Tesla TI4676 User Manual
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Tesla TI4676 User Manual

Tesla TI4676 User Manual

Micro power unit
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'%()$)-&./
TI4676
!"#$%&'%()$&*+",
Tesla Industries Inc.
109 CenterPoint Blvd.
New Castle, DE 19720
(302)324-8910 Phone
(302) 324-8912 Fax
www.TESLAind.com

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  • Page 1 '%()$)-&./ TI4676 !"#$%&'%()$&*+", Tesla Industries Inc. 109 CenterPoint Blvd. New Castle, DE 19720 (302)324-8910 Phone (302) 324-8912 Fax www.TESLAind.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TITLE Page CHAPTER 1 INTRODUCTION CHAPTER 2 UNIT DESCRIPTION AND OPERATION Section I Unit Section II Description CHAPTER 3 OPERATING LIMITS AND RESTRICTIONS Section I General Section II Operational Restrictions and Safety Limits CHAPTER 4 OPERATING AND INSTALLATION PROCEDURES Section I Installation Procedures Section II...

  • Page 4: Introduction

    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,...
  • Page 5 1-4. INDEX The index lists, in alphabetical order, every titled paragraph and fig- ure 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...
  • Page 6 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. word “should” is used to indicate a non-mandatory but preferred method of accomplishment.

  • Page 7: Unit Description And Operation

    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 28.5 VDC converter, a 24 volt unique (dry) power cell and an internal intelligent 120-240 50/60 Hz charger to recharge the power cells.

  • Page 8: Description

    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 MPU for recharging. 120 VAC Setting 240 VAC Setting (SEE PAGE 2-4 FOR DETAILS ON FUSE SETTING PROCEDURES)
  • Page 9 !"#$%&' !"#...

  • Page 10: Fuse Setting Procedures

    Fuse Setting Procedures for Switching Voltages or Changing Blown Fuses 1) Grab both tabs 2) Completely pull 3) Note: The fuses 4) GENTLY pull the on left and right side fuse clip from housing, are not fastened into white clip from the of the fuse clip.

  • Page 11: Operating Limits And Restrictions

    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 re- sult of design analysis, testing, and operating experience.
  • Page 12 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.
  • Page 13 AC Line Cords North American Old British Cont. Europe (more examples in appendix or call factory for information) CAUTION Unit will be damaged if unapproved AC power is applied by fitting * 8 $ 5 ’ ) 5 2 0 ,1 & 2 5 5 ( & 7 3 2 : ( 5 6 2 8 5 &...
  • Page 14 3-8. CONTINUOUS OUTPUT RATE, 28.5 VDC CONSTANT OUTPUT 35 Amps at 1 hour (with AC power connected) NOTE If current demand exceeds 12 amps, converter output voltage will drop below 28.5 VDC and two or more LED status indicator bars will illumi- nate.
  • Page 15 CAUTION Unit may be damaged if operated when unit’s cold or heat soaked tem- perature exceed the specified limit. If unit is operated when cold or heat soaked temperature limit is exceeded; a full functional check should be accomplished prior to continued use. NOTE If unit should overheat, an over-temperature sensor will shut down 120- 240 50/60 Hz...
  • Page 16 WARNING ********SHOCK HAZARD POTENTIAL********* Severe injury, or Death, from electrical shock is possible when person- nel and/or TI4676 are wet during use and when 120-240 50/60 Hz power is being supplied to unit. CAUTION Damage may occur if unit is operated after exposure to moisture (rain, drizzle, fog, sleet or snow) or moisture contamination is sus- pected.
  • Page 17 CAUTION Unit damage may occur if inlet and outlet vent ports are obstructed and/or cooling airflow is restricted. Back Vent Side Vents Cooling Fan 3-13. UNIT OPERATION DURING AIRCRAFT FUELING/DEFUELING Power output is restricted to 24 VDC power cell output only. DO NOT CONNECT 120 or 240 VAC POWER SUPPLY.

  • Page 18: Operating And Installation Procedures

    CHAPTER 4 OPERATING AND INSTALLATION PROCEDURES SECTION I. UNIT INSTALLATION 4-1. INSTALLATION 1. Remove original aircraft battery and dispose of properly (follow your aircraft’s manual for proper removal and disposal of aircraft battery). 2. Ensure that the TI4676 MPU is fully charged. Remove AC cord and place the TI4676 MPU in the same position of the original battery (en- sure that the DC receptacle is oriented in the same position as the original battery).

  • Page 19: Operating Procedures

    SECTION II. OPERATING PROCEDURES (cont.) 4-5. OPERATING PROCEDURES This section deals with normal procedures, and includes all steps nec- essary to ensure safe and efficient operation of the TI4676. As expe- rience is gained with the TI4676, the user will be able to maximize the unit’s unique capabilities to enhance the flexibility of aircraft maintenance and support operations.
  • Page 20 CAUTION REMEMBER, when the AC line cord is plugged in, the unit must be placed in a position to allow the cooling fan to operate properly! Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. (More than one green bar is present on bar graph) Make certian there is at least 2-3 inches clearence on the vent fan of the MPU...
  • Page 21 CAUTION Unit may overheat if cooling fan fails. Do not operate if cooling fan fails. CHECK FOR FULL CHARGE INDICATION - After 1 HR 15 minutes, LED charge indicator should show a single steady or flickering LED bar when fully charged. AC power may be left connected to unit when power cells are fully charged.

  • Page 22: Functional Check Procedures

    SECTION III. FUNCTIONAL CHECK PROCEDURES AND TROUBLE SHOOTING 4-8. FUNCTIONAL CHECK PROCEDURES This section deals with normal functional check procedures, and includes all steps necessary to ensure the TI4676 is functioning within specific operational parameters prior to operational use. As users gain experi- ence with the TI4676, they will incorporate these functional checks as a routine practice.
  • Page 23 CHECK DC VOLTAGE READING AT DC RECEPTACLE TERMINALS. Ensure power cells are fully charged (see step 6.) 28.5 (±0.57 VDC) with power cells at full state of charge. FUNCTIONAL CHECK COMPLETE - Unit should remain plugged in to AC power until ready for installtion in aircraft.

  • Page 24: Performance Data

    CHAPTER 5 PERFORMANCE DATA SECTION 1. INTRODUCTION 5-1. PURPOSE This chapter provides performance data for the TI4676. Continual refer- ence to this information will enable the user to obtain maximum perfor- mance, utilization and service life from the TI4676. Although maximum performance is not always required, regular referral to this chapter is recommended for the following reasons: To generate knowledge of unit’s performance margins to enable the...

  • Page 25: Data Criteria

    SECTION II DATA CRITERIA 5-3 DATA BASIS The type of data used is indicated at the bottom of each performance chart under DATA BASIS. The applicable report and date of the data are also given. The data provided generally are based on one of three cat- egories: Derived From Actual Controlled Testing.
  • Page 26 FIGURE 5-1...
  • Page 27 TI4676MPU-24 OUTPUT VOLTAGE MINUTES 23 AMP CONSTANT CURRENT LOAD FIGURE 5-2...
  • Page 28 MAXIMUM OUTPUT CURRENT 1500 * * * * 1350 * * * * * * * 1200 (+25 C Temp) 1050 * * * * * * * * (-29 C Temp) SECONDS Calculation based on actual test data at Pratt-Whitmey on 30 March 1992 FIGURE 5-3...

  • Page 29: Care And Maintenance

    CHAPTER 6 CARE AND MAINTENANCE SECTION I. UNIT CARE 6-1. GENERAL Although the TI4676 has been ruggedized and made weather resistant within the scope of unit’s intended use, it is essential that good gen- eral care be taken to maintain unit in good operating condition and to maximize unit’s operational life.
  • Page 30 Chapter 7 Push To Test Modification General Information And Operation 7-1. General THIS MODIFICATION HAS BECOME STANDARD EQUIPMENT FOR EACH OF OUR UNITS. BOTH MILITARY AND CIVILIAN CLIENTS HAVE FOUND THIS MODIFICATION TO BE CRITICAL TO THEIR OPERATION. THE PUSH TO TEST BUTTON IS USED TO INDICATE THE CAPACITY OF THE POWER CELLS WITHOUT APPLYING AC INPUT POWER.

  • Page 31: Dimensions

    PARAGRAPH INDEX 120-240 50/60 Hz VAC Charger and AC to DC Converter Limits, 3-4 Abbreviations, AC Power Cord Limits, After Use, Appendix A Line Cord Table Before Operation Check, Continuous Output Rate, 28.5 VDC Constant Output, Data Basis, DC Functional Check, 4-10 Definitions of Abbreviations, Dimensions, Figure...

  • Page 32: Unit Operation

    PARAGRAPH INDEX Index, Installation, 4-1 Maintenance of Unit, Maximum Output Current, Figure One (1) Hour Rate, 24 VDC Constant Output, Operating Limits and Restrictions, Operating Procedures, Operating Position, 3-12 Performance, Power Cell Recharge, Power Cell Recharge Limits, Purpose, Chapter 3, Purpose, Chapter 5, Push to test modification, Rated Peak Output (Engine Starting),...
  • Page 33 APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA PART # Afganistan TI25000-004 Old British Line Cord Set Algeria TI25000-004 Old British Line Cord Set American Samoa TI25000-011 Australian Line Cord Set Angola TI25000-100 Europlug Line Cord Set Anguilla (U.K.)
  • Page 34 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA PART # Ecuador TI25000-001 North American Line Cord Set Egypt TI25000-100 Europlug Line Cord Set El Salvador TI25000-001 North American Line Cord Set England TI25000-005 United Kingdom Line Cord Set...
  • Page 35 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA PART # Laos TI25000-001 North American Line Cord Set Latvia TI25000-003 Cont. European Line Cord Set Lebanon TI25000-100 Europlug Line Cord Set Lesotho TI25000-004 Old British Line Cord Set...
  • Page 36 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA PART # Romania TI25000-003 Cont. European Line Cord Set Russia TI25000-003 Cont. European Line Cord Set Rwanda TI25000-100 Europlug Line Cord Set Saudia Arabia 50/60 TI25000-003 Cont. European Line Cord Set...
  • Page 37 NOTE: TESLA UNIVERSAL AC LINE CORD KIT, P/N: TI25000-U00, IS FOR UNITS ORIGINALLY BUILT WITH THE UNIVERSAL AC LINE CORD OPTION ONLY. THE AC ADAPTER OPTION IS TESLA P/N TI16000-19 AND MUST BE ORDERED WITH THE ORIGINAL PROCUREMENT OF UNIT(S). UNIT(S) MAY BE RETURNED TO TESLA INDUSTRIES, FOR A NOMINAL COST, AND MODIFIED TO ALLOW OPERATION WITH THE UNIVERSAL AC LINE CORD KIT.

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