Tesla™ TI2560 12-24 GPU Ground Power Unit
Contents
1. Figure 3 11 1 Attaching DC Power Cable to GPU Connecting DC Power Cable To Vehicle or Aircraft Line up the NATO plug or aviation dc plug pins and push it in DC bus power should come on and aircraft voltmeter should indicate 24 Vdc to 23 5 Vdc 23 Vdc minimum Ensure dc power cable plug is fully seated into the vehicle or aircraft s dc receptacle Figure 3 11 2 Attaching NATO DC Power Cable to Figure 3 11 3 Attaching an Aviation DC Power Cable vehicle to aircraft A WARNING Do not allow alligator clamps to touch when connecting to de Power Figure 3 11 4 Connecting 112560 12 24 GPU to AC Power Supply with DC Power Cable Attached TI2560 12 24 GPU 19 _3 Operating Procedures Low Power Demand Low power demand is a requirement of less than 20 amps for the 12 Vdc output and 25 amps for the 24 Vdc output While power demands remain under these current levels converter outputs will remain at 14 25 Vdc and 28 5 Vdc and only one green LED on the Capacity Meters will illuminate High Power Demand High power demand is a requirement of 20 amps or more for the 12 Vdc output and 25 amps for the 24 Vdc output When current demands go above these levels the converter output voltages will drop and two or more LED Capacity Meter bars will illuminate At approximately 20 amps of current demand for the 12 Vdc output the converter output voltage will be regulated to 12 Vdc For2. serviced Contact Tesla We can be reached at 302 324 8910 Ask for customer service You can also email us at tesla1 teslaind com Once we receive the unit at our facility we will examine it Systems that are protected under warranty will be repaired at no charge If the warranty has expired you will receive a quote for necessary repairs prior to work being done Our turnaround time is 48 hours once repairs are authorized 14 Can make my own repairs to unit During the warranty period the unit can only be repaired by Tesla Industries for the warranty to remain in effect Regardless we strongly recommend allowing Tesla to repair any unit as we will analyze the complete system and re calibrate it 15 What type of maintenance does the Turbo Start require Although the systems are maintenance free please keep units plugged in while not in use This will greatly extend the life of the cells Also keep the vent areas clean and free of debris Keep units in a well ventilated area while charging Keep the unit in a protected environment when not in use maintenance facility shed etc 16 What is included with my Turbo Start Aviation customers will receive an eight 8 foot DC Aviation Cable Assembly T12007 208 Ground vehicle customers will receive a fifteen 15 foot DC NATO Cable Assembly TI2007 315 All customers receive an ac line cord for their home country and a full two year warranty 17 A
3. 2 Product Overview Figure 2 10 1 24 Vdc Output Connector outlined in blue 12 Vdc Output Connector Outlined in red 2 10 24 Volt Output Connector The 24 Vdc Output Connector provides 25 amps continuous 28 5 Vdc when plugged into ac power Cover the receptacle with the protective cover see Figure 2 10 1 when the Output Connector is not in use to protect the Output Connector from dust and foreign matter 2 11 12 Volt Output Connector The 12 Vdc Output Connector see Figure 2 10 1 provides 3000 peak starting amps and 20 amps continuous 14 25 Vdc when plugged into ac power When the Output Connector is not in use cover the receptacle with the protective cover This will protect the Output Connector from dust and foreign matter The 12 Volt DC Battery Receptacle is only compatible with the TI200 7 503 15 DC Cable with Alligator Clips A 24 Volt DC Connector will not connect to the 12 Vdc Output Connector 2 12 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 12 1 Input Voltage Selector Switch outlined in blue 10 112560 12 24 GPU Product Overview 2 Changing Input Voltage Selector Switch To change the input voltage from 115 Vac to 230 Vac simply follow these steps 1 With cross tip screwdriver remove one screw and rotate the clear protective cover to o
4. Power Anytime Anywhere Tesla 112560 12 24 GPU Ground Power Unit 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 NOTE All users must read this entire manual prior to operating the TI2560 12 24 GPU The 112560 12 24 GPU is a limited maintenance free and sealed unit No repairs are authorized Warranty will be voided if unit is tampered with in any way or if unauthorized repairs are made For technical support please contact TESLA INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 WEBSITE www teslaind com EMAIL tesla1 teslaind com CAUTION Improper use or failure to follow instructions in this user manual can result in unit damage and or injury or death by electrical shock Any attempts to open or examine the inside of the TI2560 12 24 GPU via a tool or device borescope probe etc can result in unit failure and or injury by electrical shock This GPU is maintenance free and should not be opened or disassembled for any reason Always protect the unit from short circuit Shipping Hazards The 112560 12 24 GPU contains sealed dry cell rechargeable batteries that do not pose a shipping hazard No part of this manual may be reproduced or transmitted in any form or by any means electronic or mech
5. 112560 12 24 GPU Operating Procedures 3 Check Unit Internal Resistance Test for Shorts NOTE Unit should be disconnected from any AC power sources prior to testing 1 Testing between the Chassis Ground and the 12 Vdc Output Connector Set multimeter to Volts Place the black lead of the multimeter on one of 12 Vdc Output Connector screws as shown in Figures 3 8 3 and 3 8 4 Next touch the red lead of the multimeter to the positive pin of the 12 Vdc Output Connector Shown in Figure 3 8 3 Do the same for the negative pin see Figure 3 8 4 In both cases the meter should read open circuit 3 83 DC Output 3 8 4 DC Output Connector Positive Pin Connector Negative Pin 2 Testing between the Chassis Ground and the 24 Vdc Output Connector Set multimeter to Volts Place the black lead of the multimeter on one of 24 Vdc Output Connector screws as shown in Figures 3 8 5 and 3 8 6 Next touch the red lead of the multimeter to the positive pin of the 24 Vdc Output Con nector shown in Figure 3 8 5 Do the same for the negative pin see Figure 3 8 6 In both cases the meter should read open circuit 3 8 5 DC Output 3 8 6 DC Output Connector Positive Pin Connector Negative Pin 3 Testing the NEMA Receptacle Set multimeter to Ohms Place the black lead on the ac ground post and the red lead to the dc positive post shown in Figure 3 8 7 Next move the red lead of the multimeter to the dc negative post
6. 25 6 _ 510 253 1 500 2207 290 202 280 1847 Figure 7 1 1 Temperature Conversion Chart 39 112560 12 24 GPU oo PerfommenceData 77 Output Voltage 112560 12 24 GPU 12 Vdc Output Voltage 20 3 lt 2 5 O 20 30 40 MINUTES 46 AMP CONSTANT CURRENT LOAD 1 8 Maximum Output Current 10 SECONDS Calculations based on actual test data at Pratt Whitney Canada on 30 March 1992 Maximum Output Current 30 TI2560 12 24 GPU 33 Performance Data 12 Vdc Output Loading Curves 0222 2222 222 8111111181 112560 12 24 GPU 34 Performance Data 24 Vdc Output Loading Curves cont d ial 35 TI2560 12 24 GPU Section 8 Optional Accessories 8 1 Shipping Case The optional Shipping Case is the safest way to transport the TI2560 12 24 GPU This custom case weighs 73 Ibs and comes equipped with side handles and locking latches T17000 026 Length 41 31 1049 3 mm Width 23 37 593 60 mm Height 19 62 498 35 mm Weight 73los 33 11 kg 5 2 GPU Protective Covers Protects unit from moisture sand and other damaging elements Custom fit for the TI2560 12 24 GPU T17000 142 8 3 Tesla AC Line Cords These power cables come in several lengths or can be custom ordered to fit yo
7. 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 It then provides the exact power required throughout the start up curve 6 How many engine starts will my Turbo Start provide until it is depleted The Turbo Start back charges almost instantly once the vehicle aircraft is started and the generator is on line This power flywheel feature enables the Turbo Start to recharge itself right from the vehicle it started in less than 30 seconds You can go down the line in your motor pool and start every 24V vehicle without limit T How do you prolong the life of the Turbo Start s cells All you need to do is plug the unit in to the appropriate ac power outlet the system requires AC power will recharge the system and keep the cells healthy Users who regularly plug the system in can expect to get 5 7 years from their cells before they need to be replaced Tesla cells do not have a memory like cell phone batteries There is no need to fully discharge them The recharging system will not overcharge the unit or produce excess heat 8 Is it waterproof Water resistant but not waterproof See Environmental Section 26 1125
8. C 110 05 e 25 C 100 05 e 00 C 80 05 e 20 C 65 10 e 40 C 50 10 6 112560 12 24 GPU B 2 5 Physical Dimensions 1 NNUNN NO Sos PRESEN SVSHHHYVO E H n amp 19 25 488 95 37 28 946 91 gt 15 97 405 64 _ Figure 2 5 1 112560 12 24 GPU physical dimensions 2 6 Airflow Ports CAUTION When the TI2560 12 24 GPU is plugged into ac power the internal cooling system will efficiently regulate unit temperature regardless of load At room temperature F the exhaust air will not exceed the ambient temperature by more than 5 F In more extreme temperatures greater than 90 F the exhaust air will not exceed the ambient temperature by more than 10 F pas Figure 2 6 1 Air intake exhaust ports and internal air circulation TI2560 12 24 GPU 2 Product Overview 2 Operating Positions The T12560 12 24 GPU can be operated in both the horizontal Figure 2 7 1 and vertical Figure 2 7 2 positions as shown Make sure that the airflo
9. a soft cloth to remove dust dirt etc Protect Cables from Damage 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 a Figure 5 1 1 Damaged cable DA T12560 12 24 GPU Unit Care and Maintenance 5 5 2 Unit Servicing This unit is a maintenance free sealed unit No repairs outside of Tesla are authorized Warranty will be voided if unit is tampered with in any way including any damage to the WARRANTY VOID stickers located on the case see Figure 5 2 1 below If the unit requires maintenance please contact Tesla Customer Service at 302 324 8910 A Repair Request Form can be found in the back of this manual Figure 5 2 1 Warranty Void stickers Front and Back on the unit 5 3 Packaging and Shipping Ensure proper packaging when returning the unit Transport the unit only in a sturdy shipping crate or Tesla Shipping Case It is important to enclose the Repair Request Form Seal the crate on all sides and return it to Tesla at the address listed below Please contact Customer Service at 30
10. instructions in this manual affect operational safety as well as the warranty of the unit 3 3 Operating Limits and Restrictions The minimum maximum and normal operating ranges result from careful engineering and evaluation of test data These limitations must be adhered to during all phases of operation 3 4 Performance Refer to Section 7 PERFORMANCE DATA to determine the capability of the unit Consideration must be given to changes in performance resulting from variations in ambient temperature mode of operation state of charge with or without ac power and aircraft dc bus system inefficiency voltage drops 3 5 Engine Starting Power The unitshould always be charged above 80 prior to ground support engine starting However circumstances may exist during use where unit recharge is not readily available and immediate external engine starting power is required The following provides minimum states of charge necessary to provide ample power for an efficient engine start under specific current load demands ENGINE START PEAK CURRENT Requirements MINIMUM CHARGE Under 1200 peak starting amps 0 40 charged 1200 1500 peak starting amps 40 50 charged 1500 1800 peak starting amps 50 60 charged 1800 2100 peak starting amps 60 70 charged 2100 2400 peak starting amps 10 80 charged 2400 3000 peak starting amps 80 100 charged TI2560 12 24 GPU 13 3 6 Temperature Specifications Cold Hot Soaked Temperatu
11. is pressed If you do not hear the fan s running stop pressing the button and check for any obstructions CAUTION Never press the Push to Test button while the unit is plugged into aircraft vehicle or ac power Never press the Push to Test button for more than 5 seconds This CAUTION may cause a temperature sensor to temporarily disrupt Push to Test function If this sensor is tripped allow ten minutes for unit to cool before operating Push to Test button 1111 Figure 2 13 1 Pushing to Test STATUS STATUS STATUS Full Charge Half Charge No Charge 12 TI2560 12 24 GPU Section 3 Operating Procedures 3 1 Operating Procedures This section covers normal procedures and steps necessary to ensure safe and efficient operation of the When not in use the unit should always remain plugged into a suitable ac power source to ensure operational readiness at all times unit If current demand exceeds 25 amps converter output voltage will drop below 28 5 Vdc and two or more LED status indicator bars will illuminate If all LED status indicator bars illuminate both the converter and power cells are supplying 24 Vdc power output 3 2 General The user should be well versed in both pre use and functional checks for correct operations of this unit Knowledge of the operating limits restrictions performance unit capabilities and functions aids in correct and safe operations Compliance with the
12. method to Tesla Description of shipping package Description of problem 101 Centerpoint Boulevard New Castle DE 19720 Attention Repair Department TI2560 12 24 GPU Date of return Fax Serial Serial Return to Tesla Industries Inc 43 WE GET THE MILITARY STARTED 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
13. minutes of AC power input the unit should be fully charged If the Push to Test button is pressed and the unit still indicates it is not fully charged then the cells should be replaced TI2560 12 24 GPU 21 Section 4 Post Operation 4 1 General Although the TI2560 12 24 GPU 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 4 2 After Use Unit should be protected from environmental elements and man made hazards Ideally unit should be secured in a building or shed Most importantly unit shall be fully covered if stored while exposed to environmental elements 4 3 Power Cell Recharge The TI2560 12 24 GPU incorporates a backcharge feature that enables the unit to be recharged from the vehicle once the engine is started and the starter generator is running This feature will enable you to start multiple vehicles without reconnecting to ac power if the GPU is allowed to backcharge for approximately 30 seconds Plug the TI2560 12 24 GPU into ac power to keep the cells charged whenever it is not in use even if it is at Full Charge The unit will not overcharge or overheat Connect AC Power Cord to Unit NOTE Check Input Voltage Selector Switch for proper setting Ensure 120 or 240 Vac power cord is properly connected to an approved ac power supp
14. or 200 260 Vac 5 24 Vdc Capacity Meter Indicates the 24V battery 10 Telescopic Handle Allows for easy transport of charge state power output status unit 6 12 Vdc Capacity Meter Indicates the 12V battery charge state power output status TI2560 12 24 GPU 5 2 Product Overview 2 4 General Specifications Electrical AC Input e Operates and charges from Single Phase 100 260 Vac 50 60 Hz e 14 7 amps 120 Vac 60 Hz Power Cell e Dry High Rate Discharge Rechargeable Maintenance free DC Output 24 Volt Output e 3000 peak starting amps e 25 amps continuous 28 5 Vdc when plugged into ac power e 1 amp hours 1736 watt hours with ac power e 46 amp hours 1024 watt hours of rechargeable battery power without ac 12 Volt Output e 3000 peak starting amps e 20 amps continuous 14 25 Vdc when plugged into ac power e 66 amp hours 1309 watt hours with ac power 46 amp hours 1024 watt hours of rechargeable battery power without ac Recharge Rate from full discharge e 24 Volt 115 minutes 25 C e 12 Volt 143 minutes 25 C Size e 37 28 Lx 19 25 x 15 97 H e 946 91 mm x 488 95 mm x 405 64 mm Weight e 181 5 Ibs 82 32 kg Operating Temperature e 40 C to 60 C 40 F to 140 F without ac power e 40 C to 55 C 40 F to 131 F with ac power Storage Temperature e 65 C to 105 C 85 F to 221 F Cell Capacity e 40
15. 0 69 8 11 6 13 4 T92 17 0 18 8 80 6 82 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 39 0 40 0 41 0 42 0 43 0 44 0 45 0 46 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 0 56 0 57 0 58 0 59 0 102 2 104 0 105 8 107 6 109 4 TI 113 0 114 8 116 6 118 4 120 2 122 0 123 8 125 6 127 4 1292 131 0 132 8 134 6 136 4 138 2 140 0 141 8 143 6 145 4 147 2 149 0 150 8 152 6 154 4 156 2 158 0 159 8 59 0 58 0 57 0 56 0 590 54 0 530 52 0 51 0 50 0 49 0 48 0 47 0 46 0 45 0 44 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 SE 0 32 0 31 0 30 0 29 0 28 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 10 4 12 2 14 0 6 5 0 4 0 3 0 2 0 1 0 23 0 24 8 26 6 28 4 30 2 32 0 33 8 35 6 37 4 39 2 41 0 61 0 62 0 63 0 64 0 65 0 1 0 2 0 3 0 4 0 67 0 68 0 2 10 0 71 0 Ol 6 TI 6 TI EET 600 76 0 _ 590 7427 580 7241 570 7061 560 688 650 4 0 540 52 530 54 520 416 1 510 5 1 500 580 _ 49 0 5621 48 0 844 4 0 826 1 460 508 45 0 490 7 _ 440 42 1 43 0 4547 42 0 4367 410 418 7 400 400 290 282 280 264 370 46 3260 32 8 550 40 340 29 2 530 274 520
16. 0 011 Australian Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord T125000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord 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 TI1L6000 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 TESLA UNIVERSAL AC LINE CORD KIT P N TI25000 U00 IS COMPRISED OF THE FOLLOWING FIVE PART NUMBERS TI25000 111 NORTH AMERICAN LINE CORD TI25000 113 EUROPEAN 10A 250V TI25000 114 OLD BRITISH LINE CORD TI25000 115 ENGLAND 10A 250V TI7000 131 LINE CORD POUCH 42 12560 12 24 GPU Repair Request Form Please complete the information below to ensure prompt and accurate service Include this form with the unit you are returning Thank you Company name amp Billing address Contact person Phone Email Purchase Order Model Model Shipping
17. 12 2 AC Power Connected with AC Power Supply LEDs Illuminated Connect AC Power Cord To Unit Ensure 120 or 240 Vac power cord is properly connected to an approved ac power supply After approximately 5 8 seconds unit s LED status indicator will illuminate indicating power cell state of charge Cooling fan will operate Ensure LED status indicator and cooling fan is operational prior to continuing 3 13 Charging Unit Once you have the voltage selector switch set to match the power characteristics of your line cord you can plug the unit into a wall socket to charge the batteries Until the unit is fully charged the LED status will read half or no charge Plug the T12560 12 24 GPU into ac power to keep the cells charged whenever it is not in use even if it is at Full Charge The unit will not overcharge or overheat you received this manual with a new GPU When the Unit is fully charged the LED indicator should show a single steady green bar The fan will also come on at reduced speed This is normal operation indicating the unit is in standby mode and is ready for use If you own an older GPU and this is a replacement manual Under a full charge the LED indicator should show a single steady green bar or the entire LED will be blinking The fan will also exhibit ratcheting but will not come on This is normal operation indicating the unit is in standby mode and is ready for use lf the GPU s cells need to be replaced After 60
18. 2 324 8910 with any questions or concerns TESLA INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 Website www teslaind com Email Teslal teslaind com Figure 5 3 1 Tesla Industries Shipping Case 5 4 Storage If unit can not be connected to ac power while in storage we recommend to charge the unit once a year The shelf life of 12 months is due to the battery cells inside the unit We guarantee the unit will hold 80 of its charge for a period of 12 months without being recharged When the GPU s leave the facility they are fully charged and if they are to go into storage without being used they will maintain 80 of their charge after 12 months The units has a life expectancy of 5 to 7 years if maintained properly TI2560 12 24 GPU 25 Section 6 Troubleshooting and FAQ 6 1 Frequently Asked Questions 1 Why should buy a Tesla Turbo Start System Tesla Turbo Start is a multi functional system that are ideal for support of 24 Vdc vehicles and aircraft and their electronics avionics on the bench Tesla manufactures various systems of different sizes and capacities that are man portable maintenance free and provide pure dc power in a completely safe package Designed for Military applications these systems are equally valuable in maintenance support at the main facility or in remote locations They ar
19. 25000 006 Switzerland Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 002 Italian Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord T1I25000 005 United Kingdom Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord T125000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 011 Australian Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 011 Australian Line Cord T125000 005 United Kingdom Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 005 United Kingdom Line Cord TI25000 004 Old British
20. 60 12 24 GPU oo Troubleshooting amp FAQ 6 9 Are Tesla GPUs used in shop maintenance and testing Tesla systems are gaining popularity throughout maintenance facilities instructional facilities laboratories manufacturing plants aircraft hangars and many other locations The reason is due to the precise dc power the small portable and quiet nature of our systems and the maintenance free aspect of our GPU s We can custom tailor ground power systems to fit your individual requirements 10 Can one person transport it Turbo Start is designed to be handled by one person The TI500 is our smallest GPU system to date and weighs 36 Ibs The TILOOO weighs 57 Lbs and can be carried or wheeled on a dolly Larger units have wheels incorporated directly on the system with an extendable handle 11 Is the Turbo Start in the government purchasing system Yes Tesla Industries is an approved vendor supplier our cage code is OVWE2 Most Tesla products are class IX have a National Stock Number NSN designation and can be acquired through the DLA Defense Logistics Agency 12 How long does this unit stay charged Unit should never be allowed to discharge fully In field 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 13 How do get my Turbo Start
21. Causes serious eye damage Wear protective gloves protective clothing eye protection face protection May damage fertility or the unborn child if ingested or Avoid breathing dust fume gas mist vapors spray inhaled Use only outdoors or in a well ventilated area May cause cancer if ingested or inhaled Causes skin irritation serious eye damage Causes damage to central nervous system blood and Contact with internal components may cause irritation or severe burns Avoid contact with internal acid kidneys through prolonged or repeated exposure Irritating to eyes respiratory system and skin May form explosive air gas mixture during charging Extremely flammable gas hydrogen Explosive fire blast or projection hazard Il HAZARDOUS INGREDIENTS IDENTIFY INFORMATION Components CAS Number Approximate by Weight Inorganic Lead Compound Lead 7439 92 1 Lead Dioxide 1309 60 0 Ti 7440 31 5 in Sulfuric Acid Electrolyte Sulfuric Acid Water 7664 93 9 15 20 Case Material 5 10 Polypropylene 9003 07 0 Polystyrene 9003 53 6 Styrene Acrylonitrile 9003 54 7 Acrylonitrile Butadiene Styrene 9003 56 9 Styrene Butadiene 9003 55 8 Polyvinylchloride 9002 86 2 Polycarbonate Hard Rubber Polyethylene 9002 88 4 Polyphenylene Oxide 25134 01 4 Polycarbonate Polyester Alloy Other Absorbent Glass Mat 1 2 Inorganic lead and sulfuric acid electrolyte are the primary components of every battery manufactured by Tesla
22. In both cases the Multimeter should read greater than 10 MQ Move the positive probe to the fastener screw on the dc receptacle shown in Figure 3 8 8 Multimeter should read less than 1 Q Positive Probe on the DC Positive Post 3 8 1 us Probe on 3 8 8 Positive Probe to the AC Ground Post and the the Fastener Screw on the DC Receptacle TI2560 12 24 GPU 17 3 Operating Procedures 3 9 Pre Operation 1 Be sure to check that all input and output cables are not damaged See Section 5 1 2 Check unit carefully for any evidence of damage 3 4 Check that all connections are secure and free from water Make sure that airflow is not obstructed from air intake and outlet See Section 2 6 Figure 3 9 1 TI2560 12 24 GPU 3 10 Transporting Unit The T12560 12 24 GPU has a telescoping handle that makes rolling the unit easy For transporting on uneven ground axle extensions should be added to the unit For use on sand balloon tires should be installed on the unit See Optional Accessories 18 Figure 3 10 1 Releasing Telescopic Handle 112560 12 24 GPU Operating Procedures 3 3 11 Regulated 14 25 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
23. Line Cord TI25000 001 North American Line Cord TI25000 011 Australian Line Cord TI25000 003 Continental European Line Cord T125000 001 North American Line Cord TI25000 001 North American Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 001 North American Line Cord 112560 12 24 GPU COUNTRY Romania Russia Rwanda Saudi Arabia Scotland Senegal Seychelles Sierra Leone Singapore Slovakia Somalia South Africa Spain Sri Lanka St Pierre amp Miquelon France St Kitts amp Nevis St Lucia St Vincent Sudan Surinam Svalbard Norway Swaziland Sweden Switzerland Syria Tahiti Taiwan Tanzania Thailand Togo Tonga Trinidad amp Tobago Tunisia Turkey Uganda United Arab Emir United Kingdom amp Ireland United States Uruguay Venezuela Vietnam Virgin Islands Wales Western Samoa Yemen Yugoslavia Zaire Republic of Zambia Zimbabwe TI2560 12 24 GPU VOLTS 220 220 220 220 220 220 240 230 230 220 220 220 250 220 230 115 230 240 230 240 115 220 230 220 220 220 220 110 230 220 220 115 230 220 220 220 220 240 120 220 120 220 120 220 230 220 220 220 220 220 APPENDIX A Cont OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS 50 50 50 60 20 60 20 20 20 20 20 20 TESLATM PART TI25000 003 Continental European Line Co
24. Products There are no mercury or cadmium containing products present in batteries manufactured by Tesla Products Form SDS 853027 Revised 05 14 15 Supersedes NEW ECO 1001584 SAFETY DATA SHEET IV FIRST AID MEASURES Sulfuric Acid Remove to fresh air immediately If breathing is difficult give oxygen Consult a physician Lead Remove from exposure gargle wash nose and lips consult physician Ingestion Sulfuric Acid Give large quantities of water do not induce vomiting or aspiration into the lungs may occur and can cause permanent injury or death consult a physician Lead Consult physician immediately Sulfuric Acid Flush with large amounts of water for at least 15 minutes remove contaminated clothing completely including shoes If symptoms persist seek medical attention Wash contaminated clothing before reuse Discard contaminated shoes Lead Wash immediately with soap and water Sulfuric Acid and Lead Flush immediately with large amounts of water for at least 15 minutes while lifting lids Seek immediate medical attention if eyes have been exposed directly to acid V FIRE FIGHTING MEASURES Flash Point N A Flammable Limits LEL 4 1 Hydrogen Gas UEL 74 2 Hydrogen Gas Extinguishing Media Carbon dioxide foam dry chemical Avoid breathing vapors Use appropriate media for surrounding fire Special Fire Fighting Procedures If batteries are on charge shut off power Use positiv
25. Tire For use on soft sand 1000 400 Anti FOD Flat Free Tire Rugged puncture proof foamilled tire Foreign object damage free specifically designed for the runway 3 COUNTRY Afghanistan Algeria American Samoa Angola Anguilla U K Antigua Argentina Aruba Australia Austria Azores Portugal Bahamas Bahrain Bangladesh Barbados Belgium Belize Br Hond Benin Bermuda Bolivia Botswana Brazil Bulgaria Burkina Faso Burma Now Myanmar Burundi Cambodia Cameroon Canada Canary Islands Spain Cape Verde Rep of Cayman Islands Central African Republic Chad Channel Islands Chile China Peoples Republic of Christmas Island Australia Cocos Islands Australia Columbia Congo Republic of Cook Island New Zealand Costa Rica Curacao Islands Cyprus Czech Republic of Denmark Djibouti Republic of Dominica Dominican Republic 38 VOLTS 220 220 240 220 240 230 220 115 240 220 220 120 220 220 115 220 110 220 120 220 220 110 220 220 230 220 220 230 120 220 220 120 220 220 240 220 220 240 240 220 220 240 120 110 240 220 220 220 230 110 APPENDIX A OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS HZ 50 20 60 20 20 60 20 60 20 20 20 60 20 20 20 50 50 50 60 TESLA PART TI25000 004 Old British Line Cord TI25000 004 Old British Line Cord TI25000 011 Australian Line Cord TI25000 003 Contin
26. ainers tightly closed when not in use If battery case is broken avoid contact with internal components Keep vent caps on and cover terminals to prevent short circuits Place cardboard between layers of stacked automotive batteries to avoid damage and short circuits Keep away from combustible materials organic chemicals reducing substances metals strong oxidizers and water Use banding or stretch wrap to secure items for shipping Storage Store batteries in cool dry well ventilated areas with impervious surfaces and adequate containment in the event of spills Batteries should also be stored under roof for protection against adverse weather conditions Separate from incompatible materials Store and handle only in areas with adequate water supply and spill control Avoid damage to containers Keep away from fire sparks and heat Keep away from metallic objects which could bridge the terminals on a battery and create a dangerous short circuit Charging There is a possible risk of electric shock from charging equipment and from strings of series connected batteries whether or not being charged Shut off power to chargers whenever not in use and before detachment of any circuit connections Batteries being charged will generate and release flammable hydrogen gas Charging space should be ventilated Keep battery vent caps in position Prohibit smoking and avoid creation of flames and sparks nearby Wear face and eye protection when near batteries b
27. and connectivity To extend the life of the Cobra Connector included with your unit replacement contacts posts noses and tools can be ordered through the Tesla Customer Service TI2005 238 Cobra Aviation Plug TI2005 251 DC Aviation Plug Positive Negative Contact TI2005 250 DC Aviation Plug 3 slotted Connector T12004 341 Replacement Nose for Aviation Plug 8 5 GPU Tires TI2005 654 FA DC 400Hz Aviation Plug Positive Negative Contact TI2005 23 Aviation Insertion Extraction Tool T12004 340 Replacement Nose for 400 2 Aviation Plug TI2005 078 Cobra NATO Connector NSN 6130 01 523 1270 CL IX 2004 444 NATO Replacement Post For newer NATO plugs with new style post indicated by the black tip Replacement plug uses standard 3 4 deep well socket for installation TI2005 121 NATO Negative Contact NSN 5999 01 525 0582 CL IX TI2005 126 2 NATO Negative Contact Insertion Extraction Tool NSN 5120 01 523 8761 CL II TI2005 117 NATO Positive Post NSN 5935 01 523 8914 CL IX TI27000 082 NATO Positive Contact Insertion Extraction Tool NSN 5120 01 527 7729 CL II Tesla offers several tires in order to meet various customer mobility needs 2 000 203 1 Run Flat Tire A solid foam rubber tire The stan dard tire for ground power units 21000 192 TI2560 12 24 GPU Balloon
28. anical including photocopying recording or any information storage and retrieval system without prior written permission from Tesla Industries Inc Copyright 2015 by Tesla Industries Incorporated All rights reserved 07 14 15 Form SDS 853027 Revised 05 14 15 Supersedes NEW ECO 1001584 SAFETY DATA SHEET I PRODUCT IDENTIFICATION Chemical Trade Name as used on label Chemical Family Classification Tesla Industries Inc Sealed Lead Battery Synonyms Sealed Lead Acid Battery VRLA Battery Telephone For information contact Tesla Industries Inc Manufacturer s Name Address Customer Service Dept at 302 324 8910 Tesla Industries Inc 101 Centerpoint Blvd 24 Hour Emergency Response Contact New Castle DE 19720 4180 CHEMTREC DOMESTIC 800 424 9300 CHEMTREC INT L 703 527 3877 11 GHS HAZRDS IDENTFICATION Acute Toxicity Aquatic Chronic 1 Explosive Chemical Division 1 3 Oral Dermal Inhalation Category 4 Aquatic Acute 1 Skin Corrosion Irritation Category 1A Eye Damage Category 1 Reproductive Category 1A Carcinogenicity lead compounds Category 1B Carcinogenicity acid mist Category 1A Specific Target Organ Toxicity repeated exposure Category 2 GHS LABEL HEALTH ENVIRONMENTAL PHYSICAL Hazard Statements Precautionary Statements DANGER Wash thoroughly after handling Causes severe skin burns and eye damage Do not eat drink or smoke when using this product
29. art 30 A Unit is overheating A Unit is not plugged in A Cells discharged A Weak cells Disconnect unit from ac input and dc output Switch breaker to ON position C Reconnect unit to cables and run If LEDs still do not illuminate Please contact Tesla Customer Service at 302 324 8910 Plug unit into ac power source to maintain 28 5 Stand alone Vdc is 24 Volts unplugged Plug unit into ac power source B Recheck capacity after 25 minutes Failure to hold above 23 Vdc Please contact Tesla Customer Service at 302 324 8910 Allow between 30 to 60 seconds backcharge between uses 112560 12 24 GPU Section Performance Data 1 Purpose This section provides performance data forthe 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 A 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 B To enable the user to readily recognize situations requiring maximum performance C To gain experience in accurately estimating the effects of variables for which data is not presented D To help the operator determine if a
30. can Line Cord TI25000 001 North American Line Cord T125000 005 United Kingdom Line Cord TI25000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 005 United Kingdom Line Cord 39 COUNTRY Laos Latvia Lebanon Lesotho Liberia Liechtenstein Lithuania Luxembourg Libya Macao Madagascar Maderia Portugal Majorca Malawi Malaysia Maldives Mali Republic of Malta Martinique Mauritania Mauritius Mexico Monaco Mongolia Montseurrat Morocco Mozambique Namibia W S Africa Nepal Neth Antilles Netherlands New Caledonia New Zealand Nicaragua Niger Nigeria Norfolk Islands Australia North Ireland North Mariana Islands U S Norway Okinawa Oman Pakistan Panama Papua New Guinea Paraguay Peru Philippines Piccairn Islands U K Poland Portugal Puerto Rico 40 VOLTS 220 220 220 240 120 220 220 220 230 220 220 220 220 230 240 230 220 240 220 220 230 127 220 220 230 220 220 220 250 220 220 220 220 230 120 220 230 240 220 115 220 100 120 240 230 110 240 220 110 115 240 220 220 120 APPENDIX A Cont OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS 50 50 50 50 60 50 50 50 50 TESLATM PART TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord T125000 005 United Kingdom Line Cord TI
31. ccur 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 Power output is restricted to dc power only 1 5 Extreme Environments CAUTION The unit s charger temperature switch automatically disables the unit when the internal temperature exceeds 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 TI2560 12 24 GPU 3 Section 2 Product Overview 2 1 Introduction Thank you and congratulations on the purchase of your new TI2560 12 24 GPU Ground Power Unit This manual contains the complete operating instructions and procedures for the T12560 12 24 Ground Power Unit The TI2560 12 24 GPU has been designed to serve as a stand alone source of DC electrical power for aircraft systems and ground support maintenance operations Using a single 120 Vac power source the T12560 12 24 GPU provides regulated outputs of 14 25 Vdc at 20 amps continuous and 28 5 Vdc at 25 amps continuous For vehicle and aircraft starting the 12 Vdc and 24 Vdc outputs can deliver up to 3000 peak amps The unit s high capacity power cells and circuitry are encased in a rugged enclosure This internal circuitry incorporates an in
32. e Maximum megaohm Minimum Micro Power Unit National Electrical Manufacturers Association ohm power factor power factor correction root mean square Total Harmonic Distortion Test Measurement amp Diagnostic Equipment Unmanned aerial vehicle Volts Alternating Current Volts Direct Current watts 112560 12 24 GPU 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 specific type of hazard Indicates a condition operating procedure or practice which if not WARNING adhered to could result in serious injury or death Indicates a condition or operating procedure which if not strictl CAUTION ee y adhered to could result in damage or destruction of equipment Indicates a condition operating procedure or practice which is essential to highlight 1 2 Symbols The following symbols will appear within the warning triangles to alert the user to the specific 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 TI2560 12 24 GPU 1 Al Safety Review 1 3 Hazards WARNING Sev
33. e easily transported and air portable They will also provide 28 5 Vdc when the system is connected to the appropriate ac source 2 How does a Turbo Start work The Turbo Start combines state of the art power conversion electronics with our proprietary dry cell batteries The system s electronics incorporate an intelligent charging system for the cells The cells are ideal for this application as they are non spillable absorbed electrolyte dry cells that are sealed maintenance free and safe for air transport 3 How is Turbo Start used in Aviation Support There are many ways a Turbo Start will benefit your operation By using it for pre flight testing you will avoid depleting the aircraft s battery You can start the aircraft s engine with the Turbo Start as well In the hangar when connected to ac power the Turbo Start will provide 28 5 Vdc for avionics testing and will also recondition and recharge the aircraft s battery Another benefit is the ability to fly with the Turbo Start aboard your aircraft You may take the Turbo Start anywhere you travel ensuring that you will always have power 4 How much power will my Turbo Start provide Depending on the system the Turbo Start will provide anywhere from 1500 to 3500 peak starting amps 25 to 400 continuous amps dc and 23 to 96 hours of rechargeable power See our website www teslaind com to determine the proper Turbo Start for your needs
34. e pressure self contained breathing apparatus Water applied to electrolyte generates heat and causes it to spatter Wear acid resistant clothing gloves face and eye protection Note that strings of series connected batteries may still pose risk of electric shock even when charging equipment is shut down Unusual Fire and Explosion Hazards Highly flammable hydrogen gas is generated during charging and operation of batteries To avoid risk of fire or explosion keep sparks or other sources of ignition away from batteries Do not allow metallic materials to simultaneously contact negative and positive terminals of cells and batteries Follow manufacturer s instructions for installation and service VI PRECAUTIONS FOR SAFE HANDLING AND USE Spill or Leak Procedures Stop flow of material contain absorb small spills with dry sand earth and vermiculite Do not use combustible materials If possible carefully neutralize spilled electrolyte with soda ash sodium bicarbonate lime etc Wear acid resistant clothing boots gloves and face shield Do not allow discharge of unneutralized acid to sewer Acid must be managed in accordance with local state and federal requirements Consult state environmental agency and or federal EPA Handling Unless involved in recycling operations do not breach the casing or empty the contents of the battery There may be increasing risk of electric shock from strings of connected batteries Keep cont
35. eing charged For expanded detailed info download the PDF online at http www teslaind com PDF chart Tesla Safety Data Sheet pdf or go to http www teslaind com support manuals php and click on Battery Safety Data Sheet link under Battery Info heading or use the QR Code to the right 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 Front Panel Overview 2 4 General Specifications 2 5 Physical Dimensions 2 6 Airflow Ports 2 Operating Position 2 8 AC Input Circuit Breakers 2 9 AC Input Connector 2 10 24 Volt Output Connector 2 11 12 Volt Output Connector 2 12 Input Voltage Selector Switch 2 13 Push to Test Button and LED Status Indicator Section 3 Operating Procedures 3 1 Operating Procedures 3 2 General 3 3 Operating Limits and Restrictions 3 4 Performance 3 5 Engine Starting Power 3 6 Temperature Specifications 3 7 Environmental 3 8 Normal Functional Test Procedures 3 9 Pre Operation 3 10 Transporting Unit 3 11 Regulated 28 5 Vdc Ground Power 3 12 Regulated AC Power 3 13 Charging Unit WO HF O 00 4 M OOD 16 17 18 18 19 20 20 21 21 112560 12 24 GPU Section 4 Po
36. ental European Line Cord TI25000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord TI25000 011 Australian Line Cord TI25000 001 North American Line Cord TI25000 011 Australian Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 001 North American Line Cord TI25000 005 United Kingdom Line Cord TI25000 004 Old British Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 004 Old British Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord T125000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 005 United Kingdom Line Cord TI25000 002 Italian Line Cord TI25000 011 Australian Line Cord TI25000 011 Australian Line Cord TI25000 011 Australian Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 011 Aus
37. ere injury or death from electrical shock may occur if either user or the unit is wet while the unit is connected to a power source If the unit has come into contact with water disconnect ac power from the ac source If AC Input Circuit Breaker has tripped due to water infiltration DO NOT try to reset it with the ac line voltage attached WARNING Severe injury or death from electrical shock can occur when damp electrical plugs are connected to the unit Before making any connections turn off unit Failure to use proper grounding can cause potential shock hazard In different countries the power cord may require the use of a plug adapter to achieve plug style compatibility for operation Use only adapters with proper grounding mechanism Figure 1 3 1 Proper Ground Figure 1 3 2 Proper Ground Figure 1 3 3 Improper Ground Grounded Plug with Grounding Pin Adapter with Grounding Mechanism Plug with No Grounding Pin Secured to Outlet CAUTION The use of unapproved ac power will damage the unit Check the Input Voltage Selector Switch window outlined in blue to ensure the switch setting 115V or 230V matches the ac power source hangar wall flight line ac power prior to connecting the unit for recharging Figure 1 3 4 112560 12 24 GPU Input Voltage Selector Switch 112560 12 24 GPU Safety Review 17 1 4 Important Safety Precautions Aa WARNING Severe injury or death from fire or explosion can o
38. harge with a flickering LED readout Newer models feature the illumination of one green bar on the LED readout when the unit is fully charged 8 What do do if a circuit breaker trips The AC Input Circuit Breaker is located above the AC Input Connector When the circuit breaker has been tripped either of the red buttons will pop out In the event that the breaker trips 1 Disconnect the ac and dc connectors Unplug ac line cord on military unit 2 Wait fora minimum of 60 seconds 3 Reset breaker by pressing red button 4 Reconnect ac and dc connections to the unit Plugin 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 28 112560 12 24 GPU Troubleshooting amp FAQ 6 6 3 Basic Unit Troubleshooting 1 Output Capacity LED does not come on when button is pushed 2 Unit has no output dc or ac input or both 3 Unit will not charge from ac outlet 4 Unit failed function test 5 Unit emits sparks when plugged into power source 6 Unit works then shuts down TI2560 12 24 GPU Units cells completely dead Units cells completely dead AC line cord is damaged or bad DC line cord is damaged or bad AC circuit breaker has been tripped Cables loose or corroded A AC line cord is damaged or bad Is ac line cord fully plugged into unit and wall outlet AC circuit breake
39. he data presented are accurate only for specific conditions listed under the title of each chart or graph Variables for which data are not presented but which may affect that phase of performance are discussed in associated text 5 General Conditions In addition to the specific conditions the following general conditions are applicable to the performance data A Variation in Aircraft Power demand differences between individual aircraft of the same make and model are known to exist due to variations in dc electrical system efficiency These differences however are considered insignificant and are not individually accounted for B Ground Support and Aircraft Instrument Variations The data shown in the performance charts do not account for instrument tolerance differences or inaccuracies TI2560 12 24 GPU 31 Performance Data 1 6 Temperature Conversion Chart 6 6 49 6 0 14 2 12 4 0 6 68 8 67 0 65 2 63 4 61 6 59 8 58 0 56 2 54 4 52 6 50 8 49 0 47 2 45 4 43 6 15 8 41 8 17 6 40 0 7 0 19 4 38 2 36 4 34 6 32 8 31 0 29 2 27 4 25 6 23 8 22 0 20 2 18 4 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 11 0 10 0 16 6 42 8 14 8 1 0 44 6 13 0 46 4 11 2 48 2 9 4 50 0 1 6 51 8 5 8 53 6 4 0 55 4 2 2 57 2 0 4 59 0 1 4 60 8 32 62 6 5 0 64 4 66 2 68
40. ine Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 003 Continental European Line Cord TI25000 011 Australian Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 300 Denmark Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord T125000 001 North American Line Cord TI25000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 001 North American Line Cord TI25000 001 North American Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord T1I25000 005 United Kingdom Line Cord TI25000 200 Israel Line Cord TI25000 002 Italian Line Cord TI25000 003 Continental European Line Cord TI25000 001 North Ameri
41. little or no accumulation Fog OK OK Figure 3 7 1 T17000 142 GPU Protective Rain Cover TI2560 12 24 GPU 15 3 Operating Procedures 3 8 Normal Function Test Procedures This section involves normal function test procedures and includes steps necessary to ensure that the unit is operating within specified parameters prior to use digital multimeter an example is shown in Figure 3 8 1 capable of measuring dc and ac voltage and resistance will be required to perform some of the tests These functional test procedures should become routine Figure 3 8 1 Digital Multimeter Check Unit for Evidence of Damage Check for dents punctures case distortion or misalignment and cracked or loose connectors 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 As shown in Figure 3 8 2 place the positive probe red on the positive post of the DC Output Connector and the negative probe on the negative post The multimeter display should read approximately 28 5 Vdc 0 5 Vdc when power cells are fully charged and the unit is plugged into an appropriate ac power source When the unit is not plugged into an ac power source the multimeter display should read approximately 25 5 Vdc Figure 3 8 2 Testing DC Receptacle 16
42. ly After approximately 5 8 seconds ensure unit s LED status indicator illuminates indicating power cell state of charge and cooling fan is operating Any time the unit s power cells are fully discharged the unit shall be recharged within 24 hours to prevent performance degradation and ensure maximum life l E Figure 4 3 1 Connecting TI2560 12 24 GPU to Figure 4 3 2 AC North American AC Power Supply Line Cord 99 TI2560 12 24 GPU Post Operations 4 CAUTION The TI2560 12 24 GPU s power cells may be damaged if recharged by NiCad or Lithium lon battery chargers Power cells should only be charged by either the TI2560 12 24 GPU s internal charger and the ac power cord furnished with the equipment or when connected to aircraft s external dc power receptacle Figure 4 3 3 Proper and Improper Charging Methods TI2560 12 24 GPU 23 Section 5 Unit Care and Maintenance WARNING CAUTION 5 1 Unit Care Avoid Prolonged Exposure to Extremely Damp Environments If the unit has come into contact with water disconnect ac power from the ac source If the AC Input Circuit Breaker has tripped due to water infiltration allow the unit to dry out before attempting to reset circuit breaker Cover the unit to prevent water seepage If the unit is operated in extremely damp conditions it should be stored in an environmentally controlled building when not in use Wipe unit clean periodically with
43. ne side see figure2 12 2 Flip the switch to read 230V See figure 2 12 3 Rotate cover back into place Replace and tighten screw CAUTION Do not plug unit into 230 Vac when Input Voltage Selector Switch is set on 115 Vac Neils The 115 Vac setting accommodates the voltage range of 100 130 Vac The 230 Vac setting accommodates the voltage range of 200 260 Vac N 3 Figure 2 12 3 Select Voltage Do not overtighten Selector Shield screws Be sure star locks are on screws and snug the screw Overtightening will damage the Selector Shield TI2560 12 24 GPU 11 2 Product Overview 2 13 Push to Test Button and LED Status Indicator The Push to Test button indicates the capacity of the power cells without applying ac input power The status of the capacity lets the user know if there is enough power to perform another engine start When the capacity is low the unit should be connected to ac power to allow it to recharge 1 Make sure that you wait at least 2 minutes after ac power is applied or dc power is extracted from the unit before you press the Push to Test button This ensures a correct reading 2 Without ac power input or dc power output simply press the Push to Test button on the faceplate and hold for approximately 2 to 3 seconds 3 The LED bar graph should light up indicating the status of the power cells 4 In addition the fan s should start operating when the button
44. r has been tripped No ac power at outlet Internal failure Water or moisture has seeped in unit Internal failure Unit is overheating Cooling fans and vents are obstructed or inoperable Plug the unit in to the appropriate ac power outlet and recharge If LEDs still do not illuminate Please contact Tesla Customer Service at 302 324 8910 Do a function check with digital meter see section 3 8 Do continuity test C No continuity check cables for cuts and replace if needed Clean contacts of debris and make sure connections are tight A Do a continuity test on the ac line cord Check if line cord is properly secured Check to make sure ac circuit breaker is placed in the ON position Please contact Tesla Customer Service at 302 324 8910 Move unit to dry warm air and allow to dry for over 48 hours Do Not Use Unit Please contact Tesla Customer Service at 302 324 8910 Move the unit to an area 10 20 less ambient temperature Clean and clear cooling vents turn on unit and inspect if air is flowing through unit If no airflow please contact Tesla Customer Service at 302 324 8910 29 6 Troubleshooting amp FAQ Fault T Circuit breaker continuously trips 8 Unit does not put out 28 5 volts dc power 9 Unit stand alone voltage is less than 23 volts 10 Unit weakens after first st
45. rd TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 001 North American Line Cord T125000 005 United Kingdom Line Cord TI25000 005 United Kingdom Line Cord T125000 005 United Kingdom Line Cord TI25000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 003 Continental European Line Cord T125000 006 Switzerland Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord T125000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord T125000 005 United Kingdom Line Cord TI25000 005 United Kingdom Line Cord T125000 001 North American Line Cord TI2500
46. re Exposing the unit for one 1 hour or more to the ambient temperature 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 For COLD SOAKED temperature stabilization the unit must be placed in an environment with a temperature above 10 C 41 F for 3 hours or a temperature above 20 C 68 F for 2 hours For HOT SOAKED temperature stabilization the unit must be placed in an environment with a temperature below 38 C 100 F for 1 hour Ambient Percentage of Temperature Cell Capacity Figure 3 6 1 Output power capability versus ambient temperature Hot Soaked or Cold Soaked Definition Simple terms When a material is exposed to a change in temperature its temperature will also change Some material changes temperature quickly others slowly If the ambient temperature changes and is then held constant the materials temperature will also change until its temperature stabilizes Once the material temperature has stabilized it is considered soaked Example A unit is moved from the cool shade into the hot sun That unit s temperature will increase until it stabilizes Once stabilized the unit would be considered hot soaked The unit s temperature switch automatically disables ac power functions when the internal temperature is above 150 F 65 C This pro
47. re there any HAZMAT issues or disposability problems There are none Tesla will reclaim all battery cells for disposability purposes Contact Tesla if you have questions TI2560 12 24 GPU 07 _6 Troubleshooting amp FAQ 6 2 Basic Usage Operation Questions 1 What s the best position to place the unit for use vertical or horizontal Preferred position is horizontal for stability and airflow considerations When charging the preferred position is horizontal The Turbo Start can be put in any position while it is being used as there is nothing to spill inside the system 2 Does the unit have to be plugged in all the time No but for maximum performance and cell longevity keep the unit plugged in while not in use 3 What happens if don t keep it plugged in Unit will eventually lose its charge and cell life is shortened 4 How do check the status of the charge Press the Push to Test LED bar indicator on the unit s faceplate A fully charged unit will have one green LED light showing 5 Why is the cooling fan always running when am plugged into ac power Constant cooling fan operation ensures proper and consistent ventilation of the unit 6 Why does the cooling fan slow down Cooling fan rpm varies for better temperature regulation T Why does my LED flicker when the unit is plugged in Older Turbo Starts indicated a full c
48. st Operation 22 4 1 General 22 4 2 After Use 22 4 3 Power Cell Recharge 22 23 Section 5 Unit Care and Maintenance 24 5 1 Unit Care 24 5 2 Unit Servicing 25 5 3 Packaging and Shipping 25 Section 6 Troubleshooting and FAQ 26 6 1 Frequently Asked Questions 26 2 6 2 Basic Usage Operation Questions 28 6 3 Basic Troubleshooting 29 30 Section Performance Data 31 1 1 Purpose 31 2 General 31 1 3 Data Basis 31 1 4 Specific Conditions 31 1 5 General Conditions 31 1 6 Temperature Conversion Chart 32 7 Output Voltage 33 1 8 Maximum Output Current 33 1 8 12 Vdc Output Loading Curves 34 Section 6 Optional Accessories 36 8 1 Shipping Case 36 8 2 GPU Protective Covers 36 8 3 Tesla AC Line Cords 36 8 4 Cobra DC Replacement Contacts and Tools 37 8 5 GPU Tires 37 Appendix A 38 42 Repair Request Form 43 TI2560 12 24 GPU Abbreviations and Symbols Abbreviations that may be used within the text headings and titles of this manual LIST OF ABBREVIATIONS Abbreviation Definition ac AFT AWG amp or cont C i dc EFF ft FWD GPU Hr Hz kg kHz kW LED max MQ min MPU NEMA PF PFC rms THD TMDE UAV Vac Vdc Alternating Current Airflow Technology American Wire Gauge Ampere Continuous Degree Celsius Degree Fahrenheit Direct Current Efficiency Feet Forward Ground Power Unit Hour Hertz Kilograms Kilohertz Kilowatts Light Emitting Diod
49. tects the unit from overheating and damage If the unit shuts down move the unit into a cooler climate such as shade or air conditioning when possible Perform a full function test prior to use after the unit has been allowed to cool 14 TI2560 12 24 GPU 3 Environmental WARNING If the unit is exposed to moisture preventive measures and precautions shall be taken to A Prevent accumulation of moisture on ac and dc connectors receptacles B Minimize moisture entering forward inlet and aft outlet cooling fan vent ports Unit inlet and outlet vent ports shall be covered from exposure Unit shall be kept horizontal Recommendations include a Protective Rain Cover to guard the unit from moisture see Section 8 The limits and operational constraints listed below shall apply for the following environmental weather conditions With Conditions Without Raincover Raincover Heavy or steady rain OK OPERATION NOT RECOMMENDED Precipitation falling with an intensity in excess of 0 30 inch 0 76 cm or continuously between 0 30 and 0 10 inch per hour Light rain drizzle or sleet OK DC OPERATIONS ONLY Precipitation falling on a continuous basis between 0 10 inch and less than 1 50 inch 0 5 mm per hour Heavy or steady snow OK OPERATION NOT RECOMMENDED Generally meaning an accumulation between 4 inches and less than 1 inch in a 12 hour period Light snow OK DC OPERATIONS ONLY Snow falling intermediately with
50. telligent recharging system that allows the TI2560 12 24 GPU to rapidly recharge from any standard 110 130 Vac outlet receptacle The unit also comes equipped with independent dual outputs and built in Charge Status Meters via the Push to Test button that also serve as recharge state indicators for both dc outputs Figure 2 1 1 112560 12 24 GPU 2 2 Indication of Terms Shall Should and May Within this technical manual the word shall is used to indicate a mandatory requirement for proper operation and warranty purposes The word should is used to indicate a non mandatory but preferred method of accomplishment The word may is used to indicate an acceptable method of accomplishment 4 112560 12 24 GPU Product Overview 2 2 3 Front Panel Overview 1 LA a et 1 AAI ET ra FE Tv E Lie FETI z y 25 mn P p 5 al x F Fag f A 1 _ p 5 a i iris sm men 1 men gt oa a 1 Push to Test Button Displays current battery 7 AC Input Connector Connects to standard 110 charge state when pressed 130 Vac line voltage 2 AC Input Circuit Breakers Trip if over current fault 8 Intake Ports Provide airflow for cooling condition occurs internal electronics 3 24 Vdc Output Connector 9 Input Voltage Selector Switch Allows Unit to operate within voltage range of either 100 130 Vac 4 42 Vdc Output Connector
51. the 24 Vdc output approximately 40 amps of current will cause the converter to regulate the voltage to 24 Vdc In both cases the last red LED on the Capacity Meter will illuminate When all LED status indicator bars illuminate both the converter and power cells are supplying 24 Vdc power output for current demands above 25 amps or 20 amps for 12 Vdc Engine Starting CAUTION 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 operators manual Removing DC Power Supply From Vehicle 1 Remove dc power cable GPU connector from vehicle 2 Remove dc power cable connector from 112560 12 24 GPU if necessary 3 Reinstall dc Receptacle s Protective Cover 3 12 Regulated AC Power Plugging in with AC Power When the TI2560 12 24 GPU 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 The GPU s ac to dc converter produces continuous amps of dc power depending on the size of the system NOTE Check Input Voltage Selector Switch for proper setting 20 112560 12 24 GPU Operating Procedures 3 RS ay Figure 3 12 1 Connecting 112560 12 24 GPU to Figure 3
52. tralian Line Cord T125000 001 North American Line Cord TI25000 001 North American Line Cord TI25000 005 United Kingdom Line Cord TI25000 003 Continental European Line Cord TI25000 300 Denmark Line Cord TI25000 003 Continental European Line Cord T125000 005 United Kingdom Line Cord TI25000 001 North American Line Cord 112560 12 24 GPU COUNTRY Ecuador Egypt El Salvador England Equatorial Guinea Estonia Ethiopia Fiji Finland France French Guiana Gabon Gambia Georgia Germany Ghana Gibraltar Greece Greenland Denmark Grenada Guadeloupe Guam Guatemala Guinea Guinea Bissau Guyana Haiti Honduras Hong Kong Hungary Iceland India Indonesia lran Iraq Ireland Republic of Isle of Man Israel Italy Ivory Coast Jamaica Japan Jordan Kenya Korea South Kuwait TI2560 12 24 GPU VOLTS 120 220 115 240 220 220 220 240 220 220 220 220 220 220 220 220 240 220 220 230 220 110 120 120 220 220 110 110 120 110 220 220 220 220 250 220 220 220 220 240 230 220 220 110 110 220 240 220 240 APPENDIX A Cont OPTIONAL LINE CORDS FOR WORLDWIDE OPERATIONS HZ 60 50 60 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50 60 60 50 50 50 50 60 50 60 50 TESLA PART T125000 001 North American Line Cord TI25000 003 Continental European Line Cord TI25000 001 North American Line Cord TI25000 005 United Kingdom L
53. ur needs Tesla specializes in outfitting cables with a variety of connectors and junction boxes Contact Tesla Customer Service to find out more about our selection of cables Regular Line Cords Line Cords For units with a fuse and old style receptacle For units with a circuit breaker and new style receptacle TI25000 001 North American Line Cord TI25000 211 North American Line Cord TI25000 002 Italian Line Cord TI25000 212 Italian Line Cord TI25000 003 Continental European Line Cord TI25000 213 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 214 Old British Line Cord TI25000 005 England UK Line Cord TI25000 215 England UK Line Cord TI25000 006 Swiss Line Cord TI25000 216 Swiss Line Cord TI25000 011 Australian Line Cord TI25000 201 Australian Line Cord TI25000 200 Israel Line Cord TI25000 203 Israel Line Cord TI25000 300 Denmark Line Cord TI25000 304 Denmark Line Cord T125000 032 North American Commercial Line Cord To be used for T13000 Commercial Unit only NEMA 515P Italian Continental European Old British England UK Swiss Australian Bice Denmark NEMA 520P 26 TI2560 12 24 GPU Optional Accessories 8 8 4 Cobra DC Replacement Contacts and Tools Cobra DC Plugs provide reliable high power connections up to 3000 amps even in the harshest conditions A rugged combination of advanced composite materials and corrosion resistant alloys make each plug maximized for durability
54. vehicle or an aircraft system malfunction exists by comparing actual performance with expected performance The information in this section provides data for operational planning This is helpful when planning operations under unfamiliar conditions or environmental extremes The data may also be used to establish local operating procedures and to ensure maximum usage of the unit 2 General The data presented covers the maximum range of conditions and performance that can reasonably be expected In each area of performance the effects of temperature and dc electrical load demand relating to the ground power support requirements are presented Wherever practical data is presented conservatively However NO GENERAL CONSERVATISM HAS BEEN APPLIED All performance data presented is within the applicable limits of the unit 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 categories A Derived From Actual Controlled Testing Controlled test data obtained on a similar unit type B Calculated Data Data based on tests but not on a similar unit type placed under a controlled test C Estimated Data Data based on estimates using rules of physics mathematics and electrical engineering principles and concepts but not verified by tests 1 4 Specific Conditions T
55. w is not obstructed from air intake figure 2 7 3 and outlet Figure 2 7 4 ae 55 Figure 2 7 1 Horizontal Position ere ae Figure 2 7 3 Front Inlet Figure 2 7 4 Rear Outlet gQ 112560 12 24 GPU Product Overview 2 2 8 AC Input Circuit Breaker The AC Input Circuit Breaker is located above the AC Input Connector When the circuit breaker has been tripped the red button will pop out In the event that the breaker trips 1 Disconnect the ac and dc connectors Wait for a minimum of 60 seconds Reset breaker by pressing red button Reconnect ac and dc connections to the unit go The unit should power up automatically If the breaker continues to trip return the unit to Tesla Industries for repair Figure 2 8 1 AC Input Circuit Breaker outlined in blue 2 9 AC Input Connector The GPU is outfitted with a 3 prong receptacle see figure 2 9 1 below The mating cable is keyed and will fasten securely into the AC Input Connector Figure 2 9 1 AC Input Connector outlined in blue TI2560 12 24 GPU 9
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