Tesla TI2560, TI2560 12-24 GPU User Manual

Power Anytime, Anywhere

Tesla™ TI2560 12-24 GPU

Ground Power Unit

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 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: [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 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.

Shock Hazard Potential

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

01-12-15

®™

INFORMATION ONLY - PL E A S E R E A D SE C T I O N X

SECTION I - PR O D U C T A N D MA N U F A C T U R E R ID E N T I T Y

Product Identity:

Tesla®™ Turbo Start®™ Ground Power Unit (GPU) and Micro Power Unit (MPU)
Containing Dry Cell (Starved Electrolyte) Batteries
Used on Aviation/Military Application

Manufacturer’s Name and Address: Emergency Telephone Number:
Tesla Industries Inc. [phone]
101 Centerpoint Blvd. Fax: [phone]
New Castle, Delaware 19720 www.Teslaind.com

SECTION II - IN G R E D I E N T S

Hazardous Components CAS # OSHA PEL-TWA % (By weight)

Lead 7439-92-1 50 µg/m

3

45 - 60 %

Lead Dioxide 1309-60-0 50 µg/m

3

15 - 25%

Sulfuric Acid Electrolyte 7664-93-9 1.0 mg/m

3

15 - 20%

Non-Hazardous Materials N/A N/A 5 - 10%

Revision Date: April 2, 2014

SECTION III - PH Y S I C A L /CH E M I C A L CH A R A C T E R I S T I C S

Boiling Point - N/A Specifi c Gravity (H2O=1) - NA

Vapor Pressure (mm Hg.) - N/A Melting Point - N/A

Solubility in Water - N/A Appearance & Color - N/A

SECTION IV - FI R E & EX P L O S I O N HA Z A R D DA T A

Flash Point (Method Used): N/A Flammable Limits: N/A LEL: N/A UEL: N/A

Extinguishing Media: Multipurpose Dry chemical CO

2

or water spray.

Special Fire Fighting Procedures: Cool GPU/MPU exterior to prevent rupture. Acid mists and vapors in a fi re 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 - RE A C T I V I T Y DA T A A N D SH I P P I N G /HA N D L I N G EL E C T R I C A L SA F E T Y

Stability: Stable

Conditions to Avoid: Avoid shorting, high levels of short circuit current can be developed across the battery terminals. Do not rest tools or cables on the
battery. Avoid over-charging. Use only approved charging methods. Do not charge in gas tight containers.

SECTION VI - HE A L T H HA Z A R D DA T A

Routes of Entry: N/A Health Hazards (Acute & Chronic): N/A

Emergency & First Aid Procedures: Battery contains acid electrolyte, which is absorbed in the separator material. If battery case is punctured,

completely fl ush any released material from skin or eyes with water.

Proposition 65: Warning: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals

known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemical
known to the State of California to cause cancer. Wash hands after handling

SECTION VII - PR E C A U T I O N S F O R SA F E HA N D L I N G & US E

Steps to be taken in case material is

released or spilled

Avoid contact with acid materials. Use soda ash or lime to neutralize. Flush with water.

Waste Disposal Method Dispose of in accordance with Federal, State, & Local Regulations. Do not incinerate. Batteries should be

shipped to a reclamation facility for recovery of the metal and plastic components as the proper method of
waste management. Contact distributor for appropriate product return procedures.

SECTION VIII - CO N T R O L ME A S U R E S - NO T AP P L I C A B L E

SECTION IX - OT H E R RE G U L A T O R Y IN F O R M A T I O N

Tesla™ Industries GPU/MPU batteries are starved electrolyte batteries, which means the electrolyte is absorbed in the separator material. The batteries

are also sealed.

NFPA Hazard Rating for Sulfuric Acid:

Health (Blue) = 3 Flammability (Red) = 0 Reactivity (Yellow) = 2 Sulfuric Acid is Water Reactive if concentrated.

U.S. DOT: Tesla™ Industries GPU/MPU batteries are classifi ed as Nonspillable. They have been tested and meet the nonspillable criteria listed in 49

CFR § 173.159(f) and 173.159a(d)(1).

Nonspillable batteries are excepted from 49 CFR Subchapter C requirements, provided that the following criteria are met:

The batteries must be securely packed in strong outer packagings and meet the requirements of 49 CFR § 173.159a. 1.

The batteries’ terminals must be protected against short circuit.2.

Each battery and their out packaging must be plainly and durably marked “NONSPILLABLE” or “NONSPILLABLE BATTERY”.3.

The exception from 49 CFR, Subchapter C means shipping papers need not show proper shipping name, hazard class, UN number and packing group.

Hazardous labels are not required when transporting a nonspillable battery.

IATA: Tesla™ Industries GPU/MPU batteries have been tested and meet the nonspillable criteria listed in IATA Packing Instruction 872 and Special
Provision A67. Nonspillable batteries must be packed according to IATA Packing Instructions 872. This means shipping papers need not show proper
shipping name, hazard class, UN number and packing group. Hazardous labels are not required when transporting a nonspillable battery.

These batteries are excepted from all IATA regulations provided that the batteries are packed in a suitable out packaging and their terminals are pro-

tected against short circuits.

IMDG: Tesla™ Industries GPU/MPU batteries have been tested and meet the nonspillable criteria listed in Special Provision 238. Non-spillable batteries
must be packed according to IMDG Packing Instruction P003. This means shipping papers need not show proper shipping name, hazard class, UN num­ber 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 protected against short circuits per PP16.

RCRA: Spent lead-acid batteries are not regulated as hazardous waste by the EPA when recycled, however state and international regulations may
vary.

CERCLA (Superfund) and EPCRA:

Reportable Quantity (RQ) for spilled 100% sulfuric acid under CERCLA (Superfund) and EPCRA (Emergency Planning Community (a)
Right to Know Act) is 1,000 lbs. State and local reportable quantities for spilled sulfuric acid may vary.

Sulfuric acid is a listed “Extremely Hazardous Substance” under EPCRA, with a Threshold Planning Quantity (TPQ) of 1,000 lbs.(b)

EPCRA Section 302 notifi cation is required if 1,000 lbs. or more of sulfuric acid is present at one site.(c)

EPCRA Section 312 Tier 2 reporting is required for batteries if sulfuric acid is present in quantities of 500 lbs. or more and/or if lead is (d)
present in quantities of 10,000 lbs. or more.

Supplier Notifi cation: this product contains toxic chemicals, which may be reportable under EPCRA Section 313 Toxic Chemical Release (e)

inventory (Form R) requirements.

If you are a manufacturing facility under SIC codes 20 through 39, the following information is provided to enable you to complete the required reports:

Toxic Chemicals CAS Number Approximate % by Wt.
Lead 7439-92-1 45-60
Sulfuric Acid 7664-93-9 15-20

SECTION X - AD D I T I O N A L IN F O R M A T I O N

The Tesla™ Industries GPU/MPU sealed lead acid battery is determined to be an “article” according to the OSHA Hazard Communication Standard and

is thereby excluded from any requirements of the standard. The Material Safety Data Sheet is therefore supplied for informational purposes only.

The information and recommendations contained herein have been compiled from sources believed to be reliable and represent current opinion on the

subject. No warranty, guarantee, or representation is made by Tesla™ Industries, as to the absolute correctness or suffi ciency of any representation

contained herein and Tesla™ Industries assumes no responsibility in connection therewith, nor can it be assumed that all acceptable safety measures
are contained herein, or that additional measures may not be required under particular or exceptional conditions ore circumstances.

*N/A or Not Applicable - Not applicable for fi nished product used in normal conditions.

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 Position 8

2.8 – AC Input Circuit 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 Specications 14

3.7 – Environmental 15

3.8 – Normal Functional Test Procedures 16-17

3.9 – Pre-Operation 18

3.10 – Transporting Unit 18

3.11 – Regulated 28.5 Vdc Ground Power 19-20

3.12 – Regulated AC Power 20-21

3.13 – Charging Unit 21

TI2560 12-24 GPU

Section 4 – Post 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 26-27

6.2 – Basic Usage/Operation 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 – Specic 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 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 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

TI2560 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 speci c type of hazard.

WARNING

!

CAUTION

!

NOTE

!

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.

Indicates a condition, operating procedure or practice, which if not
adhered to could result in serious injury or death.

Indicates a condition or operating procedure, which if not strictly
adhered to could result in damage or destruction of equipment.

Indicates a condition, operating procedure or practice, which is
essential to highlight.

!

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

1

Safety Review

1.3 – Hazards

WARNING

Severe injury or death from electrical shock may occur if either the
user or the unit is wet while the operating unit is connected to a power
source. Be sure to discon nect 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 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. Make sure the unit is turned off before making any connections. 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 unit will be damaged if unapproved ac power is applied. 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 – TI2560 12-24 GPU

Input Voltage Selector Switch

2

TI2560 12-24 GPU

1.4 – Important Safety Precautions

WARNING

Fire/Explosion Hazard Potential

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.

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 air conditioning when possible. Perform a
full function test after the unit has been allowed to cool prior to use.

Safety Review

1

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 TI2560-12-24 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 TI2560 12-24 GPU will provide 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 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 Test” button) that also serve as recharge state indicators for
both dc outputs.

Figure 2.1.1 – TI2560 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

TI2560 12-24 GPU

2.3 – Front Panel Overview

Product Overview

2

1

3

5

7

9

10

2

4

6

8

“Push to Test” Button1. – Displays current battery
charge state when pressed.

AC Input Circuit Breakers2. – Trip if over-current fault
condition occurs.

24 Vdc Output Connector 3.

12 Vdc Output Connector4.

24 Vdc Capacity Meter5. – Indicates the 24V battery

charge state/power output status.

12 Vdc Capacity Meter6. –Indicates the 12V battery
charge state/power output status

TI2560 12-24 GPU

AC Input Connector7. – Connects to standard 110­130 Vac line voltage.

Air Intake Ports 8. – Provide airow for cooling

internal electronics.

Input Voltage Selector Switch 9. - Allows Unit to
operate within voltage range of either 100-130 Vac
or 200 260 Vac.

Telescopic Handle 10. – 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 •

14.7 amps @ 120 Vac 60 Hz•

Power Cell:

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

DC Output:
24 Volt Output

3000 peak starting amps•
25 amps continuous @ 28.5 Vdc (when plugged into ac power)•
71 amp hours (1736 watt hours) with ac power •
46 amp hours (1024 watt hours) of rechargeable battery 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 (82.32 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

TI2560 12-24 GPU

2.5 – Physical Dimensions

19.25 [488.95]

15.97 [405.64]

37.28 [946.91]

Product Overview

2

Figure 2.5.1 – TI2560 12-24 GPU physical dimensions

2.6 – Airow Ports

CAUTION

When the TI2560 12-24 GPU 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 unit’s air intake or outlet ports are obstructed.
Ensure that ports are clear at all times.

TI2560 12-24 GPU

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

7

2

Product Overview

2.7 – Operating Positions

The TI2560 12-24 GPU can be operated in both the horizontal and vertical positions as shown. Make sure

that the airow is not obstructed from air intake and outlet.

Front Inlet Rear Outlet

Horizontal Position

8

Vertical Position

TI2560 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:

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.

Figure 2.8.1 - AC Input Circuit Breaker

(outlined in blue)

2.9 – AC Input Connector

The GPU is outtted with a 3-prong receptacle (see gure 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