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Tesla TI4676 User's Manual

1. CAUTION pamage may occur if unit is operated after exposure to moisture rain drizzle fog sleet or snow or moisture contamination is sus pected DO NOT USE until unit s exterior and receptacles are dried Operation shall be restricted to use without 120 or 240 power cord DO NOT CONNECT 120 or 240 VAC power cord until unit has been dried for a MINIMUM of one 1 hour prior to use Blowing sand or dust Minimize exposure to sand and dust when 120 240 50 60 Hz AC power is used Unit shall be kept hori zontal during use CAUTION Unit damage may occur if inlet and outlet vent ports are obstructed and or cooling airflow is restricted Back Vent Side Vents Cooling Fan 3 13 UNIT OPERATION DURING AIRCRAFT FUELING DEFUELING Power output is restricted to 24 VDC power cell output only DO NOT CONNECT 120 or 240 VAC POWER SUPPLY 120 240 50 60 Hz VAC power charger or AC DC converter functions of unit shall not be operated during any aircraft fuel handling operation WARNING JAN EIRE EXPLOSION HAZARD POTENTIAL i Severe injury or Death may occur from fire or explosion as a re sult of electrical sparks produced near fuel vapors CHAPTER 4 OPERATING AND INSTALLATION PROCEDURES SECTION I UNIT INSTALLATION 4 1 INSTALLATION 1 Remove original aircraft battery and dispose of properly follow your aircraft s manual for proper removal and disposal of aircraft batte
2. 4 8 DC Converter Limits 3 8 3 4 PARAGRAPH INDEX Index 1 4 Installation 4 1 Maintenance of Unit 6 3 Maximum Output Current Figure 5 3 One 1 Hour Rate 24 VDC Constant Output 3 6 Operating Limits and Restrictions 4 3 Operating Procedures 4 5 Operating Position 3 12 Performance 4 4 Power Cell Recharge 4 7 Power Cell Recharge Limits 3 3 Purpose Chapter 3 3 1 Purpose Chapter 5 s t Push to test modification 7 1 Rated Peak Output Engine Starting 327 Required Equipment for Functional Check 4 9 Specific Conditions 5 4 Temperature 3 10 Temperature Conversion Chart Figure ods Unit Operation During Aircraft Fueling De fueling S213 Use of Word Shall Should and May 1 7 Warning Caution and Notes Defined 1 2 COUNTRY Afganistan Algeria American Samoa Angola Anguilla U K Antigua Argentina Aruba Australia Austria Azores Portugal Bahamas Bahrain Bangladesh Barbados Belguim Belize Br Hond Benon Bermuda Bolivia Botswana Brazil Bulgaria Burkina Faso Burma Now Myanmar Burundi Cambodia Cameroon Canada Canary Islands Spain Cape Verde Rep of Cayman Islands Central African Republic Chad Channel Islands Chile China Peoples Republic of Christmas Island Australia Cocos Islands Australia Columbia Congo Republic of Cook Island New Zealand Costa Rica Curacao Isla
3. CAUTION An operating procedure practice etc which if not strictly observed could result in damage to or destruction of eguipment NOTE An operating procedure condition etc which is essential to highlight 1 3 DESCRIPTION This manual contains the complete operating instructions and procedures for the TI4676 MPU The TI4676 is intended to provide an on board bat tery along with DC electrical ground power for aircraft systems and maintenance ground support operations The unit is designed to provide 24 volt DC electrical power output for aircraft engine starting and 24 or 28 5 volts DC electrical support for ground maintenance avionics electrical trouble shooting and testing The unit also has a built in capacity tester push to test button and recharge rate indicator The TI4676 MPU has a internal independent intelligent recharger that will nable the MPU to be rapidly recharged from either the aircraft genera tor or any 120 240 50 60 Hz VAC common power source The observance of procedures limitations and performance criteria is essential to ensure peak operating efficiency and to maximize operational capabili ties and life of the TI4676 MPU 1 4 INDEX The index lists in alphabetical order every titled paragraph and fig ure contained in this manual 1 5 ABBREVIATIONS AND SYMBOLS Abbreviations and symbols are used within text headings and titles Unless othe
4. Section Section Section CHAPTER Section Section CHAPTER Section Section CHAPTER INDEX TABLE OF CONTENTS INTRODUCTION UNIT DESCRIPTION AND OPERATION Unit Description OPERATING LIMITS AND RESTRICTIONS General Operational Restrictions and Safety Limits OPERATING AND INSTALLATION PROCEDURES Installation Procedures Unit Operation Operating Procedures Functional Check Procedures PERFORMANCE DATA Introduction Data Criteria CARE AND MAINTENANCE Unit Care Maintenance Push to Test Operation LIST OF ILLUSTRATIONS Figure 2 1 2 2 5 1 5 2 5 3 Title Dimensions Fuse Setting Procedures Temperature Conversion Chart Discharge Load Curve Maximum Output Current Page Index 1 Page 2 3 2 4 5 5 4 II CHAPTER 1 INTRODUCTION 1 1 GENERAL These instructions are for use by the owner operator They apply to handling and operation of the TI4676 Micro Power Unit MPU 1 2 WARNING CAUTION AND NOTE DEFINED A warning caution or note is used to emphasize important and critical instructions as defined for the following conditions WARNING An operating procedure practice etc which if not correctly followed could result in personal injury or loss of life
5. mum states of charge necessary to provide ample power for an efficient engine start under specific current load demands ENGINE START CURRENT LOAD DEMAND MINIMUM CHARGE Under 650 peak starting amps 40 charged 650 850 peak starting amps 50 charged 850 1000 peak starting amps 60 charged 1000 1200 peak starting amps 70 charged 1200 1500 peak starting amps 80 charged 3 10 TEMPERATURE Temperatures refer to the unit s cold heat soaked temperature The ambient temperature that a unit is exposed to for one 1 hour or more shall establish a unit s cold heat soaked temperature If unit s cold heat soaked temperature exceeds operating temperature range unit shall be stabilized prior to operation as follows COLD SOAKED warmed for a minimum of 3 hours above 10C 441 F or 2 hours above 20c 68 F WARMED SOAKED cooled for 1 hour below 38C 100 F Operating range without AC power 40C 40 F TO 60C 4 140 F with AC Power 30C 22 F To 50C 124 F Storage range 60c 76 F TO 60C 140 F CONTINUED ON NEXT PAGE CAUTION Unit may be damaged if operated when unit s cold or heat soaked tem perature exceed the specified limit If unit is operated when cold or heat soaked temperature limit is exceeded a full functional check should be accomplished prior to continued use NOTE If unit should overheat an over te
6. POWERED BY T 14676 MIGRO POWER UNIT Tesla Industries Inc 109 CenterPoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www TESLAind com WARNING A xx kk kkk SHOCK HAZARD POTENTIAL IMPROPER USE FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN RE SULT IN UNIT FAILURE AND OR POSSIBLE INJURY OR DEATH BY ELECTRICAL SHOCK THE TI4676 IS A MAINTENANCE FREE SEALED UNIT NO REPAIRS ARE AUTHORIZED WARRANTY WILL BE VOID IF UNIT S TAMPERED WITH FOR TECHNICAL SUPPORT CONTACT TESLA INDUSTRIES INC 109 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PH 302 324 8910 FAX 302 324 8912 www teslaind com WARNING lp SHOCK HAZARD POTENTIAL ATTEMPTS TO OPEN OR ENTER THE INSIDE OF THIS UNIT DEVICE i e PROBE BORESCOPE etc CAN RESULT IN UNIT FAILURE AND OR POSSIBLE INJURY BY ELECTRICAL SHOCK THIS UNIT IS MAINTENANCE FREE AND SHALL NOT BE OPENED OR DISASSEMBLED FOR ANY REASON BY USING ANY TOOL OR xX SHIPPING HAZARDS NONE DRY Non spillable POWER CELL battery No Free liquids to leak or toxic gases Always protect unit from short circuit Return Power cells to Tesla for Recycling TITLE CHAPTER CHAPTER Section Section CHAPTER Section Section CHAPTER Section
7. 4 SPECIFIC CONDITIONS The data presented are accurate only for specific conditions listed under the title of each chart or graph Variables for which data are not presented but which may affect that phase of performance are dis cussed in associated text Where data is available or reasonable esti mates can be made the amount that each variable affect performance will be given 5 5 GENERAL CONDITIONS In addition to the specific conditions the following general condi tions are applicable to the performance data as Variation in Aircraft Power demand differences between indi vidual aircraft of the same mak and model are known to exist due to variations in DC electrical system efficiency These differences however are considered insignificant and are not individually ac counted for b Aircraft Instrument Variations The data shown in the perfor mance charts do not account for instrument tolerance differences or inaccuracies 5 6 DEFINITIONS OF ABBREVIATIONS Unless otherwise indicated the abbreviations defined in Chapter 1 will be applicable to all charts and graphs in this chapter TEMPERATUE CONVERSION CHART mr L F i mi id A 20 0 20 DEGREES CELSIUS FIGURE 5 1 FIGURE 5 2 25 C Temp 29 C Temp ca IGURE 5 3 CHAPTER 6 CARE AND MAINTENANCE SECTION I UNIT CARE 6 1 GENERAL Although the TI4676 has been ruggedized
8. Guinea Guinea Bissau Guyana Haiti Honduras Hong Kong Hungary Iceland India Indonesia Iran Iraq Ireland Republic of Isle of Man Israel Italy Ivory Coast Jamaica Japan Jordan Kenya Korea Kuwait South APPENDIX A Cont LINE CORDS FOR WORLDWIDE OPERATIONS VOLTS 120 220 115 240 220 220 220 240 220 220 220 220 220 220 220 220 240 220 220 230 220 110 120 120 220 220 110 110 120 110 220 220 220 220 250 220 220 220 220 240 230 220 220 110 110 220 240 220 240 HZ 60 50 60 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 60 60 50 50 50 60 50 60 60 50 50 50 50 50 50 50 50 50 50 50 50 50 50 60 50 50 60 50 A 2 TESLA PART TI25000 001 TI25000 100 TI25000 001 TI25000 005 TI25000 100 TI25000 003 TI25000 003 TI25000 011 TI25000 003 TI25000 003 TI25000 003 TI25000 003 TI25000 005 TI25000 003 TI25000 003 TI25000 005 TI25000 005 TI25000 003 TI25000 300 TI25000 005 TI25000 003 TI25000 001 TI25000 001 TI25000 003 TI25000 003 TI25000 001 TI25000 001 TI25000 001 TI25000 005 TI25000 003 TI25000 003 TI25000 004 TI25000 003 TI25000 003 TI25000 005 TI25000 005 TI25000 005 TI25000 200 TI25000 002 TI25000 100 TI25000 001 TI25000 001 TI25000 005 TI25000 005 TI25000 003 TI25000 005 North American Line Cord Set Europlug Line Cord Set North American Line Cord S
9. Mauritius Mexico Monaco Mongolia Montseurrat Morocco Mozambique Namibia W S Africa Nepal Neth Antilles Netherlands New Caledonia New Zealand Nicaragua Niger Nigeria Norfolk Islands Australia North Ireland North Mariana Islands U S Norway Okinawa Oman Pakistan Panama Papua New Guinea Paraguay Peru Philippines Piccairn Islands U K Poland Portugal Puerto Rico Qatar APPENDIX A Cont OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS VOLTS 220 220 220 240 120 220 220 220 230 220 220 220 220 230 240 230 220 240 220 220 230 127 220 220 230 220 220 220 250 220 220 220 220 230 120 220 230 240 220 115 220 100 120 240 230 110 240 220 110 115 240 220 220 120 240 HZ 60 50 60 50 50 50 60 TESLA PART TI25000 001 TI25000 003 TI25000 100 TI25000 004 TI25000 005 TI25000 006 TI25000 003 TI25000 003 TI25000 002 TI25000 004 TI25000 003 TI25000 004 TI25000 003 TI25000 005 TI25000 005 TI25000 004 TI25000 003 TI25000 005 TI25000 003 TI25000 100 TI25000 005 TI25000 001 TI25000 003 TI25000 100 TI25000 005 TI25000 003 TI25000 003 TI25000 004 TI25000 004 TI25000 003 TI25000 003 TI25000 003 TI25000 011 TI25000 001 TI25000 100 TI25000 005 TI25000 011 TI25000 005 TI25000 001 TI25000 003 TI25000 001 TI25000 005 TI25000 004 TI25000 001 TI25000 011 TI25000 100 TI25000 001 TI25000 001 TI25000 004 T
10. button which gives the user the ability to test the capacity of the power cells These built in features give the TI4676 self sufficiency in an aircraft battery and long term ground operations with AC electrical power Aircraft bat tery operations rely on the unique dry cell batteries that can be rap idly recharged from the aircraft generator or any common 120 240 50 60 Hz VAC source Ground operations incorporate the continuous 12 Amp output of the 120 240 50 60 Hz VAC to 28 5 VDC converter or a combi nation of converter and power cell output to provide 24 VDC output The following are the unit s five 5 main operational support capa bilities a 24 VDC 1500 amp peak power output for engine starting or constant one hour rated power output without a 120 240 50 60 Hz VAC power source for short term trouble shooting b 24 VDC constant one hour rated power output or variable high load demand output less than one hour with a 120 240 50 60 Hz VAC power source for extended maintenance hangar and routine flight line maintenance ground support power Cs 28 5 VDC continuous rated AC to DC converter power output with a 120 240 50 60 Hz VAC power source for hangar and routine flight line maintenance support As Rapid recharge of the unit s power cells from aircraft generator or any 120 240 50 60 Hz VAC common power source This feature elimi nates the need for special recharge eguipme
11. 0 005 TI25000 005 TI25000 005 TI25000 005 TI25000 003 TI25000 003 TI25000 004 TI25000 003 TI25000 006 TI25000 100 TI25000 003 TI25000 001 TI25000 005 TI25000 100 TI25000 003 TI25000 004 TI25000 005 TI25000 100 TI25000 003 TI25000 004 TI25000 005 TI25000 005 TI25000 001 TI25000 011 TI25000 001 TI25000 003 TI25000 001 TI25000 005 TI25000 005 TI25000 005 TI25000 003 TI25000 003 TI25000 005 TI25000 005 Cont European Line Cord Set Cont European Line Cord Set Europlug Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Old British Line Cord Set Cont European Line Cord Set Old British Line Cord Set North American Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Old British Line Cord Set Cont European Line Cord Set Switzerland Line Cord Set Europlug Line Cord Set Cont European Line Cord Set North American Line Cord Set United Kingdom Line Cord Set Europlug Line Cord Set Cont European Line Cord Set Old British Line Cord Set United Kingdom Line Cord Set Europlug Line Cord Set Cont European Line Cord Set Old British Line Cord Set United Kingdom Line Cord Set Unit
12. ALSO AVAILABLE A 5 TO SUI I THE CUSTOM
13. AN 5 NEVER DEPRESS THE PUSH TO TEST BUTTON WHILE THE UNIT IS PLUGGED INTO AC POWER FOR RECHARGE IF UNIT IS PLUGGED INTO THE AIRCRAFT MAKE CERTAIN THERE IS NO LOAD APPLIED TO THE DC SYSTEM WHILE USING THE PUSH TO TEST BUTTON OTHERWISE A FALSE READING WILL OCCUR 6 NEVER DEPRESS THE PUSH TO TEST BUTTON FOR MORE THAN 30 SECONDS THIS MAY CAUSE A TEMPERATURE SENSOR TO TEMPORARILY DISRUPT PUSH TO TEST FUNC TION IF THIS SENSOR IS TRIPPED ALLOW FIVE MINUTES FOR UNIT TO COOL BEFORE OPERATING PUSH TO TEST BUTTON Capacity M 1 390 PUSH TO TEST BUTTO N CHARGE INDICATOR 120 240 50 60 Hz Abbreviations AC Power Cord Limits After Use 6 2 VAC Charger and AC to 1 5 PARAGRAPH INDEX 3 5 Appendix A Line Cord Table Before Operation Check Continuous Output Rate Data Basis 5 3 Description 1 3 DC Functional Check Dimensions Figure 21 Discharge Load Curve Fi Engine Starting Power Environmental 3 11 4 6 28 5 V 4 10 Definitions of Abbreviations gure 3 9 Functional Check Procedures Forms and Records 1 6 General Chapter 1 1 1 General Chapter 2 2 1 General Chapter 3 3 2 General Chapter 4 4 2 General Chapter 5 5 2 General Chapter 6 6 1 General Conditions 5 5 General Details Figure General Specifications 2 2 2 2 DC Constant Output 5 6 5 2
14. I25000 003 TI25000 003 TI25000 001 TI25000 005 North American Line Cord Set Cont European Line Cord Set Europlug Line Cord Set Old British Line Cord Set United Kingdom Line Cord Set Switzerland Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Italy Line Cord Set Old British Line Cord Set Cont European Line Cord Set Old British Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Old British Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Europlug Line Cord Set United Kingdom Line Cord Set North American Line Cord Set Cont European Line Cord Set Europlug Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Old British Line Cord Set Old British Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Australian Line Cord Set North American Line Cord Set Europlug Line Cord Set United Kingdom Line Cord Set Australian Line Cord Set United Kingdom Line Cord Set North American Line Cord Set Cont European Line Cord Set North American Line Cord Set United Kingdom Line Cord Set Old British Line Cord Set North American Line Cord Set Australian Line Cord Set Europlug Line Cord Set North American Line Cord Set North American Line Cord Set Old British Line Cord Set Cont European Line Cord Set Cont Europe
15. RD POTENTIAL Failure to use proper grounding can cause a potential shock hazard In different countries the 240 VAC 50 Hz power cord may require the use of a plug adapter to achieve plug style compatibility for 240 VAC 50 Hz operation Use only adapters with proper grounding mecha n sm 3 6 ONE 1 HOUR RATE 24 VDC CONSTANT OUTPUT 23 amp hour without AC power connected power cell output see Figure 5 2 35 amp hours with AC power connected both power cell and AC to DC converter output NOTE If power output is greater than rated amp hour rate power cell dis charge rate will increase correspondingly 3 7 RATED PEAK OUTPUT ENGINE STARTING 1500 peak amps at 259C 779E See Figure 5 3 3 8 CONTINUOUS OUTPUT RATE 28 5 VDC CONSTANT OUTPUT 35 Amps at 1 hour with AC power connected NOTE If current demand exceeds 12 amps converter output voltage will drop below 28 5 VDC and two or more LED status indicator bars will illumi nate If all LED status indicator bars illuminate both the converter and power cells are supplying 24 VDC power output see paragraph 3 4 and 4 7 3 9 ENGINE STARTING POWER Operators should always ensure the unit is charged above 80 prior to ground support engine starting However circumstances may exist dur ing use where unit recharge is not readily available and immediat X ternal engine starting power is required The following provides mini
16. acked or loose connectors If no damage is evident proceed to step two IF DAMAGE S EVIDENT contact distributor or manufacturer 2 ENSURE UNIT IS NOT PLUGGED INTO 120 OR 240 VDC Unplug AC power if plugged in 3 CHECK UNIT INTERNAL RESISTANCE TEST FOR SHORTS Better than 10 Mega ohms Ensure no short exists Negative DC receptacle terminal and unit case Positive DC receptacle terminal and unit case 4 CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS 24 to 25 5 VDC depending on state of charge Dis PLUG IN 120 OR 240 POWER CORD CHECK FUSE WINDOW FOR PROPER SET TING Ensure power unit is connected to a suitable AC power source 120 USA or 240 European 6 CHECK UNIT FOR STATE OF CHARGE Unit shall be in a position to en sure unit s vent ports are free from blockage After approximately 5 8 seconds unit LED status indicator shall illuminate indicating power cell state of charge Ensure LED status indicator and cooling fan is operational Prior to continuing to step 7 the LED status indicator should show a single green bar last LED bar or a flickering LED status bar to indicate the unit s power cells are fully charged Also under full charge the fan will ratchet but not enable NOTE Under a full charge the LED indicator should show a single steady green bar or the entire LED
17. age After approximately 5 8 seconds ensure unit s LED sta tus indicator illuminates indicating power cell state of charge and cooling fan is operating CAUTION Unit may overheat if cooling fan fails Do not operate if cooling fan fails Ze CHECK FOR FULL CHARGE INDICATION After 1 HR 15 minutes LED charge indicator should show a single steady or flickering LED bar when fully charged AC power may be left connected to unit when power cells are fully charged NOTE Under a full charge the LED indicator should show a single steady green bar or the entire LED will be flickering The fan will also ex hibit ratcheting but will not come on This is normal operation and the unit will go into standby mode the unit is ready for use SECTION III FUNCTIONAL CHECK PROCEDURES AND TROUBLE SHOOTING 4 8 FUNCTIONAL CHECK PROCEDURES This section deals with normal functional check procedures and includes all steps necessary to ensure the TI4676 is functioning within specific operational parameters prior to operational use As users gain experi ence with the TI4676 they will incorporate these functional checks as a routine practice 4 9 REQUIRED EQUIPMENT FOR FUNCTIONAL CHECK FLUKE OR EQUIVALENT TYPE DIGITAL MULTIMETER 4 10 DC FUNCTIONAL CHECK 1 CHECK UNIT FOR EVIDENCE OF DAMAGE Check for dents punctures case distortion or misalignment cr
18. an Line Cord Set North American Line Cord Set United Kingdom Line Cord Set OPTIONAL COUNTRY Romania Russia Rwanda Saudia Arabia Scotland Senegal Seychelles Sierra Leone Singapore Slovakia Somalia South Africa Spain Sri Lanka St Pierre amp Miquelon France St Kitts amp Nevis St Lucia St Vincent Sudan Surinam Svalbard Norway Swaziland Sweden Switzerland Syria Tahiti Taiwan Tanzania Thailand Togo Tonga Trinadad amp Tobango Tunisia Turkey Uganda United Arab Emir United Kingdom amp Ireland United States Uraguay Venezuela Vietnam Virgin Islands Wales Western Samoa Yemen Yugoslavia Zaire Republic of Zambia Zimbabwe APPENDIX A Cont LINE CORDS FOR WORLDWIDE OPERATIONS VOLTS 220 220 220 220 220 220 240 230 230 220 220 220 250 220 230 115 230 240 230 240 115 220 230 220 220 220 220 110 230 220 220 115 230 220 220 220 220 240 120 220 120 220 120 220 230 220 220 220 220 220 HZ 50 50 50 50 60 50 50 50 50 50 50 50 50 50 50 60 60 50 50 50 60 50 50 50 50 50 50 60 50 50 50 60 60 50 50 50 50 50 60 50 60 50 60 50 50 50 50 50 50 50 TESLA PART TI25000 003 TI25000 003 TI25000 100 TI25000 003 TI25000 005 TI25000 003 TI25000 005 TI25000 005 TI25000 005 TI25000 003 TI25000 003 TI25000 004 TI25000 003 TI25000 004 TI25000 001 TI2500
19. and made weather resistant within the scope of unit s intended use it is essential that good gen eral care be taken to maintain unit in good operating condition and to maximize unit s operational life 6 2 AFTER USE Unit should be protected from the environmental ele ments and man made hazards Ideally unit should be secured in the air craft or hanger Most importantly unit shall be fully covered if stored exposed to environmental elements La KEEP UNIT RECEPTACLES AND OUTER CASE CLEAN wipe with dry cloth Da KEEP FOREIGN OBJECTS OUT OF UNIT Cover unit to prevent foreign objects water and dirt from entering vent ports and recep tacles Keep a c compartment closed when not in use 3 AFTER USE PLUG UNIT NTO AC POWER SUPPLY WHEN NOT IN USE CHECK FUSE WINDOW FOR PROPER SETTING To maximize life of power cells and to ensure unit is always ready for use unit should remain plugged in to AC power when not installed in aircraft NEVER LET DISCHARGED UNIT SIT FOR MORE THAN 24 HOURS WITHOUT FULLY RECHARGING POWER CELLS 4 PROTECT AC POWER CORD FROM DAMAGE Prevent from being cut gouged crushed dragged or otherwise abused SECTION II MAINTENANCE 6 3 MAINTENANCE OF UNIT The TI4676 MPU is a maintenance fr unit no repairs are authorized Warranty will be void if sticker is tampered with If unit fails to operate contact Manufactu
20. ed Kingdom Line Cord Set North American Line Cord Set Australian Line Cord Set North American Line Cord Set Cont European Line Cord Set North American Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set APPENDIX A Cont UNIVERSAL LINE CORD KIT FOR WORLDWIDE OPERATIONS NOTE TESLA UNIVERSAL AC LINE CORD KIT P N TI25000 U00 IS FOR UNITS ORIGINALLY BUILT WITH THE UNIVERSAL AC LINE CORD OPTION ONLY THE AC ADAPTER OPTION IS TESLA P N TI16000 19 AND MUST BE ORDERED WITH THE ORIGINAL PROCUREMENT OF UNIT S UNIT S MAY BE RETURNED TO TESLA INDUSTRIES FOR A NOMINAL COST AND MODIFIED TO ALLOW OPERATION WITH THE UNIVERSAL AC LINE CORD KIT TESLA UNIVERSAL AC LINE CORD KIT P N TI25000 U00 IS COMPRISED OF THE FOLLOWING FOUR PART NUMBERS TI25000 U01 NORTH AMERICAN LINE CORD TI25000 U04 OLD BRITISH LINE CORD TI25000 U03 EUROPEAN 10A 250V TI25000 U05 ENGLAND 10A 250V TESLA REPLACEMENT 8 FOOT DC POWER CORD P N TI2006 501 IS AVAILABLE UPON REQUEST ERS OPERAT ONAL REQU REMENTS CUSTOM LENGTHS ARE
21. et United Kingdom Line Cord Set Europlug Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Australian Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Denmark Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set North American Line Cord Set North American Line Cord Set Cont European Line Cord Set Cont European Line Cord Set North American Line Cord Set North American Line Cord Set North American Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Cont European Line Cord Set Old British Line Cord Set Cont European Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Israel Line Cord Set Italy Line Cord Set Europlug Line Cord Set North American Line Cord Set North American Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set COUNTRY Laos Latvia Lebanon Lesotho Liberia Liechtenstein Lithuania Luxembourg Libya Macao Madagascar Maderia Portugal Majorca Malawi Malaysia Maldives Mali Republic of Malta Martinique Mauritania
22. g The fan will also ex hibit ratcheting but will not come on This is normal operation and the unit will go into standby mode the unit is ready for use Capacity II 0 ER E 23 CHECK UNIT FOR EVIDENCE OF DAMAGE Check for dents punctures case distortion or misalignment cracked or loose connectors and that cooling fan is functioning cooling fan can be checked by pressing push to test button CAUTION REMEMBER when the AC line cord is plugged in the unit must be placed in a osition to allow the cooling fan to operate properly Unit may overheat if cooling fan fails Do not operate if cooling fan fails More than one green bar is present on bar graph Make certian there is at least 2 3 inches clearence on the vent fan of the MPU when connected to AC to provide sufficent ventillation 33 CHECK AIRCRAFT PLUG AND MPU CONNECTORS FOR DAMAGE Check cable for cuts chafing or evidence of being crushed Check connectors for cracks cuts distortions xcessive wear broken loose fasteners or loose cable attachment 4 7 POWER CELL RECHARGE Ts CONNECT AC POWER CORD TO UNIT CHECK FUSE WINDOW FOR PROPER SET TING Ensure 120 or 240 VAC power cord is properly connected to an approved AC power supply Unit shall be in an upright position accord ing to aircraft specifacations to ensure unit s vent ports are free from block
23. ing all phases of operation Refer to Chapter 3 Section OPERATING LIMITS AND RESTRICTIONS for detailed information 4 4 PERFORMANCE Refer to Chapter 5 PERFORMANCE DATA to determine the capability of the TI4676 Consideration must be given to changes in performance result ing from variations in ambient temperature mode of operation state of charge with or without 120 or 240 VAC power and aircraft DC bus sys tem inefficiency voltage drops SECTION II OPERATING PROCEDURES cont 4 5 OPERATING PROCEDURES This section deals with normal procedures and includes all steps nec essary to ensure safe and efficient operation of the TI4676 As expe rience is gained with the TI4676 the user will be able to maximize the unit s unique capabilities to enhance the flexibility of aircraft maintenance and support operations NOTE When the TI4676 is not in use it should always remain plugged into a suitable AC power source to insure operational readiness at all times REMEMBER when the AC line cord is plugged in the unit must be placed in a position to allow the cooling fan to operate unobstructed 4 6 BEFORE OPERATION CHECK T CHECK FUSE WINDOW FOR PROPER SETTING 120 240 BEFORE PLUGGING UNIT INTO THE AC POWER SOURCE TO BE USED NOTE Under a full charge the LED indicator should show a single steady green bar or the entire LED will be flickerin
24. mperature sensor will shut down 120 240 50 60 Hz AC functions charger and converter until unit cools to normal operating temperatures 3 11 ENVIRONMENTAL K Operating any electrical equipment in the presence of moisture creates possible safety hazards and or potential for equipment damage Every effort has been made within the scope of existing technology to pre vent foreseeable safety hazards and make the TI4676 moisture resistant to prevent damage or failure If the TI4676 is exposed to moisture preventive measures and precautions shall be taken to ds Prevent accumulation of moisture on AC and DC con nectors receptacles b Minimize moisture entering FWD inlet and AFT outlet cooling fan vent ports The limits and operational constraints listed below shall apply for the following environmental weather conditions during recharging process Heavy or steady rain OPERATION NOT RECOMMENDED DURING RECHARG ING PROCESS Light rain drizzle NO CONVERTER OR CHARGER 120 240 50 60 Hz VAC Fog snow or sleet POWER SHALL BE APPLIED Unit inlet and outlet vent ports shall be covered from exposure Unit shall be kept horizontal WARNING GA SHOCK HAZARD POTENTIAL p Severe injury or Death from electrical shock is possible when person nel and or TI4676 are wet during use and when 120 240 50 60 Hz VAC power is being supplied to unit
25. nds Cyprus Czech Republic of Denmark Djibouti Republic of Dominica Dominican Republic APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS VOLTS 220 220 240 220 240 230 220 115 240 220 220 120 220 220 115 220 110 220 120 220 220 110 220 220 230 220 220 230 120 220 220 120 220 220 240 220 220 240 240 220 220 240 120 110 240 220 220 220 230 110 HZ 50 50 60 50 50 60 50 60 50 50 50 60 50 50 50 50 60 50 60 50 50 60 50 50 50 50 50 50 60 b 50 60 50 50 50 50 50 50 50 60 50 50 60 60 50 50 50 50 50 60 TESLA PART TI25000 004 TI25000 004 TI25000 011 TI25000 100 TI25000 005 TI25000 005 TI25000 011 TI25000 001 TI25000 011 TI25000 003 TI25000 004 TI25000 001 TI25000 005 TI25000 004 TI25000 001 TI25000 003 TI25000 001 TI25000 004 TI25000 005 TI25000 003 TI25000 005 TI25000 001 TI25000 003 TI25000 100 TI25000 005 TI25000 003 TI25000 100 TI25000 003 TI25000 001 TI25000 003 TI25000 003 TI25000 001 TI25000 100 TI25000 003 TI25000 005 TI25000 002 TI25000 011 TI25000 011 TI25000 011 TI25000 100 TI25000 100 TI25000 011 TI25000 001 TI25000 001 TI25000 005 TI25000 003 TI25000 300 TI25000 003 TI25000 005 TI25000 001 Old British Line Cord Set Old British Line Cord Set Australian Line Cord Set Europlug Line Cord Set United Kingdom Line Cord Set United Kingdom Line Cord Set Australian Line Co
26. nt and dedicated mainte nance support man hours e Built in Capacity tester and state of recharge indicator WARNING fee Check fuse holder window to ensure the fuse setting reads either 120 or 240 prior to connecting recharge cord to AC power source Fuse setting 120 240 must match AC power source hangar wall flight line AC power prior to connecting MPU for recharging 120 VAC Setting 240 VAC Setting SEE PAGE 2 4 FOR DETAI LS ON FUSE SETTING PROCEDURES SECTION II DESCRIPTION 2 2 GENERAL SPECIFICATIONS WEIGHT 48 2 lbs 21 8 Kg UNIT AC POWER CORD 0 4 lbs 0 18 Kg INPUT POWER AC TI4676 OUTPUT POWER DC CONVERTER 110 240 VAC 50 60 Hz 6 50 amps max 28 5 VDC TO 12 AMPS 24 VDC 15 AMPS AND ABOVE 24 VDC 23 AMP Hour POWER CELLS PEAK OUTPUT 1500 AMPS POWER CELL DRY HIGH RATE DISCHARGE RECHARGEABLE MAINTENANCE FREE OPTIONAL ACCESORIES SHIPPING CASES Used for shipping and storage Part TI7000 023 UNIT DESCRIPTION DIMENSIONS Cooling Fan Fuso Holder DC AL annector i Coonnectort Yarram ty i WHE Mieke Charge indlemme f Copocity Indicotor a ja ea Puch jo Test ee Bartem bide Ven Cooling Fan Back Vent Cooling Fan arrant VOID Shickoors 4 Mounting Brackel Fig 2 1 2 3 1 Grab both tabs on left and right side of the fuse clip Press tabs in
27. o power unit 3 2 GENERAL The operating limitations set forth in this chapter are the direct r sult of design analysis testing and operating experience Compliance with these limitations and restrictions will ensure that owners opera tors obtain maximum continued capability from the T14676 ground power unit SECTION II OPERATIONAL RESTRICTIONS AND SAFETY LIMITS 3 3 POWER CELL RECHARGE LIMITS Any time the unit s power cells are fully discharged the unit shall be recharged within 24 hours to prevent performance degradation and ensure maximum life CAUTION Unit s power cells may be damaged if recharged by NiCad or Lead Acid type battery chargers Power cells should only be charged by either the TI4676 MPU internal charger and the AC power cord furnished with the equipment or off the aircraft generator when installed on the air craft 3 4 120 240 50 60 Hz VAC CHARGER AND AC TO DC CONVERTER LIMITS The unit is designed with a single point AC receptacle for external power to operate both the internal charger and converter The unit s AC voltage range can be factory set from 105 to 250 VAC at 50 to 60 Hz depending upon customer requirements The AC power cord provided with the unit is the mechanism that ensures the specified AC power source is properly supplied to the unit see paragraph 3 5 Use no others INTERNAL CHARGER NO LIMIT AC power cord can remain connected when power cells are full
28. ormance NOTE The information provided in this chapter is primarily intended for op erational planning and is most useful when planning operations under unfamiliar conditions or environmental extremes The data may also be used to establish local operating procedures and to ensure unit s opera tional life is maximized 5 2 GENERAL The data presented covers the maximum range of conditions and perfor mance that can reasonably be expected In each area of performance the effects of temperature and DC electrical load demand relating to the ground power support requirements are presented Wherever practical data is presented conservatively However NO GENERAL CONSERVATISM HAS BEEN APPLIED All performance data presented is within the applicable limits of the TI4676 MPU SECTION II DATA CRITERIA 5 3 DATA BASIS The type of data used is indicated at the bottom of each performance chart under DATA BASIS The applicable report and date of the data are also given The data provided generally are based on one of three cat egories a Derived From Actual Controlled Testing Controlled test data obtained on a similar unit type bs Calculated Data Data based on tests but not on a similar unit type placed under a controlled test aP Estimated Data Data based on estimates using rules of physics mathematics and electrical engineering principles and concepts but not verified by tests 5
29. rd Set North American Line Cord Set Australian Line Cord Set Cont European Line Cord Set Old British Line Cord Set North American Line Cord Set United Kingdom Line Cord Set Old British Line Cord Set North American Line Cord Set Cont European Line Cord Set North American Line Cord Set Old British Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set North American Line Cord Set Cont European Line Cord Set Europlug Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Europlug Line Cord Set Cont European Line Cord Set North American Line Cord Set Cont European Line Cord Set Cont European Line Cord Set North American Line Cord Set Europlug Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set Italian Line Cord Set Australian Line Cord Set Australian Line Cord Set Australian Line Cord Set Europlug Line Cord Set Europlug Line Cord Set Australian Line Cord Set North American Line Cord Set North American Line Cord Set United Kingdom Line Cord Set Cont European Line Cord Set Denmark Line Cord Set Cont European Line Cord Set United Kingdom Line Cord Set North American Line Cord Set OPTIONAL COUNTRY Ecuador Egypt El Salvador England Equatorial Guinea Estonia Ethiopia Fiji Finland France French Guiana Gabon Gambia Georgia Germany Ghana Gibraltar Greece Greenland Denmark Grenada Guadeloupe Guam Guatemala
30. res Warranty Claim see unit warranty Chapter 7 Push To Test Modification General Information And Operation 7 1 General THIS MODIFICATION HAS BECOME STANDARD EQUIPMENT FOR EACH OF OUR UNITS BOTH MILITARY AND CIVILIAN CLIENTS HAVE FOUND THIS MODIFICATION TO BE CRITICAL TO THEIR OPERATION THE PUSH TO TEST BUTTON IS USED TO NDICATE THE CAPACITY OF THE POWER CELLS WITHOUT APPLYING AC INPUT POWER IT ALLOWS THE END USER TO CHECK THE STATUS OF THE POWER CELLS THIS LETS THE OPERATOR KNOW IF THERE S ENOUGH POWER TO PERFORM ANOTHER ENGINE START OR IF THE UNIT HAS TO BE RETURNED TO AC POWER TO ALLOW IT TO RECHARGE 7 2 OPERATION 1 IF UNIT WAS PLUGGED IN MAKE SURE THAT YOU WAIT AT LEAST 2 MINUTES AF TER AC POWER IS REMOVED OR DC POWER IS EXTRACTED FROM THE UNIT BEFORE YOU DEPRESS THE PUSH TO TEST BUTTON THIS WILL ENSURE A CORRECT READ ING 2 WITHOUT AC POWER INPUT OR DC POWER OUTPUT SIMPLY DEPRESS THE PUSH TO TEST BUTTON ON THE FACE PLATE AND HOLD FOR APPROXIMATELY 10 15 SECONDS 3 AT THIS TIME THE LED BAR GRAPH SHOULD LIGHT UP INDICATING THE STATUS OF THE POWER CELLS 4 THE FAN SHOULD ALSO OPERATE AT THIS TIME IF YOU DO NOT HEAR THE FAN RUNNING STOP DEPRESSING THE BUTTON AND CHECK FOR ANY OBSTRUCTIONS TO THE F
31. rwise 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 Celsius cont Continuous DC Direct Current F Fahrenheit EE Feet FWD Forward MPU Micro Power Unit Hr Hour HZ Hertz Kg Kilograms KW Kilowatts i Degree LED Light Emitting Diode MAX Maximum MIN Minimum VAC Volts Alternating Current VDC Volts Direct Current VEN Explosion Hazard Potential Shock Hazard Potential Guard from moisture RER N E Guard from incorrect power source 1 2 1 6 FORMS AND RECORDS NONE REQUIRED 1 7 USE OF WORDS SHALL SHOULD AND MAY Within this technical manual the word shall is used to indicate a mandatory reguirement 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 CHAPTER 2 UNIT DESCRIPTION AND OPERATION SECTION I UNIT 2 1 GENERAL The TI4676 Figure 2 1 is a compact portable and highly versatile 24 28 5 VDC electrical MPU The unit incorporates a 120 240 50 60 Hz to 28 5 VDC converter a 24 volt unique dry power cell and an internal intelligent 120 240 50 60 Hz VAC charger to recharge the power cells In addition the MPU incorporates a push to test
32. ry 2 Ensure that the TI4676 MPU is fully charged Remove AC cord and place the TI4676 MPU in the same position of the original battery en sure that the DC receptacle is oriented in the same position as the original battery 3 Position the TI4676 MPU so that the aircraft battery tie down bolts are aligned with the bracket on the MPU Secure the aircraft tie down bolts so that the MPU is securely fastened 4 Attach the aircraft DC plug so that it is fully seated into the MPU receptacle 5 Because the TI4676 MPU uses monolithic dry cell batteries there is no need to attach the ventilation tubes to the MPU 6 Because there is no hazardous materials or liquids in the cells there is no risk of thermal runaway and therefore no need to hook up temperature sensors SECTION II OPERATING PROCEDURES 4 2 GENERAL Correct operation of the TI4676 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 in structions in this manual that affect operational safety and the war ranty of the unit 4 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 dur
33. ward and pull fuse clip outof housing GENTLY TABS 7 Replace the white clip back into the fuse clip Take care notto damage the tabs Fuse Setting Procedures for Switching Voltages or Changing Blown Fuses 2 Completely pull fuse clip from housing being careful not to drop the fuses from the fuse clip 5 Completely remove the white clip from the fuse clip 8 Completely insert white clip in to fuse clip GENTLY until it snaps into place 2 4 3 Note The fuses are not fastened into the fuse clip they are lose Take care to ensure fuses are not dropped or lost KA 6 Ensure thatthe proper voltage is selected on the white clip See Enlargement 2 amp 3 9 Insert fuse clip back into fuse housing EVEN LY on both sides DO NOTFORCE iffuse clip does notgo in easy it means fuses are mis aligned realign fuses and insert again 4 GENTLY pull the white clip from the fuse clip taking care not to bend any of the tabs See enlargement 1 EN LARG EM ENT 2 120 VAC SETTING EN LARG EM ENT 3 240 VAC SETTING 10 Snap fuse clip back into the housing G ENTLY DO UBLE CHECK VO LTAG E WINDO W PRIO R TO PLUGGING UNIT INTO AC POWER CHAPTER 3 OPERATING LIMITS AND RESTRICTIONS SECTION I GENERAL 3 1 PURPOSE Chapter 3 includes all important operating limits and restrictions that must be observed for proper and safe operation of the T14676 micr
34. will be flickering The fan will also exhibit ratcheting but will not come on This is normal operation and the unit will go into standby mode the unit is ready for use 4 5 7 CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS Ensure power cells are fully charged s step 6 28 5 0 57 VDC with power cells at full state of charge 8 FUNCTIONAL CHECK COMPLETE Unit should remain plugged in to AC power until ready for installtion in aircraft CHAPTER 5 PERFORMANCE DATA SECTION 1 INTRODUCTION 5 1 PURPOSE This chapter provides performance data for the TI4676 Continual refer ence to this information will enable the user to obtain maximum perfor mance utilization and service life from the TI4676 Although maximum performance is not always reguired regular referral to this chapter is recommended for the following reasons a To generate knowledge of unit s performance margins to enable th operator to make sound judgment when unexpected conditions or alter nate operational requirements are encountered by To enable the user to readily recognize situations requiring maximum performance Gis To gain experience in accurately estimating the effects of vari ables for which data is not presented d To help the operator determine if an aircraft system malfunction exists by comparing actual performance with expected perf
35. y charged When the power cells are fully charged the unit s intelligent charger will go to a stand by mode LED will stay green or flicker monitor the power cells state of charge and only charge the power cells to ensure they stay at maxi mum capacity INTERNAL AC TO DC CONVERTER LIMITED see paragraph 3 6 3 8 and 3 10 AC power cord does not have to be disconnected when converter power output is no longer required Once DC power demand is termi nated the unit s intelligent charger will remain on line to ensure power cells are charged to maximum capacity CAUTION vnit will be damaged if unapproved AC power is applied 3 5 AC POWER CORD LIMITS The AC power cord governs which AC power source the unit is set to operate from The TI4676 is supplied with a single customer specified AC power cord Some customers may specify a non North American AC option for worldwide mobility see appendix A Each power cord is marked accordingly FOR MORE INFORMATION ON POWER CORDS SEE APPENDIX A AC Line Cords VOO North American Old British Cont Europe more examples in appendix or call factory for information CAUTION vnit will be damaged if unapproved AC power is applied by fitting 120 or 240 VAC power cord with any kind of unapproved modification or adapter that changes the specified input power characteristics WARNING A SHOCK HAZA

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