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Power Anytime, Anywhere
Benefits
• 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
•3500 peak starting amps
•92 amp hours of rechargeable battery power without ac
•142 amp hours with ac power
•Operates and charges from 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
TI3500
GPU-24
TI3500 GPU-24
NSN: 6130-01-452-2796 (CL IX)
TIMV3500 GPU-24
NSN: 6130-01-475-5325 (CL IX)
MADE IN USA
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Table of Contents
Troubleshooting
Related Manuals for Tesla TIMV3500 GPU-24
Summary of Contents for Tesla TIMV3500 GPU-24
- Page 1 TI3500 GPU-24 TI3500 GPU-24 NSN: 6130-01-452-2796 (CL IX) TIMV3500 GPU-24 NSN: 6130-01-475-5325 (CL IX) Power Anytime, Anywhere Benefits • 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 •...
- Page 2 TI2007-208 TI2007-315 TI7000-026 Shipping Case 8ft. DC Aviation Cable Assembly 15ft. DC NATO 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 TI3500 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 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. TI3500 GPU-24 02-03-15...
- 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 §...
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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 8.1 – Shipping Case 8.2 – GPU Protective Covers 8.3 – Tesla™ AC Line Cords 8.4 – Tesla™ Universal AC Line Cords 8.5 – TI25000-U00 Unit Modification/Universal Line Cord Set 8.6 – Line Cord AC Adapter 8.7 – Cobra™ DC Replacement Contacts and Tools 8.8 –...
- 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...
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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 TI3500 GPU-24 Ground Power Unit. The TI3500 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 output for aircraft and vehicle engine starting and 24 or 28.5 volts dc output for ground maintenance, avionics/electrical trouble shooting and testing. -
Page 14: General Specifications
Product Overview 2.3 – General Specifications Electrical DC Output: • 3500 peak starting amps • 50 amps continuous @ 28.5 Vdc -1425 Watts (when plugged into ac power) • 142 amp hours (3473 watt hours) with ac power • 92 amp hours (2048 watt hours) of rechargeable battery power without ac Recharge Rate From Full Discharge: •... -
Page 15: Front Panel Overview
Product Overview 2.4 – Front Panel Overview AC Input Circuit Breakers – Trips if over-current “Push to Test” Button – Displays current battery default condition occurs. charge state when pressed. 24 Vdc Output Connector – Provides 24 Vdc to 28.5 AC Input Connector –... -
Page 16: Universal Front Panel Overview
Product Overview 2.5 – Universal Front Panel Overview AC Input Circuit Breakers – Trips if over-current default “Push to Test” Button – Displays current battery condition occurs. charge state when pressed. 24 Vdc Output Connector – Provides 24 Vdc to 28.5 AC Input Connector –... -
Page 17: Physical Dimensions
Product Overview 2.6 – Physical Dimensions 19.25 [488.95] 10.5 [266.7] 37.28 [946.91] Figure 2.6.1 – TI3500 GPU-24 physical dimensions 2.7 – Airflow Ports Damage may occur if the TI3500 GPU’s air intake or outlet ports are obstructed. Ensure CAUTION that ports are clear at all times. When the TI3500 GPU-24 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 18: Operating Positions
Product Overview 2.8 – Operating Positions The TI3500 GPU-24 can be operated in both the horizontal (Figure 2.8.1) and vertical (Figure 2.8.2) positions as shown. Make sure that the airflow is not obstructed from air intake (figure 2.8.3) and outlet (Figure 2.8.4). -
Page 19: Input Voltage Selector Switch
Product Overview 2.9 – 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 2.9.1 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 2.10 – “Push to Test” Button and LED Status 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 21: Ac Input Circuit Breakers
Reset breaker by pressing red button. Reconnect ac and dc connections to the unit. The unit should power up automatically. If the breakers continue to trip, return the unit to Tesla™ Industries for repair. Figure 2.11.1 - AC Input Circuit Breakers Figure 2.11.2 - Pressing Circuit... -
Page 22: Section 3 - Operating Procedures
Section 3 – Operating Procedures 3.1 – Operating Procedures This section deals with normal procedures, and includes all steps necessary to ensure safe and effi cient 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. -
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: Pre-Operation
Operating Procedures 3.8 – 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 2.7) Check that all connections are secure and free from water. -
Page 26: Regulated 28.5 Vdc Output Ground Power
Operating Procedures 3.10 – Regulated 28.5 Vdc Output 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 27 Operating Procedures Low Power Demand Low power demand is defined by a requirement of 50 amps or less. Connect dc power to aircraft ground power receptacle. DC bus power should come on and aircraft voltmeter should indicate 28.5 Vdc to 28 Vdc. If aircraft power demand is less than 50 amps converter output will remain at 28.5 Vdc (only one GREEN LED status indicator bar will illuminate).
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Page 28: Regulated Ac Power
Operating Procedures 3.11 – Regulated AC Power Plugging in with AC Power When the TI3500 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 29: Section 4 - Post Operation
Section 4 – Post Operation 4.1 – General Although the TI3500 GPU-24 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 Post Operations CAUTION Guard From Incorrect Power Source The TI3500 GPU’s power cells may be damaged if recharged by NiCad or Lithium Ion battery chargers. Power cells should only be charged by either the TI3500 GPU’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 31: Section 5 - Unit Care And Maintenance
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 TI3500 GPU-24. -
Page 32: 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 33: 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 5.5.1 – Digital Multimeter 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 34 Unit Care and Maintenance Check Unit Internal Resistance (Test for Shorts) NOTE Unit should be disconnected from any ac power sources prior to testing for shorts. Testing the NEMA Receptacle 2. Place the negative probe on the ac 1. Set multimeter to Ohms (Ω). 3.
- Page 35 Unit Care and Maintenance Testing the Universal Receptacle 3. Move the positive probe to the dc 2. Place the negative probe on the 4. Move the positive probe to the dc 1. Set multimeter to Ohms. AC ground probe ( J or L) and positive post on the DC Output negative post on the DC Output the positive probe on one of the...
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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. TI3500 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 TI3500 Output Voltage MINUTES MINUTES 92 AMP CONSTANT CURRENT LOAD 46 AMP CONSTANT CURRENT LOAD 7.8 – Maximum Output Current TI3500 Maximum Output Current MAXIMUM OUTPUT CURRENT 3500 * * * * * * * * 3150 * * * *... -
Page 44: Section 8 - Optional Accessories
The optional Shipping Case is the safest way to transport the TI3500 GPU-24. This custom case weighs 73 lbs and comes AC line cords come in several lengths or can be custom-ordered to fi t your needs. Tesla™ specializes in equipped with side handles and locking latches. -
Page 45: Tesla™ Universal Ac Line Cords
8.4 – Tesla™ Universal AC Line Cords 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 more about our selection of cords. -
Page 46: Cobra™ Dc Replacement Contacts And Tools
Aviation Plug 400Hz Aviation Plug NSN: 5120-01-523-8761 (CL II) NSN: 5120-01-527-7729 (CL II) 8.8 – GPU Tires Tesla™ offers several tires in order to meet various customer mobility needs. TI21000-400 TI21000-203 Anti-FOD Flat-Free Tire Run-Flat Tire Rugged, puncture-proof, foam-filled tire. - Page 47 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 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 TI3500 GPU-24... - Page 53 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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