Tesla TI3500 GPU-24 User manual

Tesla™TI3500 GPU-24
User Manual
Built Smart...Proven Tough
Power Anytime, Anywhere
Tesla Industries, Inc.
101 Centerpoint Blvd.
New Castle, DE 19720
[phone] Phone
[phone] Fax
www.teslaind.com
www.tesla1.com

TI3500 GPU-24
NOTE: All users must read this entire manual prior
to operating the TI3500 GPU-24.
The TI3500 GPU-24 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 ♦ www.tesla1.com EMAIL: t[email protected]
Shock Hazard Potential
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 unit via a tool or device (borescope, probe, etc.) can result
in unit failure and/or injury by electrical shock. This GPU is maintenance free and should not be opened or
disassembled for any reason.
Always protect the unit from short circuit.
Shipping Hazards: The unit contains sealed, dry cell rechargeable batteries that do not pose a shipping
hazard.
09-23-20
All Ground Power Units, Micro Power Units (Aviation Batteries) and including, but not limited to, Battery Chargers/
Conditioners, manufactured by Tesla™ Industries, Inc., are able to safely and effectively charge any AGM, Lead
Acid battery.
The Tesla™ GPU’s and chargers are voltage and current regulated to 0.01% (dual loop). The charging voltage is
calibrated, by Tesla™, to 28.6 volts and is pure dc (no power line ripple).
Maximum Charge Voltage by Battery Type
Type: Charging Voltage / Cell Charging Voltage / 12v Charging Voltage / 24v
SLI/Flooded 2.366v to 2.416v 14.2v to 14.5v 28.4v to 29v
Lead Acid/Flooded 2.366v to 2.416v 14.2v to 14.5v 28.4v to 29v
Sealed Lead Acid 2.366v to 2.416v 14.2v to 14.5v 28.4v to 29v
VRLA 2.366v to 2.416v 14.2v to 14.5v 28.4v to 29v
AGM 2.433v to 2.466v 14.6v to 14.8v 29.2v to 29.6v
GEL 2.350v to 2.400v 14.1v to 14.4v 28.2v to 28.8v
Copyright © 2020 by Tesla™ Industries, Incorporated. All rights reserved.

Form #: SDS 853027
Revised: AG
Supersedes: AF
ECO #: 1002195
I. PRODUCT IDENTIFICATION
Chemical Trade Name (as used on label):
Tesla™ Industries, Inc.
Chemical Family/Classification:
Sealed Lead Battery
Synonyms:
Sealed Lead Acid Battery, VRLA Battery Telephone:
For information, contact Tesla™ Industries, Inc.
Manufacturer's Name/Address:
Customer Service Department 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 HAZARDS 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 serious eye damage. Do not eat, drink or smoke when using this product.
May damage fertility or the unborn child if ingested or Wear protective gloves/protective clothing, eye protection/face protection.
inhaled. Avoid breathing dust/fume/gas/mist/vapors/spray.
May cause cancer if ingested or inhaled. Use only outdoors or in a well-ventilated area.
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. Obtain special instructions before use.
Explosive, fire, blast, or projection hazard. Do not handle until all safety precautions have been read and understood
May cause harm to breast-fed children Avoid contact during pregnancy/while nursing
Harmful if swallowed, inhaled, or contact with skin Keep away from heat./sparks/open flames/hot surfaces. No smoking
Causes skin irritation, serious eye damage.
III. COMPOSITION/INFORMATION ON INGREDIENTS
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
HEALTH
Components
SAFETY DATA SHEET
PHYSICAL
PHYSICAL
Explosive Chemical, Division 1.3
ENVIRONMENTAL
Aquatic Chronic 1
HEALTH
Aquatic Acute 1
ENVIRONMENTAL
Page 1

Form #: SDS 853027
Revised: AG
Supersedes: AF
ECO #: 1002195
SAFETY DATA SHEET
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.
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. ACCIDENTAL RELEASE MEASURES
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.
VIII. EXPOSURE CONTROLS/PERSONAL PROTECTION
Exposure Limits (mg/m3) Note: N.E.= Not Established
OSHA PEL ACGIH US NIOSH Quebec PEV Ontario OEL EU OEL
0.05 0.05 0.05 0.05 0.05 0.15 (b)
2 2222 N.E
10.2 1 1 0.2 0.05 (c)
N.E N.E N.E N.E N.E N.E
N.E N.E N.E N.E N.E N.E
N.E N.E N.E N.E N.E N.E
N.E N.E N.E N.E N.E N.E
N.E N.E N.E N.E N.E N.E
N.E N.E N.E N.E 1N.E
Polypropylene
Polyvinylchloride
INGREDIENTS
(Chemical/Common Names)
Lead and Lead Compounds
(inorganic)
Polystyrene
Styrene Butadiene
Tin
Sulfuric Acid Electrolyte
Styrene Acrylonitrile
Acrylonitrile Butadiene
Styrene
Page 2
For expanded detailed info, download the PDF online at...
http://www.teslaind.com/PDF/chart/Tesla-Safety-Data-Sheet.pdf.
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.

TI3500 GPU-24
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 – General Specications 5
2.4 – Front Panel Overview 6
2.5 – Universal Front Panel Overview 7
2.6 – Physical Dimensions 8
2.7 – Airow 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 Specications 14
3.7 – Environmental 15
3.8 – Pre-Operation 16
3.9 – Transporting Unit 16
3.10 – Regulated 28.5 Vdc Output Ground Power 17-18
3.11 – Regulated AC Power 19
Section 4 – Post Operation 20
4.1 – General 20

TI3500 GPU-24
4.2 – After Use 20
4.3 – Power Cell Recharge 20-21
Section 5 – Unit Care and Maintenance 22
5.1 – Unit Care 22
5.2 – Unit Servicing 23
5.3 – Packaging and Shipping 23
5.4 – Storage 23
5.5 – Normal Functional Test Procedures 24-26
Section 6 – Troubleshooting and FAQ 27
6.1 - Frequently Asked Questions 27-28
6.2 - Basic Usage/Operation Questions 29
6.3 - Basic Troubleshooting 30-31
Section 7 – Performance Data 32
7.1 – Purpose 32
7.2 – General 32
7.3 – Data Basis 32
7.4 – Specic 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cation/Universal Line Cord Set 36
8.6 – Line Cord AC Adapter 36
8.7 – Cobra™ DC Replacement Contacts and Tools 37
8.8 – GPU Tires 37
Appendix A 38-42
Repair Request Form 43

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

TI3500 GPU-24 1
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
!
!
!

TI3500 GPU-24
2
1Safety Review
1.3 – Hazards
WARNING Shock Hazard Potential
WARNING Shock Hazard Potential
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.
CAUTION Unit Damage Potential
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, disconnect 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.
Figure 1.3.1 – Proper Ground
Grounded Plug with Grounding Pin
Figure 1.3.2 – Proper Ground
Adapter with Grounding Mechanism
(Secured to Outlet)
Figure 1.3.3 – Improper Ground
Plug with No Grounding Pin
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.
Figure 1.3.4 – TI3500 GPU-24
Input Voltage Selector Switch

TI3500 GPU-24 3
1
Safety Review
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’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.

TI3500 GPU-24
4
Section 2 – Product Overview
2.1 – Introduction
Thank you and congratulations on the purchase of your new TI3500 GPU-24 Ground Power Unit.
The TI3500 GPU-24 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 and vehicle engine starting
and 24 or 28.5 volts dc output for ground maintenance, avionics/electrical trouble shooting and testing.
The observance of procedures, limitations and performance criteria ensures peak operating efciency and
maximizes 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 needed to
safely and efciently operate this GPU.
Figure 2.1.1 – TI3500 GPU-24
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.

TI3500 GPU-24 5
2
Product Overview
2.3 – General Specications
Electrical
DC Output:
3500 peak starting amps•
50 amps continuous @ 28.5 Vdc -1425 Watts (when plugged into ac power) •
142 amp hours (3473 watt hours) with ac power•
92 amp hours (2048 watt hours) of rechargeable battery power without ac•
Recharge Rate From Full Discharge:
115 minutes @ 25°C•
AC Input:
Operates and charges from Single-Phase 100-260 Vac, 50/60 Hz•
20 amps @ 120 Vac - 2400 Watts•
10 amps @ 240 Vac - 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 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%•

TI3500 GPU-24
6
2Product Overview
2.4 – Front Panel Overview
AC Input Circuit Breakers1. – Trips if over-current
default condition occurs.
24 Vdc Output Connector2. – Provides 24 Vdc to 28.5
Vdc @ 50 A.
24 Vdc Capacity Meter3. – Indicates the 24V battery
charge state/power output status.
Air Intake Ports4. – Provide airow for cooling internal
electronics.
“Push to Test” Button5. – Displays current battery
charge state when pressed.
AC Input Connector6. – Connects to standard 100-130
Vac line voltage or 200-260 Vac line voltage.
Input Voltage Selector Switch7. - Allows Unit to operate
within voltage range of either 100-130 Vac or 200-260
Vac.
Telescoping Handle8. – Allows for easy transport of unit.
3
4
6
1
2
5
7
8
1
2
5
3
6
8
4
7

TI3500 GPU-24 7
2
Product Overview
2.5 – Universal Front Panel Overview
AC Input Circuit Breakers1. – Trips if over-current default
condition occurs.
24 Vdc Output Connector2. – Provides 24 Vdc to 28.5
Vdc @ 50 A.
24 Vdc Capacity Meter3. – Indicates the 24V battery
charge state/power output status.
Air Intake Ports4. – Provide airow for cooling internal
electronics.
“Push to Test” Button5. – Displays current battery
charge state when pressed.
AC Input Connector6. – Connects to standard 100-130
Vac line voltage or 200-260 Vac line voltage.
Telescoping Handle7. – Allows for easy transport of unit.
3
4
6
1
2
5
7
1
2
5
3
6
7
4

TI3500 GPU-24
8
2Product Overview
2.6 – Physical Dimensions
2.7 – Airow Ports
CAUTION Damage may occur if the TI3500 GPU’s air intake or outlet ports are obstructed. Ensure
that ports are clear at all times.
When the TI3500 GPU-24 is plugged into single-phase 100-260 Vac, 50/60 Hz 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.
10.5 [266.7]
19.25 [488.95]
15.97 [405.64]
37.28 [946.91]
Figure 2.6.1 – TI3500 GPU-24 physical dimensions
Figure 2.7.1 – Air intake and exhaust ports and internal air circulation

TI3500 GPU-24 9
2
Product Overview
2.8 – Operating Positions
The TI3500 GPU-24 can be operated in both the horizontal (Figure 2.8.1) and vertical (Figure 2.8.2) positions
as shown. Make sure that the airow is not obstructed from air intake (gure 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

TI3500 GPU-24
10
2Product Overview
2.9 – Input Voltage Selector Switch
The Input Voltage Selector Switch allows the unit to operate safely within the expected voltage range of
either 100 - 130 Vac or 200 - 260 Vac.
Figure 2.9.1 Input Voltage Selector Switch (outlined in blue)
Changing Input Voltage Selector Switch
To change the input voltage from 115 Vac to 230 Vac, simply follow these steps:
1. With cross tip screwdriver, 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 Vac when Input Voltage Selector Switch is
set on 115 Vac.
!If the Unit has been modied with a Universal AC Input Receptacle, the
Input Voltage Selector Switch will not be incorporated on the front panel.
NOTE

TI3500 GPU-24 11
2
Product Overview
2.10 – “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 allows the end user to check the status of the power cells. This lets the operator know if there is enough
power to perform another engine start, or if the unit has to be connected to ac power to allow it to recharge.
Each LED indicates approximately 10% of charge.
Make sure that you wait at least 2 minutes after ac power is applied, or dc power is extracted from 1.
the unit, before you press the “Push to Test” button. This will ensure a correct reading.
Without ac power input or dc power output, simply press the “Push to Test” button on the faceplate2.
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 the4.
button and check for any obstructions to the fan.
Figure 2.10.1 “Push to Test” button location
(outlined in blue)
Figure 2.10.2 Pushing to Test
CAUTION
!Never press the “Push to Test” button while the unit is plugged into ac
power for recharge, or plugged into aircraft for dc power output.
CAUTION
!
Never press the “Push to Test” button for more than 5 seconds. This
may cause a temperature sensor to temporarily 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
STATUSSTATUS 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 indicates the capacity of the power cells without applying ac input power. The status
of the capacity lets the user know if there is enough power to perform another engine start. When the capacity is
low the unit should be connected to ac power to allow it to recharge.
Make sure that you wait at least 2 minutes after ac power is applied, or dc power is extracted from 1.
the unit, before you press the “Push to Test” button. This ensures a correct reading.
Without ac power input or dc power output, simply press the “Push to Test” button on the faceplate2.
and hold for approximately 2 to 3 seconds.
The LED bar graph should light up indicating the status of the power cells.3.
In addition, the fan(s) should start operating when the button is pressed. If you do not hear the4.
fan(s) running, stop pressing the button and check for any obstructions.
CAUTION
!Never press the “Push to Test” button while the unit is plugged into
aircraft, vehicle or ac power.
CAUTION
!
Never press the “Push to Test” button for more than 5 seconds. This
may cause a temperature sensor to temporarily disrupt “Push to
Test” function. (If this sensor is tripped, allow ten minutes for unit to
cool before operating “Push to Test” button.)

TI3500 GPU-24
12
2Product Overview
2.11 – AC Input Circuit Breakers
The AC Input Circuit Breakers are located above the AC Input Connector. When the circuit breaker has been
tripped, the red button will pop out. In the event that a 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 breakers continue to trip, return the unit to Tesla™ Industries
for repair.
Figure 2.11.1 - 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 - 24 Vdc Output Connector Protective Cover
Open Closed
WARNING
Severe injury or death from electrical shock will occur if the user or
container comes in contact with the dc positive and negative power post at
the same time. Use extreme care when using any tool around these power
posts. Remove all jewelry and dog tags while operating.

TI3500 GPU-24 13
Section 3 – Operating Procedures
3.1 – Operating Procedures
This section covers normal procedures and steps necessary to ensure safe and ef cient operation of the
unit.
NOTE
!When not in use, the unit 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, both the converter and power cells are
supplying 24 Vdc power output.
3.2 – General
The user should be well-versed in both pre-use and functional checks for correct operations of this unit.
Knowledge of the operating limits, restrictions, performance, unit capabilities and functions aids in correct
and safe operations. Compliance with the instructions in this manual affect operational safety as well as the
warranty of the unit.
3.3 – Operating Limits and Restrictions
The minimum, maximum and normal operating ranges result from careful engineering and evaluation of test
data. These limitations must be adhered to during all phases of operation.
3.4 – Performance
Refer to Section 7, PERFORMANCE DATA to determine the capability of the unit. Consideration must be given
to changes in performance resulting from variations in ambient temperature, mode of operation, state of
charge (with or without ac power), and aircraft dc bus system inef ciency (voltage drops).
3.5 – Engine Starting Power
The unit should always be 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 power for
an ef cient engine start under speci c current load demands.
ENGINE START PEAK CURRENT Requirements MINIMUM CHARGE
Under 650 peak starting amps 0-50% charged
650 - 850 peak starting amps 50-60% charged
850 - 1000 peak starting amps 60-70% charged
1000 - 1200 peak starting amps 70-80% charged
1200 - 1500 peak starting amps 80-100% charged
ENGINE START PEAK CURRENT Requirements MINIMUM CHARGE
Under 1200 peak starting amps 0-40% charged
1200 - 1500 peak starting amps 40-50% charged
1500 - 1800 peak starting amps 50-60% charged
1800 - 2100 peak starting amps 60-70% charged
2100 - 2400 peak starting amps 70-80% charged
2400 - 3000 peak starting amps 80-100% charged
ENGINE START PEAK CURRENT Requirements MINIMUM CHARGE
Under 1400 peak starting amps 40% charged
1400 - 1750 peak starting amps 50% charged
1750 - 2100 peak starting amps 60% charged
2100 - 2450 peak starting amps 70% charged
2450 - 2800 peak starting amps 80% charged
2800 - 3100 peak starting amps 90% charged
3100 - 3500 peak starting amps 100% charged
If current demand exceeds 50 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, both the converter and power cells are
supplying 24 Vdc power output.