Modtech EM-100 User manual

OPERATOR’S MANUAL
EM-100TM Lithium Ion Battery Pack
7136 Eagle Rd. •Willoughby, OH 44094-9636
Tel: [phone] •Fax: [phone] •[email protected]
TO REDUCE THE RISK OF INJURY, YOU MUST
READ THIS OPERATOR’S MANUAL AND COMPLY
WITH ALL INSTRUCTIONS AND PROCEDURES
DESCRIBED HEREIN.
FAILURE TO DO SO MAY RESULT IN FIRE,
PERSONAL INJURY, AND/OR OTHER DAMAGE.
Copyright © 2008, Modtech Corp., All rights reserved
NEW PACKS MUST BE CHARGED BEFORE FIRST
USE. THEY ARE SHIPPED AT 40% STATE OF
CHARGE AND ARE DISABLED AND WILL NOT
OPERATE UNTIL CHARGED.
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GENERAL SAFETY RULES
This manual contains important safety and operating information for the
Modtech Corp. EM-100 24V Lithium-Ion battery pack. Before using the
battery pack, read this operator’s manual. Also, read and observe all
information on the labels attached to the battery pack.
1. CAUTION! TO REDUCE THE RISK OF INJURY AND/OR
EQUIPMENT DAMAGE, CHARGE EM-100 LITHIUM ION BATTERY
PACKS USING ONLY MODTECH CORP. BATTERY CHARGERS
DESIGNATED TO CHARGE THIS SPECIFIC BATTERY PACK
MODEL. The use of other types of chargers may result in personal
injury or equipment damage. Under no circumstances attempt to
connect the battery pack to any power supplies or other equipment that
is not specifically and expressly designated for use with this model
battery pack.
2. USE THE MODTECH CORP. EM-100 LITHIUM ION BATTERY
PACK ONLY WITH MODTECH CORP. EQUIPMENT SPECIFICALLY
AND EXPRESSLY DESIGNATED FOR USE WITH THIS MODEL
BATTERY PACK. Use with other tools or equipment may result in fire,
electric shock, personal injury, and/or damage to equipment.
3. AVOID DANGEROUS CONDITIONS AND ENVIRONMENTS. Do
not charge the battery pack in damp or wet conditions. Avoid using the
pack in direct exposure to rain or snow. Do not use the battery pack or
charger in the presence of explosive gases or flammable materials
because sparks will be generated whenever the battery pack is plugged
or unplugged from chargers or other equipment.
4. AVOID USING OR STORING THE BATTERY PACK IN EITHER
EXTREME COLD OR EXTREME HOT TEMPERATURES. The battery
pack will disable itself under conditions of extreme heat (above 60 °C)
and may not function to full performance under conditions of extreme
cold (below –20 °C). Storage at elevated temperatures (above 25 °C)
will shorten the life of your battery pack.
WARNING
READ AND UNDERSTAND ALL INSTRUCTIONS
Failure to follow all instructions may result in electrical shock, fire,
equipment damage, and/or serious personal injury.
SAVE THESE INSTRUCTIONS

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5. DO NOT BURN OR INCINERATE BATTERY PACKS. Battery packs
may explode causing personal injury, fire, and/or damage. Fumes
resulting from burning of battery packs may be toxic.
6. DO NOT DROP, CRUSH, IMPACT, OR MECHANICALLY ABUSE
BATTERY PACKS. Cease use of packs that have suffered a sharp
impact, been dropped, run over, or damaged in any other way. Such
impacts may cause internal damage that is not externally visible and
that, over time, may cause short circuits, battery cell leakage, or other
events that may lead to fire, personal injury, and or equipment damage.
7. DO NOT DISASSEMBLE BATTERY PACKS. There are no user
serviceable parts within battery packs. Disassembly may result in short
circuiting or other damage that may cause fire, personal injury, and/or
other damage.
8. AVOID CONTACT WITH BATTERY CHEMICALS. If a battery pack
leaks battery chemicals, avoid any contact with skin, eyes, or mouth. In
the event of contact with skin, wash immediately with soap and water
and rinse with vinegar. For eye contact, begin flushing with clean water,
immediately call for medical help, and continue flushing for 20 minutes or
until medical help arrives.
9. AVOID SHORT CIRCUITS. A short circuit will result if conductive
materials such as wires, metal tools, coins, keys, salt water, or other
conductive objects contact the positive and negative terminals at the
same time. A short circuit may cause sparks, excessive heat, fire,
personal injury, or other equipment damage.
10. REPLACE FUSE ONLY WITH 10A 32V MINI BLADE FUSE. No
exceptions.
11. STORE BATTERY PACKS IN A COOL, DRY PLACE. Avoid
leaving the battery pack in direct sunlight, vehicle cabs, compartments,
or unventilated storage buildings during hot summer conditions. Under
extreme temperature conditions damage may occur. Elevated
temperatures in general shorten the life of your battery pack.
WARNING
READ AND SAVE THESE INSTRUCTIONS FOR
FUTURE USE.
Failure to follow all instructions may result in electrical shock, fire,
equipment damage, and/or serious personal injury.
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FUNCTIONAL DESCRIPTION
TABLE 1 - TEST PUSH BUTTON OPERATION
Press the push button firmly to actuate. The LED will flash indicating
whether the pack is enabled and how much charge it contains. A very
short, single flash of the LED indicates that the pack is disabled and will
not provide any further power until re-charged. If the pack is enabled,
one flash will be given for each 10% increment of charge. The flashes
occur in groups of three for ease of counting. If there is no flash, the
pack may be damaged and should be removed from service and sent for
repair.
NEGATIVE
CONTACT
POSITIVE
CONTACT
RETAINING
LATCH RELEASE
BUTTON
LED
PUSH
BUTTON
FUSE PULL
RING
INFO
CONTACT
EM-100
24 Volt
Lithium Ion
Battery Pack
(VERY SHORT FLASH) PACK IS DISABLED
10 – 20% CHARGE
20 – 30%
30 – 40%
40 – 50 %
50 – 60%
60 – 70%
70 – 80%
90 – 100% CHARGE

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BATTERY PACK OPERATION
The EM-100 is an intelligent, lithium ion power pack. It protects itself
automatically in several ways:
1. High voltage condition: The EM-100 will inhibit any charging
(disallow any power input) and only allow discharging (power output) in
the case of high voltage.
2. Low voltage condition: The EM-100 will inhibit any discharging
(power output) and only allow charging (power input) in the case of low
voltage.
3. High temperature condition: The EM-100 will inhibit either charging
or discharging until the temperature is below satisfactory limits.
4. Low temperature condition: The EM-100 will inhibit any charging
and only allow discharging until the temperature is above a satisfactory
limit. In the case of extreme cold, discharging and charging both will be
disabled.
5. High charge current: The EM-100 will inhibit charging momentarily
in the case of high charge (input) current. Charging will be re-enabled
after a short time, but will be disabled again quickly if charge current
remains too high. In the case of extremely highcharge current, the EM-
100 will become disabled and must be connected to the charger to re-
enable. This should never occur when the EM-100 is properly charged
using the Modtech Corp. supplied, appropriate, designated chargers.
6. High discharge current: The EM-100 will inhibit output current
momentarily in the case of high discharge current. Output will be re-
enabled after a short time, but will be disabled again quickly if discharge
current remains too high. In the case of extremely high output current,
the EM-100 will become disabled and must be connected to the charger
to re-enable.
7. External fuse: The EM-100 is programmed to disable current flow,
either charging (input to EM-100) or discharging (output from EM-100) at
levels below the rating of the supplied fuse. Inthe event that the fuse
becomes open (blown), the EM-100 may be damaged or operating
improperly. In this case, the battery pack should be removed from
service immediately and sent for inspection and repair if needed. In no
event should the external fuse be replaced with any fuse other than one
identical to the factory supplied type, 10A, 32V, mini-blade type fast blow
fuse.
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8. Internal TCO fuse: The EM-100 includes a Temperature Cutoff Fuse
(TCO) device internally. This device will open in the case of either
excessively high current or temperature. If this internal fuse opens, the
battery pack will output no power and an error will be indicated when
recharging is attempted. The pack must be removed from service in
this case. The TCO cannot be replaced or repaired by the user.
MAINTENANCE AND STORAGE
Moisture and heat are deleterious to battery pack operation and life.
Refrain from exposing the pack to rain, snow, or moisture of any kind.
When storing the pack, a cool, dry location is mandatory for good
preservation of capacity and life. It is also advantageous to store packs
for extended periods at 40% to 50% charge level if possible. This will
optimize shelf life and service life.
Battery packs placed in prolonged storage should be checked once or
twice a year. When a pack is seen to decline to 10% charge level, it may
be placed on the charger for approximately 1 hour to return it to 50%
charge level. If the pack is allowed to discharge fully, it will become
disabled but not otherwise damaged. In this case, a very short flash of
the LED will occur when the test push button is pressed (see Table 1). A
disabled pack should be charged at the user’s earliest convenience,
preferably for at about one hour if it is to be returned to storage.
If the pack is to be transported for recycling or other purposes, or at time
of disposal or recycling, remove the external fuse. This will electrically
disconnect the pack contacts from the batteries inside and provide a
safer state for avoiding short circuit conditions. The fuse may be simply
re-installed when the pack is to be returned to service.
DISPOSING OF BATTERY PACKS
Lithium ion battery packs are more environmentally friendly than many
other types of batteries (e.g. lead acid or nickel cadmium types). Always
dispose of battery packs according to federal, state, and local
regulations. Contact a recycling agency in your area for recycling
instructions and locations.
Always treat battery packs with care, do not incinerate or burn, and avoid
crushing or compacting. Remove the external fuse when the pack is to
be discarded or recycled. Do not allow the pack to become submerged
in water.

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RBRC BATTERY RECYCLING
The RBRCTM Battery Recycling Seals indicate that the battery pack may
be recycled. When a spent pack is to be retired, return it to Modtech
Corp. or a participating distributor for recycling. For more information,
visit the RBRC web site at www.rbrc.org.
SPECIFICATIONS
Battery Cell Type Lithium Ion
Nominal Pack Voltage 24 VDC
Minimum Operating Voltage 16.5 VDC
Nominal Pack Capacity 4.4 Ah
Minimum Discharge Temperature -20 °C
Minimum Charging Temperature 0 °C
Maximum Charging Temperature 45 °C
Maximum Discharge Temperature 60 °C
External Fuse 10 A, 32 V
MINI-BLADE, FAST ACTING
Maximum Charge Current 2.5 A
Maximum Continuous Discharge 4.4 A
Shutdown Discharge Current 9 A
Dimensions 5-3/4” x 3” x 2-5/8”
(146 x 76 x 67 mm)
Weight 28 oz. (794 g)
7136 Eagle Rd. •Willoughby, OH 44094-9636
Tel: [phone] •Fax: [phone] •[email protected]
Copyright © 2008, Modtech Corp., All rights reserved
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