Tesla TI500 GPU-24 User Manual
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Tesla TI500 GPU-24 User Manual

Tesla TI500 GPU-24 User Manual

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Power Anytime, Anywhere
Tesla
TI500 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

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  • Page 1 Power Anytime, Anywhere Tesla TI500 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 2 Any attempts to open or examine the inside of the TI500 GPU-24 via a tool or device (borescope, probe, etc.) can result in unit failure and/or injury by electrical shock. This GPU is mainte nance free and should not be opened or disassembled for any reason.
  • Page 3 ™ 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 4 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 5: Table Of Contents

    3.6 – Temperature Specifications 3.7 – Environmental 3.8 – Normal Functional Test Procedures 14-15 3.9 – Pre-Operation 3.10 – Transporting Unit 3.11 – Regulated 28.5 Vdc Ground Power 17-18 3.12 – Regulated AC Power 3.13 – Charging Unit TI500 GPU-24...
  • Page 6 7.6 – Temperature Conversion Chart 7.7 – Output Voltage 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 – Transport Dolly Appendix A 34-38...
  • 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 TI500 GPU-24...

  • 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 TI500 GPU-24...

  • Page 9: Hazards

    The unit will be damaged if unapproved ac power is applied. This Unit operates and charges from Single Phase 100-260 Vac, 50/60/400 Hz. This must match ac power source (hangar wall, flight line ac power) prior to connecting the TI500 GPU-24 for...

  • Page 10: Important Safety Precautions

    150°F (65°C). This protects the unit from overheating and damage. If the unit shuts down, move the unit into a cooler environment such as shade or air conditioning when possible. Perform a full function test after the unit has been allowed to cool prior to use. TI500 GPU-24...

  • Page 11: Section 2 - Product Overview

    Thank you and congratulations on the purchase of your new TI500 GPU-24 Ground Power Unit. The TI500 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/...

  • Page 12: Front Panel Overview

    24 Vdc Output Connector – Provides 24 Vdc to 28.5 Vdc @ 25 A. Carrying Handle – Allows for easy transport of unit. AC Input Connector – Connects to Single Phase 100-260 Vac line voltage. TI500 GPU-24...

  • Page 13: General Specifications

    -40°C to +50°C (-40°F to 122°F) with ac power Storage Temperature: • -65°C to +105°C (-85°F to 221°F) Cell Capacity: • +40°C 110% ± 05% • +25°C 100% ± 05% • +00°C ± 05% • -20°C ± 10% • -40°C ± 10% TI500 GPU-24...

  • Page 14: Physical Dimensions

    Ensure that ports are clear at all times. When the TI500 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. At room temperature (+77°F) the exhaust air will not exceed the ambient temperature by more than 5°F.

  • Page 15: Operating Position

    Product Overview 2.7 – Operating Positions The TI500 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...

  • Page 16: Ac Input Circuit Breakers

    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.

  • Page 17: Push To Test" Button And Led Status Indicator

    Figure 2.10.1 - “Push to Test” button location Figure 2.10.2 - Pushing to Test Figure 2.11.1 - “Push to Test” button location Figure 2.11.2 - Pushing to Test (outlined in blue) (outlined in blue) STATUS STATUS STATUS Full Charge Half Charge No Charge TI500 GPU-24...

  • Page 18: Section 3 - Operating Procedures

    1200 - 1500 peak starting amps 40-50% charged 1500 - 1800 peak starting amps 50-60% charged 1800 - 2100 peak starting amps 60-70% charged TI500 GPU-24 2100 - 2400 peak starting amps 70-80% charged 2400 - 3000 peak starting amps 80-100% charged...

  • Page 19: Temperature Specifications

    Operating any electrical equipment in the presence of moisture creates possible horizontal. WARNING TI500 GPU-24 safety hazards and/or potential for equipment damage. Every effort has been made, within the scope of existing technology to prevent foreseeable safety hazards and make theunit moisture resistant to prevent damage or failure.

  • Page 20: 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 21: 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 3.8.1 – Digital Multimeter AC Neutral Pin “M”...
  • Page 22 When the unit is not plugged into an ac power source, the Figure 3.8.3 – Testing DC Receptacle multimeter display should read approximately 25.5 Vdc. TI500 GPU-24...

  • Page 23: Pre-Operation

    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. Figure 3.9.1 - TI500 GPU-24 3.10 – Transporting Unit The TI500 can be carried for short distances by hand or inside a rucksack. If the area of operation is further then 45 meters (150 feet) the TI500 should be transported on a vehicle or in the TI7000-184 Transport Dolly.

  • Page 24: Regulated 28.5 Vdc Ground Power

    Ensure dc power cable plug is fully seated into the GPU’s DC Battery Receptacle. The unit is now ready to safely transfer power. Figure 3.11.1 Attaching DC Power Cable to TI500 GPU-24 Connecting DC Power Cable To Vehicle or Aircraft Line up the NATO plug or aviation dc plug pins and push it in.
  • Page 25 Figure 3.11.1 Starting aircraft with TI500 GPU-24 Removing DC Power Supply From Vehicle Remove dc power cable GPU connector from vehicle. Remove dc power cable connector from TI500 GPU-24 (if necessary). Reinstall dc receptacle’s protective cover. TI500 GPU-24...

  • Page 26: Regulated Ac Power

    Plugging in with AC Power When the TI500 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 27: Section 4 - Post Operation

    Section 4 – Post Operation 4.1 – General Although the TI500 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 28 The TI500 GPU-24’s power cells may be damaged if recharged by NiCad or Lithium Ion battery chargers. Power cells should only be charged by either the TI500 GPU-24’s internal charger and the ac power cord furnished with the equipment, or when connected to aircraft’s external dc power receptacle.

  • Page 29: 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 30: 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 31: 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 32 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 33: 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. TI500 GPU-24...

  • Page 34: 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 35 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 36: 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. TI500 GPU-24...

  • Page 37: Temperature Conversion Chart

    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. Figure 7.1.1 – Temperature Conversion Chart TI500 GPU-24...

  • Page 38: Output Voltage

    Performance Data 7.7 – Output Voltage TI500 Output Voltage Without AC Power MINUTES 11.5 AMP CONSTANT CURRENT LOAD TI500 GPU-24...

  • Page 39: Section 8 - Optional Accessories

    Section 8 – Optional Accessories 8.1 – Shipping Case The optional Shipping Case is the safest way to transport the TI500 GPU-24. This custom case weighs 23 lbs and comes equipped with side handles and locking latches. TI7000-024 NSN: 8145-01-445-3666 Length: 24”...

  • Page 40: Cobra™ Dc Replacement Contacts And Tools

    Tesla’s™ TI500 GPU. The TI7000-184 is the safest and easiest way to support and transport the TI500 models out in the field and through hangars and flight lines. Tesla™ stands behind the Transport Dolly with a team of customer service professionals and a 2-year warranty.
  • Page 41 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 42 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 43 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 44 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 45 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 46: 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 TI500 GPU-24...
  • Page 47 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...
  • Page 48 TI500 GPU-24 Power Anytime, Anywhere Benefits ● 50/60 Hz Vac or 400 Hz Vac aircraft power (with correct line cord) ● Ideal for hangars, FOBs, motor pools, and deployments ● Excellent for testing and troubleshooting (avionics, TMDE, electronics, and hydraulics) ●...
  • Page 49 -40°C to 55°C (-40°F to 131°F) Weight 36 lbs (16.40 kg) Warranty 2 years (3 years optional) Tesla™ Industries, Inc. • 101 Centerpoint Blvd. New Castle, DE 19720 • 9475 Double R Blvd. Suite 2, Reno, NV 89521 USA • www.teslaind.com 01-31-14...

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