Table of Contents
Troubleshooting
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Summary of Contents for Tesla TI4200 GPU-24-PFC
- Page 1 Power Anytime, Anywhere Tesla TI4200 GPU-24-PFC ™ User Manual Built Smart...Proven Tough Tesla Industries, Inc. 101 Centerpoint Blvd. New Castle, DE 19720 (302) 324-8910 Phone (302) 324-8912 Fax www.teslaind.com www.tesla1.com...
- Page 2 Conditioners, manufactured by Tesla™ Industries, Inc., are able to safely and effectively charge any AGM, Lead Acid battery. The Tesla™ GPU’s and chargers are voltage and current regulated to 0.01% (dual loop). The charging voltage is calibrated, by Tesla™, to 28.6 volts and is pure dc (no power line ripple).
- Page 3 Chemical Family/Classification: Tesla™ Industries, Inc. Sealed Lead Battery Synonyms: Telephone: Sealed Lead Acid Battery, VRLA Battery For information, contact Tesla™ Industries, Inc. Manufacturer's Name/Address: Customer Service Department at 302-324-8910 Tesla™ Industries, Inc 101 Centerpoint Blvd. 24-Hour Emergency Response Contact: New Castle, DE 19720-4180...
- Page 4 Supersedes: AF ECO #: 1002195 Inorganic lead and sulfuric acid electrolyte are the primary components of every battery manufactured by Tesla™ Products. There are no mercury or cadmium containing products present in batteries manufactured by Tesla™ Products. IV. FIRST AID MEASURES Inhalation: Sulfuric Acid: Remove to fresh air immediately.
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Page 5: Table Of Contents
15-16 3.9 – Pre-Operation 3.10 – Transporting Unit 3.11 – Regulated 28.5 Vdc Ground Power 18-19 3.12 – Operating with a Digital Volt/Amp Meter 3.13 – Regulated AC Power 3.14 – Charging Unit 3.15 – Circuit Breaker Switch TI4200 GPU-24-PFC... - Page 6 7.8 – Maximum Output Current Section 8 – Optional Accessories 8.1 – Shipping Case 8.2 – GPU Protective Covers 8.3 – Digital Volt/Amp Meter(TI3100A) 8.4 – GPU Tires 8.5 – Cobra™ DC Replacement Contacts and Tools Repair Request Form TI4200 GPU-24-PFC...
- Page 7 Maximum MΩ megaohm Minimum Micro Power Unit NEMA National Electrical Manufacturers Association Ω power factor power factor correction root-mean-square Total Harmonic Distortion TMDE Test, Measurement, & Diagnostic Equipment Unmanned aerial vehicle Volts, Alternating Current Volts, Direct Current watts TI4200 GPU-24-PFC...
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Page 8: Section 1 - Safety Review
The following symbols will appear within the warning triangles to alert the user to the specifi c type of danger or hazard. General Warning Electrical Hazard Explosion Hazard Fire Hazard Battery Warning Guard from Moisture Figure 1.2.1 – Different types of hazard and caution symbols TI4200 GPU-24-PFC... -
Page 9: Hazards
If the unit shuts down, move the unit into a cooler climate such as shade or air conditioning when possible. Perform a full function test prior to use after the unit has been allowed to cool. TI4200 GPU-24-PFC... -
Page 10: Section 2 - Product Overview
The TI4200 GPU-24-PFC was designed to provide 200 amps @ 28.5 Volts of pure regulated flat line dc power for vehicle ground support, avionics, battery charging, power for training facility operations, and for all 24 Volt systems. -
Page 11: Front Panel Overview
– Provides active cooling for internal components. Interface Connector - Used for factory calibrations. LED Charge Status Meter – Displays current battery charge status when Telescopic Handle – Allows for easy pressed. transport of unit (removed to show panel). TI4200 GPU-24-PFC... -
Page 12: General Specifications
Single Phase 200-260 Vac / 40 Hz - 450 Hz • 33.5 amps @ 208 Vac • 50 amp Service Required • Contact Tesla™ Industries for Plug Configuration Power Cell: • Dry, High Rate Discharge, Rechargeable , Maintenance-free PFC: •... -
Page 13: Physical Dimensions
2.5 – Physical Dimensions 19.25 [488.95] 10.5 [266.7] 49” [1244.6] Figure 2.5.1 – TI4200 GPU-24-PFC physical dimensions 2.6 – Airflow Ports Damage may occur if the unit’s air intake or outlet ports are obstructed. CAUTION Ensure that ports are clear at all times. -
Page 14: Operating Positions
Product Overview 2.7 – Operating Positions The TI4200 GPU-24-PFC can be operated in both the horizontal (Figure 2.7.1) and vertical (Figure 2.7.2) positions as shown. Make sure that the airflow is not obstructed from air intake (figure 2.7.3) and outlet (Figure 2.7.4). -
Page 15: Push To Test" Button And Led Status Indicator
The voltage will drop from NOTE 28.60 to 28.10 volts (±0.10). When a load greater than 2 amps is applied, the unit will return to normal operation. Figure 2.8.1 - Pushing to Test STATUS STATUS STATUS Full Charge Half Charge No Charge TI4200 GPU-24-PFC... -
Page 16: Active Power Factor Correction
Tesla™ Industries was able to develop a wide bandwidth active Power Factor Correction that runs from 40 Hz to 450 Hz which pulls unity power only at the fundamental frequency. This was achieved by forcing the current to follow the voltage waveform (see Figure 2.9.2) so that current is pulled through the entire... -
Page 17: Ac Input Circuit Breaker
The ac line cord is a 25’ long SOOW 600 Volt 8/3 Cable with a 50 Amp Twist Lock. (TI25000-058 (CS8265) 25ft. Hardwired Single Phase Plug AC Line Cord ) 50 Amp service is required to use the unit. Contact Tesla™... -
Page 18: 24 Vdc Output Connector
2.12.1). This will protect the Output Connector from dust and foreign matter. Closed Open Figure 2.12.1 24 Vdc Output Connector Protective Cover 2.13 – Interface Connector The Interface Connector is used by a Tesla™ factory technician to calibrate the unit. Figure 2.13.1 - Interface Connector location TI4200 GPU-24-PFC... -
Page 19: Section 3 - Operating Procedures
50-60% charged 1800 - 2100 peak starting amps 60-70% charged 1800 - 2100 peak starting amps 60-70% charged TI4200 GPU-24-PFC 2100 - 2400 peak starting amps 70-80% charged 2100 - 2400 peak starting amps 70-80% charged 2400 - 3000 peak starting amps... -
Page 20: Temperature Specifications
If the unit shuts down, move the unit into a cooler climate, such as shade or air conditioning when possible. Perform a full function test prior to use after the unit has been allowed to cool. TI4200 GPU-24-PFC... -
Page 21: Environmental
B. Minimize moisture entering forward inlet and outlet cooling fan vent ports Figure 3.7.1 – TI4200 GPU-24-PFC with TI7000-104 Protective Rain Cover When not in use, unit inlet and outlet vent ports shall be covered from exposure. Unit shall be kept horizontal. -
Page 22: Normal Functional Test Procedures
Check Unit for Evidence of Damage Check for dents, punctures, case distortion or misalignment, and cracked or loose connec tors. If no damage is evident, proceed to the next step. If damage is evident, contact Tesla™ Industries, Inc. Figure 3.8.2 – Damaged Unit... - Page 23 If unit is left charging after the batteries are fully charged, the unit will enter a standby mode. The voltage will drop from 28.60 to 28.10 volts (±0.10). NOTE When a load greater than 2 amps is applied, the unit will return to normal operation. TI4200 GPU-24-PFC...
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Page 24: Pre-Operation
3.10 – Transporting Unit The TI4200 GPU-24-PFC has a telescoping handle that makes rolling the unit easy. For transporting on uneven ground, axle extensions should be added to the unit. For use on sand, balloon tires should be installed on the unit (see Optional Accessories). -
Page 25: Regulated 28.5 Vdc Ground Power
Line up the plug with the receptacle. Push forward while rotating the T-handle one full turn clockwise. The unit is now ready to safely transfer power. Figure 3.11.1 Attaching DC Power Cable to TI4200 GPU-24-PFC Connecting DC Power Cable To Vehicle or Aircraft Line up the NATO plug or aviation dc plug pins and push it in. -
Page 26: Operating With A Digital Volt/Amp Meter
The DVAM (Digital Volt/Amp Meter) 3100A provides measurements for all voltage ranges and amperage draws between zero and 2,000. The DVAM 3100A indicates the aircraft or vehicle’s current demand. Integrated with the Tesla™ GPU power supply, the DVAM is a valuable tool for troubleshooting and system checks. -
Page 27: Regulated Ac Power
3.13 – Regulated AC Power Plugging in with AC Power When the TI4200 GPU-24-PFC is plugged into ac power, the output is 28.5 volts. This voltage allows the system to recondition and recharge the vehicle’s battery(ies). It is also an optimum voltage for powering avionics and lighting on most aircraft. -
Page 28: Charging Unit
Once you have the fuse set to match the power characteristics of your line cord, you can plug the unit into a wall socket to charge the batteries. Until the unit is fully charged, the LED status will read half or no charge. Figure 3.14.1 Connecting TI4200 GPU-24-PFC to AC Power Supply If you received this manual with a new GPU. -
Page 29: Section 4 - Post Operation
Section 4 – Post Operation 4.1 – General Although the TI4200 GPU-24-PFC has been ruggedized and made weather resistant within the scope of unit’s intended use, it is essential that good general care be taken to maintain unit in good operating condition and to maximize unit’s operational life. - Page 30 The GPU’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 GPU’s internal charger and the ac power cord furnished with the equipment, or when connected to aircraft’s external dc power receptacle. Figure 4.3.2 Proper and Improper Charging Methods TI4200 GPU-24-PFC...
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Page 31: Section 5 - Unit Care And Maintenance
Do not cut, crush, or drag the input or output power cables when handling the unit. Always inspect cables prior to use. If no damage is evident, proceed to the next step. If damage is evident, contact Tesla™ Customer Service. Do not attempt to use any other type of power cables other than the Tesla™ cables included with the unit. -
Page 32: Unit Servicing
Ensure proper packaging when returning the unit. Transport the unit only in a sturdy shipping crate or Tesla™ Shipping Case. It is important to enclose the Repair Request Form. Seal the crate on all sides and return it to Tesla™ at the address listed below. Please contact Tesla™ Customer Service at (302) 324-8910 with any questions or concerns. -
Page 33: Section 6 - Troubleshooting And Faq
5. Will a Tesla™ Turbo Start™ spool up a turbine engine? Nothing will start a turbine engine faster or safer than the right Tesla™ Turbo Start™. Not only will it eliminate hot starts, but it will extend the life of your starter, your engine and your battery while reducing maintenance. The Turbo Start™ senses the impedance from the starter/generator. - Page 34 Unit should never be allowed to discharge fully. In-fi eld use, it receives a dc back charge directly from a running engine. When not in use, unit should be plugged into ac power (outlet) all the time. Tesla™ systems will retain 80% of their capacity after one year of storage.
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Page 35: Basic Usage/Operation Questions
Reset breaker by pressing red button. Reconnect ac and dc connections to the unit. (Plug in ac line cord on military unit.) The unit should power up automatically. If the breaker continues to trip, return the unit to Tesla™ Industries for repair. TI4200 GPU-24-PFC... -
Page 36: Basic Troubleshooting
If LEDs still do not illuminate, Please contact Tesla™ Customer Service at (302) 324-8910. 2. Unit has no output dc or ac Units cells completely dead. Do a function check with digital meter, input or both. - Page 37 Switch breaker to ON position. Reconnect unit to cables and run. If LEDs still do not illuminate, Please contact Tesla™ Customer Service at (302) 324-8910. 8. Unit does not put out 28.5 Unit is not plugged in. Plug unit into ac power source to volts dc power.
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Page 38: Section 7 - Performance Data
These differences, however, are considered insignifi cant and are not individually accounted for. Ground Support and Aircraft Instrument Variations: The data shown in the performance charts do not account for instrument tolerance differences or inaccuracies. TI4200 GPU-24-PFC... -
Page 39: Temperature Conversion Chart
152.6 -31.0 -23.8 35.6 35.0 95.0 68.0 154.4 -30.0 -22.0 37.4 36.0 96.8 69.0 156.2 -29.0 -20.2 39.2 37.0 98.6 70.0 158.0 -28.0 -18.4 41.0 38.0 100.4 71.0 159.8 Figure 12.6.1 – Temperature conversion from Celsius to Fahrenheit. TI4200 GPU-24-PFC... -
Page 40: Output Voltage
* * * * 1350 * * * * * * * 1200 (+25 C Temp) 1050 * * * * * * * * (-29 C Temp) SECONDS Calculation based on actual test data at Pratt-Whitmey on 30 March 1992 TI4200 GPU-24-PFC... -
Page 41: Section 8 - Optional Accessories
Section 8 – Optional Accessories 8.1 – Shipping Case The optional Shipping Case is the safest way to transport the TI4200 GPU-24-PFC. This custom case weighs 95 lbs and comes equipped with side handles and locking latches. TI7000-175 Length: 54.5”... -
Page 42: Cobra™ Dc Replacement Contacts And Tools
A rugged combination of advanced composite materials and corrosion-resistant alloys make each plug maximized for durability and connectivity. To extend the life of the Cobra™ Connector included with your unit, replacement contacts, posts, noses and tools can be ordered through the Tesla™ Customer Service. TI2005-238 TI2005-078 Cobra™... -
Page 43: Repair Request Form
Email: _______________________________________________________________________________________ Purchase Order #: ______________________________________________________________________________ Model #: ____________________________________ Serial #: ________________________________________ Model #: ____________________________________ Serial #: ________________________________________ Shipping method to Tesla™: ______________________________________________________________________ Description of shipping package: ________________________________________________________________ Description of problem: _________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ Return to Tesla™ 101 Centerpoint Boulevard, New Castle, DE 19720 Attention: Repair Department... - Page 44 Tesla™ 101 Centerpoint Blvd. New Castle, DE 19720 USA Tel: 302-324-8910 Fax: 302-324-8912 9475 Double R Blvd., Suite 2 Reno, NV 89521 Tel: 775-622-8801 Fax: 775-622-8810 www.teslaind.com ♦ www.tesla1.com...
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