Tesla TI2560 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
Tesla™TI2560 12-24 GPU
Ground Power Unit
User Manual

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]
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 maintenance 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.
Copyright © 2015 by Tesla™ Industries, Incorporated. All rights reserved.
01-12-15
Shock Hazard Potential
CAUTION

Page 1 of 2
®™
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/m345 - 60 %
Lead Dioxide 1309-60-0 50 µg/m315 - 25%
Sulfuric Acid Electrolyte 7664-93-9 1.0 mg/m315 - 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 CO2or 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

Page 2 of 2
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 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 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.

TI2560 12-24 GPU
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