Tesla™ TI100-PFC Ground Power Unit
Contents
1. Figure 3 8 3 Attaching DC Power Cable to aircraft fN NOJS Unit is not rated for engine starting It is to be used for ground maintenance only TILOO PFC 3 Operating Procedures 3 9 Turning on AC Input Circuit Breaker With the ac line cord plugged in and the dc cable connected to the TI100 PFC push the ac rocker switch to the On position After approximately 5 8 seconds the unit s LED status indicator will illuminate indicating output power status and cooling fans will operate When the TI100 PFC is operational the system will recondition and recharge vehicle batteries power avionics and any additional ground support y Figure 3 9 1 Turning On AC Input Circuit Breaker Low Power Demand Low power demand is defined by a requirement of 100 amps or less If the load demand is less than 100 amps converter output will remain at 28 5 Vdc only one GREEN LED status indicator bar will illuminate If load demand exceeds 100 amps converter voltage output will decrease and two or more LED status indicator bars will illuminate High Power Demand High power demand is defined by a requirement of greater than 100 amps Connect to aircraft ground power receptacle DC bus power should come on and aircraft voltmeter should indicate 28 5 Vdc to 23 5 Vdc 23 VCD minimum If current demand is greater than 100 amps converter output voltage will drop below 28 0 Vdc and LED status indicator lights will illuminate2. Normal Functional Test Procedures 19 20 5 3 Unit Servicing 20 5 4 Transporting Unit 21 5 5 Packaging and Shipping 21 section 6 Troubleshooting and FAQ 22 6 1 Frequently Asked Questions 22 23 6 2 Basic Unit Troubleshooting 24 Section 7 Optional Accessories 25 7 1 Transport Dolly 25 2 Cobra DC Replacement Contacts and Tools 20 7 3 Shipping Case 26 1 4 Protective Cover 26 7 5 Digital Volt Amp Meter TI3100A 26 Repair Request Form 21 TILOO PFC 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 i 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 TILOO PFC section 1 Safety Review 1 1 Safety Notices Safety notices appear throughout
3. Power Anytime Anywhere Tesla TI 100 P FC Ground Power Unit User Manual gt 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 T1100 PFC The TI100 PFC 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 TI100 PFC via a tool or device borescope probe etc can result in unit failure and or injury by electrical shock This GPU is maintenance free and should not be opened or disassembled for any reason Always protect the unit from short circuit Shipping Hazards The TI100 PFC does not pose a shipping hazard 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 retri
4. get my Tesla Power Supply serviced Contact Tesla 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 TILOO PFC Troubleshooting and FAQ 8 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 9 What type of maintenance does the Tesla Power Supply require The systems is maintenance free Keep the vent areas clean and free of debris Keep the unit in a protected environment when not in use maintenance facility shed 10 What is included with my Tesla Power Supply Customers will receive an eight 8 foot DC Aviation Cable Assembly T12007 208 or a fifteen 15 foot DC Mechanized Cable Assembly TI2007 315 or a fifteen 15 foot DC Cable with Alligator Clips TI12007 515 Additionally customers receive a full two year warranty 11 Are there any HAZMAT issues or disposability problems There are none Contact Tesla if you have questions TIL
5. in length It has a Hardwired Single Phase Plug TI25000 013 2621 25ft Hardwired Single Phase Plug AC Line Cord Contact Tesla Industries for additional plug configurations Figure 2 10 1 Connecting T1100 PFC to AC Figure 2 10 2 Hardwired Single Power Supply Phase Plug 2 11 24 Vdc Output Connector The 24 Vdc Output Connector will provide 100 amps continuous 28 5 Vdc when plugged into ac power When the Output Connector is not in use cover the receptacle with the protective cover See Figure 2 11 1 This will protect the Output Connector from dust and foreign matter Figure 2 11 1 24 Vdc Output Connector Protective Cover TILOO PFC Product Overview 2 2 12 Interface Connector The Interface Connector is used by a Tesla factory technician to calibrate the T1100 PFC W Figure 2 12 1 Interface Connector location outlined in blue 2 13 Output Power Status LED Indicator The Output Power Status LED Indicator provides a way for the user to visually see the amount of available power that the T1100 PFC can supply This lets the operator know if there is enough power to perform ground maintenance For example 1 green bar means 100 of power 100 amps is available 3 green bars means 80 80 amps of power is left 3 green bars and 3 yellow bars means that only 50 50 amps is available and so on T j an ey a rewu f Te M eae EL 5 barr T eTe f W
6. indicating current is being drawn from the power cells The greater the current draw the quicker the LED status indicator will approach red Note the LED status indicator shows the status of the power cells 3 10 Removing DC Power Supply From Vehicle or Aircraft 1 Turn Off AC Input Circuit Breaker 2 Remove dc power cable GPU connector from vehicle or aircraft Follow the installation instructions in reverse 3 Remove dc power cable connector from TI100 PFC if necessary Follow the installation instructions in reverse 4 Reinstall dc receptacle s protective cover 5 Unplug ac line cord from the wall by twisting the plug a quarter turn counter clockwise then pull out of the receptacle TILOO PFC section 4 Post Operation 4 1 General Although the TI100 PFC 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 4 2 After Use Unit should be protected from environmental elements and man made hazards Ideally unit should be secured in a building or shed TILOO PFC Section 5 Unit Care and Maintenance WARNING CAUTION 5 1 Unit Care Avoid Prolonged Exposure to Extremely Damp Environments Be sure to disconnect ac power from the ac source if the unit has come into contact with water If the AC Input Circuit Breaker has tripped due t
7. injury or death from electrical shock can occur when damp electrical plugs are connected to the TI100 PFC Make sure the electrical outlet is switched off before making any connections Failure to use proper grounding can cause potential shock hazard CAUTION The unit will be damaged if unapproved ac power is applied This Unit operates from Single Phase 200 260 Vac 40 Hz 450 Hz This must match ac power source hangar wall flight line ac power prior to connecting the T1100 PFC 1 4 Important Safety Precautions WARNING Severe injury or death from fire or explosion can occur if electrical sparks are produced near fuel vapors Power output is 28 5 Vdc DO NOT CONNECT ac power to GPU while operating or handling any aircraft fuel 1 5 Extreme Environments CAUTION The TILOO PFC 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 TILOO PFC Section 2 Product Overview 2 1 Introduction Thank you and congratulations on the purchase of your new TILOO PFC Ground Power Unit This GPU is one of Tesla Industries latest advancements in power technology development This G
8. 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 ee y adhered to could result in damage or destruction of equipment Indicates a condition operating procedure or practice which is essential to highlight 1 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 1 2 1 Different types of hazard and caution symbols TILOO PFC Safety Review 1 3 Hazards WARNING Severe injury or death from electrical shock will occur if either the user or the TIZOO PFC is wet while operating the unit with the 200 260 Vac power source attached Be sure to disconnect ac power from the ac source if the T1100 PFC has come into contact with water If the AC Input Circuit Breaker has tripped due to water infiltration DO NOT try to reset circuit breaker until GPU has dried completely WARNING Severe
9. ATIONS ONLY Snow falling intermediately with little or no accumulation Fog OK OK TILOO PFC 3 Operating Procedures 3 6 Pre Operation Be sure to check that all input and output cables are not damaged See Section 5 1 Check unit carefully for any evidence of damage See Section 5 2 Make sure that airflow is not obstructed from air intake and outlet See Section 2 6 P YN PR Check that all connections are secure and free from water Figure 3 6 1 TILQQ PFC 3 Regulated AC Power Plugging in with AC Power When attaching the ac line cord the user must make sure the plug is firmly seated all the way into the receptacle Figure 3 7 1 Connecting T1100 PFC to AC Power Supply TILOO PFC Operating Procedures 3 3 8 Regulated 28 5 Vdc Ground Power Connecting DC Power Cable To Unit Attaching a dc plug is quick and easy Line up the plug with the receptacle Push forward while rotating the T handle one full turn clockwise Ensure dc power cable plug is fully seated into the GPU s dc receptacle The unit is now ready to safely transfer power Figure 3 8 1 Attaching DC Power Cable to TI100 PFC Connecting DC Power Cable To Vehicle or Aircraft Line up the NATO plug or aviation dc plug pins and push it in DC bus power should come on and aircraft voltmeter should indicate 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
10. OO PFC Troubleshooting and FAQ 6 2 Basic Unit Troubleshooting Fault 1 Output Capacity LED does not come on 2 Unit will not power from ac outlet 3 Unit failed function test 4 Unit emits sparks when plugged into power source 5 Unit works then shuts down 6 Circuit breaker continuously trips gt Possible Cause Circuit Breaker has tripped No outlet power AC line cord is damaged or bad Is ac line cord fully plugged into unit and wall outlet AC circuit breaker has been tripped No ac power at outlet Internal failure Water or moisture has seeped in unit Internal failure Unit is overheating Cooling fans and vents are obstructed or inoperable A Unit is overheating Internal Short Remedy Plug the unit in to the appropriate ac power outlet B If LEDs still do not illuminate Please contact Tesla Customer Service at 302 324 8910 A Do a continuity test on the ac line cord B Check if line cord is properly secured C Check to make sure ac circuit breaker is placed in the ON position Please contact Tesla Customer Service at 302 324 8910 Move unit to dry warm air and allow to dry for over 48 hours Do Not Use Unit Please contact Tesla Customer Service at 302 324 8910 Move the unit to an area 10 20 less ambient temperature Clean and clear cooling vents turn o
11. Operation e One person can maneuver and operate the unit e Thermal Overload protection e Built in Power Output Indicator Pure Power e Operates from Single Phase 200 260 Vac power 40 450 Hz e 100 amps continuous 28 5 Vdc when plugged into ac power e 99 95 efficient active power factor correction e 1 THD Total Harmonic Distortion Tesla Industries Inc www teslaind com Email tesla1 teslaind com Headquarters 302 324 8910 101 Centerpoint Blvd New Castle DE 19720 USA Western Regional Office 775 622 8801 9475 Double R Blvd Suite 2 Reno NV 89521 USA PASEANTE Dimensions and Technical Specifications 27 61 701 3 23 75 WIIVSSS SOON POVI OVINOS BRIO SRS SSTN K Front View Side View All dimensions are in inches millimeters Technical Specifications DC Output 100 amps continuous 28 5 Vdc plugged into ac power AC Input Power e Operates from Single Phase 200 260 Vac 40 Hz 450 Hz e 16 5 amps 208 Vac 60 Hz e 20 amp Service Required e Contact Tesla Industries for plug configurations Includes an Option of one of the following DC Cable Assemblies Please contact Tesla Customer Service at 302 324 8910 for more dc cable options sft DC Aviation Cable 15ft DC Mechanized Cable 15ft DC Cable with Alligator TI2007 208 TI2007 315 Clips TI2007 515 Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 9475 Double R B
12. PU features a 6 5kW active Power Factor Correction PFC that is capable of pulling a current waveform identical to the applied voltage waveform This is the only PFC on the market that is capable of operating at 40 Hz to 450 Hz with 1 THD Total Harmonic Distortion What this means for the end user is that this GPU is capable of producing the same output power of one of our three phase GPU s while operating off of single phase power It offers a wide versatility of power options while effectively lowering energy consumption The TILOO PFC was designed to provide 100 amps 28 5 Volts of pure regulated flat line dc power for vehicle ground support avionics battery charging power for training facility operations and for all 24 Volt systems This manual contains the complete operating instructions and procedures for the T1100 PFC that the end user will need to safely and efficiently operate this GPU Figure 2 1 1 T1100 PFC Unit is not rated for engine starting It is to be used for NOEs ground maintenance only 2 2 Indication of Terms 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 TILOO PFC 2 3 Front Panel Overview 24 V
13. Power Factor while doing the same work Power Factor PF in ac systems is defined as the ratio of the real power W watts flowing to the load over the apparent power VA volts amps in the circuit This is represented by a number between O and 1 For example this is a percentage 5PF 5 PF A power supply is considered to be a non linear load in which the ac power is rectified and then filtered It is these non linear loads that reshape the current waveform into something different introducing harmonics and distortion known as THD Total Harmonic Distortion THD is defined as the ratio of the sums of all the powers of the harmonics to the power of the fundamental frequency i e the fundamental frequency would be the line frequency 60 Hz and the 2nd order harmonic 120 Hz the 3rd order 240 Hz etc THD A 24 Pn PF NI l AT 1 THD 2 L When the mains instantaneous voltage exceeds the voltage of the Input Capacitors the Rectifiers conduct which causes a current spike see Figure 2 8 1 These spikes induce harmonics and distortion These additional harmonics over the fundamental frequency are what contribute to a poor Power Factor The higher order harmonics in the ac current cause the skin effect of the conductors carrying the ac currents to the load to increase Skin effect in ac circuits is where the higher frequency currents do not penetrate the entire conductor due to the opposing eddy currents causing them to ride along the surfa
14. RMANCE DATA to determine the capability of the T1100 PFC Consideration must be given to changes in performance resulting from variations in ambient temperature mode of operation state of charge and aircraft DC bus system inefficiency voltage drops TILOO PFC Operating Procedures 3 5 Environmental 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 Unitinlet and outlet vent ports shall be covered from exposure Unitshall be kept horizontal It is recommended thatthe Tesla Protective Rain Cover be fitted onto the unit to guard it from moisture See Section 8 The limits and operational constraints listed below shall apply for the following environmental weather conditions With Conditions Without Raincover Raincover Heavy or steady rain OK OPERATION NOT RECOMMENDED 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 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 OPER
15. ce of the conductor Itis these magnetic fields generated by the eddy currents which cause the resistivity of the conductor to increase with frequency This means the conductor needs to carry additional currents plus the load current to compensate for the higher order harmonics These extra currents generate magnetic fields and are stored in the power lines the switch gear and the power supply They then return back to the power grid during the off periods of the cycle resulting in wasted energy in the form of heat Tesla Industries was able to develop a wide bandwidth active Power Factor Correction that runs from 40 Hz to 450 Hz which pulls unity power only at the fundamental frequency This was achieved by forcing the current to follow the voltage waveform See Figure 2 8 2 so that current is pulled through the entire sinusoidal waveform on a cycle by cycle basis This eliminates the current spikes and strips out the additional harmonics causing a massive increase in efficiency TILOO PFC Product Overview Figure 2 8 1 Non PFC Power Supply Figure 2 8 2 Tesla s PFC Power Supply 2 9 AC Input Circuit Breaker This unit is equipped with a 20 Amp AC Input Circuit Breaker located above the AC Input Connector The AC Input Circuit Breaker acts as an On Off switch for the unit Figure 2 9 1 AC Input Circuit Breaker outlined in blue TILOO PFC 2 Product Overview 2 10 AC Line Cord The ac line cord is 25
16. ckers Front and Back on the T1100 PFC TI100 PFC Unit Care and Maintenance 5 4 Transporting Unit The TI100 PFC can be carried for short distances by hand If the area of operation is further then 45 meters 150 feet the TILOO PFC should be transported on a vehicle or in the TI7000 184 Transport Dolly see Section 8 Optional Accessories Figure 5 4 1 TI7000 184 Transport Dolly 5 5 Packaging and Shipping When returning the GPU please ensure that it is properly packaged The only method for transport is in a sturdy shipping crate be sure to enclose the Repair Request Form Seal 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 Email Tesla1 teslaind com TILOO PFC section 6 Troubleshooting and FAQ 6 1 Frequently Asked Questions 1 Why should buy a Tesla Power Supply Tesla Power Supply are multi functional systems 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 flat line dc power in a completely safe package Designed for Mi
17. dc Output Connector Provides 100 amps continuous at 28 5 Vdc when plugged into ac power Output Connector Protective Cover Protects Output Connector from dust and foreign materials Air Intake Ports Provide airflow for cooling internal electronics Carrying Handle Allows for easy transport of unit 2 Product Overview Output Power Status Indicator Displays the amount of available power the GPU can supply External AC Circuit Breaker Protects the internal electrical circuit from damage caused by overload or short circuit Interface Connector Used for factory calibrations Hardwired Single Phase AC Power Cord Provides 16 5 amps 208 Vac 6OHz AC cord length is 25ft TILOO PFC Product Overview 2 4 General Specifications Electrical AC Input Power e 6 5 kW active Power Factor Correction e Operates from Single Phase 200 260 Vac 40 Hz 450 Hz e 16 5 amps 208 Vac 60 Hz 3432 Watts e 20 amp Service Required e Contact Tesla Industries for Plug Configuration PFC e 99 95 EFF efficiency e 1 THD Total Harmonic Distortion DC Output Power e 100 amps continuous 28 5 Vdc when plugged into ac power Size e 27 61 long x 5 2 wide x 10 56 high e 01 3 mm x 132 08 mm x 268 25 mm Weight e 29 5 Ibs 13 4 kg Operating Temperature e 40 C to 55 C 40 F to 131 F Storage Temperature e 65 C to 105 C 85 F to 221 F TILOO PFC Product Overvie
18. eval system without prior written permission from Tesla Industries Inc Nei Unit is not rated for engine starting It is to be used for ground maintenance only Copyright 2015 by Tesla Industries Incorporated All rights reserved TILOO PFC 02 13 15 Table of Contents Section 1 Safety Review 1 1 Safety Notices 1 2 Symbols 1 3 Hazards 1 4 Important Safety Precautions 1 5 Extreme Environments Section 2 Product Overview 2 1 Introduction 2 2 Indication of Terms Shall Should May 2 3 Front Panel Overview 2 4 General Specifications 2 5 Physical Dimensions 2 6 Airflow Ports 2 Operating Positions 2 8 Active Power Factor Correction 2 9 AC Input Circuit Breaker 2 10 AC Line Cord 2 11 24 Vdc Output Connector 2 12 Interface Connector 2 13 Output Power Status LED Indicator Section 3 Operating Procedures 3 1 Operating Procedures 3 2 General 3 3 Operating Limits and Restrictions 3 4 Performance 3 5 Environmental 3 6 Pre Operation 3 7 Regulated AC Power 3 8 Regulated 28 5 Vdc Output Ground Power 3 9 Turning On AC Input Circuit Breaker 3 10 Removing DC Power Supply from Vehicle or Aircraft MR N NFP RF FE O ONO DO OH BWW W ee ee ee ER OO 12 12 12 12 12 13 14 14 15 16 16 TILOO PFC Section 4 Post Operation 17 4 1 General 17 4 2 After Use 17 Section 5 Unit Care and Maintenance 18 5 1 Unit Care 18 5 2
19. ge is evident contact Tesla Industries Inc Check Unit Internal Resistance Test for Shorts 1 Set multimeter to Ohms 2 Without ac power place the nega 3 Without ac power place the nega tive probe on a screw of the dc re tive probe on a screw of the dc re ceptacle Move the positive probe ceptacle Move the positive probe to the dc positive post Multimeter to the dc negative post Multimeter Should read OL Open Line should read OL Open Line TILOO PFC 9 Unit Care and Maintenance Check DC Voltage Reading at DC Receptacle Terminals 1 Plug unit into ac power and turn on AC 2 Testing DC Receptacle reading should be Input Breaker See Section 3 7 and approximately 28 5 3 9 One green LED should illuminate Set multimeter to Vdc S 4 E a r 5 E o 3 i er a k a gt l 7 k a 3 Move the positive probe to the dc positive post 4 Move the positive probe to the dc negative Reading should be O post Reading should be O 5 3 Unit Servicing The TI100 PFC is a maintenance free sealed unit No repairs outside of Tesla are authorized 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 5 3 1 below If the unit requires maintenance please contact Tesla s Customer Service at 302 324 8910 A Repair Request Form can be found in the back of this manual Figure 5 3 1 Warranty Void sti
20. i te ba e q j A il ee mm A d T Figure 2 13 1 Output Power Status Indicator location outlined in blue 50 50 i 60 60 100 Output 50 Output Less Than 20 Power Remaining Power Remaining Output Power Remaining TILOO PFC section 3 Operating Procedures 3 1 Operating Procedures This section deals with normal procedures and includes all steps necessary to ensure safe and efficient operation of the TILOO PFC Nell Unit is not rated for engine starting It is to be used for ground maintenance only 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 the converter is supplying 24 Vdc power output 3 2 General Correct operation of the T1100 PFC 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 3 3 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 3 4 Performance Refer to Section 7 PERFO
21. litary applications 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 are Tesla Power Supply used in Aviation Support There are many ways a Tesla Power Supply will benefit your operation By using it for pre flight testing you will avoid depleting the aircraft s battery In the hangar when connected to ac power the Tesla Power Supply will provide 28 5 Vdc for avionics testing 3 How much power will my Tesla Power Supply provide The TIZOO PFC will provide up to 100 amps continuous regulated dc power at 28 5 Vdc 4 Is it waterproof Water resistant but not waterproof 5 Are Tesla Power Supply s 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 flat line 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 6 Can one person transport it The T1100 PFC is designed to be handled by one person The T1100 PFC weighs 29 5 Ibs and can be carried or wheeled on a dolly Tl 7000 184 T How do I
22. lvd Suite 2 Reno NV 89521 USA www teslaind com 01 14 15
23. n unit and inspect if air is flowing through unit If no airflow please contact Tesla Customer Service at 302 324 8910 Disconnect unit from ac input and dc output Switch breaker to ON position Reconnect unit to cables and run If LEDs still do not illuminate Please contact Tesla Customer Service at 302 324 8910 TILOO PFC section Optional Accessories 7 1 Transport Dolly The Tesla TI7O00 184 is a custom aluminum dolly designed especially to transport the TILOO PFC The TI7000 184 is the safest and easiest way to support and transport the TIZOO PFC out in the field and through hangars and flight lines The Transport Dolly comes with a 2 year warranty Dimensions 16 87 Lx 14 5 W x 49 25 H 428 50 mm x 368 30 mm x 1250 95 mm Weight 18 5 Ibs 8 39 kg 1 2 Cobra DC Replacement Contacts and Tools Cobra DC Plugs are designed to provide reliable high power connections up to 3000 amps even in the harshest conditions Each plug is constructed from a rugged combination of advanced composite materials and corrosion resistant alloys to maximize durability and connectivity To extend the life of the Cobra Connector included with your unit replacement contacts posts noses and tools can be ordered through the Tesla Customer Service TI2005 238 Cobra Aviation Plug TI2005 654 TI2005 251 a DC Aviation Plug DC 400Hz Aviation Plug Positive Negati
24. o water infiltration allow the unit to dry out before attempting to reset circuit breaker 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 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 cable TILOO PFC Unit Care and Maintenance 5 5 2 Normal Function Test Procedures This section deals with normal function test procedures and includes all steps necessary to ensure that the T1100 PFC is operating within specified parameters prior to use A digital multimeter an example is shown in Figure 5 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 5 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 dama
25. ring 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 the DVAM is a valuable tool for troubleshooting and conducting systems checks The DVAM 3100A can be ordered through customer service at Tesla TILOO PFC 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 lesla Industries Inc 101 Centerpoint Boulevard New Castle DE 19720 Attention Repair Department TILOO PFC 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 Bivd Suite 2 Reno NV 89521 Tel 775 622 8801 Fax 775 622 8810 www teslaind com TI100 PFC Power Anytime Anywhere Benefits e Perfect for testing and troubleshooting avionics TMDE and electronics e Will charge and maintain batteries when unit is left connected to vehicle or aircraft ac power required e Safe easy maintenance free operation Safe and Easy
26. ve Positive Negative Contact Contact 2005250 OO e DC Aviation Plug 3 slotted Connector T12004 341 A Replacement Nose for Aviation Plug Aviation Insertion Extraction Tool TI2004 340 BE Replacement Nose for 400Hz Aviation Plug TILOO PFC TI2005 078 Cobra NATO Connector NSN 6130 01 523 1270 CLIX T12004 444 NATO Replacement Post eo For newer NATO plugs with new style post indicated by the black tip Replacement plug uses standard 3 4 deep well socket for installation TI2005 121 NATO Negative Contact NSN 5999 01 525 0582 CL IX TI2005 126 as NATO Negative Contact Insertion Extraction Tool NSN 5120 01 523 8761 CL II TI2005 117 NATO Positive Post NSN 5935 01 523 8914 CL IX TI27000 082 NATO Positive Contact Insertion Extraction Tool NSN 5120 01 527 7729 CL Il 8 Optional Accessories 1 3 Shipping Case The optional Shipping Case is the safest way to transport the TI1O0 PFC This custom case weighs 23 Ibs and comes equipped with side handles and locking latches T17000 024 NSN 8145 01 445 3666 Length 24 64 625 85 mm Width 9 14 232 15 mm Height 19 26 489 2 mm Weight 23 Ibs 10 5 kg 1 4 Protective Cover Protects unit from moisture sand and other damaging elements Custom fit for the T1100 PFC T17000 046 7 5 Digital Volt Amp Meter TI3100A The Tesla Digital Volt Amp Meter is a high powered measu
27. w 2 5 Physical Dimensions 27 61 701 3 _ 23 75 eo SOR ORRAKRARRAR A SESS SSS i UN L VENEN NN ree i CAUVO GLVL NON IN N SAQA SC SISSIES Figure 2 5 1 T1100 PFC physical dimensions 2 6 Airflow Ports CAUTION When the TI100 PFC 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 ambient temperature by more than 10 F M l o q l a Al 9 Figure 2 6 1 Air intake exhaust ports and internal air circulation TILOO PFC Product Overview 2 2 Operating Positions The TI100 PFC can be operated 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 T m 7 J Figure 2 7 2 Horizontal Position a 4 1 4 Figure 2 7 1 Vertical Position Figure 2 7 3 Front Inlet Figure 2 7 4 Rear Outlet TILOO PFC Product Overview 2 8 Active Power Factor Correction In electric power systems a power supply with a low Power Factor will draw more current than the same power supply with a high
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