IMPROPER USE/FAILURE TO FOLLOW INSTRUCTIONS IN OPERATORS MANUAL CAN RESULT IN UNIT FAILURE AND/OR POSSIBLE INJURY, OR DEATH, BY ELECTRICAL
SHOCK.
THE TI4100GPU-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.(302)324-8910
FAX (302)324-8912
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.
These instructions are for use by the owner/operator. They apply to
handling and operation of the TI4100GPU-24 (Turbo Start 4100) 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 TI4100GPU-24 (Turbo Start 4100) ground power unit. The
Turbo Start 4100 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 4100
ground power unit.
1-1
1-4. INDEX
㺦㺷
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
AbbreviationDefinition
ampAmpere
ACAlternating Current
CCelsius
contContinuous
DCDirect Current
FFahrenheit
FtFeet
FWDForward
GPUGround Power Unit
HrHour
HzHertz
KgKilograms
KwKilowatts
°Degree
LEDLight Emitting Diode
MAXMaximum
MINMinimum
VACVolts, Alternating Current
VDCVolts, Direct Current
Explosion Hazard Potential
Shock Hazard Potential
Guard from moisture
㺪㺸㺤㺵㺧㺃㺩㺵㺲㺰㺃㺬㺱㺦㺲㺵㺵㺨
㺳㺲㺺㺨㺵㺃㺶㺲㺸㺵㺦㺨
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 TI4100GPU-24 (Turbo Start 4100) (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 208-240 single phase VAC to 28.5 VDC converter, a 24 volt
unique (dry) power cell and an internal intelligent 208 to 240 volt AC
charger to recharge the power cells. These built-in features give the Turbo
Start 4100 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 208-240 single
phase VAC electrical outlet. Longer term operations incorporate the continuous 100 amp output of the 208-240 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 1500 amp peak power output for engine starting or constant (one
hour) rated power output (without a 208-240 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 208-240 single phase 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 208240 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 208-240 VAC common
power source. This feature eliminates the need for special recharge equipment and dedicated maintenance support man-hours.
2-1
SECTION II DESCRIPTION
2.2. GENERAL SPECIFICATIONS
WEIGHT
UNIT:100 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
TI4100GPU-24:
OUTPUT POWER DC
CONVERTER:28.5 VDC TO 100 AMPS, 24 VDC 121 AMPS AND
POWER CELLS:24 VDC
PEAK OUTPUT:1500 AMPS
POWER CELL
DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE
DC POWER CABLE
LENGTH: 8 FT
AIRCRAFT CONNECTOR: 3 PIN RECEPTACLE (MS25488)
AC POWER CORD: 8 Ft. 208-240 Single Phase VAC
208-240 Single Phase VAC 50/60 Hz 30.0 amps max.
ABOVE.
2-2
UNIT DISCRIPTION AND DEMENTIONS
2-3
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 TI4100GPU24 (Turbo Start 4100) 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 4100 ground power unit.
SECTION II. OPERATIONAL RESTRICTIONS AND SAFETY LIMITS
3-3. POWER CELL RECHARGE LIMITS
Any time the unit’s power cells are discharged the unit shall be
recharged within 24 hours to prevent performance degradation and ensure maximum life.
CAUTION
This unit is set up to recharge off of 208-240 Single Phase 50/60 Hz
VAC Power. Any other type of AC power may cause damage to the unit.
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. 208-240 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 208 to 240 VAC SINGLE PHASE30 AMPS MAX at 50/60 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 standby mode,
monitor the power cells state of charge, and only charge the power
cells to ensure they stay at maximum 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 terminated the unit’s intelligent charger will remain on line to
ensure power cells are charged to maximum capacity.
CAUTION
*8$5’ )520 ,1&255(&7
32:(5 628 5&(
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 4100 is supplied with a single customer specified AC power cord.
3-2
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