Tesla TI45014D User Manual

TI45014D Battery

Power Anytime, Anywhere

Charger/Conditioner

NSN: 6130-01-625-6382

User Manual

Built Smart...Proven Tough

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]

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 this unit via a tool or device (borescope, probe, etc.) can
result in unit failure and/or injury by electrical shock. This unit is mainte nance 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.

Shock Hazard Potential

Copyright © 2015 by Tesla™ Industries, Incorporated. All rights reserved.

01-22-15

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

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

1

1

Safety Review

1.3 – Hazards

WARNING

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 discon nect
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

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 pro­cedures in wet conditions.

CAUTION

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.

Shock Hazard Potential

Shock Hazard Potential

Unit Damage Potential

1.4 – Important Safety Precautions

WARNING

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.

Fire/Explosion Hazard Potential

2

TI45014D Battery Charger/Conditioner

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 Char­ger/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 mount­ing 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.•

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 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.

TI45014D Battery Charger/Conditioner

3

2

Product Overview

2.3 - Front and Top Panel Overview

4

6

7

5

1

2

7

3

Mounting Base –1) Allows mounting of the TI45014D Battery Charger/Conditioner via eight mounting holes.

Main DC Output 2) – Provides 14.25 Vdc @ 80 amps max or 28.5 Vdc @ 40 amps max.

AC Input Circuit Breaker 3) – Protects the internal electrical circuit from damage caused by overload or short

circuit. Acts as an “On/Off” switch for the Battery Charger/Conditioner.

5

DC Output Circuit Breakers 4) – 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.

4

TI45014D Battery Charger/Conditioner

2.4 – Rear Panel Overview

Product Overview

2

1

2

3

AC Input Receptacle 1) – Connects to standard ac cable. Detachable ac line cord included.

AC Input Voltage Selector Switch 2) – 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.

TI45014D Battery Charger/Conditioner

5

2

(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]

Product Overview

2.5 – Physical Dimensions

Measurements are in inches and millimeters

Figure 2.5.1 – TI45014D Battery Charger/Conditioner Physical

Dimensions

6

TI45014D Battery Charger/Conditioner

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)•

Product Overview

2

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

7

2

Product Overview

2.7 – Airow Ports

CAUTION

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.

Damage may occur if the TI450's air intake or outlet ports are
obstructed. Ensure that both ports are clear at all times

8

Figure 2.7.1 – Air intake and exhaust ports and the internal air circulation

TI45014D Battery Charger/Conditioner

Section 3 – Features Overview

3.1 – AC Input Receptacle

WARNING

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)

Failure to use proper grounding can create a shock hazard.
Please refer to Section 4.2 for proper grounding techniques.

Figure 3.1.2 – Connecting AC line cord

3.1a – IEC Line Cord Options

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

3.2 – 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 screw 1.
and rotate the clear protective cover to one
side.

Flip the switch to desired position (115V or 2.
230V).

Rotate cover back into place. Replace and 3.
tighten screw.

Figure 3.2.1 – AC Input Selector Switch

(highlighted in blue)

TI45014D 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. 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)

10

TI45014D Battery Charger/Conditioner

Features Overview

3

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)

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.

Full Charge Half Charge <20%

Figure 3.6.1 – Power Output Indicators

(highlighted in blue)

Figure 3.6.2 - Power Cells’ Charge State

TI45014D Battery Charger/Conditioner

11

3

(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]

Features 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 mount­ing 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

12

TI45014D Battery Charger/Conditioner

Section 4 – Pre-Operation Procedures

4.1 – Installing the Charger

The TI45014D 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 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

Unit damage may occur if the wrong voltage is used.

CAUTION

Make sure the line voltage is appropriate for your

specic model.

WARNING

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

Figure 4.2.1– Illustrations of proper and improper grounding

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).

Failure to use proper grounding can create a shock
hazard. Please follow proper wiring procedures below.

Proper Ground

Improper Ground

TI45014D Battery Charger/Conditioner

13

4

Pre-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gu­ration (see gure 4.3.1) for labeling of output cables.

4.4 – Attaching the DC Power Cable

Unit damage may occur if the dc output cable is

CAUTION

Before wiring up the DC Output Cable, turn off all circuit breakers 1.
on the top of the unit, by pushing the rocker switch to
the OFF position (outlined in yellow).

improperly wired. Make sure voltage is appropriate for

your specic model.

Figure 4.3.1 DC Output

Pin-Out Conguration

Connect Duel Output Mini DC to Main DC Output 2.
(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.

WARNING

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.

14

TI45014D Battery Charger/Conditioner

Pre-Operation Procedures

4

Figure 4.3.2 – TI2007-029 Dual Output Mini

DC to Alligator Clamps

Red- Positive +

Black - Negative -

Figure 4.3.3 – Alligator Clamp Connectors and color coding

TI45014D Battery Charger/Conditioner

15

Section 5- Operating Procedures

5.1 – Before Operation

The TI45014D Battery Charger/Conditioner is engineered to provide continuous output power. The charger
can be left connected to a battery until it is ready for use, because of the intelligent recharging system that
prevents the TI45014D from overcharging the battery. Prior to connecting the TI45014D 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.

Make sure that the unit is at least 20 feet (6 meters)

WARNING

5.2 – Connecting the Battery Charger

When you are ready to charge the battery in question, simply follow procedures below. 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 24 V battery with a 45 Ah rating
using 24 Vdc TI45014D Battery Charger will take approximately 1 hour to charge. The TI45014D 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.

away from the nearest fueling source before connecting
ac power.

1. If the TI45014D 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.

Check to see that the LED shows that status of the charge. B.

Check to see that the fan is running when the Battery Status LED is below 100%.C.

CAUTION

2. If the TI45014D Battery Charger is not connected to the battery:

Disconnect the DC Output Cable Assembly.A.

Attach the Alligator Clamps to the Battery. Positive connector rst, then negative.B.

Plug in the AC Line Cord to the TI45014D (if disconnected).C.

Plug in the AC Line Cord to the appropriate AC source.D.

Connect the DC Output Cable Assembly.E.

Check to see that the LED shows that status of the charge.F.

Failure to follow these steps in order can cause arcing
and or sparks.

16

TI45014D Battery Charger/Conditioner

Operation Procedures

5.3 – Disconnecting the Battery Charger

1. If the TI45014D Battery Charger is hard mounted to the vehicle:

Disconnect the AC Line Cord from the AC Source.A.

Disconnect the AC Line Cord from the Battery Charger.B.

Stow the AC Line Cord for later use.C.

2. If the TI45014D Battery Charger is not hard mounted to the vehicle:

Unplug the AC Line Cord from AC Source.A.

Unplug the AC Line Cord from the TI450.B.

Disconnect the Negative (Black) lead of the Alligator Clamp from the Battery.C.

Disconnect the Positive (Red) lead of the Alligator Clamp from the Battery.D.

Disconnect the DC Output cable.E.

5.4 – 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.

5

TI45014D Battery Charger/Conditioner

17

5

Operation Procedures

5.5 – Congurations for 24V

In this setup, the two batteries are connected in SERIES. Connect the Negative(-) from Battery 1 to the
Positive(+) terminal using a jumper wire or jumper bar. Connect Set A Positive(Red) to Positive terminal on
Battery 1. Connect Set B Negative(black) to Negative(-) terminal on Battery 2. *Connect Set B Positve(Red)
to Positive(-) terminal on Battery 2. Connect Set A Negative(Black) to Negative(-) terminal on Battery 1.

*Alternative conguration: The Negative(black) from Set A can also be connected or clamped together

to the Positive(red) from Set B, as opposed to connecting the lines directly to the battery.

• 24V 40 amps to each battery

SET A SET B

12V+

12V-

24V+

1 2

24V-

24V 24V

24V

Jumper Wire or Bar

In this setup, one battery is connected in SERIES. The Negative (Black) from set A is connected or clamped
to Positive (Red) from Set B. Set A Positive (Red) is connect to Positive(+) terminal. Set B Negative (Black) is
connected to the Negative(-) terminal.

• 24V 40 amps to battery

SET A SET B

18

24V-24V+

24V

TI45014D Battery Charger/Conditioner

Operation Procedures

5.6 – Congurations for 12V

In this setup, two batteries are connected but are charging separate. Connect Positive(Red) from Set A
to the Positive(+) terminal on Battery 1. Connect Negative(Black) from Set A to the Negative(-) terminals
on Battery 1. Connect Positive(Red) from Set B to the Positive(+) terminals on Battery 2. Lastly, connect
Negative(Black) from Set B to the Negative(-) terminal on Battery 2.

• 12V 40 amps to each battery

SET A SET B

12V+

12V-

5

12V+

1 2

12V-

12V 12V

In this setup, one battery is connected in PARALLEL with the two sets of cords. Connect both Positive(Red)
cords from Set A and B to the Positive(+) terminal of the battery. Then connect both Negative(black) cords
from Set A and B to the Negative(-) terminal of the battery.

• 12V 80 amps to battery

SET A SET B

TI45014D Battery Charger/Conditioner

12V+ 12V-

12V

19

Section 6- Unit Care and Maintenance

6.1 – Unit Care

Avoid Prolonged Exposure to Extremely Damp Environments

Be sure to disconnect the TI45014D Battery Charger/Condi tioner 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.

Severe injury or death from electrical shock will occur

DANGER

Protect Cables from Damage

Do not cut, crush, or drag the input or output power cables when handling the TI45014D 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 TI45014D 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.

if either the user or the TI45014D Battery Charger/
Conditioner is wet while operating the unit with an ac
power source attached.

20

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: [e-mail]

TI45014D Battery Charger/Conditioner

Unit Care and Maintenance

6.2 – Normal Function Test Procedure

This section deals with “normal function” test proce dures. It includes
all steps necessary to ensure that the TI45014D Battery Charger/Con-

ditioner is operating within spe cied para meters prior to use. A digital

multimeter (an example is shown in Figure 6.2.1) capable of measuring
dc voltage and resis tance will be required to perform some of the tests.
These functional test procedures should become routine.

6

Check Unit for Evidence of Damage

Check for dents, punctures, case distortion or misalignment, and cracked or loose connec tors. If any
damage is evident, contact the Tesla™ Customer Service.

Severe injury or death from electrical shock can occur.

WARNING

Ensure that both the ac input cable and dc output cable
are disconnected before performing any tests.

Figure 6.2.1 - Digital Meter

Checking Unit Internal Resistance (Testing for Shorts)

It is essential to test for shorts to detect any problems with the unit. To do so, you will need to set your mul-

timeter to measure Ω or “resistance.” You can test to see if both the ac input and dc output terminals are

isolated from the case and line ground in the following steps.

Step 1 Place the negative probe (black) of the multimeter on the ac plug ground pin and the positive

probe (red) on one of the screws of the ac input (gure 6.2.2)
> The multimeter should read nearly 0 Ω.

Step 2 Move the positive probe to one of the two ac plug blades.

> The multimeter should now read greater than 1 MΩ.

Step 3 Move the positive probe to the other ac plug blade.

> The multimeter should again read greater than 1 MΩ.

Step 4 Next, move the positive probe to the dc output cable black alligator clamp.

> The multimeter should read greater than 1 MΩ.

Step 5 Finally, move the positive probe to the dc output cable red alligator clamp.

> The multi meter should read greater than 1 MΩ.

If the following multimeter measurements correspond to the above steps, the unit has no internal shorts.

TI45014D Battery Charger/Conditioner

Figure 6.2.2 - AC Input

21

6

Unit Care and Maintenance

Checking DC Voltage at the DC Output Cable

In order to properly test the dc output the unit needs to be connected to a battery. Make sure to reconnect
the DC Output Cable according to Section 5 Pre-Operation procedures. Then, plug the unit into the appro­priate line voltage. Once this is accomplished, set your digital multimeter to measure dc voltage. Place
the positive probe (red) of the multimeter on the positive clamp (red) of the DC Output Cable. Next, place
the negative probe (black) on the negative clamp (black) of the DC Output Cable. The multimeter display
should read between 14.240 ± 50mV for the TI45014D charger. If the unit is not providing any output
voltage refer to Section 8 under Troubleshooting. Otherwise, contact the Tesla™ Customer Service at (302)
324-8910.

Once the TI45014D Battery Charger/Conditioner has fully passed function test procedures, the unit is
ready for use.

6.3 – Unit Servicing

The TI45014D Battery Charger/Conditioner is a maintenance-free,
sealed unit. No repairs outside of Tesla™ are authorized. Warranty
will be voided if unit is tampered with in any way including any dam­age to the WARRANTY VOID stickers located on the case (see Figure

6.3.1 below). If the unit requires maintenance, please contact Tesla™

Customer Service at [phone]. A Repair Request Form can be
found on the last page of this manual or online at www.teslaind.com.

Figure 6.3.1 – Warranty Void

Sticker

6.4 – Packaging and Shipping

When returning the TI45014D Battery Charger/Conditioner, please ensure that it is properly packaged.
Pack the unit in a box with at least 2-3 inches of clearance on all sides (be sure to enclose the Repair
Request Form). To guarantee that the unit remains centered within the box, do not use loose packing
materials such as packing peanuts. Instead, wrap the unit tightly in foam or other dense material until it

ts snugly in the box. Seal the box on all sides and return it to Tesla™. Please contact Tesla™ Customer

Service at [phone] with any questions or concerns.

22

TI45014D Battery Charger/Conditioner

Section 7 – Frequently Asked Questions

1. How does a Tesla™ TI45014D Battery Charger/Conditioner work?

The Tesla™ TI45014D Battery Charger/Conditioner incorporates an intelligent
charging system with a pure dc output that allows it to rapidly charge and condition a
battery without overcharging or damaging it.

2. How much DC power will the TI45014D Battery Charger/Conditioner provide?

The TI45014D Battery Charger/Conditioner will provide up to 80 conti nuous amps
@ 14.25 Vdc or 40 continuous amps @ 28.5 Vdc depending on if they are set up in
series or parallel.

2. How long will it take to charge my battery?

Battery charge time can be determined by taking the battery’s rated amp hours and
dividing this number by the TI45014D’s maximum output current. For example, a
12 V / 20 Ah battery will take one hour to charge using a TI45014 series Battery
Charger/Conditioner.

3. What is included with my TI45014D Battery Charger/Conditioner?

The Battery Charger/Conditioner comes with a Tesla™ approved ac input power
cable (TI25000-211 NEMA North American Line Cord), a dc output power cable with
a color coded alligator clamp cable assembly(TI2007-029 Dual Output Mini DC to
Alligator Clamps 6AWG, 6’ Cable Assembly), a user manual, and a limited two-year
warranty.

4. Is the TI45014D Battery Charger/Conditioner waterproof?

The TI45014D Battery Charger/Conditioner is NOT waterproof. See Section 1.3
under Water Hazards for further information regarding safe operation in damp
environments.

5. Are there any HAZMAT or disposal issues?

No. Contact Tesla™ for more information.

TI45014D Battery Charger/Conditioner

23

Section 8 – Troubleshooting

1. When I connect the TI45014D Battery Charger/Conditioner to ac power my battery
does not charge.

While charging, the Charge Level Indicator should be illuminated. If this LED is not
lit follow the procedure listed below.

Is there AC line voltage at the Outlet?

No: Consult an electrician. Yes: Contact Tesla™ Industries.

2. The Charge Level Indicator is illuminated, but my battery still does not charge.

The Charge Level Indicator illuminates when there is voltage present at the DC
Output. The DC Output Circuit Breaker controls voltage going out to the DC Output

Cable.

Is the DC Output Circuit Breaker tripped (see Section 4.4)?

No: Proceed to next step. Yes: Reset the breaker.

With the Battery Charger plugged into ac line voltage, check the dc output with a
multimeter on the dc output terminals (See Section 6.2 under Checking DC Voltage
for proper testing procedures).

Does the DC Output show the proper voltage?

No: Contact Tesla™ Industries. Yes: Replace your battery

3. When I apply ac power to the Battery Charger, the Cooling Fan does not turn on.

The Cooling Fan inside the TI45014D Battery Charger/Conditioner is designed to run
only when a load is applied. It will tick when no load is present. If the fan is not on
when the Battery Charger is under load, this may indicate that the Cooling Fan has
failed. Disconnect power imme diately and contact Tesla™ for further instructions.

24

TI45014D Battery Charger/Conditioner

Troubleshooting

8

4. Can I make repairs to the unit?

No. The TI45014D Battery Charger/Conditioner is a maintenance-free, sealed
unit. No repairs outside of Tesla™ are authorized. Warranty will be voided if unit
is tampered with in any way, including any damage to the WARRANTY VOID stickers

located on the case.

5. How do I get my TI45014D Battery Charger/Conditioner serviced?

If the unit needs to be serviced, please contact Tesla™ Customer Service by phone
at [phone] or by email at [e-mail], and a representative will
explain the return process. For your convenience, a Repair Request Form can be
found on the last page of this manual. The form can also be found online at www.
teslaind.com.

6. What type of special maintenance does the TI45014D Battery Charger/ Conditioner

require?

Keep the unit in a well ventilated, climate-controlled environment while charging.
Always keep the vent areas clean and free of debris. See Section 1.3 regarding
Water Hazards and Section 6 under Unit Care.

TI45014D Battery Charger/Conditioner

25

Section 9- Performance Data

9.1 – Purpose

This chapter provides performance data for the TI45014D Battery Charger/Conditioner. This information
will allow the user to obtain maximum performance and life from the unit. Regular referral to this chapter
is recommended to:

A) Gain knowledge of the unit’s performance characteristics to anticipate unexpected conditions or

extreme operational requirements.

B) Readily identify situations requiring maximum performance.

Note: The information provided in this chapter is most useful when anticipating operations under unknown
conditions or environmental extremes. The data can also be used to es tablish local operating procedures
and to maximize the unit’s life.

9.2 – Explanation of Data

The data presented covers the full range of operating conditions and expected perfor mance. In each area
of performance, temperature effects and dc electrical load demands in relation to ground power support
requirements are presented. In some cases, data is presented conservatively. In all cases, performance
data presented is within the applicable limits of the TI45014D Battery Charger/Conditioner. Any attempt to
exceed maximum recommended limits will cause the unit to malfunction and may cause permanent dam-

age.

9.3 – Denition of Abbreviations

Unless otherwise indicated, the abbreviations dened before page 1 will be applicable to all charts and

graphs in this chapter.

26

TI45014D Battery Charger/Conditioner

9.4 – Performance Graph

Approximate charging time @ 25°C needed to fully recharge battery.

24V BATTERY - 40 AMP CHARGER

Performance Data

9

30 60 90 120 150 180

12V BATTERY - 80 AMP CHARGER

TI45014D Battery Charger/Conditioner

15 30 45 60 75 90

27

9

12.6 – Temperature Conversion Chart

°C °F °C °F °C °F °C °F

-60.0 -76.0 -27.0 -16.6 6.0 42.8 39.0 102.2

-59.0 -74.2 -26.0 -14.8 7.0 44.6 40.0 104.0

-58.0 -72.4 -25.0 -13.0 8.0 46.4 41.0 105.8

-57.0 -70.6 -24.0 -11.2 9.0 48.2 42.0 107.6

-56.0 -68.8 -23.0 -9.4 10.0 50.0 43.0 109.4

-55.0 -67.0 -22.0 -7.6 11.0 51.8 44.0 111.2

-54.0 -65.2 -21.0 -5.8 12.0 53.6 45.0 113.0

-53.0 -63.4 -20.0 -4.0 13.0 55.4 46.0 114.8

-52.0 -61.6 -19.0 -2.2 14.0 57.2 47.0 116.6

-51.0 -59.8 -18.0 -0.4 15.0 59.0 48.0 118.4

-50.0 -58.0 -17.0 1.4 16.0 60.8 49.0 120.2

-49.0 -56.2 -16.0 3.2 17.0 62.6 50.0 122.0

-48.0 -54.4 -15.0 5.0 18.0 64.4 51.0 123.8

-47.0 -52.6 -14.0 6.8 19.0 66.2 52.0 125.6

-46.0 -50.8 -13.0 8.6 20.0 68.0 53.0 127.4

-45.0 -49.0 -12.0 10.4 21.0 69.8 54.0 129.2

-44.0 -47.2 -11.0 12.2 22.0 71.6 55.0 131.0

-43.0 -45.4 -10.0 14.0 23.0 73.4 56.0 132.8

-42.0 -43.6 -9.0 15.8 24.0 75.2 57.0 134.6

-41.0 -41.8 -8.0 17.6 25.0 77.0 58.0 136.4

-40.0 -40.0 -7.0 19.4 26.0 78.8 59.0 138.2

-39.0 -38.2 -6.0 21.2 27.0 80.6 60.0 140.0

-38.0 -36.4 -5.0 23.0 28.0 82.4 61.0 141.8

-37.0 -34.6 -4.0 24.8 29.0 84.2 62.0 143.6

-36.0 -32.8 -3.0 26.6 30.0 86.0 63.0 145.4

-35.0 -31.0 -2.0 28.4 31.0 87.8 64.0 147.2

-34.0 -29.2 -1.0 30.2 32.0 89.6 65.0 149.0

-33.0 -27.4 0.0 32.0 33.0 91.4 66.0 150.8

-32.0 -25.6 1.0 33.8 34.0 93.2 67.0 152.6

-31.0 -23.8 2.0 35.6 35.0 95.0 68.0 154.4

-30.0 -22.0 3.0 37.4 36.0 96.8 69.0 156.2

-29.0 -20.2 4.0 39.2 37.0 98.6 70.0 158.0

-28.0 -18.4 5.0 41.0 38.0 100.4 71.0 159.8

Performance Data

9.5 - Temperature Conversion Chart

Figure 9.5.1 – Temperature conversion from Celsius to °Fahrenheit

28

TI45014D Battery Charger/Conditioner

Glossary

Amp-Hour (Ah) The technical term for how much electrical

Digital Multimeter A digital multimeter, also known as a volt/

Intelligent Recharging A system which continuously monitors

charge a particular battery will hold. This
number can also be used to determine
charge and discharge rates.

ohm meter or VOM, is an electronic mea­surement device that combines sev­eral functions into one unit. A standard
multimeter may include features such as
the ability to measure voltage, current and
resistance.

the cell’s charge state and automatically
adjusts the recharge rate to maximum per­formance and minimize cell degradation.

Lead Acid Battery A battery that uses the reaction of lead and

lead oxide with sulfuric acid electrolytes to
produce a voltage (e.g. a car battery).

Memory Effect If a NiCd battery is only partially discharged

and then recharged many times, it will
begin to "remember" the level at which it
was discharged and will no longer fully
recharge. Lead Acid Batteries do not suffer
from memory effect.

Monolithic Dry-Cell A one-piece battery that is hermetically

sealed and designed for maintenance-free
operation.

NiCd Battery The NiCd, or nickel-cadmium battery,

is a type of rechargeable battery that
uses nickelic hydroxide and cadmium as
electrodes (e.g. rechargeable power tools).

TI45014D Battery Charger/Conditioner

29

Section 10 - Optional Accessories

10.1 – TI2007-070 Mini-DC to Aviation Cable Assembly

The Tesla™ TI2007-070 Mini-DC to Aviation makes it possible to charge and condition aviation batteries
with the Tesla™ TI45014D Battery Charger/Condition.

DC output result from TI45014D Battery Charger/Conditioner using TI2007-070 is 40 amps continuous @

28.5 Vdc to charge and condition aviation batteries.

*4 AWG, 25’ Cable Assembly

10.2 – TI2007-071 Mini-DC to Compact NATO Cable Assembly

The Tesla™ TI2007-071 Mini-DC to Compact NATO makes it possible to charge and condition 24 Volt
vehicle batteries with the Tesla™ TI45014D Battery Charger/Condition.

DC output result from TI45014D Battery Charger/Conditioner using TI2007-071 is 40 amps continuous @

28.5 Vdc to charge and condition vehicle’s batteries.

*4 AWG, 25’ Cable Assembly

30

TI45014D Battery Charger/Conditioner

Repair Request Form

Please complete the information below to ensure prompt and accurate service. Include this form with the unit you are returning.
Thank you.

Date of return: ________________________

Company name & ____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

Billing address: ____________________________________________________________________

____________________________________________________________________

____________________________________________________________________

Contact person: ________________________________________________________________________________

Phone #: _____________________________________ Fax #: ______________________________________

Email: _______________________________________________________________________________________

Purchase Order #: ______________________________________________________________________________

Model #: ____________________________________ Serial #: ________________________________________

Model #: ____________________________________ Serial #: ________________________________________

Shipping method to Tesla™: ______________________________________________________________________

Description of shipping package: ________________________________________________________________

Description of problem: _________________________________________________________________________

_________________________________________________________________________________________________

_________________________________________________________________________________________________

_________________________________________________________________________________________________

Return to Tesla™ Industries, Inc.

101 Centerpoint Boulevard, New Castle, DE 19720 Attention: Repair Department

TI45014D Battery Charger/Conditioner

31

Tesla™ Industries, Inc.

101 Centerpoint Blvd.
New Castle, DE 19720 USA
Tel: [phone]
Fax: [phone]

9475 Double R Blvd., Suite 2
Reno, NV 89521
Tel: [phone]
Fax: [phone]

www.teslaind.com