Tesla TI45014D User manual

TI45014D Battery
Charger/Conditioner
NSN: 6130-01-625-6382
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 TI45014D Battery Charger/Conditioner.
The TI45014D 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
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 me-
chanical, 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.
Shock Hazard Potential
CAUTION
01-22-15

TI45014D 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 – Rear Panel Overview 5
2.5 – Physical Dimensions 6
2.6 – General Specications 7
2.7 – Airow Ports 8
Section 3 – Features Overview 9
3.1 – AC Input Receptacle 9
3.1a – IEC Line Cord Options 9
3.2 – AC Input Selector Switch 9
3.3 – AC Input Circuit Breaker 10
3.4 – DC Output Receptacle 10
3.5 – DC Output Circuit Breakers 11
3.6 – Power Output Indicators 11
3.7 – Integrated Heatsinks 12
3.8 – Mounting Base 12
Section 4 – Pre-Operation Procedures 13
4.1 – Installing the Charger 13
4.2 – Attaching AC Power 13
4.3 – DC Power Cable Assemblies 14
4.4 – Attaching the DC Power Cable 14-15

TI45014D Battery Charger/Conditioner
Section 5 – Operating Procedures 16
5.1 – Before Operation 16
5.2 – Connecting the Battery Charger 16
5.3 – Disconnecting the Battery Charger 17
5.4 – After Operation 17
5.5 – Congurations for 24V 18
5.6 – Congurations for 12V 19
Section 6 – Unit Care and Maintenance 20
6.1 – Unit Care 20
6.2 – Normal Function Test Procedures 21-22
6.3 – Unit Servicing 22
6.4 – Packaging and Shipping 22
Section 7 – Frequently Asked Questions 23
Section 8 – Troubleshooting 24-25
Section 9 – Performance Data 26
9.1 – Purpose 26
9.2 – Explanation of Data 26
9.3 – Denition of Abbreviations 26
9.4 – Performance Graph 27
9.5 – Temperature Conversion Chart 28
Glossary 29
Section 10 - Optional Accessories 30
10.1 – TI2007-070 Mini-DC to Aviation Cable Assembly 30
10.2 – TI2007-071 Mini-DC to Compact NATO Cable Assembly 30
Repair Request Form 31

TI45014D 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

TI45014D 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
!
!
!

TI45014D 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 TI45014D 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 TI45014D 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
TI45014D Battery Charger/Conditioner are plugged into ac line voltage. See Section 6.1 for standard pro-
cedures in wet conditions.
CAUTION Unit Damage Potential
Damage may occur if the TI45014D 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 TI45014D 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.

TI45014D Battery Charger/Conditioner 3
Figure 2.1.1 – TI45014D 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 oper-
ation 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 TI45014D Battery Charger/Conditioner.
This manual contains the complete operating instructions and procedures for the TI45014D Battery Char-
ger/Conditioner. The TI45014D Battery Charger/Conditioner has been designed to rapidly recharge any
12 or 24 volt battery. This Battery Charger/Conditioner incorporates an intelligent recharging circuit that
prevents overcharging and provides pure dc output for efcient battery charging and conditioning.
The TI45014D 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 mount-
ing base. All models include a detachable ac line cord and an interchangeable dc output cable (alligator
clamps for rapid connect and disconnect).
Accepts both 120 Vac or 240 Vac and charges 12V and 24V batteries.•

TI45014D Battery Charger/Conditioner
4
2Product Overview
2.3 - Front and Top Panel Overview
Mounting Base –1) Allows mounting of the TI45014D Battery Charger/Conditioner via eight mounting holes.
Main DC Output2) – Provides 14.25 Vdc @ 80 amps max or 28.5 Vdc @ 40 amps max.
AC Input Circuit Breaker3) – 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 Breakers4) – Trips if an over-current condition occurs.
Air Intake Ports –5) Provides continuous airow for cooling internal circuitry.
Integrated Heatsink –6) Provide additional heat dissipation under heavy loading conditions.
Power Output Indicators7) – Displays current battery charge level when connected to a battery.
6
3
1
2
4
5
5
7
7

TI45014D Battery Charger/Conditioner 5
2
Product Overview
2.4 – Rear Panel Overview
AC Input Receptacle1) – Connects to standard ac cable. Detachable ac line cord included.
AC Input Voltage Selector Switch2) – Allows manual selection of either 120 Vac or 240 Vac input voltage
(see Section 3.2 for proper selection).
Cooling Fans3) – Expel heated air drawn in by Air Intake Ports.
1
3
2

TI45014D Battery Charger/Conditioner
6
2Product Overview
2.5 – Physical Dimensions
Measurements are in inches and millimeters
Figure 2.5.1 – TI45014D Battery Charger/Conditioner Physical
Dimensions
(20.16 [512.1])
16.46 [418.2]
18.99 [482.3]
4.00 [101.7]
3.32 [84.4]
10.53 [267.5]
9.50 [241.4]
17.50 [444.5]
5.83 [148.2]
10.00 [254.1]
Ø.22 [Ø5.6]

TI45014D Battery Charger/Conditioner 7
2
Product Overview
2.6 – General Specications
TI45014D Battery Charger/Conditioner:
Input:
Operates from Single Phase 100-260 Vac / 40-500 Hz•
1968 W (8.2 A rms @ 240 Vac 60 Hz)•
1944 W (16.2 A rms @ 120 Vac 60 Hz)•
Output:
1140 W (80 A continuous @ 14.25 Vdc ) or (40 A continuous @ 28.5 Vdc)•
Frequency
45-400 Hz•
Temperature Ratings
Operating temperature: -40°F to +60°F (-40°C to +140°C)•
Storage temperature: -65°F to +105°F (-85°C to +221°C)•
Physical Specications
Dimensions: 19.98” L (507.6 mm) x 9.75” W (247.7 mm) x 4.63” H (117.5 mm)•
Weight: 17.45 lbs (7.92 kg)•

TI45014D Battery Charger/Conditioner
8
2Product Overview
2.7 – Airow Ports
When the TI45014D 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.
CAUTION Damage may occur if the TI450's air intake or outlet ports are
obstructed. Ensure that both ports are clear at all times
Figure 2.7.1 – Air intake and exhaust ports and the internal air circulation

TI45014D Battery Charger/Conditioner 9
Section 3 – Features Overview
3.1 – AC Input Receptacle
WARNING Failure to use proper grounding can create a shock hazard.
Please refer to Section 4.2 for proper grounding techniques.
The TI45014D 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). 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.
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 Voltage Selector Switch is located below the AC Input Receptacle on the rear panel (shown in
Figure 3.2.1). This switch allows manual selection of either 120 (115) Vac or 240 (230) Vac input voltage.
To change voltage input, simply follow these steps:
With cross tip screwdriver, remove one screw1.
and rotate the clear protective cover to one
side.
Flip the switch to desired position (115V or2.
230V).
Rotate cover back into place. Replace and3.
tighten screw.
Figure 3.2.1 – AC Input Selector Switch
(highlighted in blue)

TI45014D Battery Charger/Conditioner
10
3Features 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 in-
ternal electrical circuit from damage caused by overload or short circuit. It 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 Receptacle
The main DC Output Receptacle (shown in Figure 3.4.1) will provide either 14.25 Vdc or 28.5 Vdc. When
properly connected, the TI45014D can deliver up to 80 amps at 14.25 Vdc or 40 amps at 28.5 Vdc. See
Section 4.3 for proper connecting procedures.
Figure 3.4.1 – Main DC Output
(highlighted in blue)

TI45014D Battery Charger/Conditioner 11
3
Features Overview
3.6 – Power Output Indicators
The Power Output Indicators are located on the top of the TI45014D (See Figure 3.6.1). When attached to
a battery and ac line voltage, the Power Output Indicator shows the power cells’ charge state (See Figure
3.6.2). A full charge will be indicated by a single green bar next to the 100 on the indicator.
Figure 3.6.2 - Power Cells’ Charge State
Full Charge Half Charge <20%
Figure 3.6.1 – Power Output Indicators
(highlighted in blue)
3.5 – DC Output Circuit Breakers
The DC Output Circuit Breakers are located on the top panel of the TI45014D (See Figure 3.5.1). Each
circuit breaker has an output of 40 amps. They can be used individually or combined together to output
up to 80 amps or up to 40 amps. When the circuit breakers have been tripped, the button will pop up. 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 trip, see Section 8 under Troubleshooting.
Figure 3.5.1 – DC Output Circuit Breaker
(highlighted in blue)

TI45014D Battery Charger/Conditioner
12
3Features Overview
3.7 – Integrated Heatsinks
In conjunction with the cooling system, the TI45014D is equipped
with heatsinks (See Figure 3.7.1) on top and both sides of the unit to
provide additional heat dissipation under full load conditions.
Figure 3.7.1 - Integrated Heat Sinks
(highlighted in blue)
3.8 – Mounting Base
The Mounting Base allows for easy mounting of the unit to any vehicle or other hard surface. Eight mount-
ing holes have been strategically placed to properly secure the TI45014D. See Figure 3.8.1 for Mounting
Base dimensions and hole locations.
Measurements are in inches and millimeters
Figure 3.8.1 – Mounting Base with Hole Locations
(20.16 [512.1])
16.46 [418.2]
18.99 [482.3]
4.00 [101.7]
3.32 [84.4]
10.53 [267.5]
9.50 [241.4]
17.50 [444.5]
5.83 [148.2]
10.00 [254.1]
Ø.22 [Ø5.6]

TI45014D Battery Charger/Conditioner 13
Section 4 – Pre-Operation Procedures
4.1 – Installing the Charger
The TI45014D Battery/Charger is designed to be permanently integrated into vehicles and other equip-
ment, or can be used as a free standing unit. Mounting is accomplished by using the eight holes in the
base of the unit. The holes are 0.213” (5.41 mm) and will accept up to 10-24 size bolts or M5 in metric.
See Figure 3.8.1 in Section 3.8 for mounting hole dimensions. Once the TI45014D 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 stan-
dard 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.
WARNING Failure to use proper grounding can create a shock
hazard. Please follow proper wiring procedures below.
Before plugging the TI45014D into ac power check the dc output cable to make sure the no two output
wires are not touching (by disconnecting quick disconnect to prevent shorting).

TI45014D Battery Charger/Conditioner
14
4Pre-Operation Procedures
4.3 – DC Power Cable Assemblies
The unit includes the TI2007-029 Dual Output Mini DC to Alligator Clamps 6 AWG,
6’ Cable Assembly (shown if Figure 4.3.2). Depending on conguration (see page
18-19), if all four connectors are connected to same device, they can output up to
80 amps to battery. They can work in series or parallel. Refer to the pin-out congu-
ration (see gure 4.3.1) for labeling of output cables.
4.4 – Attaching the DC Power Cable
CAUTION
Unit damage may occur if the dc output cable is
improperly wired. Make sure voltage is appropriate for
your specic model.
Before wiring up the DC Output Cable, turn off all circuit breakers1.
on the top of the unit, by pushing the rocker switch to
the OFF position (outlined in yellow).
Connect Duel Output Mini DC to Main DC Output2.
(outlined in blue)
Determine which conguration is suited for your use on 3.
pages 18-19.
Connect the alligator clips determined from conguration from 4.
your selection.
Check voltage selector switch (refer to Section 3.2).5.
Plug the ac line cord into the unit, then plug the ac line cord into a 120 or 240 power source.6.
Push the ac input circuit breaker rocker switch to the ON position.7.
Push both dc output circuit breaker rocker switches to the ON position.8.
Your TI45014D Battery Charger/Conditioner should now be charging and conditioning the battery.9.
Do not hook up one set of alligator clamps and leave the other set loose. If
the two clamps touch while charging, death or serious injury can occur. If
using one alligator clamp, leave the Circuit Breaker OFF to the unused set.
WARNING
Figure 4.3.1 DC Output
Pin-Out Conguration

TI45014D Battery Charger/Conditioner 15
4
Pre-Operation Procedures
Figure 4.3.3 – Alligator Clamp Connectors and color coding
Red- Positive +
Black - Negative -
Figure 4.3.2 – TI2007-029 Dual Output Mini
DC to Alligator Clamps