Tesla TI2000GPU-24 User Manual

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TI2000 GPU-24

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WARNING

*******SHOCK HAZARD POTENTIAL*******

IMPROPER USE/FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN
RESULT IN UNIT FAILURE AND/OR POSSIBLE INJURY, OR DEATH, BY ELECTRI­CAL SHOCK.

THE TI2000GPU-24 IS A MAINTENANCE FREE, SEALED UNIT

NO REPAIRS ARE AUTHORIZED.

WARRANTY WILL BE VOID IF

UNIT IS TAMPERED WITH.

FOR TECHNICAL SUPPORT CONTACT:

TESLA INDUSTRIES INC.
109 CENTERPOINT BLVD.

CENTERPOINT INDUSTRIAL PARK

NEW CASTLE,DELAWARE 19720

PH.[phone]

FAX [phone]

WARNING

*******SHOCK HAZARD POTENTIAL*******

ATTEMPTS TO OPEN OR ENTER THE INSIDE OF THIS UNIT (BY USING ANY TOOL
OR 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.

***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.

i

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 PROCEDURES 4-1
Section I Unit Operation 4-1
Section II Operating Procedures 4-2
Section III Functional Check Procedures 4-5
CHAPTER 5 PERFORMANCE DATA 5-1
Section I Introduction 5-1
Section II Data Criteria 5-2
CHAPTER 6 CARE AND MAINTENANCE 6-1
Section I Unit Care 6-1
Section II Maintenance 6-2
INDEX Index 1

LIST OF ILLUSTRATIONS

Figure Title Page
2-1 Dimensions 2-3
2-2 General Details 2-2
2-3 Fuse Setting Procedures 2-4
5-1 Temperature Conversion Chart 5-3
5-2 Discharge Load Curve 5-4
5-3 Maximum Output Current 5-5

ii

CHAPTER 1

INTRODUCTION

1-1. GENERAL

These instructions are for use by the owner/operator. They apply to
handling and operation of the TI2000GPU-24 (Turbo Start 2000) ground
power unit.

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.

CAUTION

An operating procedure, practice, etc., which,

if not strictly observed, could result in

damage to or destruction of equipment.

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 TI2000GPU-24 (Turbo Start 2000) ground power unit. The
Turbo Start 2000 is intended to provide DC electrical ground power
for aircraft flight line 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 observance of procedures, limitations and performance
criteria is essential to ensure peak operating efficiency and to
maximize operational capabilities and life of the Turbo Start 2000
ground power unit.

1-1

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1-4. INDEX

The index lists, in alphabetical order, every titled paragraph and
figure 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
Abbreviation Definition

amp Ampere
AC Alternating Current
C Celsius
cont Continuous
DC Direct Current
F Fahrenheit
Ft Feet
FWD Forward
GPU Ground Power Unit
Hr Hour
Hz Hertz
Kg Kilograms
Kw Kilowatts
° Degree
LED Light Emitting Diode
MAX Maximum
MIN Minimum
VAC Volts, Alternating Current
VDC Volts, Direct Current

Explosion Hazard Potential

Shock Hazard Potential

Guard from moisture

䩢䩰䩜䩭䩟䨻䩡䩭䩪䩨䨻䩤䩩䩞䩪䩭䩭䩠

䩫䩪䩲䩠䩭䨻 䩮䩪䩰䩭䩞䩠

Guard from incorrect power source

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 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.

1-3

CHAPTER 2

UNIT DESCRIPTION AND OPERATION

SECTION I. UNIT

2-1. GENERAL

The TI2000GPU-24 (Turbo Start 2000) (Figure 2-1 and 2-2) is a compact, portable
and highly versatile 24/28.5 VDC electrical ground power unit. The unit incor­porates a 120-240 VAC to 28.5 VDC converter, a 24 volt unique (dry) power cell
and an internal intelligent 120 to 240 volt AC charger to recharge the power
cells. These built-in features give the Turbo Start 2000 self-sufficiency and
mobility for short-term operations without AC electrical power or long term
operations with AC electrical power. Short term operations rely solely on
power cell output and the fast recharge rates that the unit’s internal charger
provides from any standard 120 or 240 VAC electrical outlet. Longer term op­erations incorporate the continuous 20 amp output of the 120-240 VAC to 28.5
VDC converter, or a combination of converter and power cell output to provide
24 VDC output. The following are the unit’s four (4) main operational support
capabilities:

a. 24 VDC 3000 amp peak power output for engine starting or constant (one
hour) rated power output (without a 120-240 VAC power source) for short term
trouble shooting and flexible flight line support ground power.

b. 24 VDC constant (one hour) rated power output or variable high load de­mand output (less than one hour) with a 120-240 VAC power source for extended
maintenance (hangar) and routine flight line maintenance, ground support
power.

c. 28.5 VDC continuous rated (AC to DC converter) power output with a 120­240 VAC power source for hangar and routine flight line maintenance support,
and avionics bench testing.

d. Rapid recharge of the unit’s power cells from any 120-240 VAC common
power source. This feature eliminates the need for special recharge equip­ment and dedicated maintenance support man-hours.

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 TURBO START for recharging.

(SEE PAGE 2-4 FOR

FUSE SETTING PROCEDURES)

120 VAC Setting 2-1 240 VAC Setting

SECTION II DESCRIPTION

2.2. GENERAL SPECIFICATIONS
WEIGHT

UNIT: 111 lbs (50.39 Kg)
DC POWER CABLE: 8.5 lbs (3.86 Kg)
AC POWER CORD: 0.4 lbs (0.18 Kg)

INPUT POWER AC

TI2000GPU-24:
TI2000GPU-24-UNV:

TI25000-U01 NORTH AMERICAN LINE CORD

TI25000-U04 OLD BRITISH LINE CORD

TI25000-U03 EUROPEAN 10A/250V

TI25000-U05 ENGLAND 10A/250V

OUTPUT POWER DC

CONVERTER: 28.5 VDC TO 20 AMPS, 24 VDC 21 AMPS AND ABOVE.
POWER CELLS: 24 VDC
PEAK OUTPUT: 3000 AMPS

105-125 VAC 60 Hz 6.50 amps max.
210-250 VAC 50/60 Hz 3.25 amps max.

105-125 VAC 60 Hz 6.50 amps max.

210-250 VAC 50/60 Hz 3.25 amps max.

210-250 VAC 50/60 Hz 3.25 amps max.

210-250 VAC 50/60 Hz 3.25 amps max.

POWER CELL

DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE

DC POWER CABLE

LENGTH: 8 FT

AIRCRAFT CONNECTOR: 3 PIN RECEPTACLE (MS25488)

2-3

Fuse Setting Procedures

for Switching Voltages or Changing Blown Fuses

1) Grab both tabs
on left and right side
of the fuse clip. Press
tabs inward and pull
fuse clip out of housing
GENTLY.

TABS

ENLARGEMENT 1

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.

3) Note: The fuses
are not fastened into
the fuse clip, they are
lose. Take care to ensure
fuses are not dropped or
lost.

ENLARGEMENT 2 120 VAC SETTING

ENLARGEMENT 3 240 VAC SETTING

6) Ensure that the
proper voltage is selected
on the white clip. (See
Enlargement 2 & 3)

4) GENTLY pull the
white clip from the
fuse clip, taking care
not to bend any of
the tabs. (See
enlargement 1)

7) Replace the
white clip back into
the fuse clip. Take
care not to damage
the tabs.

8) Completely insert
white clip in to fuse
clip (GENTLY) until
it snaps into place.

9) Insert fuse clip
back into fuse housing
EVENLY on both sides.
DO NOT FORCE, if fuse
clip does not go in easy,
it means fuses are mis­aligned, realign fuses and
insert again.

2-4

10) Snap fuse clip
back into the housing
(GENTLY). DOUBLE

CHECK VOLTAGE
WINDOW PRIOR
TO PLUGGING UNIT
INTO AC POWER

2-2

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 TI2000GPU­24 (Turbo Start 2000) ground power unit.

3-2. GENERAL

The operating limitations set forth in this chapter are the direct
result of design analysis, testing, and operating experience. Com­pliance with these limitations and restrictions will ensure that own­ers/operators obtain maximum continued capability from the Turbo
Start 2000 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 TURBO START internal charger and the AC power cord furnished with

the equipment, or when connected aircraft external DC power recep-

tacle.

3-1

3-4. 120-240 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 units
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 fully charged. When the power cells are fully
charged the unit’s intelligent charger will go to a stand-by mode,
monitor the power cells state of charge, and only charge the power
cells to ensure they stay at maximum capacity.

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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 terminated the unit’s intelligent charger will remain on line to
ensure power cells are charged to maximum capacity.

CAUTION

Unit 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 Turbo Start 2000 is supplied with a single cus­tomer specified AC power cord. Some customers may specify a univer­sal AC option (for worldwide mobility), which comes with two (2)
power cords, one for 120 VAC 60 Hz and the other for 240 VAC 50 Hz
(SEE APPENDIX A). Each power cord is marked accordingly. Below are
the following three (3) types of AC power cords available and their
limits.

120 VAC 60 Hz power cord (USA): LIMITED TO 105-125 VAC 60 Hz power
source only.

120 VAC 60 Hz power cord (Universal): LIMITED TO 105 VAC to 250 VAC
50/60 Hz power source using proper cord set.

240 VAC 50 Hz power cord (European): LIMITED TO 210-250 VAC 50-60 Hz
power source only.

FOR MORE INFORMATION ON POWER CORDS SEE APPENDIX A