Tesla TI2560 Page 2 User Manual Download

Page: 2 / 51

NOTE: All users must read this entire manual prior

to operating the TI2560 12-24 GPU.

The TI2560 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: [email protected]

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 mainte nance free and should not

be opened or disassembled for any reason.
Always protect the unit from short circuit.
Shipping Hazards: The TI2560 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

mechanical, including photocopying, recording, or any information storage and retrieval system, without prior

written permission from Tesla™ Industries, Inc.

01-12-15

Shock Hazard Potential

AUTION

Summary of Contents for TI2560

Page 1: ...mart 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 Tesla TI2560 12 24 GPU Ground Power Unit User Manual ...

Page 2: ...ry 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 mainte nance free and should not be opened or disassembled for any reason Always protect the unit from short circuit Shipping Hazards The TI2560 12 24 GPU contains sealed dry cell recharg...

Page 3: ...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 4: ...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 5: ...ircuit Breakers 9 2 9 AC Input Connector 9 2 10 24 Volt Output Connector 10 2 11 12 Volt Output Connector 10 2 12 Input Voltage Selector Switch 10 11 2 13 Push to Test Button and LED Status Indicator 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 ...

Page 6: ... Questions 28 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 7 8 12 Vdc Output Loading Curves 34 Section 8 Optional Accessories 36 8 1 Shipping Case 36 8 2 GPU Protective Covers 36 8 3 Tesla AC Li...

Page 7: ...nheit 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 Diagnos...

Page 8: ...rd 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 appe...

Page 9: ...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 10: ...ng 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 o...

Page 11: ...ts 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 intelligent 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...

Page 12: ...or 4 24 Vdc Capacity Meter 5 Indicates the 24V battery charge state power output status 12 Vdc Capacity Meter 6 Indicates the 12V battery charge state power output status AC Input Connector 7 Connects to standard 110 130 Vac line voltage Air Intake Ports 8 Provide airflow for cooling internal electronics Input Voltage Selector Switch 9 Allows Unit to operate within voltage range of either 100 130 ...

Page 13: ...ery power without ac 12 Volt Output 3000 peak starting amps 20 amps continuous 14 25 Vdc when plugged into ac power 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 24 Volt 115 minutes 25 C 12 Volt 143 minutes 25 C Size 37 28 L x 19 25 W x 15 97 H 946 91 mm x 488 95 mm x 405 64 mm Weight 181 5 lbs 82 ...

Page 14: ...nternal 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 TI2560 12 24 GPU physical dimensions Figure 2 6 1 Air intake exhaust ports and inte...

Page 15: ...perating Positions The TI2560 12 24 GPU 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 16: ...Disconnect the ac and dc connectors 1 Wait for a minimum of 60 seconds 2 Reset breaker by pressing red button 3 Reconnect ac and dc connections to the unit 4 The unit should power up automatically If the breaker continues to trip return the unit to Tesla 5 Industries for repair 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 an...

Page 17: ...ector see Figure 2 10 1 will provide 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 TI2007 503 15 DC Cable with Alligator Clips A 24 Volt DC Conne...

Page 18: ...or Switch is set on 115 Vac NOTE Do not overtighten Selector Shield screws Be sure star locks are on screws and snug the screw Overtightening will damage the Selector Shield Changing Input Voltage Selector Switch To change the input voltage from 115 Vac to 230 Vac simply follow these steps With cross tip screwdriver remove one screw and rotate the clear protective cover to one side see 1 figure2 1...

Page 19: ...will ensure a correct reading 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...

Page 20: ... amps 70 80 charged 2400 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 indicat...

Page 21: ...ure 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 ...

Page 22: ...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 continuously between 0 30 an...

Page 23: ...istortion 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 3 8 2 place the positive probe red on the positive post of the DC Output ...

Page 24: ...C Positive Post 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 In both cases the Multimeter should read greater than 10 MΩ Move the positive probe to the fastener screw on the dc receptacle shown in Figure 3 8 8 Multimeter ...

Page 25: ...m air intake and outlet See Section 2 6 3 Check that all connections are secure and free from water 4 Figure 3 9 1 TI2560 12 24 GPU 3 10 Transporting Unit The TI2560 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 F...

Page 26: ...e 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 vehicle Figure 3 11 3 Attaching an Aviation ...

Page 27: ...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 CAUTION Unplug ac power cord before starting engine with unit NOTE Check Input Voltage Selector Switch for proper setting 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 out...

Page 28: ...The unit will not overcharge or overheat If 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...

Page 29: ...it 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 NOTE 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 ov...

Page 30: ...be damaged if recharged by NiCad or Lithium Ion 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 OK OK NO ...

Page 31: ...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 Figure 5 1 1 Damaged cable W...

Page 32: ...uest 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 Ship...

Page 33: ...tart 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 ...

Page 34: ... 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 i...

Page 35: ...always 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 gr...

Page 36: ... ac 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 Servic...

Page 37: ... put 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 ...

Page 38: ...o 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 no...

Page 39: ...66 2 52 0 125 6 46 0 50 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...

Page 40: ...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 Maximum Output Current TI2560 12 24 GPU 12 Vdc Output Voltage MINUTES 46 AMP CONSTANT CURRENT LOAD 7 7 Output Voltage 7 8 Maximum Output Current ...

Page 41: ...TI2560 12 24 GPU 34 7 Performance Data 7 8 12 Vdc Output Loading Curves ...

Page 42: ...TI2560 12 24 GPU 35 7 Performance Data 24 Vdc Output Loading Curves cont d ...

Page 43: ... 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 fuse and old style ...

Page 44: ...igh power connections 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 ...

Page 45: ...pean 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 ...

Page 46: ...rd 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 Co...

Page 47: ...an 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 Con...

Page 48: ...25000 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 E...

Page 49: ...16000 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 TI2...

Page 50: ...______________________________________________________________________________________ Purchase Order ______________________________________________________________________________ Model ____________________________________ Serial ________________________________________ Model ____________________________________ Serial ________________________________________ Shipping method to Tesla ____________...

Page 51: ...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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