TI2000-054 Step Down Transformer
Contents
1. O CO NOD O1 BWW W TI2Z000 054 Transformer Section 5 Operating Procedures 15 5 1 General 15 5 2 Operating Limits and Restrictions 15 5 3 Connect to VAC Power 15 5 4 Connect Ground Power Unit to Transformer 16 5 5 Connect DC Cable to Ground Power Unit 16 5 6 Connect DC Cable to Aircraft 1 Section 6 Post Operating Procedures 18 6 1 General 18 Section 7 Unit Care and Maintenance 19 7 1 Unit Care 19 7 2 Normal Functional Test Procedures 20 21 Section 8 Frequently Asked Questions 29 30 Repair Request Form 31 TI2Z000 054 Transformer 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 Degree Celsius cont Continuous DC Direct Current F Degree Fahrenheit Ft Feet FWD Forward GPU Ground Power Unit Hr Hour Hz Hertz Kg Kilograms KW Kilowatts LED Light Emitting Diode MAX Maximum MIN Minimum MPU Micro Power Unit VAC Volts Alternating Current VDC Volts Direct Current T12000 054 Transformer Section 1 Safety Review 1 1 Safety Notices Safety notices appear throughout this manual to alert the user to important information regarding proper installation operation maintenance and storage of the unit These notices as illustrated below contain2. Phase Indicator Lights The Phase indicator lights indicate that each phase is live All three lights should activate when the unit is plugged into the AC power source If all three lights do not activate then there is a problem with the AC power source Disconnect the unit and troubleshoot the power source Figure 2 9 2 Indicator Lights OFF Figure 2 9 3 Indicators Lights ON 1000 T12000 054 Transformer Product Overview 2 2 10 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 054 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 Customer Service at 302 324 8910 with any questions or concerns Figure 2 10 1 Replaceable Fuses TI2000 054 Transformer 11 2 Product Overview 2 11 Transporting Unit The T12000 054 has a telescopic handle that makes it easy to roll or push the unit It is also equipped with four wheels Telescopic Handle Wheels Figure 4 6 1 Telescopic Handle and Wheel Locations Lockable Casters and Run flat Tires The Transformer is equipped with two ten inch run flat tires and two lockable casters The transformer can be man
3. 3 1 Transformer connected to VAC Power TI2Z000 054 Transformer 5 Operating Procedures 5 4 Connect Ground Power Unit to Transformer NOTE Before plugging the unit into the Transformer switch CAUTION pee ne 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 5 4 1 Transformer connected to GPU 5 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 EJ Pr i Ba h T FE i P ee iy C 1 Figure 5 5 2 DC ON OFF buttons Figure 5 5 3 DC cable plugged into GPU 460 112000 084 Transformer Operating Procedures 5 5 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 indicate 23 5 to 24 VDC 23 VDC minimum Starting Aircraft Engine Check power cable for security
4. Do not allow the unit to be exposed to precipitation or excessive moisture Figure 2 5 1 Air intake and exhaust ports and internal air circulation TI2Z000 054 Transformer Product Overview 2 2 6 Features Overview The T12000 054 is designed to convert 480 three phase VAC to 208 three phase VAC The unit s exterior features an input receptacle an output receptacle phase indicator lights and a telescopic handle and wheels for transport The inside of the unit features replaceable fuses Locking Casters and Run flat tires 480 Three Phase Input 208 Three Phase Output A B and C Phase Indicator Lights Telescopic Handle op wn bp TI2Z000 054 Transformer 7 2 Product Overview 2 7 480 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 RR T12000 054 Transformer Product Overview 2 2 8 280 VAC Output The TI2000 054 has a 208 three phase VAC output located on the front of the unit The output is a female receptacle and is used for plugging in the TI5400 GHMD 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 TI2Z000 054 Transformer 2 Product Overview 2 9
5. 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 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 o
6. S 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 054 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 Industries Incorporated All rights reserved 04 18 14 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 Use of Words Shall Should May 2 3 General Specifications 2 4 Physical Dimensions 2 5 Airflow Ports 2 6 Features Overview 2 717 480 VAC Input 2 8 280 VAC Output 2 9 Phase Indicator lights 2 10 Fuses 1 11 Transport Features Section 4 Pre Operation 4 1 Maintenance Checks N N NFP RF FE
7. TI2000 054 Step Down Transformer Power Anytime Anywhere e 15 kVA 3 phase 60 Hz e Input 480 VAC 18 Amps Max 60 Hz e Output 208 VAC 42 Amps Max 60 Hz e Converts 480 VAC 3 phase to 208 VAC 3 phase e Used with the TI14200 TI14400 TI5200 and TI5400 GPUs e Size 21 3 Lx 24 5 W x 28 63 H 539 2 mm x 622 3 mm x 727 2 mm Weight 195 Ibs 88 45 kg 13 44 341 3 13 19 335 0 24 98 634 6 28 64 727 3 10 00 254 0 HEE 18 13 460 4 TT Biel f AN 24 50 622 3 FRONT VIEW SIDE VIEW All dimensions are in inches millimeters Tesla Industries Inc Headquarters 302 324 8910 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 Power Anytime Anywhere Tesla TI2Z000 054 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 T12000 054 Transformer The T12000 054 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 INDUSTRIE
8. 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 TI2Z000 054 Transformer 1 3 Hazards WARNING Severe injury or death from electrical shock may occur if either the user or the unit is wet while the operating unit is connected to a power source Be sure to disconnect AC power from the AC source if the unit has come into contact with water If AC Input Circuit Breaker has tripped due to water infiltration DO NOT try to reset it with the AC line voltage attached WARNING Severe injury or death from electrical shock can occur when damp electrical plugs are connected to the unit Make sure the unit is turned off before making any connections Failure to use proper grounding can cause potential shock ha
9. and correct installation prior to engine start Follow ground power unit engine starting procedure as specified in aircraft operator s manual Figure 5 6 1 Connecting DC cable to aircraft and starting engine TI2Z000 054 Transformer 17 Section 6 Post Operating Procedures 6 1 General When not in use the T12000 054 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 18 0 000000 T12000 054 Transformer Section 7 Unit Care and Maintenance WARNING CAUTION 7 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 to 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 ne
10. euvered on all four or tilted with the handle onto the rear tires for transport Figure 2 11 2 Lockable Casters Figure 2 11 3 10 inch run flat tires 12 0 TI2000054 Transformer Product Overview 2 Telescopic Handle The Transformer has a telescoping handle that makes rolling the unit easy 3 Handle in up position TI2Z000 054 Transformer 1 Handle in down position ao met 2 Loosen knobs by turning counter clockwise 4 Tighten knobs by turning counter clockwise 13 Section 4 Pre Operation 4 1 Maintenance Check Before operating the T12000 054 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 Tires The T12000 054 is equipped with solid Run Flat tires No air is required However if the tires are damaged they can be easily replaced 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 excessive wear broken loose fasteners and cable attachment Replace contacts or entire plug if necessary TI2Z000 054 Transformer Section 5 Operating Procedures 5 1 General This secti
11. f you have questions TI2Z000 054 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 Company name amp Billing address Contact person Phone ff Fax ff Email Purchase Order ff Model ff Serial Model ff Serial ff Shipping method to Tesla Description of shipping package Description of problem Return to Tesla Industries Inc Date of return 101 Centerpoint Boulevard New Castle DE 19720 Attention Repair Department TI2Z000 054 Transformer 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 Blivd Suite 2 Reno NV 89521 Tele 775 622 8801 Fax 775 622 8810 www teslaind com
12. hout 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 TILOOO 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 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 rece
13. ive 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 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 cord for their home country and a full two year warranty 17 Are there any HAZMAT issues or disposability problems There are none Tesla will reclaim all battery cells for disposability purposes Contact Tesla i
14. nly 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 7 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 excess heat 8 Is it waterproof Water resistant but not waterproof See Environmental Section TI2Z000 054 Transformer Frequently Asked Questions 8 9 Are Tesla GPUs used in shop maintenance and testing Tesla systems are gaining popularity throug
15. on defines the operating procedures which includes all steps necessary to ensure safe and efficient operation Correct operation of the T12000 054 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 5 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 5 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 the 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
16. rm some of the tests These functional test procedures should become routine Check Unit Approximately 120 VAC 1s lt i 1 Place the negative probe on the 2 Move the positive probe to the 3 Move the positive probe to the receptacle s left ground insert and right side phase 2 positive insert lower phase 3 positive post the positive probe on top side phase 1 insert Check Unit Approximately 208 VAC H _ 1 Move the negative probe to the 2 Move the positive probe to the 3 Move the negative probe to the upper phase 1 probe and the positive lower phase 3 positive post right side phase 2 probe and the probe to right side phase 2 probe positive probe to lower phase 3 probe TI2Z000 054 Transformer 21 Section 8 Frequently Asked Questions 1 Why should I 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 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 does a Turbo Start
17. ures limitations and performance criteria is essential to ensure peak operating efficiency and to maximize operational capabilities and life of the TI2000 054 Transformer Figure 2 1 1 T12000 054 Transformer 2 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 TI2Z000 054 Transformer 3 2 3 General Specifications Electrical Input Power e 480 VAC 18 Amps e 32 e 50 60Hz e 15 KVA e 18 Amps e Class 220 C e 150 C Temperature Rise Output Power e 208 VAC e 3 e 50 60Hz e 15 KVA e 42 Amps Size e 22 long x 25 wide x 25 high e 558 80mm x 635mm x 635mm Weight e 195 Ibs 88 45kg Delta TI2Z000 054 Transformer Product Overview 2 2 4 Physical Dimensions piia ur ees 2 Figure 2 4 1 T12000 054 physical dimensions TI2000 054 Transformer 2 5 Airflow Ports CAUTION The T12000 054 is intended for indoor use only If outdoor use is necessary contact Tesla for a sealed weather proof cover Make sure the airflow is not obstructed and air vents are clear Do not allow foreign objects blowing sand or dust to enter the air vents
18. xt 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 TI2Z000 054 Transformer 19 l Unit Care and Maintenance 7 2 Normal Function Test Procedures This section deals with normal function test procedures and includes all steps necessary to ensure that the T12000 054 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 FE oe ee ee 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 D 0 0000 T12000 054 Transformer Unit Care and Maintenance 7 Check Unit Internal Resistance Test for Shorts This section deals with normal function 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 perfo
19. zard In different countries the power cord may require the use of a plug adapter to achieve plug style compatibility for operation Use only adapters with proper grounding mechanism Important Safety Precautions WARNING Severe injury or death from fire or explosion can occur if electrical soarks are produced near fuel vapors DO NOT CONNECT AC Power Supply WHILE FUELING AC power functions of unit shall not be operated during any fuel handling operation Power output is restricted to DC power only 1 5 Extreme Environments CAUTION The unit is equipped with a charger temperature switch that 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 the unit has been allowed to cool prior to use NOTE This Transformer is for Indoor use only TI2Z000 054 Transformer Section 2 Product Overview 2 1 Introduction This manual contains the complete operating instructions and procedures for the TI2000 054 Transformer The TI2000 054 Transformer is intended for converting 480 three phase VAC to 208 three phase VAC This manual makes specific reference to the TI2000 054 Transformer being used as an accessory providing 208 three phase VAC to Tesla Industries Ground Power Units The observance of proced
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