Tesla TI500 GPU-24 User manual

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™TI500 GPU-24

NOTE: All users must read this entire manual prior
to operating the TI500 GPU-24.
The TI500 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
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 TI500 GPU-24 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 TI500 GPU-24 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 © 2014 by Tesla™ Industries, Incorporated. All rights reserved.
12-30-14
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 andAddress: 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.

TI500 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 – 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 – 24 Vdc Output Connector 9
2.10 – “Push to Test” Button and LED Status Indicator 10
Section 3 – Operating Procedures 11
3.1 – Operating Procedures 11
3.2 – General 11
3.3 – Operating Limits and Restrictions 11
3.4 – Performance 11
3.5 – Engine Starting Power 11
3.6 – Temperature Specications 12
3.7 – Environmental 13
3.8 – Normal Functional Test Procedures 14-15
3.9 – Pre-Operation 16
3.10 – Transporting Unit 16
3.11 – Regulated 28.5 Vdc Ground Power 17-18
3.12 – Regulated AC Power 19
3.13 – Charging Unit 19

TI500 GPU-24
Section 4 – Post Operation 20
4.1 – General 20
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
Section 6 – Troubleshooting and FAQ 24
6.1 – Frequently Asked Questions 24-25
6.2 – Basic Usage/Operation Questions 26
6.3 – Basic Troubleshooting 27-28
Section 7 – Performance Data 29
7.1 – Purpose 29
7.2 – General 29
7.3 – Data Basis 29
7.4 – Specic Conditions 29
7.5 – General Conditions 29
7.6 – Temperature Conversion Chart 30
7.7 – Output Voltage 31
Section 8 – Optional Accessories 32
8.1 – Shipping Case 32
8.2 – GPU Protective Covers 32
8.3 – Tesla™ AC Line Cords 32
8.4 – Cobra™ DC Replacement Contacts and Tools 33
8.5 – Transport Dolly 33
Appendix A 34-38
Repair Request Form 39

TI500 GPU-24
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

TI500 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
!
!
!

TI500 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. 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.
CAUTION Unit Damage Potential
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 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 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 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.
The unit will be damaged if unapproved ac power is applied. This Unit operates and charges from Single Phase 100-260 Vac,
50/60/400 Hz. This must match ac power source (hangar wall, ight line ac power) prior to connecting the TI500 GPU-24 for
recharging.

TI500 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 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.

TI500 GPU-24
4
Figure 2.1.1 – TI500 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.
Section 2 – Product Overview
2.1 – Introduction
Thank you and congratulations on the purchase of your new TI500 GPU-24 Ground Power Unit.
The TI500 GPU-24 is intended to provide dc electrical ground power for aircraft ight line, maintenance, and
ground support operations. The unit is designed to provide 24 volt dc electrical power output for vehicle
and aircraft engine starting and 24 or 28.5 volts dc electrical support for ground maintenance, avionics/
electrical troubleshooting and testing. The observance of procedures, limitations and performance criteria
is essential to ensure peak operating efciency and to maximize operational capabilities and life of the
TI500 GPU-24.
This manual contains the complete operating instructions and procedures for the TI500 GPU-24 that the end
user will need to safely and efciently operate this GPU.

TI500 GPU-24 5
2
Product Overview
2.3 – Front Panel Overview
AC Input Circuit Breaker1. – Trips if over-
current fault condition occurs.
“Push to Test” Button2. – Displays current
battery charge state when pressed.
24 Vdc Output Connector3. – Provides 24
Vdc to 28.5 Vdc @ 25 A.
AC Input Connector4. – Connects to Single
Phase 100-260 Vac line voltage.
24 Vdc Capacity Meter5. – Indicates the
24V battery charge state/power output
status.
Air Intake Ports6. – Provide airow for
cooling internal electronics.
Carrying Handle7. – Allows for easy
transport of unit.
3
5
1
2
4
6
7

TI500 GPU-24
6
2Product Overview
2.4 – General Specications
Electrical
AC Input:
Operates and charges from Single Phase 100-260 Vac, 50/60/400 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:
750 peak starting amps•
25 amps continuous @ 28.5 Vdc (when plugged into ac power)•
36.5 amp hours (968 watt hours) with ac power•
11.5 amp hours (256 watt hours) of rechargeable battery power without ac•
Rechargeable Rate:
33 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
36 lbs (16.4 kg)•
Operating Temperature:
-40°C to +60°C (-40°F to 140°F) without ac power•
-40°C to +50°C (-40°F to 122°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%•

TI500 GPU-24 7
2
Product Overview
2.5 – Physical Dimensions
2.6 – Airow Ports
CAUTION Damage may occur if the TI1000 GPU-24’s air intake or outlet ports are
obstructed. Ensure that ports are clear at all times.
When the TI500 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.
Figure 2.5.1 – TI500 GPU-24 physical dimensions
Figure 2.6.1 – Air intake, exhaust ports and internal air circulation

TI500 GPU-24
8
2Product Overview
2.7 – Operating Positions
The TI500 GPU-24 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.
Vertical Position
Horizontal Position
Front Inlet Rear Outlet

TI500 GPU-24 9
2
Product Overview
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. (Unplug ac line cord on military unit.)1.
Wait for a minimum of 60 seconds.2.
Reset breaker by pressing red button.3.
Reconnect ac and dc connections to the unit. (Plug in ac line cord on military unit.)4.
The unit should power up automatically. If the breaker continues to trip, return the unit to Tesla™ Industries
for repair.
Figure 2.8.1 - AC Input Circuit Breaker
(outlined in blue)
2.9 – 24 Vdc Output Connector
The 24 Vdc Output Connector will provide 25 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 2.9.1).
This will protect the Output Connector from dust and foreign matter.
Figure 2.9.1 - 24 Vdc Output Connector Protective Cover
Closed
Open

TI500 GPU-24
10
2Product Overview
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 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.
Make sure that you wait at least 2 minutes after ac power is applied, or dc power is extracted from1.
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.
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.)
Figure 2.11.1 - “Push to Test” button location
(outlined in blue)
Figure 2.11.2 - Pushing to Test
2.10 – “Push to Test” Button and LED Status Indicator
Figure 2.10.1 - “Push to Test” button location
(outlined in blue)
Figure 2.10.2 - Pushing to Test
Section 3 – Operating Procedures
3.1 – Operating Procedures
This section deals with normal procedures, and includes all steps necessary to ensure safe and ef cient
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 indicator bars illuminate, both the converter and power cells are
supplying 24 Vdc power output.
3.2 – General
Correct operation of the unit includes both pre-use and operational checks of the unit. Knowledge of the
operating limits, restrictions, performance, unit capabilities and functions is fundamental to correct and safe
operation. The operator shall ensure compliance with the instructions in this manual that affect operational
safety and 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
Operators should always ensure the unit is 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

TI500 GPU-24 11
Section 3 – Operating Procedures
3.1 – Operating Procedures
This section deals with normal procedures, and includes all steps necessary to ensure safe and ef cient
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 indicator bars illuminate, both the converter and power cells are
supplying 24 Vdc power output.
3.2 – General
Correct operation of the unit includes both pre-use and operational checks of the unit. Knowledge of the
operating limits, restrictions, performance, unit capabilities and functions is fundamental to correct and safe
operation. The operator shall ensure compliance with the instructions in this manual that affect operational
safety and 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
Operators should always ensure the unit is 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 375 peak starting amps 0-50% charged
375 - 450 peak starting amps 50-60% charged
450 - 525 peak starting amps 60-70% charged
525 - 600 peak starting amps 70-80% charged
600-750 peak starting amps 80-100% charged

TI500 GPU-24
12
3Operating Procedures
120%
100%
80%
60%
40% +40°C +25°C +0°C -20°C -40°C
Ambient
Temperature
+40°C (+104°F)
+25°C (+77°F)
+0°C (+32°F)
-20°C (-4°F)
-40°C (-40°F)
110% ±5%
100% ±5%
80% ±5%
65% ±10%
50% ±10%
Percentage of
Cell Capacity
Figure 3.6.1 – Output power capability versus ambient temperature
3.7 – Environmental
If the unit is exposed to signi cant moisture, preventive measures and precautions shall be taken to:
A. Prevent accumulation of moisture on ac and dc connectors/receptacles
B. Minimize moisture entering forward inlet and outlet cooling fan vent ports
When not in use, unit inlet and outlet vent ports shall be covered from exposure. Unit shall be kept
horizontal.
Hot Soaked or Cold Soaked De nition
Simple terms: When a material is exposed to a change in temperature, its temperature will also change.
Some material changes temperature quickly, others slowly. If the ambient temperature changes and is then
held constant, the materials temperature will also change until its temperature stabilizes. Once the material
temperature has stabilized, it is considered “soaked”.
Example: The unit is moved from the cool shade into the hot sun. The unit’s temperature will increase until
it stabilizes. Once stabilized, the unit would be considered “hot soaked”.
NOTE
!The unit is equipped with a temperature switch that automatically disables
AC power functions when the internal temperature is above 150°F (65°C).
This protects the unit from overheating and damage. If the unit shuts down,
move the unit into a cooler climate such as shade or air conditioning when
possible. Perform a full function test prior to use after the unit has been
allowed to cool.
3.6 – Temperature Speci cations
Cold/Hot Soaked Temperature
The ambient temperature that a unit is exposed to for one (1) hour or more establishes the unit’s cold/
hot soaked stabilization temperature. If the unit’s cold/hot soaked temperature is outside the normal
operating temperature range, the unit must be stabilized prior to operation. For COLD SOAKED temperature
stabilization, the unit must be placed in an environment with a temperature above +10°C (+41°F) for 3
hours or a temperature above +20°C (+68°F) for 2 hours. For HOT SOAKED temperature 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 damage or failure.
3.7 – Environmental
If the unit is exposed to signi cant moisture, preventive measures and precautions shall be taken to:
A. Prevent accumulation of moisture on ac and dc connectors/receptacles
B. Minimize moisture entering forward inlet and outlet cooling fan vent ports
When not in use, unit inlet and outlet vent ports shall be covered from exposure. Unit shall be kept
horizontal.
Hot Soaked or Cold Soaked De nition
Simple terms: When a material is exposed to a change in temperature, its temperature will also change.
Some material changes temperature quickly, others slowly. If the ambient temperature changes and is then
held constant, the materials temperature will also change until its temperature stabilizes. Once the material
temperature has stabilized, it is considered “soaked”.
Example: The unit is moved from the cool shade into the hot sun. The unit’s temperature will increase until
it stabilizes. Once stabilized, the unit would be considered “hot soaked”.
NOTE
!The unit is equipped with a temperature switch that automatically disables
AC power functions when the internal temperature is above 150°F (65°C).
This protects the unit from overheating and damage. If the unit shuts down,
move the unit into a cooler climate such as shade or air conditioning when
possible. Perform a full function test prior to use after the unit has been
allowed to cool.
3.6 – Temperature Speci cations
Cold/Hot Soaked Temperature
The ambient temperature that a unit is exposed to for one (1) hour or more establishes the unit’s cold/
hot soaked stabilization temperature. If the unit’s cold/hot soaked temperature is outside the normal
operating temperature range, the unit must be stabilized prior to operation. For COLD SOAKED temperature
stabilization, the unit must be placed in an environment with a temperature above +10°C (+41°F) for 3
hours or a temperature above +20°C (+68°F) for 2 hours. For HOT SOAKED temperature 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 damage or failure.

TI500 GPU-24 13
3
Operating Procedures
3.7 – Environmental
If the unit is exposed to moisture, preventive measures and precautions shall be taken to:
A. Prevent accumulation of moisture on ac and dc connectors/receptacles
B. Minimize moisture entering forward inlet and aft outlet cooling fan vent ports
Unit inlet and outlet vent ports shall be covered from exposure. Unit shall be kept horizontal. It is recommended
that the Tesla™ Protective Rain Cover be  tted onto the unit to guard it from moisture (see Section 8). The limits
and operational constraints listed below shall apply for the following environmental (weather) conditions:
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 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 and 0.10 inch per hour.
OK OPERATION NOT RECOMMENDED
Light rain, drizzle or sleet:
Precipitation falling on a continuous basis between 0.10 inch
and less than 1/50 inch (0.5 mm) per hour
OK DC OPERATIONS ONLY
Heavy or steady snow:
Generally meaning an accumulation between 4 inches and less
than 1 inch in a 12 hour period.
OK OPERATION NOT RECOMMENDED
Light snow:
Snow falling intermediately with little or no accumulation.
OK DC OPERATIONS ONLY
Fog: OK OK
Figure 3.7.1 – TI500 GPU-24 with TI7000-046
Protective Rain Cover