Tesla TI150 Series User manual

TI150 Series Battery
Charger/Conditioner
HARDWIRED
TI15014-120 & TI15014-240 (12V)
TI15028-120 & TI15028-240 (24V)
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

TI150 Series Hardwired Battery Charger/Conditioner 08-30-19
NOTE: All users must read this entire manual prior to operating
the TI150 Series Battery Charger/Conditioner.
The TI150 Battery Charger/Conditioner 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 MPU is mainte nance 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.
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 © 2019 by Tesla™ Industries, Incorporated. All rights reserved.

TI150 Series Hardwired Battery Charger/Conditioner
Table of Contents
Section 1 – Safety Review 1
1.1 – Safety Notices 1
1.2 – Symbols 1
1.3 – Water Hazards 2
1.4 – Important Safety Precautions 2
Section 2 – Product Overview 3
2.1 – Introduction 3
2.2 – Indication of Terms: Shall, Should, and May 3
2.3 – Front and Top Panel Overview 4
2.4 – Physical Dimensions 5
2.5 – General Specications 6
2.6 – Airow Ports 7
Section 3 – Features Overview 8
3.1 – AC Input Receptacle 8
3.1a – IEC Line Cord Options 8
3.2 – AC Input Circuit Breaker 9
3.3 – DC Output Cable 9
3.4 – DC Output Circuit Breaker 9
3.5 – Charge Level Indicator 10
3.6 – Integrated Heatsinks 10
3.7 – Mounting Base 10-11
Section 4 – Pre-Operation Procedures 12
4.1 – Installing the Charger 12
4.2 – Attaching AC Power 12
Section 5 – Operating Procedures 13
5.1 – Unit Care 13

TI150 Series Hardwired Battery Charger/Conditioner
5.2 – Connecting the Battery Charger 13
5.3 – After Operation 13-14
Section 6 – Unit Care and Maintenance 15
6.1 – Unit Care 15
6.2 – Normal Function Test Procedures 16-17
6.3 – Unit Servicing 18
6.4 – Packaging and Shipping 18
Section 7 – Frequently Asked Questions 19
Section 8 – Troubleshooting 20-21
Section 9 – Performance Data 22-23
9.1 – Purpose 22
9.2 – Explanation of Data 22
9.3 – Denition of Abbreviations 22
9.4 – Performance Graph 22
9.5 – Temperature Conversion Chart 23
Glossary 24
Repair Request Form 25

TI150 Series Hardwired Battery Charger/Conditioner
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

TI150 Series Hardwired Battery Charger/Conditioner 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
!
!
!

TI150 Series Hardwired Battery Charger/Conditioner
2
1Safety Review
1.3 – Hazards
WARNING Shock Hazard Potential
Severe injury or death from electrical shock will occur if either the user or the TI150 Battery Charger/
Conditioner is wet while operating the unit with the 120 or 240 Vac plug attached. Be sure to disconnect
ac power from the ac outlet if the TI150 Battery Charger/Conditioner has come into contact with water.
If the DC Output Circuit Breaker has tripped due to water inltration, DO NOT try to reset it with the unit
plugged into line voltage. Follow standard procedures for resetting the DC Output Circuit Breaker under
Section 3.5.
WARNING Shock Hazard Potential
Severe injury or death from electrical shock can occur when damp electrical connections from the TI150
Battery Charger/Conditioner are plugged into ac line voltage. See Section 6.1 for standard procedures in
wet conditions.
CAUTION Unit Damage Potential
Damage may occur if the TI150 Battery Charger/Conditioner is operated after exposure to moisture (rain,
fog, snow, etc.). If water inltration is suspected, DO NOT CONNECT to ac voltage. Move the unit to a non-
humid location and allow it to dry for a minimum of one (1) hour before operating again. DO NOT USE the
unit if the exterior is damp. See Section 6.1 for standard procedures in wet conditions.
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.
Make sure the TI150 Battery Charger/Conditioner is at least 20 feet (6 meters) away from the nearest
fueling source before connecting either the ac or dc power cables.

TI150 Series Hardwired Battery Charger/Conditioner 3
Figure 2.1.1 – TI150 Series Battery Charger/Conditioner
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 TI150 Series Battery Charger/Conditioner.
This manual contains the complete operating instructions and procedures for the TI150 Series Battery
Charger/Conditioner models: TI15014-120 and TI15028-120. The TI150 Battery Charger/Conditioner
has been designed to rapidly recharge any 12 or 24 volt battery, depending on the model. Both models
incorporate an intelligent recharging circuit that prevents overcharging and provides pure dc output for
efcient battery charging and conditioning.
The TI150 Battery Charger/Conditioner is encased in a rugged enclosure, and is designed to be mounted
to a vehicle or other xed object using the integrated mounting base. Both models include a detachable
line cord and two interchangeable dc output cables (ring terminals for direct battery connection or alligator
clamps for rapid connect and disconnect. See Figure 2.1.1). Each model’s capabilities and requirements
are listed below:
• Model TI15014-120 accepts 120 Vac and charges 12V batteries
• Model TI15028-120 accepts 240 Vac and charges 12V batteries
• Model TI15014-240 accepts 120 Vac and charges 24V batteries
• Model TI15028-240 accepts 240 Vac and charges 24V batteries

TI150 Series Hardwired Battery Charger/Conditioner
4
2Product Overview
Integrated Heatsinks –1) Provide additional cooling under heavy loading conditions.
Mounting Base –2) Allows mounting of the TI150 series Battery Charger/Conditioner via four mounting holes.
AC Input Receptacle3) – Connects to standard ac cable.
Charge Level Indicator4) – Displays current battery charge level when connected to a battery.
Cooling Fan5) – Provides continuous airow for cooling internal circuitry (only when under a load.).
AC Input Circuit Breaker6) – Protects the internal electrical circuit from damage caused by overload or short
circuit. Acts as an “On/Off” switch for the Battery Charger/Conditioner.
Air Exhaust Ports –7) Expel heated air drawn in by Cooling Fan.
DC Output Circuit Breaker8) – Trips if an over current condition occurs (30 amps for TI15014-120-240, and
15 amps for TI15028-120-240).
DC Output Cable9) – Provides 14.25 Vdc @ 20 A max (TI15014-120-240) or 28.5 Vdc @ 10 A max
(TI15028-120-240).
2.3 - Front and Top Panel Overview
1
2
3
45 6 7 8 9

TI150 Series Hardwired Battery Charger/Conditioner 5
2
Product Overview
2.4 – Physical Dimensions
Measurements are in inches and millimeters
Figure 2.4.1 – TI150 Battery Charger/Conditioner Physical Dimensions
10.930 [277.6]
7.488 [190.2] 4.684 [119.0]
2.869 [72.9]
5.683 [144.3]
10.930 [277.6]
7.488 [190.2] 4.684 [119.0]
2.869 [72.9]
5.683 [144.3]

TI150 Series Hardwired Battery Charger/Conditioner
6
2Product Overview
2.5 – General Specications
Input
Operates from Single Phase 100-260 Vac / 40-500 Hz•
4.7 amps @ 120 Vac•
2.35 amps @ 240 Vac•
Output
Models TI15014-120 and TI15014-240 (12 Vdc Output)•
- 20 amps continuous @ 14.25 Vdc (when plugged into ac power)•
Models TI15028-120 and TI15025-240 (24 Vdc Output)•
- 10 amps continuous @ 28.5 Vdc (when plugged into ac power)•
Frequency
50-450 Hz•
Temperature Ratings
Operating temperature: -40°F to +140°F (-40°C to +60°C)•
Storage temperature: -85°F to +140°F (-65°C to +60°C)•
Physical Specications
Dimensions: 7.49” L (190.2 mm) x 5.68” W (144.3 mm) x 2.87” H (72.9 mm)•
Weight: 6.00 lbs (2.72 kg)•
Warranty
2 Years (3 Year Optional)•

TI150 Series Hardwired Battery Charger/Conditioner 7
2
Product Overview
2.6 – Airow Ports
When the TI150 Charger/Conditioner 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.
Figure 2.6.1 – Air intake and exhaust ports and the internal air circulation
CAUTION Damage may occur if the TI150's air intake or outlet ports are
obstructed. Ensure that both ports are clear at all times

TI150 Series Hardwired Battery Charger/Conditioner
8
Section 3 – Features Overview
3.1 – AC Input Receptacle
WARNING Failure to use proper grounding can create a shock hazard.
Please refer to Section 5.2 for proper grounding techniques.
The TI150 series battery charger/conditioner comes with a quick disconnect ac receptacle (see Figure
3.1.1) and is designed to plug into either a standard 120 or 240 Vac outlet with the supplied line cord (see
Figure 3.1.2. and see also Section 3.1a for the proper line cord for your country and region). Please ensure
that the unit is properly grounded at all times (see Section 4.2 for proper grounding techniques).
Figure 3.1.1 – AC Input Receptacle
(circled in blue)
TI25000-053 North American Line Cord
TI25000-002 Italian Line Cord
TI25000-003 Continental European Line Cord
TI25000-004 Old British Line Cord
TI25000-005 England / UK Line Cord
TI25000-006 Swiss Line Cord
TI25000-011 Australian Line Cord
TI25000-200 Israel Line Cord
TI25000-300 Denmark Line Cord
3.1a – IEC Line Cord Options

TI150 Series Hardwired Battery Charger/Conditioner 9
3
Features Overview
3.2 – AC Input Circuit Breaker
The AC Input Circuit Breaker located above the AC Input Receptacle (shown in Figure 3.1.2. Circled in
Yellow) protects the internal electrical circuit from damage caused by overload or short circuit. The AC
Input Circuit Breaker also acts as an “On/Off” switch for the Battery Charger/Conditioner.
3.3 – DC Output Cable
The DC Output Cable (shown in Figure 3.1.2 Circled in red) will provide either 14.25 Vdc or 28.5 Vdc
depending on the model, and comes with a quick disconnect for either ring terminals or alligator clamps.
When properly connected, the TI150 can deliver up to 20 amps at 14.25 Vdc or 10 amps at 28.5 Vdc. See
Section 4.3 for proper connecting procedures.
3.4 – DC Output Circuit Breaker
The DC Output Circuit Breaker (30 amp in 12V and 15 amp in 24V models) is located above the DC
Output Cable (See Figure 3.1.2 Circled in blue). When the circuit breaker has been tripped, the button
will pop out. In the event the breaker trips, verify that all connections are correct (polarity, line voltage,
etc.) and reset the breaker by pushing the switch to the “ON” position. The unit should provide dc power
automatically. If the breaker continues to trips, see Section 8 under Troubleshooting.
Figure 3.1.2

TI150 Series Hardwired Battery Charger/Conditioner
10
3Features Overview
3.5 – Charge Level Indicator
The Charge Level Indicator is located on the top of the TI150 to the left of the Cooling Fan. When attached
to a battery and ac line voltage, the Charge Level Indicator shows the power cells’ charge state (See
Figures 3.5.1 and 3.4.2). A full charge will be indicated by a single green bar next to the 100 on the
indicator.
Figure 3.5.1 - Full Charge Figure 3.5.2 - <20% Charge
3.6 – Integrated Heatsinks
In conjunction with the Cooling system, the TI150 is equipped with heatsinks (See Figure 3.6.1) on both
sides of the unit to provide additional heat dissipation under full load conditions.
Figure 3.6.1 - Integrated Heat Sinks an Mounting Base
(follow the blue arrows)
3.7 – Mounting Base
The Mounting Base allows for easy mounting of the unit to any vehicle or other hard surface. Four (4)
mounting holes have been strategically placed to properly secure the TI150. See Figure 3.7.1 for Mounting
Base dimensions and hole locations. The actual size PDF can be found on our website.

6.737 [171.1]
7.487 [190.2]
5.183 [131.6]
5.683 [144.3]
Actual Hole Size 0.213 [5.41]
Measurements are in inches and millimeters
TI150 Series Battery Charger/ Conditioner Mounting Base Template with
Hole Locations
Tesla™ Industries, Inc.
• 101 Centerpoint Blvd. New Castle, DE 19720 / [phone]
• 9475 Double R Blvd. Suite 2, Reno, NV 89521 / [phone]
• www.teslaind.com
Figure 3.7.1 - Mounting Base

TI150 Series Hardwired Battery Charger/Conditioner
12
Section 4 – Pre-Operation Procedures
4.1 – Installing the Charger
The TI150 Series Battery/Charger is designed to be permanently integrated into vehicles and other
equipment. Mounting is accomplished by using the four holes in the base of the unit. The holes are
0.190” (4.826 mm) and will accept up to 10-24 size bolts or M5 in metric. Once the TI150 is securely
mounted to the vehicle or other equipment, proceed to the next step.
4.2 – Attaching AC Power
Failure to use proper grounding can create a shock hazard. Depending on geographic location, the
standard 220 Vac 50 Hz power cord may require a foreign plug adapter for compatibility. Use only
adapters with a proper grounding mechanism.
Proper Ground Improper Ground
Proper Ground
Figure 4.2.1– Illustrations of proper and improper grounding
CAUTION Unit damage may occur if the wrong voltage is used.
Make sure the line voltage is appropriate for your specic
model. See Model numbers in Figure 4.3.2
WARNING Failure to use proper grounding can create a shock haz-
ard. Please follow proper wiring procedures below.
Before plugging the TI150 into ac power check the dc output cable to make sure the two output wires are
not touching (by disconnecting quick disconnect to prevent shorting).

TI150 Series Hardwired Battery Charger/Conditioner 13
Section 5- Operating Procedures
5.1 – Unit Care
The TI150 Series Battery Charger/Conditioner is engineered to provide continuous output power. Thus, the
charger can be left connected to a battery until it is ready for use. This is due to the intelligent recharging
system that prevents the TI150 from overcharging the battery. Prior to connecting the TI150 to an ac
power source, be sure that the charger is at least 20 feet away from any fuel source to avoid a potential
explosion due to sparking.
5.2 – Connecting the Battery Charger
When you are ready to charge the battery in question, simply follow procedures on page 16. The LED will
show the battery’s state of charge, and the cooling fan will start running after approximately one second.
Let the battery fully recharge. The amount of time needed to charge the battery can be determined by
dividing the amp hour rating of the battery by the output of the charger. For example, a 12 V battery with
a 20 Ah rating using a 12 V model TI150 will take approximately 1 hour to charge. The TI150 can be left
connected to the battery past the charge time due to the intelligent recharge system and will continue to
maintain and condition the battery while connected.
5.3 – After Operation
Although the battery charger is ruggedized, good
general care should be taken to maximize its life.
Therefore, protect the unit from the elements and
man-made hazards whenever possible. Do not expose
to wet or dusty environments (rain, snow, sand, etc.)
as this may damage internal circuitry. See Section 1.3
for more information concerning water inltration.
Make sure that the unit is at least 20 feet (6 meters)
away from the nearest fueling source before connecting
ac power.
WARNING
Figure 5.3 – TI150 Unit with
circuit breakers set to OFF

TI150 Series Hardwired Battery Charger/Conditioner
14
5Operating Procedures
1. If the TI150 Battery Charger is already connected to the battery and hard
mounted to the vehicle:
Plug the ac line cord into the appropriate AC Source.A.
Push the AC Input to the ON positionB.
Push the DC Output Circuit Breaker to the ON PositionC.
Check to see that the LED shows that status of the charge.D.
Check to see that the fan is running when the Battery Status LED is belowE.
100%.
2. If the TI150 Battery Charger is not connected to the battery:
Make sure both Circuit Breakers are on the OFF positionA.
Connect the Positive (Red) lead to the Positive Post of the Battery.A.
Connect the Negative (Black) lead to the Negative Post of the Battery.B.
Plug in the ac line cord to the appropriate AC source.C.
Push the AC Input to the ON positionD.
Push the DC Output Circuit Breaker to the ON PositionE.
Check to see that the LED shows that status of the charge.F.
Disconnecting the TI150 Battery Charger
1. If the TI150 Battery Charger is hard mounted to the vehicle:
Turn both Circuit Breakers to the OFF PositionA.
Disconnect the ac line cord from the ac source.B.
2. If the TI150 Battery Charger is not hard mounted to the vehicle:
Turn both Circuit Breakers to the OFF positionA.
Unplug the ac line cord from AC Source.B.
Disconnect the Negative (Black) lead from the Battery.C.
Disconnect the Positive (Red) lead from the Battery.D.
Connecting the TI150 Battery Charger.
CAUTION Failure to follow these steps in order can cause arcing
and or sparks.
CAUTION Prior to any main engine starts, ensure that the unit’s circult
breakers are set to the OFF position (See Figure 5.3).

TI150 Series Hardwired Battery Charger/Conditioner 15
Section 6- Unit Care and Maintenance
6.1 – Unit Care
Avoid Prolonged Exposure to Extremely Damp Environments
Be sure to disconnect the TI150 Series Battery Charger/Conditioner from ac
power if has come into contact with water. If the DC Output Circuit Breaker
has tripped due to water inltration, allow the unit to dry out before attempting
to reset circuit breaker. Cover the unit to prevent water inltration. If the unit
is operated in extremely damp conditions, it should be stored in an environ-
mentally controlled building when not in use.
Protect Cables from Damage
Do not cut, crush, or drag the input or output power cables when handling the TI150 Series Battery
Charger/Conditioner. Always inspect cables prior to use. If damage is evident (as shown in Figure 6.1.1),
contact Tesla™ Customer Service. Do not attempt to use any other type of power cables other than the
Tesla™ cables included with the TI150 Series Battery Charger/Conditioner. Do not use the input or output
cables as a carrying handle, damage to the cables and/or internal circuitry can occur.
Figure 6.1.1 – Damaged cable
TESLA™ INDUSTRIES, INCORPORATED
101 CENTERPOINT BLVD.
CENTERPOINT INDUSTRIAL PARK
NEW CASTLE, DELAWARE 19720
PHONE: [phone] FAX: [phone]
WEBSITE: www.teslaind.com EMAIL: [email protected]
Severe injury or death from electrical shock will occur if
either the user or the TI150 Battery Charger/Conditioner
is wet while operating the unit with an ac power source
attached.
DANGER