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Power Anytime, Anywhere
Innumerable Vehicle Starts
•3000 peak starting amps
•System back-charges from the started vehicle's engine
•Ideal power for motor pools and deployment
Pure Power
•No spikes or surges
•71 amp hours (1736 watt hours) with ac power from each connector
•46 amp hours (1024 watt hours) of rechargeable battery power without ac from each connector
• 25 amp hours of continuous dc power from each connector
(50 amps if used with optional Y-Cable Assembly TI2000-071)
Maintenance-Free Performance
• Currently being used with the Bell AH-1 Super Cobra
• Designed for 24/48V simultaneous starts
• Ideal for hangars, motor pools, and deployments
• Perfect for testing and troubleshooting (avionics, TMDE, electronics, and hydraulics)
• One person can easily maneuver and operate the unit
• Will charge and maintain vehicle batteries when unit is left connected to vehicle (ac power required)
• Safe, easy, maintenance-free operation
•"Push to Test" feature provides instant state of charge
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
TI2500 GPU-24
TI2500GPU-24 (Aviation)
NSN: 6130-01-452-2777 (CL IX)
TIMV2500GPU-24 (Mechanized)
NSN: 6130-01-475-5319 (CL IX)
MADE IN USA
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Summary of Contents for Tesla TI2500GPU-24
- Page 1 TI2500 GPU-24 TI2500GPU-24 (Aviation) NSN: 6130-01-452-2777 (CL IX) TIMV2500GPU-24 (Mechanized) NSN: 6130-01-475-5319 (CL IX) Power Anytime, Anywhere Innumerable Vehicle Starts •3000 peak starting amps •System back-charges from the started vehicle’s engine •Ideal power for motor pools and deployment Pure Power •No spikes or surges...
- Page 2 8ft. DC Aviation Cable Assembly 15ft. DC NATO Cable Assembly TI7000-026 Shipping Case TI7000-142 Protective Cover TI2000-071 Y-Cable Assembly Tesla™ Industries, Inc. • 101 Centerpoint Blvd. New Castle, DE 19720 • 9475 Double R Blvd. Suite 2, Reno, NV 89521 USA • www.teslaind.com 11-13-14...
- Page 3 Power Anytime, Anywhere Tesla TI2500 GPU-24 ™ 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 TESLA...
- Page 5 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. 11-20-14...
- Page 6 ™ 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 7 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 §...
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Page 8: 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, May 2.3 –... - Page 9 8.1 – Shipping Case 8.2 – GPU Protective Covers 8.3 - TI2000-071 Y-Cable Assembly 8.4 – Digital Volt/Amp Meter 8.5 – Tesla™ AC Line Cords 8.6 – Tesla™ DC Replacement Contacts and Tools 8.7 – Tesla™ GPU Tires Appendix 37-41 Repair Form...
- Page 10 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...
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Page 11: 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 12: 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 13: 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 14: Section 2 - Product Overview
Section 2 – Product Overview 2.1 – Introduction Thank you and congratulations on the purchase of your new TI2500 GPU-24 Ground Power Unit. The TI2500 GPU-24 is intended to provide dc electrical ground power for aircraft flight line, maintenance, and ground support operations. The unit is designed to provide 24 volt dc electrical power output for vehicle and aircraft engine starting and 24 or 28.5 volts dc electrical support for ground maintenance, avionics/ electrical troubleshooting and testing. -
Page 15: Front Panel Overview
Product Overview 2.3 – Front Panel Overview AC Input Circuit Breakers – Trips if over- Vdc Capacity Meters – Indicates the battery current fault condition occurs. charge state/power output status. “Push to Test” Button – Displays current AC Input Connector –... -
Page 16: General Specifications
Product Overview 2.4 – General Specifications Electrical Power Cell: • Dry, High Rate Discharge, Rechargeable , Maintenance-free DC Output: • 3000 peak starting amps or 6000 peak starting amps • 25 amps continuous from each connector • (50 amps if used with optional Y-cable assembly TI2000-071) •... -
Page 17: Physical Dimensions
Product Overview 2.5 – Physical Dimensions 19.25 [488.95] 37.28 [946.91] Figure 2.5.1 - TI2500 GPU-24 physical dimensions 2.6 – Airflow Ports Damage may occur if the TI2500 GPU’s air intake or outlet ports are CAUTION obstructed. Ensure that ports are clear at all times. When the TI2500 GPU-24 is plugged into AC power, the internal cooling system will efficiently regulate unit temperature regardless of load. -
Page 18: Operating Position
Product Overview 2.7 – Operating Positions The TI2500 GPU-24 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 TI2500 GPU-24... -
Page 19: Ac Input Circuit Breakers
Reset breaker(s) by pressing red button(s). 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 20: Changing Input Voltage Selector Switch
Product Overview 2.10 – Changing Input Voltage Selector Switch To change the input voltage from 115 Vac to 230 Vac, simply follow these steps: With phillips-head screwdriver, remove one screw and rotate the clear protective cover to one side. Flip the switch to read 230V. Rotate cover back into place. -
Page 21: Push To Test" Button And Led Status Indicator
Product Overview 2.12 – “Push to Test” Button and LED Indicator 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. -
Page 22: 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 23: 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 24: 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 25: 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. Checking DC Voltage at DC Output Receptacle Pins To verify that the power cells are fully charged, set the digital multimeter to measure DC voltage. - Page 26 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 3. Move the positive probe to the DC 1. Set multimeter to Ohms. ground post and the positive probe negative post.
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Page 27: 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 28: Regulated 28.5 Vdc Output Ground
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 29 Operating Procedures Engine Starting CAUTION Unplug AC Power cord before starting engine with TI2500 GPU-24 Prior to engine start, ensure power cell charge is sufficient to provide an efficient engine start. Check DC power cable for secure and correct installation prior to engine starting. Follow ground power engine starting procedure as specified in vehicle operator’s manual.
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Page 30: Operating With 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 31000A indicates the aircraft or vehicle’s current demand. Integrated with the Tesla™ Turbo Start™ GPU power supply, the DVAM is a valuable tool for troubleshooting and system checks. -
Page 31: Regulated Ac Power
Operating Procedures 3.13 – Regulated AC Power Plugging in with AC Power When the TI2500 GPU-24 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 32: Section 4 - Post Operation
Section 4 – Post Operation 4.1 – General Although the TI2500 GPU-24 (Turbo Start 2500) 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 33 Post Operations CAUTION Guard From Incorrect Power Source The TI2500 GPU-24’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 TI2500 GPU-24’s internal charger and the ac power cord furnished with the equipment, or when connected to aircraft’s external dc power receptacle.
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Page 34: 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™ Protect Cables from Damage Customer Service. -
Page 35: 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 36: 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 37 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 38: 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. TI2500 GPU-24... -
Page 39: 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 40 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 41: 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 42: 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 43: Output Voltage
Performance Data 7.7 – Output Voltage TI5400GPU-24 OUTPUT VOLTAGE TI2500 Output Voltage MINUTES MINUTES 46 AMP CONSTANT CURRENT LOAD 46 AMP CONSTANT CURRENT LOAD 7.8 – Maximum Output Current MAXIMUM OUTPUT CURRENT TI2500 Maximum Output Current 3000 * * * * * * * * 2700 * * * *... -
Page 44: Section 8 - Optional Accessories
Section 8 – Optional Accessories 8.1 – Shipping Case The optional Shipping Case is the safest way to transport the TI2500 GPU-24. This custom case weighs 73 lbs and comes equipped with side handles and locking latches. TI7000-026 Length: 41.31” (1049.3 mm) Width: 23.37”... -
Page 45: Digital Volt/Amp Meter
8.4 – Digital Volt/Amp Meter TI3100A AC line cords come in several lengths or can be custom-ordered to fi t your needs. Tesla™ specializes in outfi tting cables with a variety of connectors and junction boxes. Contact Tesla™ customer service to fi nd out The DVAM (Digital Volt/Amp Meter) 3100A provides measurements for all voltage ranges and amperage more about our selection of cords. -
Page 46: Tesla™ Dc Replacement Contacts And Tools
Aviation Plug 400Hz Aviation Plug NSN: 5120-01-523-8761 (CL II) NSN: 5120-01-527-7729 (CL II) 8.7 – GPU Tires Tesla™ offers several tires in order to meet various customer mobility needs. TI21000-400 TI21000-203 Anti-FOD Run-flat Hybrid Tire Run-Flat Tire A rugged, puncture-proof, foam-filled A solid foam rubber tire. -
Page 47: Appendix
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 48 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 49 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 50 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 51 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).
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Page 52: Repair 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 TI2500 GPU-24... - Page 53 TESLA...
- Page 54 Tesla™ Industries, Inc. 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...
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