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