blackburn 144-CHR-HLI User manual

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Operating Instructions for
BATTERY CHARGER
Catalog Number: 144-CHR-HLI
These products are intended to be supplied by a Listed LPS Power Supply,
rated output 24VDC, 2.5A for the single bay and 24VDC, 5.0A for the multi-bay.
TABLE OF CONTENTS
1.0 GENERAL INFORMATION.............................................................. 2
1.1 ABOUT THIS GUIDE ................................................................ 2
1.2 DESCRIPTION.......................................................................... 3
1.2 SAFETY GUIDELINES .............................................................. 3
2.0 PARTS & ACCESSORIES ............................................................... 3
2.1 CHARGER ................................................................................ 3
2.2 POWER CORD ......................................................................... 3
3.0 SPECIFICATIONS........................................................................... 3
3.1 CHARGER ................................................................................ 3
3.2 POWER SUPPLY. ..................................................................... 3
3.3 BATTERIES............................................................................... 3
4.0 OPERATING INSTRUCTIONS ...................................................... 3-6
4.1 OPERATING TEMPERATURE RANGES................................... 3
4.2 POWER SUPPLY CONNECTION ............................................. 4
4.3 BATTERY STATUS DISPLAY.....................................................5
4.4 CHARGING THE BATTERY....................................................... 5
4.5 CONDITIONING THE BATTERY................................................ 5
4.6 TROUBLESHOOTING .............................................................. 6
WARRANTY...........................................................................................8

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IMPORTANT: Read and understand all of the
instructions and safety information in this manual
before operating or servicing this tool.
1.0 GENERAL INFORMATION
SAFETY GUIDELINES
1.3
DESCRIPTION
1.2
This battery charging system is designed to charge or condition multiple
battery chemistries and congurations. This includes Thomas & Betts
Nickel-Cadmium (NiCd) cat. no. CRCTBP, and Lithium-Ion (Li-Ion) cat. no.
144-BAT-HLI battery packs. The charger can be used with either 110V AC or
220V AC power supply.
ABOUT THIS GUIDE
1.1
This guide presents the setup, use, maintenance and troubleshooting of the
charger along with instructions for conditioning your batteries.
Before using the battery charger, read all instructions and cautionary markings
on the battery charger, battery and on any product using the battery.
WARNING
To reduce risk of injury, use this charger only with authorized products.
Other batteries or adapters may cause personal injury and/or damage.
• Do not expose the charger to rain, snow or direct sunlight.
• Use the charger at room temperature 68°F (20°C) to 77°F (25°C).
• Place the charger in a well-ventilated area free of foreign
objects/matter.
• To reduce risk of electric shock, unplug the charger from the outlet
before cleaning or changing adapters.
• Dispose of used batteries in accordance with local hazardous
material laws.
• Do not disassemble, incinerate, modify or short circuit batteries,
charger or related components.

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2.0 PARTS & ACCESSORIES
3.0 SPECIFICATIONS
CHARGER (144-CHR-HLI)
2.1
CHARGER
3.1
POWER SUPPLY
2.2
•Accommodates Ni-Cd / Ni-MH and
Li-Ion batteries
• Condition feature for Nickel-based
products
• Charge control inside each charger
• Power supply: Single Unit Charger:
24V @ 2.5 Amp International switching
power supply
• Agency approvals: UL/CUL
• Fault indicators for open or shorted
cells and temperature faults
POWER SUPPLY
3.2
POWERTRON ELECTRONICS CORP
(E248122), model PA1060-240T1A250,
input rated 100-240 Vac, 50/60 Hz, 1.8A;
output rated 24 Vdc, 2.5A, 60W max.
BATTERIES
3.3
Thomas & Betts batteries Cat. No.
CRCTBP, Ni-Cd rated Maximum 14.4V
dc, 1.9 Ah, and Cat. No. 144-BAT-HLI
Li-Ion rated Maximum 14.4V, 3Ah.
SINGLE UNIT CHARGER AC POWER CORD WITH POWER SUPPLY
• Charge termination methods:
Ni-Cd / Ni-MH:
Delta temperature
Negative Delta V
Maximum voltage
Timeout
Maximum temperature
Li-Ion:
Minimum current
Timeout
temperature 68°F -77°F (20°C - 25°C).
Batteries charged in conditions above or
below room temperature will exhibit
battery cycle life and capacity below their
rated values. This also applies to the
temperature of the battery itself. Allow
batteries to adjust to room temperature
before charging.
OPERATING TEMPERATURE RANGES
CAUTION
Do not charge a battery that is below
32°F (0°C). Allow the battery to warm up
to room temperature before charging.
The operating temperature of the charger
is 32°F (0°C) - 113°F (45°C). For best
results, charge batteries at room
4.1
4.0 OPERATING INSTRUCTIONS

GROUNDING PIN
COVER OF GROUNDED
OUTLET BOX
ADAPTER
METAL SCREW
4.5
4.0 OPERATING INSTRUCTIONS....Continued
Connect the power supply and charger to a nominal 110 volt circuit. The power supply
manages and conditions the power input to the charger. The power supply does not use
a resettable or replaceable fuse. If a power surge occurs the power supply temporarily
interrupts the current supply until the condition is corrected. If the power light on the
power supply fails to light, an an internal fuse may have blown and must be serviced by
the manufacturer. Return the power supply for repair or replacement immediately.
A temporary adapter can be used to connect the grounding plug to a properly grounded
two-prong outlet. A 110-volt adapter is shown below. Connect the grounding plug on
the adapter to the outlet box using the cover plate screw. Use the temporary adapter
only until a properly grounded, three-prong outlet can be installed by a qualied
electrician.
POWER SUPPLY CONNECTION
4.2
WARNING
Never alter an AC cord or its plug. If it does not fit into your outlet, have a
proper outlet installed by a qualied electrician. An improper connection can
cause an electric shock. To reduce the risk of electric shock, the charger must
be grounded.
WARNING
Before using an adapter, ensure that the outlet box is grounded. If you are not
sure the box is grounded, have it checked and repaired, if necessary, by a
qualied electrician.
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®
144-CHR-HLT
Battery Charger
Amber Green
Charging/Conditioning
100%Full
Fault
Charge/
Ready
Power
Press to
Condition
TA04674 A
4.0 OPERATING INSTRUCTIONS....Continued
Insert the battery into the charger. When
the battery is inserted, the charging
system begins the rapid charge cycle.
When the charge cycle is completed, the
“READY” indicator turns solid green, and
the battery is fully charged. To attain 100%
of its capacity, the battery should remain
in the charger for 1-2 hours depending on
the battery chemistry. A charged battery
may be stored in the charger indenitely.
Upon completion of the charging cycle of
the Nickel-based battery, the charger
switches to “Maintenance Mode” where it
maintains the battery at 100% of its rated
capacity. This will not damage your
battery.
CHARGING THE BATTERY
4.4
(Nickel-based Battery Packs Only)
To condition a battery exhibiting a decrease in capacity, insert the battery into the
charger and push and release the “CONDITION” button. The charger performs a
complete (100%) discharge of the battery and recharges it to full available capacity,
eliminating conditions that may cause it to perform below its rated capacity. This deep
discharge cycle may take up to 15 hours to complete.
NOTE: The condition cycle should only be used once every several weeks. Performing
the conditioning cycle on a daily or weekly basis shortens the usable life of the battery.
If conditioning the battery fails to eliminate the problem, the battery may have exceeded
its usable life and may need replacement. Most batteries have a usable life of
approximately 500 charge/discharge cycles under normal use.
Battery Rejection
If the Fault indicator on the Battery Status Display ashes, the battery is faulty or
damaged. If the battery is still within its warranty period, contact your local
Representative or Customer Service for replacement information.
See Troubleshooting table on page 12 for actions to be taken. If the rejected
indicator continues to flash the battery should be removed and disposed of in
accordance with local regulations.
CONDITIONING THE BATTERY
4.5
Battery Status
Display
NO LIGHT:
• Charger in stand by mode, ready for battery
SOLID AMBER:
• Battery is charging or being conditioned.
FLASHING AMBER (2 per second):
• Battery is rejected.
SOLID GREEN:
• Battery is 100% charged.
BATTERY STATUS DISPLAY
4.3
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4.5
4.0 OPERATING INSTRUCTIONS
TROUBLESHOOTING 4.6
Symptom/Situation Probable Cause Corrective Action
Power indicator (charger) is not
lit/displayed.
AC power supply cord not
connected to wall outlet.
Power supply cord not
connected to battery charger.
Bad power supply.
Bad fuse.
Check power supply
connections.
Replace power supply.
Replace fuse.
Battery Rejected indicator is
displayed. (Amber ashing)
Faulty condition identied.
Over discharge of battery.
Defective Battery.
Remove battery from
charger and reinsert.
Allow to sit in charger for
15 minutes, then reinsert.
Replace battery.
Charger goes to ready in a short
period of time (5-15 minutes).
Battery is fully charged.
Faulty battery.
New Battery.
Try conditioning battery.
(Nickel Based Only)
Replace battery.
Remove battery from charger
and reinsert.
Charger will not go into Charge
mode. (Amber solid indicator)
Battery not seated correctly.
Bad charger.
Defective battery.
Faulty LED.
Re-insert battery.
Replace charger.
Replace battery.
Send in for repair.
Charger will not go into
Condition mode. (Amber solid
indicator)
(NiMH only)
(Li-Ion does not condition)
Battery too hot.
Battery not designed to
condition in the charger.
Faulty LED.
Remove battery, allow to cool
& reinsert.
Do not condition.
Send in for repair.
Battery becomes hot Defective battery. Immediately remove battery
from charger and replace.
Power supply shuts down
temporarily.
Power line surge. Power will automatically reset.

NOTES:
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WARRANTY: Thomas & Betts sells this product with the understanding that the user will perform
all necessary tests to determine the suitability of this product for the user's intended application.
Thomas & Betts warrants that this product will be free from defects in materials and workmanship
for the period stated on the enclosed warranty card. Upon prompt notication of any warranted
defect, Thomas & Betts will, at its option, repair or replace the defective product or refund the
purchase price. Proof of purchase is required. Misuse or unauthorized modication of the product
voids all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY
CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE
SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE WARRANTY IS
LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO
CIRCUMSTANCES WILL THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL,
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
© 2012 Thomas & Betts. All Rights Reserved.
Thomas & Betts Corporation.
Memphis, Tennessee
www.tnb.com
TA04678 A Page 8 of 8
For parts and service, contact the tool service center at 1-800-284-TOOL (8665).