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Tesla TI4676 manual

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Table of contents for the manual

  • Page 1

    !"#$%& '%()$& *+", '%()$)-&./ T esla Industries Inc. 109 CenterPoint Blvd. New Castle, DE 19720 (302)324-8910 Phone (302) 324-8912 Fax www .TESLAind.com TI 4676[...]

  • Page 2

    WARNING *******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 IS TAMPERED WITH. FOR TECHNICAL SUPPORT CONTACT: TESLA[...]

  • Page 3

    TABLE OF CONTENTS TITLE Page CHAPTER 1 INTRODUCTION 1-1 CHAPTER 2 UNIT DESCRIPTION AND OPERATION 2-1 Section I Unit 2-1 Section II Description 2-2 CHAPTER 3 OPERATING LIMITS AND RESTRICTIONS 3-1 Section I General 3-1 Section II Operational Restrictions and Safety Limits 3-1 CHAPTER 4 OPERATING AND INSTALLATION PROCEDURES 4-1 Section I Installation [...]

  • Page 4

    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 operatin[...]

  • Page 5

    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 otherwise indicated, the following list of abbreviations and symbols are used in this manual: LIST OF ABBREVIATIONS AND SYMBOLS Ab[...]

  • Page 6

    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 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 indi[...]

  • Page 7

    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.[...]

  • Page 8

    WARNING 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 DETAILS ON FUSE SETTING PROCEDURES) [...]

  • Page 9

    !"#$%&' !"#[...]

  • Page 10

    2-4 7) Replace the white clip back into the fuse clip. T ake care not to damage the tabs. 8) Completely insert white clip in to fuse clip (GENTL Y) until it snaps into place. 9) Insert fuse clip back into fuse housing EVENL Y on both sides. DO NO T FORCE, if fuse clip does not go in easy , it means fuses are mis- aligned, realign fuses and insert a[...]

  • Page 11

    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 TI4676 micro power unit. 3-2. GENERAL The operating limitations set forth in this chapter are the direct re- sult of design analysis, testing, and o[...]

  • Page 12

    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 un[...]

  • Page 13

    AC Line Cords North American Old British U.K Cont. Europe (more examples in appendix or call factory for information) CAUTION *8 $5’ )52 0 ,1&255( &7 32: (5 6285&( Unit 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 i[...]

  • Page 14

    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 [...]

  • Page 15

    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-temperature sensor will shut down 120- 240 50/60 [...]

  • Page 16

    WARNING ********SHOCK HAZARD POTENTIAL********* 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. CAUTION Damage may occur if unit is operated after exposure to moisture (rain, drizzle, fog, sleet or snow) or moisture contaminat[...]

  • Page 17

    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-D[...]

  • Page 18

    CHAPTER 4 OPERATING AND INSTALLATION PROCEDURES SECTION I. UNIT INST ALLA TION 4-1. INSTALLATION 1. Remove original aircraft battery and dispose of properly (follow your aircraft’s manual for proper removal and disposal of aircraft battery). 2. Ensure that the TI4676 MPU is fully charged. Remove AC cord and place the TI4676 MPU in the same positi[...]

  • Page 19

    SECTION II. OPERA TING 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 m[...]

  • Page 20

    CAUTION REMEMBER, when the AC line cord is plugged in, the unit must be placed in a position 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 [...]

  • Page 21

    CAUTION Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. 2. 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 indi[...]

  • Page 22

    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 incorpo[...]

  • Page 23

    7. CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS. Ensure power cells are fully charged (see 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. 4-6[...]

  • Page 24

    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 required, regular referral to this chapter is [...]

  • Page 25

    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[...]

  • Page 26

    FIGURE 5-1 5-3[...]

  • Page 27

    FIGURE 5-2 5-4 TI4676MPU -24 OUTPUT VOL T AGE OUTPUT V OL T AGE MINUTES 23 AMP CONST ANT CURRENT L OAD 24 20 16 12 8 4 0 0 10 20 30 40 50 60[...]

  • Page 28

    MAXIMUM OUTPUT CURRENT AMPS Calculation based on actual test data at Pratt-Whitmey on 30 March 1992 SECONDS 1500 1350 1200 1050 900 750 600 450 150 300 0 0 5 10 15 20 25 30 (-29 C T emp) (+25 C T emp) * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * FIGURE 5-3 5-5[...]

  • Page 29

    CHAPTER 6 CARE AND MAINTENANCE SECTION I. UNIT CARE 6-1. GENERAL Although the TI4676 has been ruggedized 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 prote[...]

  • Page 30

    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 INDICATE THE CAPACITY OF THE POWER CELLS WITHOUT APPLYING AC I[...]

  • Page 31

    PARAGRAPH INDEX 120-240 50/60 Hz VAC Charger and AC to DC Converter Limits, 3-4 Abbreviations, 1-5 AC Power Cord Limits, 3-5 After Use, 6-2 Appendix A Line Cord Table Before Operation Check, 4-6 Continuous Output Rate, 28.5 VDC Constant Output, 3-8 Data Basis, 5-3 DC Functional Check, 4-10 Definitions of Abbreviations, 5-6 Dimensions, Figure 2-1 Di[...]

  • Page 32

    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, C[...]

  • Page 33

    APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS HZ TESLA PART # Afganistan 220 50 TI25000-004 Old British Line Cord Set Algeria 220 50 TI25000-004 Old British Line Cord Set American Samoa 24 0 6 0 TI25000-011 Australian Line Cord Set Angola 220 50 TI25000-100 Europlug Line Cord Set Anguilla (U.K.) 24 0 5 0 TI25000-005 United K[...]

  • Page 34

    APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS HZ TESLA PART # Ecuador 120 60 TI25000-001 North American Line Cord Set Egypt 220 50 TI25000-100 Europlug Line Cord Set El Salvador 11 5 6 0 TI25000-001 North American Line Cord Set England 240 50 TI25000-005 United Kingdom Line Cord Set Equatorial Guinea 22 0 50 TI25000-[...]

  • Page 35

    APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS HZ TESLA PART # Laos 220 50 TI25000-001 North American Line Cord Set Latvia 220 50 TI25000-003 Cont. European Line Cord Set Lebanon 220 50 TI25000-100 Europlug Line Cord Set Lesotho 240 50 TI25000-004 Old British Line Cord Set Liberia 120 60 TI25000-005 United Kingdom Lin[...]

  • Page 36

    APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS HZ TESLA PART # Romania 220 50 TI25000-003 Cont. European Line Cord Set Russia 220 50 TI25000-003 Cont. European Line Cord Set Rwanda 220 50 TI25000-100 Europlug Line Cord Set Saudia Arabia 22 0 50/60 TI25000-003 Cont. European Line Cord Set Scotland 220 50 TI25000-005 Un[...]

  • Page 37

    A-5 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 INDU[...]