Tesla TI3500 GPU-24, Manual

Page 1: ...ectronics 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 P...

Page 2: ...perates and charges from Single Phase 100 260 Vac 50 60Hz 20 amps 120 Vac 60 Hz 2400 Watts 10 amps 240 Vac 50 60 Hz 2400 Watts Recharging Rate 115 minutes from full discharge 25 C Vibration Exceeds MIL STD 810F Storage Temperature 65 C to 105 C 85 F to 221 F Operating Temperature w o AC Power 40 C to 60 C 40 F to 140 F Operating Temperature w AC Power 40 C to 55 C 40 F to 131 F Weight 234 lbs 106 ...

Page 3: ...Tesla TI3500 GPU 24 User Manual Built Smart Proven Tough Power Anytime Anywhere Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www teslaind com ...

Page 4: ... and or injury or death by electrical shock Any attempts to open or examine the inside of the TI3500 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 Always protect the unit from short circuit Shipping Hazards The TI3500 GPU 24 contains sealed dry cell r...

Page 5: ...se Dry chemical CO2 or water spray Special Fire Fighting Procedures Cool GPU MPU exterior to prevent rupture Acid mists and vapors in a fire are toxic and corrosive Unusual Fire and Explosion Hazards Hydrogen gas may be produced and may explode if ignited Remove all sources of ignition SECTION V REACTIVITY DATA AND SHIPPING HANDLING ELECTRICAL SAFETY Stability Stable Conditions to Avoid Avoid short...

Page 6: ...pillable batteries must be packed according to IMDG Packing Instruction P003 This means shipping papers need not show proper shipping name hazard class UN num ber and packing group Hazardous labels are not required when transporting an nonspillable battery These batteries are excepted from all IMDG codes provided that the batteries are packed in a suitable out packaging and their terminals are pro...

Page 7: ...7 Airflow Ports 8 2 8 Operating Positions 9 2 9 Input Voltage Selector Switch 10 2 10 Push to Test button and LED Status Indicator 11 2 11 AC Input Circuit Breakers 12 2 12 24 Vdc Output Connector 12 Section 3 Operating Procedures 13 3 1 Operating Procedures 13 3 2 General 13 3 3 Operating Limits and Restrictions 13 3 4 Performance 13 3 5 Engine Starting Power 13 3 6 Temperature Specifications 14 ...

Page 8: ...g 30 31 Section 7 Performance Data 32 7 1 Purpose 32 7 2 General 32 7 3 Data Basis 32 7 4 Specific Conditions 32 7 5 General Conditions 32 7 6 Temperature Conversion Chart 33 7 7 Output Voltage 34 7 8 Maximum Output Current 34 Section 8 Optional Accessories 35 8 1 Shipping Case 35 8 2 GPU Protective Covers 35 8 3 Tesla AC Line Cords 35 8 4 Tesla Universal AC Line Cords 36 8 5 TI25000 U00 Unit Modi...

Page 9: ... Direct Current EFF Efficiency ft Feet FWD Forward GPU Ground Power Unit Hr Hour Hz Hertz kg Kilograms kHz Kilohertz kW Kilowatts LED Light Emitting Diode max Maximum MΩ megaohm min Minimum MPU Micro Power Unit NEMA National Electrical Manufacturers Association Ω ohm PF power factor PFC power factor correction rms root mean square THD Total Harmonic Distortion TMDE Test Measurement Diagnostic Equi...

Page 10: ...d WARNING Indicates a condition operating procedure or practice which if not adhered to could result in serious injury or death CAUTION Indicates a condition or operating procedure which if not strictly adhered to could result in damage or destruction of equipment NOTE Indicates a condition operating procedure or practice which is essential to highlight 1 2 Symbols The following symbols will appea...

Page 11: ...user or the unit is wet while the operating unit is connected to a power source Be sure to disconnect ac power from the ac source if the unit has come into contact with water If AC Input Circuit Breaker has tripped due to water infiltration DO NOT try to reset it with the ac line voltage attached Figure 1 3 1 Proper Ground Grounded Plug with Grounding Pin Figure 1 3 2 Proper Ground Adapter with Gr...

Page 12: ...g any fuel handling operation Power output is restricted to dc power only 1 5 Extreme Environments CAUTION Unit Damage Potential The unit is equipped with a charger temperature switch that 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...

Page 13: ... limitations and performance criteria is essential to ensure peak operating efficiency and to maximize operational capabilities and life of the Turbo Start 3500 ground power unit This manual contains the complete operating instructions and procedures for the TI3500 GPU 24 that the end user will need to safely and efficiently operate this GPU Figure 2 1 1 TI3500 GPU 24 2 2 Indication of Terms Shall...

Page 14: ... AC Input Operates and charges from Single Phase 100 260 Vac 50 60 Hz 20 amps 120 Vac 60 Hz 2400 Watts 10 amps 240 Vac 60 Hz 2400 Watts Physical Properties Size 37 28 L x 19 25 W x 15 97 H 946 91 mm x 488 95 mm x 405 64 mm Weight 234 lbs 106 14 kg Power Cell Dry High Rate Discharge Rechargeable Maintenance free Operating Temperature 40 C to 60 C 40 F to 140 F without ac power 40 C to 55 C 40 F to ...

Page 15: ...e power output status Air Intake Ports 4 Provide airflow for cooling internal electronics Push to Test Button 5 Displays current battery charge state when pressed AC Input Connector 6 Connects to standard 100 130 Vac line voltage or 200 260 Vac line voltage Input Voltage Selector Switch 7 Allows Unit to operate within voltage range of either 100 130 Vac or 200 260 Vac Telescoping Handle 8 Allows f...

Page 16: ...A 24 Vdc Capacity Meter 3 Indicates the 24V battery charge state power output status Air Intake Ports 4 Provide airflow for cooling internal electronics Push to Test Button 5 Displays current battery charge state when pressed AC Input Connector 6 Connects to standard 100 130 Vac line voltage or 200 260 Vac line voltage Telescoping Handle 7 Allows for easy transport of unit 3 4 6 1 2 5 7 1 2 5 3 6 ...

Page 17: ...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 In more extreme temperatures greater than 90 F the exhaust air will not exceed the ambient temperature by more than 10 F 10 5 266 7 19 25 488 95 15 97 405 64 37 28 946 91 Figure 2 6 1 TI3500 GPU 24 physical...

Page 18: ...an 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 2 8 2 Vertical Position 2 8 1 Horizontal Position 2 8 3 Front Inlet 2 8 4 Rear Outlet ...

Page 19: ...ewdriver remove one screw and rotate the clear protective cover to one side 2 Flip the switch to read 230V 3 Rotate cover back into place Replace and tighten screw Figure 2 9 2 Unscrew Protective Cover Figure 2 9 3 Select Voltage The 115 Vac setting accommodates the voltage range of 100 130 Vac The 230 Vac setting accommodates the voltage range of 200 260 Vac NOTE CAUTION Do not plug unit into 230...

Page 20: ...porarily disrupt Push to Test function If this sensor is tripped allow ten minutes for unit to cool before operating Push to Test button Full Charge Half Charge No Charge STATUS STATUS STATUS R Y G 0 1 2 OK R Y G 0 1 2 OK R Y G 0 1 2 OK 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 al...

Page 21: ...11 1 AC Input Circuit Breakers outlined in blue Figure 2 11 2 Pressing Circuit Breaker 2 12 24 Vdc Output Connector The 24 Vdc Output Connector will provide 50 amps continuous 28 5 Vdc when plugged into ac power When the Output Connector is not in use cover the receptacle with the protective cover see Figure 2 12 1 This will protect the Output Connector from dust and foreign matter Figure 2 12 1 2...

Page 22: ...nd aircraft dc bus system inefficiency voltage drops 3 5 Engine Starting Power Operators should always ensure the unit is 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 p...

Page 23: ...e stabilization the unit must be placed in an environment with a temperature below 38 C 100 F for 1 hour WARNING Operating any electrical equipment in the presence of moisture creates possible 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 da...

Page 24: ...afety 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 the unit moisture resistant to prevent damage or failure Conditions With Raincover Without Raincover Heavy or steady rain Precipitation falling with an intensity in excess of 0 30 inch 0 76 cm or continuously between 0 30 and 0 10 inc...

Page 25: ...alloon tires should be installed on the unit see Optional Accessories Figure 3 9 1 Releasing Telescopic Handle 3 8 Pre Operation Be sure to check that all input and output cables are not damaged see section 5 1 1 Check unit carefully for any evidence of damage 2 Make sure that airflow is not obstructed from air intake and outlet see section 2 7 3 Check that all connections are secure and free from...

Page 26: ...fely transfer power Figure 3 10 1 Attaching DC Power Cable to TI3500 GPU 24 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 10 2 DC Power C...

Page 27: ...High power demand is defined by a requirement of over 50 amps Connect to aircraft ground power receptacle DC bus power should come on and aircraft voltmeter should indicate 27 5 Vdc to 23 5 Vdc If current demand greater than 50 amps converter output voltage will drop below 28 Vdc and two or more LED status indicator bars will illuminate indicating current is being drawn from the power cells The gr...

Page 28: ...inate indicating power cell state of charge Cooling fan will operate Ensure LED status indicator and cooling fan is operational prior to continuing Charging Unit 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 Under a full charge the LED indicator should show a single steady green bar The fan will run at reduced sp...

Page 29: ...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 NOTE Plug the TI3500 GPU 24 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 CAUTION Check Input Vol...

Page 30: ...e 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 Figure 4 3 3 Proper and Improper Charging Methods OK OK NO ...

Page 31: ...n periodically with a soft cloth to remove dust dirt etc WARNING Severe injury or death from electrical shock will occur if either the user or the unit is wet while operating the unit with an ac power source attached CAUTION Damage may occur if an unapproved or modified ac line cable or input plug is attached to the GPU Do not use any type of ac voltage converter Protect Cables from Damage Do not ...

Page 32: ... 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 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 Figure 5 3 1 Tesla Industries Shipping...

Page 33: ...s case distortion or misalignment and cracked or loose connec tors If no damage is evident proceed to the next step If damage is evident contact Tesla Industries Inc Check DC Voltage Reading at DC Receptacle Terminals To verify that the power cells are fully charged set the digital multimeter to measure dc voltage As shown in Figure 5 2 4 place the positive probe red on the positive post of the DC...

Page 34: ...an 10 MΩ 3 Move the positive probe to the dc negative post Multimeter should read greater than 10 MΩ 4 Move the positive probe to the fas tener screw on the dc receptacle Multimeter should read less than 1Ω 2 Place the positive probe to the fas tener screw on the dc receptacle Move the negative probe to the DC negative post Multimeter should read 0 Volts 3 Place the negative probe to the fas tener...

Page 35: ...tive probe to the dc positive post on the DC Output Connector Multimeter should read greater than 10 MΩ 4 Move the positive probe to the dc negative post on the DC Output Connector Multimeter should read greater than 10 MΩ M to Case GND Open MΩ K to Case Open MΩ J and L to Case Less than 1 Ω A and H to Case Open MΩ Figure 5 5 3 AC Input Connector wiring diagram AC Hot Pin K AC Neutral Pin M AC Gro...

Page 36: ...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 5 Will a Tesla Turbo...

Page 37: ...get my Turbo Start 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...

Page 38: ...ways running when I 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 7 Why does my LED flicker when the unit is plugged in Older Turbo Starts indicated a full charge with a flickering LED readout Newer models feature the illumination of one gree...

Page 39: ...c outlet AC line cord is damaged or bad A Is ac line cord fully plugged into unit B and wall outlet AC circuit breaker has been tripped C No ac power at outlet D Do a continuity test on the ac line cord A Check if line cord is properly secured B Check to make sure ac circuit breaker C is placed in the ON position 4 Unit failed function test Internal failure A Please contact Tesla Customer Service ...

Page 40: ...ut out 28 5 volts dc power Unit is not plugged in A Plug unit into ac power source to A maintain 28 5 Stand alone Vdc is 24 Volts B unplugged 9 Unit stand alone voltage is less than 23 volts Cells discharged A Plug unit into ac power source A Recheck capacity after 25 minutes B Failure to hold above 23 Vdc Please C contact Tesla Customer Service at 302 324 8910 10 Unit weakens after first start We...

Page 41: ... given The data provided generally are based on one of three categories Derived From Actual Controlled Testing Controlled test data obtained on a similar unit type A Calculated Data Data based on tests but not on a similar unit type placed under a controlled test B Estimated Data Data based on estimates using rules of physics mathematics and electrical engineering C principles and concepts but not...

Page 42: ...0 8 13 0 8 6 20 0 68 0 53 0 127 4 45 0 49 0 12 0 10 4 21 0 69 8 54 0 129 2 44 0 47 2 11 0 12 2 22 0 71 6 55 0 131 0 43 0 45 4 10 0 14 0 23 0 73 4 56 0 132 8 42 0 43 6 9 0 15 8 24 0 75 2 57 0 134 6 41 0 41 8 8 0 17 6 25 0 77 0 58 0 136 4 40 0 40 0 7 0 19 4 26 0 78 8 59 0 138 2 39 0 38 2 6 0 21 2 27 0 80 6 60 0 140 0 38 0 36 4 5 0 23 0 28 0 82 4 61 0 141 8 37 0 34 6 4 0 24 8 29 0 84 2 62 0 143 6 36 ...

Page 43: ...ctual test data at Pratt Whitney Canada on 30 March 1992 SECONDS AMPS MAXIMUM OUTPUT CURRENT 0 0 TI3500 Maximum Output Current TI5400GPU 24 OUTPUT VOLTAGE OUTPUT VOLTAGE MINUTES 46 AMP CONSTANT CURRENT LOAD 24 20 16 12 8 4 0 0 10 20 30 40 50 60 TI3500 Output Voltage MINUTES 92 AMP CONSTANT CURRENT LOAD 7 7 Output Voltage 7 8 Maximum Output Current ...

Page 44: ...la Customer Service to find out more about our selection of cables Regular Line Cords TI25000 001 North American Line Cord TI25000 002 Italian Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord TI25000 005 England UK Line Cord TI25000 006 Swiss Line Cord TI25000 011 Australian Line Cord TI25000 200 Israel Line Cord TI25000 300 Denmark Line Cord For units with a ...

Page 45: ...les come in several lengths or can be custom ordered to fit your needs Tesla specializes in outfitting cables with a variety of connectors and junction boxes Contact Tesla Customer Service to find out more about our selection of cables Regular Line Cords TI25000 001 North American Line Cord TI25000 002 Italian Line Cord TI25000 003 Continental European Line Cord TI25000 004 Old British Line Cord T...

Page 46: ...tomer Service TI2005 238 Cobra Aviation Plug TI2005 078 Cobra NATO Connector NSN 6130 01 523 1270 CL IX TI2005 251 DC Aviation Plug Positive Negative Contact TI2005 250 DC Aviation Plug 3 slotted Connector TI2004 341 Replacement Nose for Aviation Plug TI2005 654 DC 400Hz Aviation Plug Positive Negative Contact TI2005 239 Aviation Insertion Extraction Tool TI2004 340 Replacement Nose for 400Hz Avia...

Page 47: ...an Line Cord Burma Now Myanmar 230 50 TI25000 005 United Kingdom Line Cord Burundi 220 50 TI25000 003 Continental European Line Cord Cambodia 220 50 TI25000 003 Continental European Line Cord Cameroon 230 50 TI25000 003 Continental European Line Cord Canada 120 60 TI25000 001 North American Line Cord Canary Islands Spain 220 50 TI25000 003 Continental European Line Cord Cape Verde Rep of 220 50 TI...

Page 48: ...d Guadeloupe 220 50 TI25000 003 Continental European Line Cord Guam 110 120 60 TI25000 001 North American Line Cord Guatemala 120 60 TI25000 001 North American Line Cord Guinea 220 50 TI25000 003 Continental European Line Cord Guinea Bissau 220 50 TI25000 003 Continental European Line Cord Guyana 110 50 60 TI25000 001 North American Line Cord Haiti 110 120 50 60 TI25000 001 North American Line Cor...

Page 49: ... Line Cord Montseurrat 230 60 TI25000 005 United Kingdom Line Cord Morocco 220 50 TI25000 003 Continental European Line Cord Mozambique 220 50 TI25000 003 Continental European Line Cord Namibia W S Africa 220 250 50 TI25000 004 Old British Line Cord Nepal 220 50 TI25000 004 Old British Line Cord Neth Antilles 220 50 60 TI25000 003 Continental European Line Cord Netherlands 220 50 TI25000 003 Conti...

Page 50: ...000 004 Old British Line Cord Sweden 220 50 TI25000 003 Continental European Line Cord Switzerland 220 50 TI25000 006 Switzerland Line Cord Syria 220 50 TI25000 003 Continental European Line Cord Tahiti 220 50 TI25000 003 Continental European Line Cord Taiwan 110 60 TI25000 001 North American Line Cord Tanzania 230 50 TI25000 005 United Kingdom Line Cord Thailand 220 50 TI25000 003 Continental Eur...

Page 51: ...000 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 TI250...

Page 52: ...____________________________________________________________________________________ Purchase Order ______________________________________________________________________________ Model ____________________________________ Serial ________________________________________ Model ____________________________________ Serial ________________________________________ Shipping method to Tesla ______________...

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 ...