Tesla TIMV3000 GPU-24 Manual

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Power Anytime, Anywhere

Features

• Ideal for hangars, FOBs, motor pools, and deployments

• Perfect for testing and troubleshooting (avionics, TMDE, electronics, and hydraulics)

• System back-charges from the started vehicles engine in minutes

• Will charge and maintain vehicle batteries when unit is left connected to vehicle (ac power required)

• Safe, easy, maintenance-free operation

Safe and Easy Operation

•One person can maneuver and operate the unit

•Safe for flight, non-hazardous, dry-cell technology

•"Push to Test" feature provides instant state of charge

Pure Power

•No spikes or surges

•3000 peak starting amps

•46 amp hours (1024 watt hours) of rechargeable battery power without ac power

•96 amp hours (2449 watt hours) with ac power

•Operates and charges from Single Phase 100-260 Vac power 50/60 Hz

•50 amps continuous @ 28.5 Vdc (when plugged into ac power)

Tesla™

Industries, Inc.

www.teslaind.com

Email: tesla1@teslaind.com

Headquarters: (302) 324-8910

101 Centerpoint Blvd. New Castle, DE 19720 USA

Western Regional Office: (775) 622-8801

9475 Double R Blvd. Suite 2, Reno, NV 89521 USA

TI3000 GPU-24

Commercial Version

TIMV3000 GPU-24

NSN: 6130-01-475-5321 (CL II)

TI3000 GPU-24

NSN: 6130-01-440-2712 (CL IX)

TI3000 GPU-24 UAV

NSN: 6130-01-455-5531 (CL IX)

MADE IN USA

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Page 1 TI3000 GPU-24 Commercial Version TIMV3000 GPU-24 NSN: 6130-01-475-5321 (CL II) TI3000 GPU-24 NSN: 6130-01-440-2712 (CL IX) Power Anytime, Anywhere TI3000 GPU-24 UAV NSN: 6130-01-455-5531 (CL IX) Features • Ideal for hangars, FOBs, motor pools, and deployments • Perfect for testing and troubleshooting (avionics, TMDE, electronics, and hydraulics) •...
Page 2 TI3000 GPU-24 (commercial version) includes TI2007-208 8ft. DC Aviation Cable Assembly and TI25000-032 NEMA 520P North American Line Cord Tesla™ Industries, Inc. • 101 Centerpoint Blvd. New Castle, DE 19720 • 9475 Double R Blvd. Suite 2, Reno, NV 89521 • www.teslaind.com 05-16-14...
Page 3 Power Anytime, Anywhere Tesla TI3000 GPU-24 UAV UAV ™ 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...
Page 4 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. Copyright © 2014 by Tesla™ Industries, Incorporated. All rights reserved. 06-06-14...
Page 5 ™ Ground Power Unit (GPU) and Micro Power Unit (MPU) Containing Dry Cell (Starved Electrolyte) Batteries Used on Aviation/Military Application Manufacturer’s Name and Address: Emergency Telephone Number: Tesla Industries Inc. (302)324-8910 101 Centerpoint Blvd. Fax: (302)324-8912 New Castle, Delaware 19720 www.Teslaind.com...
Page 6 Reactivity (Yellow) = 2 Sulfuric Acid is Water Reactive if concentrated. U.S. DOT: Tesla™ Industries GPU/MPU batteries are classiﬁ ed as Nonspillable. They have been tested and meet the nonspillable criteria listed in 49 CFR § 173.159(f) and 173.159a(d)(1). Nonspillable batteries are excepted from 49 CFR Subchapter C requirements, provided that the following criteria are met: The batteries must be securely packed in strong outer packagings and meet the requirements of 49 CFR §...
Page 7: Table Of Contents
Table of Contents Section 1 – Safety Review 1.1 – Safety Notices 1.2 – Symbols 1.3 – Hazards 1.4 – Important Safety Precautions 1.5 – Extreme Environments Section 2 – Product Overview 2.1 – Introduction 2.2 – Indication of Terms: Shall, Should, and May 2.3 –...
Page 8 7.8 – Maximum Output Current Section 8 – Optional Accessories 8.1 – Shipping Case 8.2 – GPU Protective Covers 8.3 – Tesla™ AC Line Cords 8.4 – Cobra™ DC Replacement Contacts and Tools 8.5 – GPU Tires Appendix A 35-39...
Page 9 Abbreviations and Symbols Abbreviations that may be used within the text, headings and titles of this manual. LIST OF ABBREVIATIONS Abbreviation Deﬁ nition Alternating Current Airfl ow Technology American Wire Gauge amp or A Ampere cont Continuous °C Degree Celsius °F Degree Fahrenheit Direct Current...
Page 10: Section 1 - Safety Review
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 specifi c type of hazard. Indicates a condition, operating procedure or practice, which if not WARNING adhered to could result in serious injury or death.
Page 11: Hazards
Safety Review 1.3 – Hazards WARNING Shock Hazard Potential Severe injury or death from electrical shock may occur if either the user or the unit is wet while the operating unit is connected to a power source. Be sure to discon nect ac power from the ac source if the unit has come into contact with water.
Page 12: Important Safety Precautions
Safety Review 1.4 – Important Safety Precautions WARNING Fire/Explosion Hazard Potential Severe injury or death from fi 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.
Page 13: Section 2 - Product Overview
Section 2 – Product Overview 2.1 – Introduction Thank you and congratulations on the purchase of your new TI3000 GPU-24 UAV Ground Power Unit. The TI3000 GPU-24 UAV is intended to provide dc electrical ground power for aircraft flight line, maintenance, and ground support operations.
Page 14: Front Panel Overview
Product Overview 2.3 – Front Panel Overview Figure 2.3.1 - TI3000 GPU-24 UAV Military version AC Input Circuit Breaker – Trips if over-current 24 Vdc Capacity Meter – Indicates the 24V battery fault condition occurs. charge state/power output status. “Push to Test” Button –...
Page 15: General Specifications
Product Overview 2.4 – General Specifications Electrical AC Input: • Operates and charges from Single Phase 100-260 Vac, 50/60 Hz • 20 amps @ 120 Vac 60 Hz - 2400 Watts • 10 amps @ 240 Vac 60 Hz - 2400 Watts Power Cell: •...
Page 16: Physical Dimensions
Product Overview 2.5 – Physical Dimensions Figure 2.5.1 – TI3000 GPU-24 UAV 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. When the TI3000 GPU-24 UAV is plugged into Single Phase 100-260, Vac 50/60 Hz ac power, the internal cooling system will efficiently regulate unit temperature regardless of load.
Page 17: Operating Position
Product Overview 2.7 – Operating Positions The TI3000 GPU-24 UAV can be operated in both the horizontal and vertical positions as shown. Make sure that the airflow is not obstructed from air intake and outlet. Front Inlet Rear Outlet Horizontal Position Vertical Position TI3000 GPU-24 UAV...
Page 18: Ac Input Circuit Breakers
3. Reset breaker by pressing red button. 4. 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.
Page 19: Input Voltage Selector Switch
Product Overview 2.10 – Input Voltage Selector Switch The Input Voltage Selector Switch allows the unit to operate safely within the expected voltage range of either 100 - 130 Vac or 200 - 260 Vac. Figure 2.10.1 Input Voltage Selector Switch (outlined in blue) Changing Input Voltage Selector Switch To change the input voltage from 115 Vac to 230 Vac, simply follow these steps:...
Page 20: Push To Test" Button And Led Status Indicator
Product Overview 2.11 – “Push to Test” Button and LED Status Indicator The “Push to Test” button is used to indicate the capacity of the power cells without applying ac input power. It allows the end user to check the status of the power cells. This lets the operator know if there is enough power to perform another engine start, or if the unit has to be connected to ac power to allow it to recharge.
Page 21: Section 3 - Operating Procedures
operation of the unit. When the unit is not in use, it should always remain plugged into a suitable ac NOTE power source to ensure operational readiness at all times. Section 3 – Operating Procedures If current demand exceeds 25 amps, converter output voltage will drop below NOTE 3.1 –...
Page 22: Temperature Specifications
Operating Procedures 3.6 – Temperature Specifi cations Cold/Hot Soaked Temperature The ambient temperature that a unit is exposed to for one (1) hour or more establishes the unit’s cold/ hot soaked stabilization temperature. If the unit’s cold/hot soaked temperature is outside the normal operating temperature range, the unit must be stabilized prior to operation.
Page 23: Environmental
Unit inlet and outlet vent ports shall be covered from exposure. Unit shall be kept horizontal. It is recommended that the Tesla™ Protective Rain Cover be fi tted onto the unit to guard it from moisture (see Section 8). The limits...
Page 24: Normal Functional Test Procedures
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. Check DC Voltage Reading at DC Receptacle Terminals To verify that the power cells are fully charged, set the digital multimeter to measure dc voltage.
Page 25 Operating Procedures Check Unit Internal Resistance (Test for Shorts) NOTE Unit should be disconnected from any ac power sources prior to testing. 2. Place the negative probe on the ac 1. Set multimeter to Ohms. 3. Move the positive probe to the dc ground post and the positive probe negative post.
Page 26: Pre-Operation
Operating Procedures 3.9 – Pre-Operation Be sure to check that all input and output cables are not damaged. (See Section 5.1) Check unit carefully for any evidence of damage. Make sure that airflow is not obstructed from air intake and outlet. (See Section 2.6) Check that all connections are secure and free from water.
Page 27: Regulated 28.5 Vdc Ground Power
Operating Procedures 3.11 – Regulated 28.5 Vdc Ground Power Connecting DC Power Cable To Unit Line up the dc plug with the receptacle. Push forward while rotating the T-handle one full turn clockwise. Ensure dc power cable plug is fully seated into the GPU’s DC Battery Receptacle. The unit is now ready to safely transfer power.
Page 28 Operating Procedures High Power Demand High power demand is defined by a requirement of greater than 50 amps. Connect to aircraft ground power receptacle. DC bus power should come on and aircraft voltmeter should indicate 28.5 Vdc to 23.5 Vdc (23 VCD minimum).
Page 29: Regulated Ac Power
Operating Procedures 3.12 – Regulated AC Power Plugging in with AC Power When the TI3000 GPU-24 UAV 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 30: Section 4 - Post Operation
Section 4 – Post Operation 4.1 – General Although the TI3000 GPU-24 UAV 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 31 Post Operations CAUTION Guard From Incorrect Power Source The TI3000 GPU-24 UAV’s power cells may be damaged if recharged by NiCad or Lithium Ion battery chargers. Power cells should only be charged by either the TI3000 GPU-24 UAV’s internal charger and the ac power cord furnished with the equipment, or when connected to aircraft’s external dc power receptacle.
Page 32: 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 33: Unit Servicing
Tesla™ Shipping Case (be sure 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 34: 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 35 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.
Page 36: 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. TI3000 GPU-24 UAV...
Page 37: 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 38 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.
Page 39: Section 7 - Performance Data
Section 7 – Performance Data 7.1 – Purpose This section provides performance data for the unit. Continual reference to this information will enable the user to obtain maximum performance, utilization and service life from the unit. Although maximum performance is not always required, regular referral to this section is recommended for the following reasons: To generate knowledge of unit’s performance margins to enable the operator to make sound judgment when unexpected conditions or alternate operational requirements are encountered.
Page 40: Temperature Conversion Chart
Performance Data 12.6 – Temperature Conversion Chart 7.6 – Temperature Conversion Chart °C °F °C °F °C °F °C °F -60.0 -76.0 -27.0 -16.6 42.8 39.0 102.2 -59.0 -74.2 -26.0 -14.8 44.6 40.0 104.0 -58.0 -72.4 -25.0 -13.0 46.4 41.0 105.8 -57.0 -70.6...
Page 41: Output Voltage
Performance Data 7.7 – Output Voltage TI3000 Output Voltage Without AC Power MINUTES 46 AMP CONSTANT CURRENT LOAD 7.8 – Maximum Output Current MAXIMUM OUTPUT CURRENT TI3000 Maximum Output Current 3000 * * * * * * * * 2700 * * * * * * * * (+25 C Temp)
Page 42: Section 8 - Optional Accessories
8.3 – Tesla™ AC Line Cords DC power cables come in several lengths or can be custom-ordered to fit your needs. Tesla™ specializes in outfitting cables with a variety of connectors and junction boxes. Contact Tesla’s™ Customer Service to find out more about our selection of cables.
Page 43: Cobra™ Dc Replacement Contacts And Tools
Each plug is constructed from a rugged combination of advanced composite materials and corrosion-resistant alloys to maximize durability and connectivity. To extend the life of the Cobra™ Connector included with your GPU, replacement contacts and tools can be ordered through the Tesla™ Customer Service.
Page 44 APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA™ PART # Afghanistan TI25000-004 Old British Line Cord Algeria TI25000-004 Old British Line Cord American Samoa TI25000-011 Australian Line Cord Angola TI25000-003 Continental European Line Cord Anguilla (U.K.) TI25000-005 United Kingdom Line Cord...
Page 45 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA™ PART # Ecuador TI25000-001 North American Line Cord Egypt TI25000-003 Continental European Line Cord El Salvador TI25000-001 North American Line Cord England TI25000-005 United Kingdom Line Cord Equatorial Guinea...
Page 46 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA™ PART # Laos TI25000-001 North American Line Cord Latvia TI25000-003 Continental European Line Cord Lebanon TI25000-003 Continental European Line Cord Lesotho TI25000-004 Old British Line Cord Liberia TI25000-005 United Kingdom Line Cord...
Page 47 APPENDIX A (Cont.) OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS COUNTRY VOLTS TESLA™ PART # Romania TI25000-003 Continental European Line Cord Russia TI25000-003 Continental European Line Cord Rwanda TI25000-003 Continental European Line Cord Saudi Arabia 50/60 TI25000-003 Continental European Line Cord...
Page 48 APPENDIX A (Cont.) UNIVERSAL LINE CORD KIT FOR WORLDWIDE OPERATIONS 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).
Page 49: Repair Request Form
Model #: ____________________________________ Serial #: ________________________________________ Shipping method to Tesla™: ______________________________________________________________________ Description of shipping package: ________________________________________________________________ Description of problem: _________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ Return to Tesla™ Industries, Inc. 101 Centerpoint Boulevard, New Castle, DE 19720 Attention: Repair Department TI3000 GPU-24 UAV...

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Tesla TIMV3000 GPU-24 Manual

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