130 01 523 1270 CL IX TI2005 251 DC Aviation Plug Positive Negative Contact TI2005 250 DC Aviation Plug 3 slotted Connector TI2004 341 Replacement Nose for Aviation Plug TI2005 654 DC 400Hz Aviation Plug Positive Negative Contact TI2005 239 Aviation Insertion Extraction Tool TI2004 340 Replacement Nose for 400Hz ...

Page 42: ...mail _______________________________________________________________________________________ Purchase Order ______________________________________________________________________________ Model ____________________________________ Serial ________________________________________ Model ____________________________________ Serial ________________________________________ Shipping method to Tesla ______...

Page 43: ...Tesla 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 www tesla1 com ...