Tesla TI50A User Manual

Power Anytime, Anywhere

Tesla

DC Power Supply

TI50A

User Manual

™

Built Smart...Proven Tough

Tesla Industries, Inc.

101 Centerpoint Blvd.
New Castle, DE 19720
[phone] Phone
[phone] Fax

www.teslaind.com

NOTE: All users must read this entire manual prior

to operating the TI50A DC Power Supply.

The TI50A DC Power Supply is a limited maintenance-free and sealed unit. No repairs are authorized.
Warranty will be voided if unit is tampered with in any way, or if unauthorized repairs are made. For technical
support please contact:

TESLA™ INDUSTRIES INCORPORATED

101 CENTERPOINT BLVD.

CENTERPOINT INDUSTRIAL PARK

NEW CASTLE, DELAWARE 19720

PHONE: [phone]

FAX: [phone]

WEBSITE: www.teslaind.com

EMAIL: [e-mail]

CAUTION

Improper use or failure to follow instructions in this user manual can result in unit damage and/or injury or
death by electrical shock.

Any attempts to open or examine the inside of the TI50A DC Power Supply via a tool or device (borescope,
probe, etc.) can result in unit failure and/or injury by electrical shock. This unit is mainte nance free and
should not be opened or disassembled for any reason.

Always protect the unit from short circuit.

Shipping Hazards: None.

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, or any information storage and retrieval system, without prior
written permission from Tesla™ Industries, Inc.

!

NOTE

Unit is not rated for engine starting.
It is to be used for ground maintenance only.

Shock Hazard Potential

Copyright © 2016 by Tesla™ Industries, Incorporated. All rights reserved.

09-01-16

Table of Contents

Section 1 – Safety Review 1

1.1 – Safety Notices 1

1.2 – Symbols 1

1.3 – Hazards 2

1.4 – Important Safety Precautions 3

1.5 – Extreme Environments 3

Section 2 – Product Overview 4

2.1 – Introduction 4

2.2 – Indication of Terms: Shall, Should, and May 4

2.3 – Front Panel Overview 5

2.4 – General Specications 6

2.5 – Physical Dimensions 7

2.6 – Airow Ports 7

2.7 – Operating Position 8

2.8 – AC Input Circuit Breakers 9

2.9 – 24 Vdc Output Connector 9

2.10 – DC Output Circuit Breaker 9

2.11 – Input Voltage Selector Switch 10

2.12 – AC Input Receptacle 11

2.13 – “Available Power” LED Indicator 11

Section 3 – Operating Procedures 12

3.1 – Operating Procedures 12

3.1 – General 12

3.2 – Operating Limits and Restrictions 12

3.4 – Environmental 13

3.5 – Normal Functional Test Procedures 14-15

3.6 – Pre-Operation 16

3.7 – Transporting Unit 16

3.8 – Regulated 28.5 Vdc Ground Power 18

TI50A DC Power Supply

Section 4 – Post Operation 18

4.1 – General 18

4.2 – After Use 18

Section 5 – Unit Care and Maintenance 19

5.1 – Unit Care 19

5.2 – Unit Servicing 20

5.3 – Packaging and Shipping 20

Section 6 – Troubleshooting and FAQ 21

6.1 – Frequently Asked Questions 21-22

6.2 – Basic Usage/Operation Questions 22

6.3 – Basic Troubleshooting 23

Section 7 – Optional Accessories 24

7.1 – Shipping Case 24

7.2 – Protective Covers 24

7.3 – Tesla™ AC Line Cords 24

7.4 – Cobra™ DC Replacement Contacts and Tools 25

7.5 – Transport Dolly 25

Appendix A 26-30

Repair Request Form 31

TI50A DC Power Supply

Abbreviations and Symbols

Abbreviations that may be used within the text, headings and titles of this manual.

LIST OF ABBREVIATIONS

Abbreviation Defi nition

ac Alternating Current

AFT Air ow Technology

AWG American Wire Gauge
amp or A Ampere
cont Continuous
°C Degree Celsius
°F Degree Fahrenheit
dc Direct Current

EFF Ef ciency

ft Feet
FWD Forward
GPU Ground Power Unit
Hr Hour
Hz Hertz
kg Kilograms
kHz Kilohertz
kW Kilowatts
LED Light Emitting Diode
max Maximum

MΩ megaohm

min Minimum
MPU Micro Power Unit
NEMA National Electrical Manufacturers Association

Ω ohm

PF power factor
PFC power factor correction
rms root-mean-square
THD Total Harmonic Distortion
TMDE Test, Measurement, & Diagnostic Equipment
UAV Unmanned aerial vehicle
Vac Volts, Alternating Current
Vdc Volts, Direct Current
W watts

TI50A DC Power Supply

Section 1 – Safety Review

1.1 - Safety Notices

Safety notices appear throughout this manual to alert the user to important information regarding proper
installation, operation, maintenance and storage of the unit. These notices, as illustrated below, contain a

key word that indicates the level of hazard and a triangular icon that indicates the speci c type of hazard.

WARNING

!

CAUTION

!

NOTE

!

1.2 - Symbols

The following symbols will appear within the warning triangles to alert the user to the speci c type of danger

or hazard.

Indicates a condition, operating procedure or practice, which if not
adhered to could result in serious injury or death.

Indicates a condition or operating procedure, which if not strictly
adhered to could result in damage or destruction of equipment.

Indicates a condition, operating procedure or practice, which is
essential to highlight.

!

General Warning Electrical Hazard Explosion Hazard Fire Hazard

Battery Warning Guard from Moisture

Figure 1.2.1 – Different types of hazard and caution symbols

TI50A DC Power Supply

1

1

Safety Review

1.3 – Hazards

WARNING

Severe injury or death from electrical shock may occur, if either user
or the unit is wet, while the unit is connected to a power source. If the
unit has come into contact with water, discon nect ac power from the ac

source. If AC Input Circuit Breaker has tripped due to water in ltration,

DO NOT try to reset it with the ac line voltage attached.

WARNING

Severe injury or death from electrical shock can occur when damp electrical plugs are connected to the
unit. Before making any connections, turn off unit. Failure to use proper grounding can cause potential
shock hazard! In different countries, the power cord may require the use of a plug adapter to achieve plug
style compatibility for operation. Use only adapters with proper grounding mechanism.

Shock Hazard Potential

Shock Hazard Potential

Figure 1.3.1 – Proper Ground

Grounded Plug with Grounding Pin

CAUTION

The use of unapproved ac power will damage the unit. Check the
Input Voltage Selector Switch window (outlined in blue) to ensure
the switch setting (115V or 230V) matches the ac power source

(hangar wall,  ight line ac power) prior to connecting the unit for

recharging.

Unit Damage Potential

Figure 1.3.2 – Proper Ground

Adapter with Grounding Mechanism

(Secured to Outlet)

Figure 1.3.3 – Improper Ground

Plug with No Grounding Pin

Figure 1.3.4 – TI50A DC Power Supply

Input Voltage Selector Switch

2

TI50A DC Power Supply

1.4 – Important Safety Precautions

Safety Review

1

WARNING

Severe injury or death from  re or explosion can occur if electrical sparks are produced near fuel vapors. DO

NOT CONNECT ac power supply WHILE FUELING. AC power functions of unit shall not be operated during any
fuel handling operation. Power output is restricted to dc power only.

Fire/Explosion Hazard Potential

1.5 – Extreme Environments

CAUTION

The unit’s charger temperature switch automatically disables the unit when the internal temperature exceeds
150°F (65°C). This protects the unit from overheating and damage. If the unit shuts down, move the unit
into a cooler environment such as shade or air conditioning when possible. Perform a full function test, after
the unit has been allowed to cool, prior to use.

Unit Damage Potential

TI50A DC Power Supply

3

Section 2 – Product Overview

2.1 – Introduction

Thank you and congratulations on the purchase of your new TI50A DC Power Supply.

The TI50A DC Power Supply is intended to provide dc electrical ground power for aircraft ight line and

maintenance ground support operations. The unit is designed to provide 28.5 volts dc electrical support
for ground maintenance, avionics/electrical troubleshooting and testing. The observance of procedures,

limitations and performance criteria is essential to ensure peak operating efciency and to maximize

operational capabilities and life of the TI50A DC Power Supply.

This manual contains the complete operating instructions and procedures for the TI50A DC Power Supply

that the end user will need to safely and efciently operate this DC Power Supply.

Figure 2.1.1 – TI50A DC Power Supply

2.2 – Indication of Terms: 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.

4

TI50A DC Power Supply

2.3 – Front Panel Overview

1

Product Overview

5

6

7

2

2

3

4

8

9

24 Vdc Output Connector1. – Provides
50 amps continuous @ 28.5 Vdc (when
plugged into ac power)

Output Connector Protective Cover2. ­Protects Output Connector from dust
and foreign materials.

Air Intake Ports 3. – Provide airow for

cooling internal electronics.

Carrying Handle 4. – Allows for easy
transport of unit.

TI50A DC Power Supply

AC Input Circuit Breakers5. – Trip if over­current fault condition occurs.

“Available Power” Meter6. – Displays
status of power output.

AC Input Connector 7. – Connects to
Single Phase 100-260 Vac line voltage.

Input Voltage Selector Switch8. – Allows
unit to operate within voltage range of
either 100-130 Vac or 200-260 Vac.

DC Output Breakers9. - Trips if an over­current condition occurs.

5

2

Product Overview

2.4 – General Specications

Electrical

AC Input Power:

Operates from Single Phase 100-260 Vac, 50/60 Hz •
20 amps @ 120 Vac - 2400 Watts•
10 amps @ 240 Vac - 2400 Watts•

DC Output Power:

50 amps continuous @ 28.5 Vdc - 1425 Watts•

Size:

21.25” long x 5.2” wide x 10.56” high•

539.7mm x 132.1mm x 268.25mm•

Weight

15.85 lbs (7.19 kg)•

Operating Temperature:

-40°C to +55°C (-40°F to 131°F) with AC power•

Storage Temperature:

-65°C to +105°C (-85°F to 221°F)•

6

TI50A DC Power Supply

2.5 – Physical Dimensions

FRONT VIEW SIDE VIEW

5.20

[132.1]

10.20 [259.0]

21.25 [539.7 ]

18.75 [476.2]

Product Overview

2

Figure 2.5.1 – TI50A DC Power Supply Physical Dimensions

2.6 – Airow Ports

CAUTION

When the TI50A DC Power Supply is plugged into ac power, the internal cooling system will efciently regulate

unit temperature regardless of load. At room temperature (+77°F) the exhaust air will not exceed the ambient
temperature by more than 5°F. In more extreme temperatures (greater than 90°F) the exhaust air will not
exceed the ambient temperature by more than 10°F.

Damage may occur if the TI50A DC Power Supply’s air intake or outlet
ports are obstructed. Ensure that ports are clear at all times.

Figure 2.6.1 – Air intake, exhaust ports and internal air circulation

TI50A DC Power Supply

7