TI150 (IEC) - Tesla™ Industries Inc
Contents
1. 3 When I apply ac power to the Battery Charger the Cooling Fan does not turn on The Cooling Fan inside the T1150 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 immediately and contact Tesla for further instructions TI150 Series Battery Charger Conditioner 4 Can make repairs to the unit No The T1150 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 TI150 Battery Charger Conditioner serviced If the unit needs to be serviced please contact Tesla s Customer Service by phone at 302 324 8910 or by email at tesla1 teslaind com 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 TI150 Battery Charger Conditioner re quire 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 Car2. 622 8801 e www teslaind com Actual Hole Size 0 213 5 41 O 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 CAUTION 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 Proper Ground Improper Ground Figure 4 2 1 Illustrations of proper and improper grounding 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 oo Preperation Procedures 4 4 3 Attaching the DC Power Cable CAUTION 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 discharg
3. 5 68 144 3 Measurements are in inches and millimeters Figure 2 4 1 T1150 Battery Charger Conditioner Physical Dimensions T1150 Series Battery Charger Conditioner 2 Product Overview 2 5 General Specifications Input e Operates from Single Phase 100 260 Vac 40 500 Hz e 4 7 amps 120 Vac 60 Hz e 2 35 amps 240 Vac 60 Hz Output e Models TI15014 120 240 12 Vdc Output e 20 amps continuous 14 25 Vdc when plugged into ac power e Models TI15028 120 240 24 Vdc Output e 10 amps continuous 28 5 Vdc when plugged into ac power Frequency e 50 450 Hz Temperature Ratings e Operating temperature 40 F to 140 F 40 C to 60 C e Storage temperature 85 F to 140 F 65 C to 60 C Physical Specifications e Dimensions 13 37 L 314 3 mm x 5 68 W 144 3 mm x 3 50 H 88 9 mm e Weight 4 11 Ibs 1 87 kg Warranty e 2 Years 3 Year Optional TI150 Series Battery Charger Conditioner Product Overview 2 2 6 Airflow Ports CAUTION When the T1150 Charger Conditioner is plugged into ac power the internal cooling system will efficiently 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 a
4. 6 _ 360 32 8 350 31 0 340 29 2 33 0 274 320 25 6 _ 31 0 23 8 _ 30 0 22 0 _ 29 0 20 2 _ 28 0 18 4 TI150 Series Battery Charger Conditioner Glossary Amp Hour Ah Digital Multimeter Intelligent Recharging Lead Acid Battery Memory Effect Monolithic Dry Cell NiCd Battery TI150 Series Battery Charger Conditioner The technical term for how much electrical charge a particular battery will hold This number can also be used to determine charge and discharge rates A digital multimeter also Known as a volt ohm meter or VOM is an electronic mea surement device that combines sev eral functions into one unit A standard multimeter may include features such as the ability to measure voltage current and resistance A system which continuously monitors the cell s charge state and automatically adjusts the recharge rate to maximum per formance and minimize cell degradation A battery that uses the reaction of lead and lead oxide with sulfuric acid electrolytes to produce a voltage e g a car battery lf 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 A one piece battery that is hermetically sealed and designed for maintenance free operation The NiCd or nickel cadmium battery is a type of rechar
5. Conditioner Features Overview 3 6 Charge Level Indicator The Charge Level Indicator is located on the top of the T1150 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 lt 20 Charge 3 Integrated Heatsinks In conjunction with the Cooling system the T1150 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 T1150 See Figure 3 8 1 for Mounting Base dimensions and hole locations The actual size PDF can be found on our website TI150 Series Battery Charger Conditioner 8 99 228 3 8 24 209 2 5 68 144 3 oii 5 18 131 6 Measurements are in inches and millimeters TI150 Series Battery Charger Conditioner Mounting Base Template with Hole Locations Tesla Industries Inc e 101 Centerpoint Blvd New Castle DE 19720 302 324 8910 e 9475 Double R Blvd Suite 2 Reno NV 89521 775
6. Panel Overview 1 2 3 4 5 6 7 8 9 10 11 Mounting Base Allows mounting of the T1150 series Battery Charger Conditioner via four mounting holes AC Input Receptacle Connects to standard ac cable Included with both the TI15014 120 240 and T115028 120 240 AC Input Selector Switch Allows manual selection of either 120 Vac or 240 Vac Input voltage see Sec tion 4 2 for proper selection Quick Disconnect Connector T12010 095 12 24 V Cable Assembly with female connector DC Output Cable Provides 14 25 Vdc 20 A max T115014 120 240 or 28 5 Vdc 10 A max TI15028 120 240 AC Input Circuit Breaker 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 Breaker Trips if an over current condition occurs 30 amps for T115014 120 240 and 15 amps for T115028 120 240 Air Exhaust Ports Expel heated air drawn in by Cooling Fan Integrated Heatsinks Provide additional cooling under heavy loading conditions Charge Level Indicator Displays current battery charge level when connected to a battery Cooling Fan Provides continuous airflow for cooling internal circuitry only when under a load TI150 Series Battery Charger Conditioner et Overview 2 2 4 Physical Dimensions 9 03 229 3 ___ 3 50 88 9
7. cable black ring terminal gt The multimeter should read greater than 1 MQ see Figure 6 2 3 Step 5 Finally move the positive probe to the dc output cable red ring terminal gt The multimeter should read greater than 1 MQ see Figure 6 2 3 If the following multimeter measurements correspond to the above steps the unit has no internal shorts TI150 Series Battery Charger Conditioner Unit Care and Maintenance 6 HOLD MikimdAX RELA An Figure 6 2 2 Multimeter reading Figure 6 2 3 Multimeter reading continuity open circuit 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 terminal red of the DC Output Cable Next place the negative probe black on the negative terminal black of the DC Output Cable The multimeter display should read between 12 0 and 14 25 Vdc for the T115014 series charger see Figure 6 2 4 and between 24 0 and 28 5 Vdc for the T115028 series charger see Figure 6 2 5 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 He ma RAN
8. or concerns TI150 Series Battery Charger Conditioner Section Frequently Asked Questions 1 How does a Tesla TI150 Battery Charger Conditioner work The Tesla T1150 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 TI150 Series Battery Charger Conditioner provide The TI15014 120 240 Battery Charger Conditioner will provide up to 20 continuous amps 14 25 Vdc The TI15028 120 240 Battery Charger Conditioner will provide up to 10 continuous amps 28 5 Vdc 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 TI150 s maximum output current For example a 12 V 20 Ah battery will take one hour to charge using a TI15014 series Battery Charger Conditioner Refer to Section 5 2 for more information 3 What is included with my TI150 Series Battery Charger Conditioner The Battery Charger Conditioner comes with a Tesla approved ac input power cable a 3 ft DC Output power cable with color coded alligator clamp ring terminal Quick Disconnect cable assemblies TI2010 096 12 24V Cable Assembly Quick Disconnect DC Output with Ring Terminals amp TI2010 095 12 24V Cable Assembly Quick Disconnect DC Output with Alligator Clips a North American line cord TI2
9. 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 06 22 15 Table of Contents Section 1 Safety Review 1 1 Safety Notices 1 2 Symbols 1 3 Water Hazards 1 4 Important Safety Precautions Section 2 Product Overview 2 1 Introduction 2 2 Indication of Terms Shall Should and May 2 3 Front and Top Panel Overview 2 4 Physical Dimensions 2 5 General Specifications 2 6 Airflow Ports Section 3 Features Overview 3 1 AC Input Receptacle 3 1a IEC Line Cord Options 3 2 AC Input Selector Switch 3 3 AC Input Circuit Breaker 3 4 DC Output Cable 3 5 DC Output Circuit Breaker 3 6 Charge Level Indicator 3 7 Integrated Heatsinks 3 8 Mounting Base Section 4 Pre Operation Procedures 4 1 Installing the Charger 4 2 Attaching AC Power 4 3 Attaching the DC Power Cable MONRPR E NO Ol BWW W 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 Optio
10. 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 T1150 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 T1150 Battery Charger Conditioner is operated after exposure to moisture rain fog snow etc If water infiltration 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 Aa WARNING Severe injury or death from fire 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 Section 2 Product Overview 2 1 Introduction Thank you and congratulations on the purchase of your new T1150 Series Battery Charger Conditioner This manual contains the complete operating instructions and procedures for the T1150 Series Battery Charger Conditioner models 1115014 120 24
11. 0 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 efficient 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 fixed 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 e Model TI15014 120 240 accepts both 120 Vac or 240 Vac and charges 12V batteries e Model TI15028 120 240 accepts both 120 Vac or 240 Vac and charges 24V batteries Minis nn Figure 2 1 1 T1150 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 TI150 Series Battery Charger Conditioner 2 3 Front and Top
12. 5 4 2 2 51 2 0 4 59 0 1 4 60 8 32 62 6 5 0 64 4 66 2 68 0 69 8 11 6 13 4 T92 7 0 18 8 80 6 82 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 39 0 40 0 41 0 42 0 43 0 44 0 45 0 46 0 47 0 48 0 49 0 50 0 51 0 52 0 53 0 54 0 55 0 56 0 57 0 58 0 59 0 102 2 104 0 105 8 107 6 109 4 TI 113 0 114 8 116 6 118 4 120 2 122 0 123 8 125 6 127 4 1292 131 0 132 8 134 6 136 4 138 2 140 0 141 8 143 6 145 4 147 2 149 0 150 8 152 6 154 4 156 2 158 0 159 8 59 0 58 0 57 0 56 0 590 54 0 530 52 0 51 0 50 0 49 0 48 0 47 0 46 0 45 0 44 0 43 0 42 0 41 0 40 0 39 0 38 0 37 0 36 0 35 0 34 0 25 0 32 0 31 0 30 0 29 0 28 0 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 32 0 33 0 34 0 35 0 36 0 37 0 38 0 10 4 12 2 14 0 o 5 0 4 0 3 0 2 0 1 0 23 0 24 8 26 6 28 4 30 2 32 0 33 8 35 6 37 4 39 2 41 0 61 0 62 0 63 0 64 0 65 0 1 0 2 0 3 0 4 0 67 0 68 0 2 N TI 10 0 71 0 Ol O o TI o TI EET 60 0 76 0 _ 59 0 74 2 58 0 72 4 570 70 6 56 0 68 8 55 0 67 0 54 0 65 2 53 0 63 4 520 616 51 0 598 500 58 0 _ 49 0 56 2 _ 480 544 ro 52 6 460 50 8 45 0 49 0 440 47 2 430 45 4 420 43 6 410 418 400 40 0 390 38 2 38 0 364 370 34
13. 5000 053 American Line Cord a user manual and a limited two year warranty 4 Is the TI150 Series Battery Charger Conditioner waterproof The TI150 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 TI150 Series Battery Charger Conditioner section 8 Troubleshooting 1 When I connect the TI150 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 ts 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 Figure 4 4 2 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
14. 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 T1150 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 infiltration Figure 5 3 T1150 Unit with circuit breakers set to OFF T1150 Series Battery Charger Conditioner _5 Operating Procedures Connecting the T1150 Battery Charger If the TI150 Battery Charger is already connected to the battery and hard mounted to the vehicle 1 A B C Plug the ac line cord into the appropriate AC Source Check to see that the LED shows that status
15. Data The data presented covers the full range of operating conditions and expected performance 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 TI150 Battery Charger Conditioner Any attempt to exceed maximum recommended limits will cause the unit to malfunction and may cause permanent damage 10 3 Definition of Abbreviations Unless otherwise indicated the abbreviations defined on page 29 will be applicable to all charts and graphs in this chapter 10 4 Performance Graph Percentage of Full Charge 30 60 120 180 240 300 300 Charge Time minutes Figure 10 4 1 Estimated time needed to fully recharge battery TI150 Series Battery Charger Conditioner 10 Performance Data 10 5 Temperature Conversion Chart o o 6 0 14 2 12 4 10 6 68 8 67 0 65 2 63 4 61 6 59 8 58 0 56 2 54 4 52 6 50 8 49 0 47 2 45 4 43 6 15 8 41 8 17 6 40 0 7 0 19 4 38 2 36 4 34 6 32 8 31 0 29 2 27 4 25 6 23 8 22 0 20 2 18 4 27 0 26 0 25 0 24 0 23 0 22 0 21 0 20 0 19 0 18 0 17 0 16 0 15 0 14 0 13 0 12 0 11 0 10 0 16 6 42 8 14 8 1 0 44 6 13 0 46 4 11 2 48 2 9 4 50 0 1 6 51 8 5 8 53 6 4 0 5
16. GE Figure 6 2 4 Multimeter reading typical Figure 6 2 5 Multimeter reading typical 12 V power cell voltage 24 V power cell voltage Once the T1150 Series Battery Charger Conditioner has fully passed function test procedures the unit is ready for use TI150 Series Battery Charger Conditioner 6 Unit Care and Maintenance 6 3 Unit Servicing The T1150 Series 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 302 324 8910 A Repair Request Form can be found on the last page of this manual MNN Figure 6 3 1 Warranty Void Stickers highlighted in blue 6 4 Packaging and Shipping When returning the T1150 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 fits snugly in the box Seal the box on all sides and return it to Tesla Please contact Tesla Customer Service at 302 324 8910 with any questions
17. TI150 Series Battery Power anvtime Anywhere C h a rge r Co n d it O n e r T115014 120 240 12V T115028 120 240 24V User Manual Built Smart Proven Tough Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 302 324 8910 Phone 302 324 8912 Fax www teslaind com NOTE All users must read this entire manual prior to operating the T1150 Series Battery Charger Conditioner The T1150 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 302 324 8910 FAX 302 324 8912 WEBSITE www teslaind com EMAIL tesla1 teslaind com 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 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
18. e TI150 Series Battery Charger Conditioner section 9 Optional Accessories 9 1 TI200 7 013 Mini NATO Quick Disconnect Cable Assembly The Tesla TI2007 013 Mini NATO Quick Disconnect Cable Assembly connects to the TI150 IEC International Electrotechnical Commission cord 12 24V Battery Charger Conditioner The NATO plug will withstand the harshest battlefield conditions and other extreme environments It is rated to 25 Amps max and is tested to withstand 50 G of force Along with highly conductive contact materials O the virtually indestructible design and fast in the field Figure 10 1 1 TI2007 013 Mini NATO component replacement make it the last NATO plug you will Quick Disconnect Cable Assembly ever need 9 2 TI2007 019 Mini DC to LOAWG Quick Disconnect Cable Assembly The TI2007 019 Mini DC to 10AWG Quick Disconnect Cable Assembly is equipped with a male Quick Disconnect connector This will connect with the female end of the connector which is attached to the T1150 IEC cord 12 24V Battery Charger Conditioner Manufactured from highly conductive alloys the contacts feature threads that are resistant to damage and ideal for superior torquing and 10 2 1 TI2007 019 Mini DC to 10AWG surface contact Quick Disconnect Cable Assembly 9 3 Cobra DC Replacement Contacts and Tools Manufactured from highly conductive alloys the negative contact is specially tapered and has memory to maximize contact sur
19. e 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 T1150 DC Quick Disconnect Cable Assembly to the negative terminal of the battery This is the terminal marked with the symbol a Red Positive ae OG Black Negative Figure 4 3 1 Quick Disconnect Connectors and color coding TI15014 120 240 14 25 Vdc 20A TI15028 120 240 28 5 Vdc 10 A Figure 4 3 2 Model numbers and corresponding dc output voltages 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 TI150 Series Battery Charger Conditioner 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 1 Hold the male end of the connector in one hand and the female in the other Note that the white plastic covers around the
20. face area and to minimize deformity over time Once installed contacts are hermetically sealed within the plug Additionally contacts can be easily replaced in the field without discarding the entire plug using the Insertion Extraction Tools The tools and contact replacements can be ordered through Tesla Customer Service at 302 324 8910 B Negative Insertion Extraction Tool TI2005 126 D E C si NSN 5120 01 523 8761 C Cobra NATO Plug Positive Post TI2005 117 qu W gt NSN 5935 01 523 8914 _ D Cobra NATO Plug Negative Contact TI2005 121 NSN 5999 01 525 0582 A Positive Insertion Extraction Tool TI27000 082 NSN 5120 01 527 7729 TI150 Series Battery Charger Conditioner Section 10 Performance Data 10 1 Introduction This chapter provides performance data for the TI150 Series 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 establish local operating procedures and to maximize the unit s life 10 2 Explanation of
21. geable battery that uses nickelic hydroxide and cadmium as electrodes e g rechargeable power tools 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 Company name amp Billing address Contact person Phone Fax Email Purchase Order Model Serial Model Serial Shipping method to Tesla Description of shipping package Description of problem Date of return Return to Tesla Industries Inc 101 Centerpoint Boulevard New Castle DE 19720 Attention Repair Department TI150 Series Battery Charger Conditioner tai is te iW n j T i a e i a e i n Fa a CIO Raf e ea n Tar Te ge o n a oP ei 7 LI 3 ETE r sii i a or i e N aP WE GET THE MILITARY STARTED Tesla Industries Inc 101 Centerpoint Blvd New Castle DE 19720 USA Tel 302 324 8910 Fax 302 324 8912 9475 Double R Blvd Suite 2 Reno NV 89521 Tel 775 622 8801 Fax 775 622 8810 www teslaind com
22. ir circulation T1150 Series Battery Charger Conditioner Section 3 Features Overview 3 1 AC Input Receptacle WARNING 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 Figure 3 1 2 Connecting AC line cord highlighted in blue 3 1a IEC Line Cord Options TI25000 053 North American Line Cord TI25000 006 Swiss Line Cord TI25000 002 Italian Line Cord TI25000 011 Australian Line Cord TI25000 003 Continental European Line Cord TI25000 200 Israel Line Cord TI25000 004 Old British Line Cord TI25000 300 Denmark Line Cord TI25000 005 England UK Line Cord 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 flat 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 1 AC Input Selector Switch Figure 3 2 2 Turning switch highlighted in blue TI150 Series Battery Charger Conditione
23. nal Accessories 24 9 1 TI2007 013 Mini NATO Quick Disconnect Cable Assembly 24 9 2 TI2007 019 Mini DC to LOAWG 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 Definition of Abbreviations 25 10 4 Performance Graph 25 10 5 Temperature Conversion Chart 26 Glossary 21 Repair Request Form 28 TI150 Series Battery Charger Conditioner Abbreviations and Symbols Abbreviations that may be used within the text headings and titles of this manual LIST OF ABBREVIATIONS Abbreviation Definition ac AFT AWG amp or A cont C SP dc EFF ft FWD GPU Hr Hz kg KHZ KW LED max MQ min MPU NEMA PF PFC rms THD TMDE UAV Vac Vdc Alternating Current Airflow Technology American Wire Gauge Ampere Continuous Degree Celsius Degree Fahrenheit Direct Current Efficiency Feet Forward Ground Power Unit Hour Hertz Kilograms Kilohertz Kilowatts Light Emitting Diode Maximum megaohm Minimum Micro Power Unit National Electrical Manufacturers Association ohm power factor power factor correction root mean square Total Harmonic Distortion Test Measurement amp Diagnostic Equipment Unmanned aerial vehicle Volts Alternating Current Volts Direct Current watts TI150 Series Battery Charger Conditioner section 1 Safety Review 1 1 Safety Notices Safety notices a
24. of the charge Check to see that the fan is running when the Battery Status LED is below 100 CAUTION N If the TI150 Battery Charger is not connected to the battery A mmo Disconnect the DC Quick Disconnect QD and remove the QD Cable As sembly from the DC Output Cable Assembly Attach the either the QD Alligator Clips or Ring Terminals to the Battery Positive connector first then negative Plug in the ac line cord to the T1150 if disconnected Plug in the ac line cord to the appropriate AC source Connect the DC Output QD Check to see that the LED shows that status of the charge CAUTION Disconnecting the TI150 Battery Charger 1 N If the TI150 Battery Charger is hard mounted to the vehicle A B C Disconnect the ac line cord from the ac source Disconnect the ac line cord from the Battery Charger Stow the ac line cord for later use If the TI150 Battery Charger is not hard mounted to the vehicle A Disconnect the DC Output cable Quick Disconnect QD B Unplug the ac line cord from AC Source C D Disconnect the Negative Black lead of the QD Alligator or Ring Terminal Unplug the ac line cord from the T1150 from the Battery Disconnect the Positive Red lead of the QD Alligator or Ring Terminal from the Battery TI150 Series Battery Charger Conditioner Section 6 Unit Care and Maintenance 6 1 Unit Care Avoid Prolonged Exposure to Extremely Damp Environmen
25. pins and sockets are D shaped 2 Align the pins and sockets so that the D shapes are facing Figure 4 3 3 Male the same direction end of connector 3 Slide the pins into the sockets until the two side latches 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 4 Gently pull on each end to ensure that the two ends are Figure 4 3 4 locked together Female end of connector Figure 4 3 5 Correctly connected ends To disconnect the ends 1 Hold the male end of the connector in one hand and the female in the other 2 Gently press them together 3 Grasp the two side latches of the male connector and press them together until latches clear the catch Figure 4 3 6 Disconnecting the ends 4 While holdings the latches pull the ends apart TI150 Series Battery Charger Conditioner 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 T1150 from overcharging the battery Prior to connecting the T1150 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 WARNING 5 2 Connecting the Battery
26. ppear 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 specific type of hazard Indicates a condition operating procedure or practice which if not WARNING adhered to could result in serious injury or death Indicates a condition or operating procedure which if not strictl CAUTION ee y adhered to could result in damage or destruction of equipment 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 specific type of danger or hazard General Warning Electrical Hazard Explosion Hazard Fire Hazard Battery Warning Guard from Moisture Figure 1 2 1 Different types of hazard and caution symbols T1150 Series Battery Charger Conditioner _1 Safety Review 1 3 Hazards WARNING Severe injury or death from electrical shock will occur if either the user or the T1150 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 T1150 Battery Charger Conditioner has come into contact with water If the DC Output Circuit Breaker has tripped due to water infiltration DO NOT
27. r 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 ew 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 T1150 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 1 DC Output Cable Figure 3 4 2 Quick disconnect cables 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
28. sary to ensure that the T1150 Series Battery Charger Conditioner is operating within specified parameters prior to use A digital multimeter an example is shown in Figure 6 2 1 capable of measuring dc voltage and resistance will be required to perform some of the tests These functional test procedures should become routine Check Unit for Evidence of Damage Figure 6 2 1 Digital Meter Check for dents punctures case distortion or misalignment and cracked or loose connectors If any damage is evident contact the Tesla Customer Service WARNING 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 multimeter to measure Q 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 any exposed part of the metal casing or screw gt The multimeter should read nearly O Q see Figure 6 2 2 Step 2 Move the positive probe to one of the two ac plug blades gt The multimeter should now read greater than 1 MQ see Figure 6 2 3 Step 3 Move the positive probe to the other ac plug blade gt The multimeter should again read greater than 1 MO see Figure 6 2 3 Step 4 Next move the positive probe to the dc output
29. ts Be sure to disconnect the T1150 Series Battery Charger Conditioner from ac power if has come into contact with water If the DC Output Circuit Breaker has tripped due to water infiltration allow the unit to dry out before attempting to reset circuit breaker Cover the unit to prevent water infiltration If the unit is operated in extremely damp conditions it should be stored in an environ mentally controlled building when not in use DANGER Protect Cables from Damage Do not cut crush or drag the input or output power cables when handling the T1150 Series Battery Charger Conditioner Always inspect cables prior to use If damage is evident as shown in Figure 6 1 1 contact Tesla Customer Service Do not attempt to use any other type of power cables other than the Tesla cables included with the T1150 Series Battery Charger Conditioner Do not use the input or output cables as a carrying handle damage to the cables and or internal circuitry can occur Figure 6 1 1 Damaged cable TESLA INDUSTRIES INCORPORATED 101 CENTERPOINT BLVD CENTERPOINT INDUSTRIAL PARK NEW CASTLE DELAWARE 19720 PHONE 302 324 8910 FAX 302 324 8912 WEBSITE www teslaind com EMAIL tesla1 teslaind com T1150 Series Battery Charger Conditioner 6 2 Normal Function Test Procedure This section involves normal function test procedures It includes steps neces
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