Tesla TI15014-120-240 User manual

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

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 au-
thorized. 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 this unit via a tool or device (borescope, probe, etc.) can
result in unit failure and/or injury by electrical shock. This unit is maintenance free and should not be
opened or disassembled for any reason.
Always protect the unit from short circuit.
Shipping Hazards: NONE
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.
Shock Hazard Potential
CAUTION
06-05-14

TI150 Series 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 Selector Switch 8
3.3 – AC Input Circuit Breaker 9
3.4 – DC Output Cable 9
3.5 – DC Output Circuit Breaker 9
3.6 – Charge Level Indicator 10
3.7 – Integrated Heatsinks 10
3.8 – Mounting Base 10-11
Section 4 – Pre-Operation Procedures 12
4.1 – Installing the Charger 12
4.2 – Attaching AC Power 12
4.3 – Attaching the DC Power Cable 13-14

TI150 Series Battery Charger/Conditioner
Section 5 – Operating Procedures 15
5.1 – Unit Care 15
5.2 – Connecting the Battery Charger 15
5.3 – After Operation 15-16
Section 6 – Unit Care and Maintenance 17
6.1 – Unit Care 17
6.2 – Normal Function Test Procedures 18-19
6.3 – Unit Servicing 20
6.4 – Packaging and Shipping 20
Section 7 – Frequently Asked Questions 21
Section 8 – Troubleshooting 22-23
Section 9 – Optional Accessories 24
9.1 – TI2007-013 Mini NATO Quick Disconnect Cable Assembly 24
9.2 – TI2007-019 Mini DC to 10AWG Quick Disconnect Cable Assembly 24
9.3 – Cobra™ DC Replacement Contacts and Tools 24
Section 10 – Performance Data 25
10.1 – Purpose 25
10.2 – Explanation of Data 25
10.3 – Denition of Abbreviations 25
10.4 – Performance Graph 25
10.5 – Temperature Conversion Chart 26
Glossary 27
Repair Request Form 28

TI150 Series Battery Charger/Conditioner
Abbreviations and Symbols
Abbreviations are used within text, headings and titles. Unless otherwise indicated, the following list of
abbreviations and symbols are used in this manual:
LIST OF ABBREVIATIONS
Abbreviation Defi nition
Amp Ampere
AC Alternating Current
°C Degree Celsius
cont Continuous
DC Direct Current
°F Degree Fahrenheit
Ft Feet
FWD Forward
GPU Ground Power Unit
Hr Hour
Hz Hertz
Kg Kilograms
KW Kilowatts
LED Light Emitting Diode
MAX Maximum
MIN Minimum
MPU Micro Power Unit
VAC Volts, Alternating Current
Vdc Volts, Direct Current
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 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 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 Battery Charger/Conditioner 3
Figure 2.1.1 – TI150 Series Battery Charger/Conditioner IEC
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: TI15014-120-240 and TI15028-120-240. 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 used as a
free standing unit, or 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 TI15014-120-240 accepts both 120 Vac or 240 Vac and charges 12V batteries
 •Model TI15028-120-240 accepts both 120 Vac or 240 Vac and charges 24V batteries

TI150 Series Battery Charger/Conditioner
4
2Product Overview
Mounting Base –1) Allows mounting of the TI150 series Battery Charger/Conditioner via four mounting holes.
AC Input Receptacle2) – Connects to standard ac cable (Included with both the TI15014-120-240 and TI15028-
120-240).
AC Input Selector Switch3) – Allows manual selection of either 120 Vac or 240 Vac Input voltage (see Sec-
tion 4.2 for proper selection).
Quick Disconnect Connector4) – TI2010-095 12/24 V Cable Assembly with female connector.
DC Output Cable5) – Provides 14.25 Vdc @ 20 A max (TI15014-120-240) or 28.5 Vdc @ 10 A max
(TI15028-120-240).
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.
DC Output Circuit Breaker7) – Trips if an over current condition occurs (30 amps for TI15014-120-240, and
15 amps for TI15028-120-240).
Air Exhaust Ports –8) Expel heated air drawn in by Cooling Fan.
Integrated Heatsinks –9) Provide additional cooling under heavy loading conditions.
Charge Level Indicator10) – Displays current battery charge level when connected to a battery.
Cooling Fan11) – Provides continuous airow for cooling internal circuitry (only when under a load.)
10
9
8
6
5
1
34
7
2
11
2.3 - Front and Top Panel Overview

TI150 Series Battery Charger/Conditioner 5
2
Product Overview
3.50 [88.9]
4.68 [119.0]
5.68 [144.3]
2.4 – Physical Dimensions
12.37 [314.3]
9.03 [229.3]
Measurements are in inches and millimeters
Figure 2.4.1 – TI150 Battery Charger/Conditioner Physical Dimensions

TI150 Series 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 60 Hz•
2.35 amps @ 240 Vac 60 Hz•
Output
Models TI15014-120-240 (12 Vdc Output)•
- 20 amps continuous @ 14.25 Vdc (when plugged into ac power)•
Models TI15028-120-240 (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: 13.37” L (314.3 mm) x 5.68” W (144.3 mm) x 3.50” H (88.9 mm)•
Weight: 4.11 lbs (1.87 kg)•
Warranty
2 Years (3 Year Optional)•

TI150 Series 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 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
(highlighted in blue)
Figure 3.1.2 – Connecting AC line cord
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
3.2 – AC Input Selector Switch
The AC Input Selector Switch (shown in Figure 3.2.1) allows manual selection of either 120 (115) Vac or
240 (230) Vac input voltage. To change voltage input, simply insert a at head screwdriver into the opening
on the switch and select the desired voltage before plugging in the unit (see Figure 3.2.2).
Figure 3.2.2 – Turning switch
Figure 3.2.1 – AC Input Selector Switch
(highlighted in blue)

TI150 Series Battery Charger/Conditioner 9
3
Features Overview
3.3 – AC Input Circuit Breaker
The AC Input Circuit Breaker located above the AC Input
Receptacle(shown in Figure 3.3.1) 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.
Figure 3.3.1 – AC Input Circuit Breaker
(highlighted in blue)
3.4 – DC Output Cable
The DC Output Cable (shown in Figure 3.4.1) 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.
Figure 3.4.2 – Quick disconnect cables
Figure 3.4.1 – DC Output Cable
(highlighted in blue)
3.5 – 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 3.5.1). 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 3.5.1 – DC Output Circuit Breaker
(highlighted in blue)

TI150 Series Battery Charger/Conditioner
10
3Features Overview
3.6 – 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 3.6.1 and 3.6.2). A full charge will be indicated by a single green bar next to the 100 on the
indicator.
Figure 3.6.1 - Full Charge Figure 3.6.2 - <20% Charge
3.7 – Integrated Heatsinks
In conjunction with the Cooling system, the TI150 is equipped with heatsinks (See Figure 3.7.1) on both
sides of the unit to provide additional heat dissipation under full load conditions.
Figure 3.7.1 - Integrated Heat Sinks an Mounting Base
(highlighted in blue)
3.8 – 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 3.8.1 for Mounting
Base dimensions and hole locations. The actual size PDF can be found on our website.

8.24 [209.2]
5.18 [131.6]
5.68 [144.3]
8.99 [228.3]
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

TI150 Series 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, or can be used as a free standing unit. 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 Battery Charger/Conditioner 13
4
Pre-Operation Procedures
4.3 – Attaching the DC Power Cable
Before wiring up the DC Output Cable, make sure both the ac line voltage and the Quick Disconnect
Connector Cable are disconnected. The TI150 may have a residual charge. Allow approximately 5 minutes
for complete discharge. The wires coming out of the dc output cable are internally connected as illustrated
in Figure 3.4.1. Connect the “red” ring terminal or alligator clamp of the TI150 DC Quick Disconnect Cable
Assembly to the positive terminal of the battery. This is the terminal marked with the + symbol. Next
connect the “black” ring terminal or alligator clamp of the TI150 DC Quick Disconnect Cable Assembly to
the negative terminal of the battery. This is the terminal marked with the - symbol.
Plug the ac line cord into the unit, then plug the ac line cord into a 120 or 240 power source. Once the unit
has been plugged in, the Quick Disconnect can be reattached.
TI15014-120-240 14.25 Vdc @ 20 A
TI15028-120-240 28.5 Vdc @ 10 A
Figure 4.3.2– Model numbers and corresponding dc output voltages
Figure 4.3.1 – Quick Disconnect Connectors and color coding
Red- Positive +
Black - Negative -
CAUTION
Unit damage may occur if the DC output cable is im-
properly wired. Make sure voltage is appropriate for
your specic model. See model numbers below in
Figure 4.3.2

TI150 Series Battery Charger/Conditioner
14
4Pre-Operation Procedures
Connecting and Disconnecting the Quick Disconnect DC Cable
The TI2010-095 12/24 V Cable Assembly is equipped with a female Quick Disconnect connector. The
TI2010-095 12/24 V Quick Disconnect Cable Assembly with Ring Terminals and the TI2010-096 12/24 V
Quick Disconnect Cable
Assembly with Alligator Clips are equipped with the male side of the connector.
To connect the ends:
Hold the male end of the connector in one hand, and the1.
female in the other. Note that the white plastic covers around
the pins and sockets are “D” shaped.
Align the pins and sockets so that the “D” shapes are facing2.
the same direction.
Slide the pins into the sockets until the two side latches3.
on the until the two side latches on the male end click into
place. Gently pull on each end to ensure that the two ends
are locked together.
Gently pull on each end to ensure that the two ends are4.
locked together.
Figure 4.3.4 –
Female end of
connector
Figure 4.3.3 – Male
end of connector
Figure 4.3.5 – Correctly connected ends
To disconnect the ends:
Hold the male end of the connector in one hand, and1.
the female in the other.
Gently press them together2.
Grasp the two side latches of the male connector and3.
press them together until latches clear the catch.
While holdings the latches, pull the ends apart.4. Figure 4.3.6 –
Disconnecting the
ends

TI150 Series Battery Charger/Conditioner 15
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