Tesla TI4676 User Manual

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TI4676

Tesla Industries Inc.

109 CenterPoint Blvd.
New Castle, DE 19720
[phone] Phone

[phone] Fax

www.TESLAind.com

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 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 INDUSTRIES INC.
109 CENTERPOINT BLVD.

CENTERPOINT INDUSTRIAL PARK

NEW CASTLE,DELAWARE 19720

PH.[phone]

FAX [phone]

www.teslaind.com

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 AND INSTALLATION PROCEDURES 4-1
Section I Installation Procedures 4-1
Section II Unit Operation 4-1
Section III Operating Procedures 4-2
Section IV 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
CHAPTER 7 Push to Test Operation 7-1
INDEX Index 1

LIST OF ILLUSTRATIONS

Figure Title Page
2-1 Dimensions 2-3
2- 2 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 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.

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 TI4676 MPU. The TI4676 is intended to provide an on-board bat­tery 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
enable the MPU to be rapidly recharged from either the aircraft genera­tor 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 capabili­ties and life of the TI4676 MPU.

1-1

1-4. INDEX

᭾ᮏ

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
MPU Micro 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

ᮂᮐ᭼ᮍ᭿᭛ᮁᮍᮊᮈ᭛ᮄᮉ᭾ᮊᮍᮍᮀ

ᮋᮊᮒᮀᮍ᭛ ᮎᮊᮐᮍ᭾ᮀ

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 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 button which gives the
user the ability to test the capacity of the power cells These built­in features give the TI4676 self-sufficiency in an aircraft battery,
and long term ground operations with AC electrical power. Aircraft bat­tery operations rely on the unique dry-cell batteries that can be rap­idly 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 combi­nation of converter and power cell output to provide 24 VDC output.
The following are the unit’s five (5) main operational support capa­bilities:

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.

c. 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.

d. Rapid recharge of the unit’s power cells from aircraft generator
or any 120-240 50/60 Hz VAC common power source. This feature elimi­nates the need for special recharge equipment and dedicated mainte­nance support man-hours.

e. Built in Capacity tester and state of recharge indicator.

2-1

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WARNING

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Check fuse holder window to ensure the fuse setting reads either

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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)

SECTION II DESCRIPTION

2.2. GENERAL SPECIFICATIONS
WEIGHT

UNIT: 48.2 lbs. (21.8 Kg)

AC POWER CORD: 0.4 lbs. (0.18 Kg)

INPUT POWER AC

TI4676:

OUTPUT POWER DC

CONVERTER: 28.5 VDC TO 12 AMPS, 24 VDC 15 AMPS AND ABOVE.
POWER CELLS: 24 VDC 23 AMP Hour
PEAK OUTPUT: 1500 AMPS

POWER CELL

DRY, HIGH RATE DISCHARGE, RECHARGEABLE, MAINTENANCE-FREE

SHIPPING CASES

Used for shipping and storage.

110-240 VAC 50/60 Hz 6.50 amps max.

OPTIONAL ACCESORIES

Part # TI7000-023

2-2

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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

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 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 TI4676 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.

3-1

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 fully 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 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

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Unit will be damaged if unapproved AC power is applied.

32:(5 628 5&(

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

3-2