Tesla™ TI2000-009 Transformer
Contents
1. Power Anytime Anywhere Tesla TI2000 009 Transformer 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 TI2000 009 Iransformer The TI2000 009 Step Down Transformer is a limited maintenance free and sealed unit No repairs are authorized Warranty will be voided if unit is tampered with in any way 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 CAUTION 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 the TI2000 009 Step Down Transformer via a tool or device borescope probe etc can result in unit failure and or injury by electrical shock Always protect the unit from short circuit No part of this manual may be 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 Indus2. 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 M cables included with the transformer CAUTION TI2000 009 Transformer 15 8 Unit Care and Maintenance 8 2 Normal Function Test Procedures This section deals with normal function test procedures and includes all steps necessary to ensure that the TI2000 009 is operating within specified parameters prior to 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 Figure 8 2 1 Digital Multimeter 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 2 Damaged Unit Misaligned Case with Bent Faceplate AG T12000 009 Transformer Unit Care and Maintenance 8 Check Unit Internal Resistance Test for Shorts This section deals with normal function
3. test procedures and includes all steps necessary to ensure that the transformer is operating within specified parameters prior to 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 Approximately 120 VAC 1 Place the negative probe on the re 2 Move the positive probe to the right 3 Move the positive probe to the lower ceptacle s left ground insert and side phase 2 positive insert phase 3 positive post the positive probe on top side phase 1 insert Check Unit Approximately 208 VAC adi a M e 1 Move the negative probe to the up 2 Move the positive probe to the lower 3 Move the negative probe to the right per phase 1 probe and the positive phase 3 positive post side phase 2 probe and the positive probe to right side phase 2 probe probe to lower phase 3 probe TI2000 009 Transformer 17 Section 9 Frequently Asked Questions 1 Why should buy a Tesla Turbo Start System Tesla Turbo Start is a multi functional system that are ideal for support of 24 VDC vehicles and aircraft and their electronics avionics on the bench Tesla manufactures various systems of different sizes and capacities that are man portable maintenance free and provide pure DC power in a completely safe package Designed for Military ap
4. cord for their home country and a full two year warranty 1 Are there any HAZMAT issues or disposability problems There are none Tesla will reclaim all battery cells for disposability purposes Contact Tesla if you have questions TI2000 009 Transformer Abbreviations and Symbols Abbreviations 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 Abbreviation Amp AC C cont DC F Ft FWD GPU Hr Hz Kg KW LED MAX MIN MPU VAC VDC Definition Ampere Alternating Current Degree Celsius Continuous Direct Current Degree Fahrenheit Feet Forward Ground Power Unit Hour Hertz Kilograms Kilowatts Light Emitting Diode Maximum Minimum Micro Power Unit Volts Alternating Current Volts Direct Current TI2000 009 Transformer 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 TI2000 009 Transfo
5. de of the unit features replaceable fuses 1 1 208 Three Phase Output 2 480 Three Phase Input 3 Locking Casters TI2000 009 Transformer 5 4 Features 4 2 480 VAC Input The 480 Three Phase VAC input cable is twenty feet long with a plug Figure 4 2 1 480 VAC Input cable location CAUTION Unit may be damaged if incorrect AC power is applied Check to make sure the unit is plugged into 480 phase VAC Figure 4 2 2 480 VAC cable plugged in G T12000 009 Transformer Features 4 4 3 280 VAC Output The TI2000 009 has a 208 three phase VAC output located on the top of the unit The output is a female receptacle and is used for plugging in the TI4200 GPU 24 TI4400 GPU 24 TI5200 GPU 24 or TI5400 GPU 24 male plug Figure 4 3 1 208 VAC Input cable location Figure 4 3 2 208 VAC receptacle Figure 4 3 3 208 VAC cable plugged in TI2000 009 Transformer 7 4 Features 4 4 Fuses To protect the unit from damage there are three fuses inside the unit In order to replace the fuses the unit must be opened The TI2000 009 has a three 30A 600V fuses located on the backside of the front panel Check with multimeter to ensure the fuses are blown before replacing CAUTION Be sure unit is completely disconnected from power before opening unit NOTE This is the only repair authorized for the user For all other repairs please contact Tesla s Customer Service Department at 302 324 8910 with any que
6. dicate 23 5 to 24 VDC 23 VDC minimum starting Aircraft Engine Check power cable for security and correct installation prior to engine start Follow ground power unit engine starting procedure as specified in aircraft operator s manual Figure 6 6 1 Connecting DC cable to aircraft and starting engine TI2000 009 Transformer 13 section Post Operating Procedures 7 1 General When not in use the TI2000 009 Transformer should be covered and stored in a dry temperature controlled area Protect the unit from the elements and man made hazards whenever possible Make sure to keep the transformer s receptacle plugs and air vents clear of debris Disconnect unit and allow cooling time 14 TI2000 009 Transformer Section amp Unit Care and Maintenance 8 1 Unit care Avoid Prolonged Exposure to Extremely Damp Environments Be sure to disconnect AC power from the AC source if the TI2000 009 has come into contact with water If the fuse has tripped due to water seepage allow the unit to dry out before attempting to replace Cover the unit to prevent water seepage If the unit is operated in extremely damp conditions it should be stored in an environmentally controlled building when not in use Wipe unit clean periodically with a soft 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 TI2000 009 Always inspect cables prior to use
7. e unit and troubleshoot the power source Unit may be damaged if incorrect AC power is applied The transformer CAUTION must be plugged into a 480 three phase VAC power source Figure 6 3 1 Transformer connected to VAC Power TI2000 009 Transformer 6 Operating Procedures 6 4 Connect Ground Power Unit to Transformer Before plugging the unit into the Transformer switch the GPU s input power circuit breaker to the OFF position The TI5400 400HZ GHMD can then be plugged into the transformer s output socket Once the plug is securely in place the input power circuit breaker can be switched to the ON position Figure 6 4 1 Transformer connected to GPU 6 5 Connect DC Cable to Ground Power Unit The chances of accidental arching are low but for added safety press the DC Output OFF button Ensure power cable connector is fully seated into the DC output receptacle Figure 6 5 1 DC ON OFF buttons location Figure 6 5 3 DC cable plugged into GPU AZ T12000 009 Transformer Operating Procedures 6 6 6 Connect DC Cable to Aircraft To prevent arching while connecting DC power to the aircraft press the DC output OFF button then connect DC power to the vehicle Ensure ground power cable connector is fully seated into aircraft receptacle When you are ready to supply DC power press the DC output ON button and it will illuminate DC bus power should come on and the aircraft s voltmeter should in
8. ess heat 8 Is it waterproof Water resistant but not waterproof See Environmental Section TI2000 009 Transformer FAQ 9 Are Tesla M GPUs used in shop maintenance and testing Tesla systems are gaining popularity throughout maintenance facilities instructional facilities laboratories manufacturing plants aircraft hangars and many other locations The reason is due to the precise DC power the small portable and quiet nature of our systems and the maintenance free aspect of our GPU s We can custom tailor ground power systems to fit your individual requirements 10 Can one person transport it Turbo Start is designed to be handled by one person The TI500 is our smallest GPU system to date and weighs 36 Ibs The TI1000 weighs 57 Lbs and can be carried or wheeled on a dolly Larger units have wheels incorporated directly on the system with an extendable handle 11 Is the Turbo Start in the government purchasing system Yes Tesla Industries is an approved vendor supplier our cage code is OVWE2 Most Tesla products are class IX have a NSN National Stock Number designation and can be acquired through the DLA Defense Logistics Agency 12 How long does this unit stay charged Unit should never be allowed to discharge fully In field use it receives a DC back charge directly from a running engine When not in use unit should be plugged into AC power outlet all the time Tesla systems will retain 80 of
9. fuel handling operation 2 5 Extreme Environments CAUTION The TI2000 009 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 NOTE This Transformer is for Indoor use only TI2000 009 Transformer Section 3 Unit Specifications 3 1 General Specifications Electrical Input Power 480 VAC 30 Amps 3g 60Hz 15 KVA 30 Amps Max Class 220 C 150 C Temperature Rise Output Power 208 VAC 3g 60Hz 15 KVA TO Amps Max Size e 25 8 long x 19 25 wide x 24 66 high 655 5mm x 489mm x 626 3mm Weight e 265 lbs 120 2 kg 3 2 Physical Dimensions 4 _ 14 88 377 9 E Side View All dimensions are in inches millimeters 22 90 581 7 26 24 666 6 Delta 9 39 238 5 Front View 24 89 632 2 20 30 515 6 7 H i y IH Top View TI2000 009 Transformer Section 4 Features 4 1 Features Overview The TI2000 009 is designed to convert 480 VAC three phase to 208 VAC three phase The unit s exterior features an input receptacle an output receptacle and wheels for transport The insi
10. hree phase VAC This manual makes specific reference to the TI2000 009 Transformer being used as an accessory providing 208 three phase VAC to Tesla Industries Ground Power Units The observance of procedures limitations and performance criteria is essential to ensure peak operating efficiency and to maximize operational capabilities and life of the TI2000 009 Transformer Figure 1 1 1 TI2000 009 Transformer 1 2 Use of Words Shall Should and May Within this technical manual the word shall is used to indicate a mandatory requirement for proper operation and warranty purposes The word should is used to indicate a non mandatory but preferred method of accomplishment The word may is used to indicate an acceptable method of accomplishment TI2000 009 Transformer 1 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 TI2000 009 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 CAUTION Indicates a condition or operating procedure which if not strictly adhered to could result in damage or destruction of equipment DANGER Indicate
11. ive wear broken loose fasteners and cable attachment Replace contacts or entire plug if necessary TI2000 009 Transformer section 6 Operating Procedures 6 1 General This section defines the operating procedures which includes all steps necessary to ensure safe and efficient operation Correct operation of the TI2000 009 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 6 2 Operating Limits and Restrictions The minimum maximum and normal operating ranges result from careful engineering and evaluation of test data These limitations must be adhered to during all phases of operation WARNING Severe injury or death from fire or explosion can occur if electrical sparks are produced near fuel vapors To prevent this make sure electrical outlets are switched to OFF position before connecting electrical plugs For added safety this unit shall not be operated during any aircraft fuel handling operation 6 3 Connect to VAC Power Plug the transformers VAC input plug into the appropriate 480 three phase VAC outlet All three phase lights will come on If all three lights do not activate then there is a problem with the AC power source Disconnect th
12. of rechargeable power See our website www teslaind com to determine the proper Turbo Start for your needs 5 Will a Tesla Turbo Start spool up a turbine engine Nothing will start a turbine engine faster or safer than the right Tesla Turbo Start Not only will it eliminate hot starts but it will extend the life of your starter your engine and your battery while reducing maintenance The Turbo Start senses the impedance from the starter generator It then provides the exact power required throughout the start up curve 6 How many engine starts will my Turbo Start provide until it is depleted The Turbo Start back charges almost instantly once the vehicle aircraft is started and the generator is on line This power flywheel feature enables the Turbo Start to recharge itself right from the vehicle it started in less than 30 seconds You can go down the line in your motor pool and start every 24V vehicle without limit f How do you prolong the life of the Turbo Start s cells All you need to do is plug the unit in to the appropriate AC power outlet the system requires AC power will recharge the system and keep the cells healthy Users who regularly plug the system in can expect to get 5 7 years from their cells before they need to be replaced Tesla cells do not have a memory like cell phone batteries There is no need to fully discharge them The recharging system will not overcharge the unit or produce exc
13. plications these systems are equally valuable in maintenance support at the main facility or in remote locations They are easily transported and air portable They will also provide 28 5 VDC when the system is connected to the appropriate AC source 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 intelligent charging system for the cells The cells are ideal for this application as they are non spillable absorbed electrolyte dry cells that are sealed maintenance free and safe for air transport 3 How is Turbo Start used in Aviation Support There are many ways a Turbo Start will benefit your operation By using it for pre flight testing you will avoid depleting the aircraft s battery You can start the aircraft s engine with the Turbo Start as well In the hangar when connected to AC power the Turbo Start will provide 28 5 VDC for avionics testing and will also recondition and recharge the aircraft s battery Another benefit is the ability to fly with the Turbo Start 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
14. rmer WE GET THE MILITARY STARTED Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 USA Tele 302 324 8910 Fax 302 324 8912 9475 Double R Blvd Suite 2 Reno NV 89521 Tele 775 622 8801 Fax 775 622 8810 www teslaind com TI2000 009 Step Down Transformer Power Anytime Anywhere 15 kVA 3 phase 60 Hz Input 480 VAC 30 Amps Max 60 Hz Output 208 VAC 70 Amps Max 60 Hz Converts 480 VAC 3 phase to 208 VAC 3 phase Used with the TI4200 Tl4400 TI5200 and TI5400 GPUs Size 25 8 Lx 19 25 W x 24 66 H 655 5 mm x 489 mm x 626 3 mm Weight 265 Ibs 120 2 kg 9 39 238 5 9 03 229 4 an gu TT 9m 22 90 581 7 26 24 666 6 24 89 632 2 20 30 515 6 7 m _ 14 88 377 9 Side View Front View Top View All dimensions are in inches millimeters Tesla Industries Inc Headquarters 302 324 8910 e 101 Centerpoint Blvd New Castle DE 19720 Email tesla1 teslaind com Western Regional Office 775 622 8801 9475 Double R Blvd Suite 2 Reno NV 89521 USA www teslaind com 02 11 14
15. s a condition operating procedure or practice which if not adhered to could result in serious injury or death 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 specific 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 TI2000 009 Transformer Safety Review 2 3 Hazards WARNING Severe injury or death from electrical shock will occur if either the user or the TI2000 009 is wet while operating the unit with the 480 208 VAC power source attached Be sure to disconnect power from the source if the TI2000 009 has come into contact with water WARNING Severe injury or death from electrical shock can occur when damp electrical plugs are connected to the TI2000 009 Make sure the electrical outlet is switched off before making any connections Failure to use proper grounding can cause potential shock hazard 2 4 Important Safety Precautions WARNING Severe injury or death from fire or explosion can occur if electrical sparks are produced near fuel vapors To prevent this make sure electrical outlets are switched to OFF position before connecting electrical plugs For added safety this unit shall not be operated during any aircraft
16. stions or concerns Figure 4 4 1 Replaceable Fuses BS T12000 009 Transformer Features 4 4 5 Transporting Unit The TI2000 009 has a telescopic handle that makes it easy to roll or push the unit It is also equipped with four wheels Handle Lockable casters Figure 4 5 1 Handle and Wheel Locations Lockable Casters and Handle The Transformer is equipped with a handle and four lockable casters The transformer can be maneuvered on all four or you can remove the wheel base and mount the transformer to a solid surface wall floor etc Figure 4 5 2 Transformer Handle Figure 4 5 3 Lockable Casters TI2000 009 Transformer 9 Section 5 Pre Operation 5 1 Maintenance Check Before operating the TI2000 009 check for any signs of damage or wear to the unit tires cables and plugs Check Unit Check the unit for dents punctures case distortion or mis alignment cracked or loose connectors If no external damage is evident user may proceed If damage is evident contact Tesla Industries Check Casters The TI2000 009 is equipped with four lockable casters Before moving the transformer make sure all four casters are unlocked so it can properly be moved to the desired location Check DC Power Cable And AC Power Cord For Damage Crushed or torn cables will need to be replaced before any operations can occur Check DC Power Cable Connections For Damage Check connectors for cracks cuts distortions excess
17. their capacity after one year of storage 13 How do 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 48 hours once repairs are authorized 14 Can make my own repairs to unit During the warranty period the unit can only be repaired by Tesla Industries for the warranty to remain in effect Regardless we strongly recommend allowing Tesla to repair any unit as we will analyze the complete system and re calibrate it 15 What type of maintenance does the Turbo Start require Although the systems are maintenance free please keep units plugged in while not in use This will greatly extend the life of the cells Also keep the vent areas clean and free of debris Keep units in a well ventilated area while charging Keep the unit in a protected environment when not in use maintenance facility shed etc 16 What is included with my Turbo Start V Aviation customers will receive an eight 8 foot DC Aviation Cable Assembly TI2007 208 Ground vehicle customers will receive a fifteen 15 foot DC NATO Cable Assembly TI2007 315 All customers receive an AC line
18. tries Incorporated All rights reserved TI2000 009 Transformer 02 11 14 Table of Contents Section 1 Product Overview 1 1 Introduction 1 2 Use of Words Shall Should May 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 Physical Dimensions Section 4 Features 4 1 Features Overview 4 2 480 VAC Input 4 3 280 VAC Output 4 4 Fuses 4 5 Transport Features Section 5 Pre Operation 5 1 Maintenance Checks Section 6 Operating Procedures 6 1 General 6 2 Operating Limits and Restrictions 6 3 Connect to VAC Power 6 4 Connect Ground Power Unit to Transformer 6 5 Connect DC Cable to Ground Power Unit 6 6 Connect DC Cable to Aircraft Section 7 Post Operating Procedures 7 1 General Section 8 Unit Care and Maintenance 8 1 Unit Care 8 2 Normal Functional Test Procedures Section 9 Frequently Asked Questions Abbreviations and Definitions Repair Request Form 0 I DU OQ h sa W WWNN NE FE e e O FRR RP PR PB RR WIN NE E RB RB e Hm o a RR 16 17 18 19 20 21 TI2000 009 Transformer Section 1 Product Overview 1 1 Introduction This manual contains the complete operating instructions and procedures for the TI2000 009 Transformer The TI2000 009 Transformer is intended for converting 480 three phase VAC to 208 t
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