Tesla TI1000 GPU-24 UAV User Manual

Power Anytime, Anywhere

Tesla™ TI1000 GPU-24 UAV

User Manual

Built Smart...Proven Tough

Tesla Industries, Inc.

101 Centerpoint Blvd.
New Castle, DE 19720
[phone] Phone
[phone] Fax

www.teslaind.com

NOTE: All users must read this entire manual prior

to operating the TI1000 GPU-24 UAV.

The TI1000 GPU-24 UAV 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: [phone]

FAX: [phone]

WEBSITE: www.teslaind.com

EMAIL: [e-mail]

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 TI1000 GPU-24 UAV 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 TI1000 GPU-24 UAV 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.

Shock Hazard Potential

Copyright © 2015 by Tesla™ Industries, Incorporated. All rights reserved.

TI1000 GPU-24 UAV

07-13-15

Form #: SDS 853027

Revised: 05/14/15

Supersedes: NEW

ECO #: 1001584

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

II GHS HAZRDS IDENTFICATION

Acute Toxicity
(Oral/Dermal/Inhalation) Category 4
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:

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.

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.

III. HAZARDOUS INGREDIENTS/IDENTIFY INFORMATION

CAS Number

Approximate % by

Weight

Inorganic Lead Compound:

Lead 7439-92-1 45 - 60
Lead Dioxide 1309-60-0 15 - 25
Tin 7440-31-5 0.1 - 0.2

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™ Products.
There are no mercury or cadmium containing products present in batteries manufactured by Tesla™ Products.

Explosive Chemical, Division 1.3

SAFETY DATA SHEET

HEALTH

ENVIRONMENTAL

PHYSICAL

Aquatic Chronic 1

Aquatic Acute 1

HEALTH

ENVIRONMENTAL

PHYSICAL

Components

Form #: SDS 853027

Revised: 05/14/15

Supersedes: NEW

ECO #: 1001584

SAFETY DATA SHEET

IV. FIRST AID MEASURES
Inhalation:

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.

Skin:

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.

Eyes:

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 positive 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.

VII. HANDLING AND STORAGE
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 containers 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 being 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

1.1 – Safety Notices 1

1.2 – Symbols 1

1.3 – Hazards 2

1.4 – Important Safety Precautions 3

1.5 – Extreme Environments 3

Section 2 – Product Overview 4

2.1 – Introduction 4

2.2 – Indication of Terms: Shall, Should and May 4

2.3 – Front Panel Overview 5

2.4 – General Specications 6

2.5 – Physical Dimensions 7

2.6 – Airow Ports 7

2.7 – Operating Positions 8

2.8 – AC Input Circuit Breaker 9

2.9 – 24 VDC Output Connector 9

2.10 – Input Voltage Selector Switch 10

2.11 – “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 – Temperature Specications 13

3.6 – Environmental 14

3.7 – Normal Functional Test Procedures 15-16

3.8 – Pre-Operation 17

3.9 – Transporting Unit 17

3.10 – Regulated AC Power 18

3.11 – Charging Unit 18

TI1000 GPU-24 UAV

Section 4 – Post Operation 19

4.1 – General 19

4.2 – After Use 19

4.3 – Power Cell Recharge 19-20

Section 5 – Unit Care and Maintenance 21

5.1 – Unit Care 21

5.2 – Unit Servicing 22

5.3 – Packaging and Shipping 22

5.4 – Storage 22

Section 6 – Troubleshooting and FAQ 23

6.1 - Frequently Asked Questions 23-24

6.2 - Basic Usage/Operation Questions 24

6.3 - Basic Troubleshooting 25

Section 7 – Performance Data 26

7.1 – Purpose 26

7.2 – General 26

7.3 – Data Basis 26

7.4 – Specic Conditions 26

7.5 – General Conditions 26

7.6 – Temperature Conversion Chart 27

7.7 – Output Voltage 28

7.8 – Maximum Output Current 28

Section 8 – Optional Accessories 29

8.1 – Tesla™ Shipping Case 29

8.2 – GPU Protective Covers 29

8.3 – Tesla™ AC Line Cords 29

8.4 – Transport Dolly 30

Appendix A 31-35

Repair Request Form 37

TI1000 GPU-24 UAV

Abbreviations and Symbols

Abbreviations that may be used within the text, headings and titles of this manual.

LIST OF ABBREVIATIONS

Abbreviation Defi nition

ac Alternating Current

AFT Air ow Technology

AWG American Wire Gauge
amp or A Ampere
cont Continuous
°C Degree Celsius
°F Degree Fahrenheit
dc Direct Current

EFF Ef ciency

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 Equipment

UAV Unmanned aerial vehicle
Vac Volts, Alternating Current
Vdc Volts, Direct Current
W watts

TI1000 GPU-24 UAV

Figure 1.2.1 – Different types of hazard and caution symbols

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 speci c type of hazard.

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 appear within the warning triangles to alert the user to the speci c type of danger

or hazard.

General Warning Electrical Hazard Explosion Hazard Fire Hazard

Battery Warning Guard from Moisture

!

Section 1 – Safety Review

!

!

!

TI1000 GPU-24 UAV

1

1

Safety Review

1.3 – Hazards

WARNING

Severe 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, discon nect ac power from the ac

source. If AC Input Circuit Breaker has tripped due to water in ltration,

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.

Shock Hazard Potential

Shock Hazard Potential

Figure 1.3.1 – Proper Ground

Grounded Plug with Grounding Pin

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,  ight line ac power) prior to connecting the unit for

recharging.

Unit Damage Potential

Figure 1.3.2 – Proper Ground

Adapter with Grounding Mechanism

(Secured to Outlet)

Figure 1.3.3 – Improper Ground

Plug with No Grounding Pin

Figure 1.3.4 – TI1000 GPU-24 UAV

Input Voltage Selector Switch

2

TI1000 GPU-24 UAV

1.4 – Important Safety Precautions

Safety Review

1

WARNING

Severe injury or death from  re or explosion can occur 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.

Fire/Explosion Hazard Potential

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.

Unit Damage Potential

TI1000 GPU-24 UAV

3

Section 2 – Product Overview

2.1 – Introduction

Thank you and congratulations on the purchase of your new TI1000 GPU-24 UAV Ground Power Unit.

The TI1000 GPU-24 UAV provides DC electrical ground power for aircraft ight line, maintenance, and

ground support operations. The unit is designed to provide 24 volt DC output for aircraft engine starting
and 24 or 28.5 volts DC output for ground maintenance, avionics/electrical troubleshooting and testing.

The observance of procedures, limitations and performance criteria ensures peak operating efciency and

maximizes operational capabilities and life of the TI1000 GPU-24 UAV.

This manual contains the complete operating instructions and procedures for the TI1000 GPU-24 UAV

needed to safely and efciently operate this GPU.

Figure 2.1.1 – TI1000 GPU-24 UAV

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

TI1000 GPU-24 UAV

2.3 – Front Panel Overview

Product Overview

2

1

3

2

5

4

7

6

8

9

AC Input Circuit Breaker1. – Trips if over-current

fault condition occurs.

“Push to Test” Button2. – Displays current battery

charge state when pressed.

DC Output Circuit Breaker3. – Trips if over-current

fault condition occurs.

24 VDC Output Connector4. – Provides 24 Vdc to

28.5 Vdc @ 10 A.
AC Input Connector5. – Connects to Single Phase

100-260 Vac line voltage.

TI1000 GPU-24 UAV

24 VDC Capacity Meter6. – Indicates the 24V battery

charge state/power output status.

Input Voltage Selector Switch7. – Allows unit to

operate within voltage range of either 100-130

Vac or 200-260 Vac.

Air Intake Ports8. – Provide airow for cooling

internal electronics.

Carrying Handle9. – Allows for easy transport of unit.

5

2

Product Overview

2.4 – General Specications

Electrical

AC Input:

Operates and charges from Single Phase 100-260 Vac, 50/60 Hz•
10 Amps @ 120 Vac 60 Hz - 1200 Watts•
5 Amps @ 240 Vac 60 Hz - 1200 Watts•

Power Cell:

Dry, High Rate Discharge, Rechargeable , Maintenance-free•

DC Output:

10 amps continuous @ 28.5 Vdc (when plugged into ac power)•

Rechargeable Rate:

60 minutes (from full discharge) @ 25°C•

Size:

20.61” long x 5.2” wide x 10.56” high•

523.49mm x 132.08mm x 268.25mm•

Weight

57 lbs (28.85 kg)•

Operating Temperature:

-40°C to +60°C (-40°F to 140°F) without ac power•

-40°C to +55°C (-40°F to 131°F) with ac power•

Storage Temperature:

-65°C to +105°C (-85°F to 221°F)•

Cell Capacity:

+40°C 110% ± 05%•
+25°C 100% ± 05%•
+00°C 80% ± 05%•

-20°C 65% ± 10%•

-40°C 50% ± 10%•

6

TI1000 GPU-24 UAV

2.5 – Physical Dimensions

Product Overview

2

Figure 2.5.1 – TI1000 GPU-24 UAV physical dimensions

2.6 – Airow Ports

CAUTION

When the TI1000 GPU-24 UAV is plugged into ac power, the internal cooling system will efciently 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.

Damage may occur if the TI1000 GPU-24 UAV’s air intake or outlet ports
are obstructed. Ensure that ports are clear at all times.

TI1000 GPU-24 UAV

Figure 2.6.1 – Air intake, exhaust ports and internal air circulation

7