Tesla 6130-01-452-2777 Manual Download

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Tesla

™

TI2500 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

Summary of Contents for 6130-01-452-2777

Page 1: ... amp hours of continuous dc power from each connector 50 amps if used with optional Y Cable Assembly TI2000 071 Maintenance Free Performance Currently being used with the Bell AH 1 Super Cobra Designed for 24 48V simultaneous starts Ideal for hangars motor pools and deployments Perfect for testing and troubleshooting avionics TMDE electronics and hydraulics One person can easily maneuver and opera...

Page 2: ...60 Hz 10 amps 240 Vac 50 60 Hz Recharging Rate 115 minutes from full discharge 25 C 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 235 lbs 106 6 kg Warranty 2 years 3 years optional Dimensions and Technical Specifications All dimensions are in inches millimeters 19 25 4...

Page 3: ...Tesla TI2500 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: ...TESLA ...

Page 5: ...r death by electrical shock Any attempts to open or examine the inside of the TI2500 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 TI2500 GPU 24 contains sealed dry cell rechargeable batt...

Page 6: ...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 7: ...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 8: ...akers 9 2 9 AC Input Connector 9 2 10 Changing Input Voltage Selector Switch 10 2 11 DC Output Connectors 10 2 12 Push to Test button and LED Status Indicator 11 Section 3 Operating Procedures 12 3 1 Operating Procedures 12 3 2 General 12 3 3 Operating Limits and Restrictions 12 3 4 Performance 12 3 5 Engine Starting Power 12 3 6 Temperature Specifications 13 3 7 Environmental 14 3 8 Normal Functi...

Page 9: ...6 3 Basic Troubleshooting 29 30 Section 7 Performance Data 31 7 1 Purpose 31 7 2 General 31 7 3 Data Basis 31 7 4 Specific Conditions 31 7 5 General Conditions 31 7 6 Temperature Conversion Chart 32 7 7 Output Voltage 33 7 8 Maximum Output Current 33 Section 8 Optional Accessories 34 8 1 Shipping Case 34 8 2 GPU Protective Covers 34 8 3 TI2000 071 Y Cable Assembly 34 8 4 Digital Volt Amp Meter 35 ...

Page 10: ...heit dc 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 Diagnost...

Page 11: ...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 12: ...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 13: ...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 14: ...observance of procedures limitations and performance criteria is essential to ensure peak operating efficiency and to maximize operational capabilities and life of the TI2500 GPU 24 This manual contains the complete operating instructions and procedures for the TI2500 GPU 24 that the end user will need to safely and efficiently operate this GPU Figure 2 1 1 TI2500 GPU 24 2 2 Indication of Terms Sh...

Page 15: ...ectors 3 Provides 24 Vdc to 28 5 Vdc 25 A 50 A possible when using Y cable connector TI2000 071 Telescopic Handle 4 Allows for easy transport of unit Vdc Capacity Meters 5 Indicates the battery charge state power output status AC Input Connector 6 Connects to Single Phase 95 260 Vac line voltage Input Voltage Selector Switch 7 Allows unit to operate within voltage range of either 100 130 Vac or 20...

Page 16: ...ble battery power without ac from each connector Recharge Rate From Full Discharge 115 minutes 25 C AC Input Operates and charges from Single Phase 100 260 Vac 50 60 Hz 10 amps 120 Vac 60 Hz 5 amps 240 Vac 60 Hz 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 235 lbs 106 6 kg Operating Temperature 40 C to 60 C 40 F to 140 F without ac power 40 C to 55 ...

Page 17: ... 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 Figure 2 5 1 TI2500 GPU 24 physical dimensions Figure 2 6 1 Air intake exhaust ports and inter...

Page 18: ...perating Positions The TI2500 GPU 24 can be operated in both the horizontal and vertical positions as shown Make sure that the airflow is not obstructed from air intake and outlet Vertical Position Horizontal Position Front Inlet Rear Outlet ...

Page 19: ...2 Reset breaker s by pressing red button s 3 Reconnect ac and dc connections to the unit Plug in ac line cord on military unit 4 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 Breakers outlined in blue 2 9 AC Input Connector The GPU is outfitted with a 3 prong receptacle see figure 2 9 1 below The...

Page 20: ...o get one output capable of 50 amps of continuous dc power and 92 amp hours of rechargeable battery power Figure 2 11 1 24 Vdc Output Connectors outlined in blue 2 10 Changing Input Voltage Selector Switch To change the input voltage from 115 Vac to 230 Vac simply follow these steps With phillips head screwdriver remove one screw and rotate the clear protective cover to one side 1 Flip the switch ...

Page 21: ...ng Without ac power input or dc power output simply press the Push to Test button on the faceplate 2 and hold for approximately 2 to 3 seconds At this time the LED bar graph should light up indicating the status of the power cells 3 The fan should also operate at this time If you do not hear the fan running stop pressing the 4 button and check for any obstructions to the fan CAUTION Never press th...

Page 22: ...400 3000 peak starting amps 80 100 charged operation of the unit NOTE When the unit is not in use it should always remain plugged into a suitable ac power source to ensure operational readiness at all times NOTE 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 bo...

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: ...ce 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 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 conti...

Page 25: ...se distortion or misalignment and cracked or loose connec tors If no damage is evident proceed to the next step If damage is evident contact Tesla Industries Inc Checking DC Voltage at DC Output Receptacle Pins To verify that the power cells are fully charged set the digital multimeter to measure DC voltage As shown in Figure 3 8 2 place the positive probe red on the positive post of the DC Output...

Page 26: ...be 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 fastener screw on the dc recep tacle Move...

Page 27: ...ge 2 Make sure that airflow is not obstructed from air intake and outlet See Section 2 6 3 Check that all connections are secure and free from water 4 Figure 3 9 1 TI2500 GPU 24 3 10 Transporting Unit The TI2500 has a telescoping handle that makes rolling the unit easy For transporting on uneven ground axle extensions should be added to the unit Figure 3 10 1 Releasing Telescopic Handle ...

Page 28: ...ceptacle 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 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...

Page 29: ...the cable that connects to the far side of the craft is approximately 26 feet Figure 3 11 5 TI2500 GPU 24 and AH 1W Engine Starting Prior to engine start ensure power cell charge is sufficient to provide an efficient engine start Check DC power cable for secure and correct installation prior to engine starting Follow ground power engine starting procedure as specified in vehicle operator s manual ...

Page 30: ...raws between zero and 2 000 The DVAM 31000A indicates the aircraft or vehicle s current demand Integrated with the Tesla Turbo Start GPU power supply the DVAM is a valuable tool for troubleshooting and system checks The left meter indicates dc voltage output and the right meter indicates amperage draw The meter s range changes from 0 200 amps to 0 2 000 amps with the flip of a switch The 200 amp s...

Page 31: ...ully charged the LED status will read half or no charge Plug the TI2500 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 If you received this manual with a new GPU Under a full charge the LED indicator should show a single steady green bar The fan will also come on at reduced speed This is normal operatio...

Page 32: ... multiple vehicles without reconnecting to ac power if the GPU is allowed to backcharge for approximately 30 seconds NOTE Plug the TI2500 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 Voltage Selector Switch for proper setting Do not plug unit into 230 ...

Page 33: ...damaged if recharged by NiCad or Lead Acid type battery chargers Power cells should only be charged by either the TI2500 GPU 24 s internal charger and the ac power cord furnished with the equipment or when connected to aircraft s external dc power receptacle Figure 4 3 3 Proper and Improper Charging Methods OK OK NO ...

Page 34: ...hed to the unit Do not use any type of ac voltage converter Section 5 Unit Care and Maintenance 5 1 Unit Care Avoid Prolonged Exposure to Extremely Damp Environments Be sure to disconnect ac power from the ac source if the unit has come into contact with water If the AC Input Circuit Breaker has tripped due to water infiltration allow the unit to dry out before attempting to reset circuit breaker ...

Page 35: ...Repair Request Form can be found in the back of this manual 5 3 Packaging and Shipping When returning the GPU please ensure that it is properly packaged The only method for transport is in a sturdy shipping crate or Tesla Shipping Case be sure to enclose the Repair Request Form Seal the crate on all sides and return it to Tesla at the address listed below Please contact Tesla Customer Service at 3...

Page 36: ...art 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 Start spool up a...

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: ...e 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 A at 302 324 89...

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: ... 50 60 TI2500 Output Voltage MINUTES 46 AMP CONSTANT CURRENT LOAD 0 0 300 600 900 1200 1500 1800 2100 3000 2700 2400 5 10 15 20 25 30 25 C Temp 29 C Temp Calculations based on actual test data at Pratt Whitney Canada on 30 March 1992 SECONDS AMPS MAXIMUM OUTPUT CURRENT 0 0 TI2500 Maximum Output Current 7 7 Output Voltage 7 8 Maximum Output Current ...

Page 44: ...ve Cover Protects unit from moisture sand and other damaging elements TI7000 026 Length 41 31 1049 3 mm Width 23 37 593 60 mm Height 19 62 498 35 mm Weight 73 lbs 33 11 kg TI2000 071 TI7000 142 8 3 Optional Y Cable Assembly Ties both 25 amp DC Connectors together to get one output capable of 50 amps of continuous DC Power and 96 amp hours of rechargeable battery power Also has a port to connect th...

Page 45: ...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 fuse and old style receptacle Line Co...

Page 46: ...ctions up to 3000 amps even in the harshest conditions Each plug is constructed from a rugged combination of advanced composite materials and corrosion resistant alloys to maximize durability 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 T...

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 ...

Page 54: ...Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 USA Tel 302 324 8910 Fax 302 324 8912 9475 Double R Blvd Suite 2 Reno NV 89521 Tel 775 622 8801 Fax 775 622 8810 www teslaind com ...

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