Modtech CHG-50 Operator's Manual

OPERATOR’S MANUAL

CHG-50

TM

Lithium Ion Battery Charger

7136 Eagle Rd.  Willoughby, OH 44094-9636
Tel: [phone]  Fax: [phone]  [e-mail]

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

PATENTS AND PATENTS PENDING

7,838,142 • 7,990,102 • 8,025,118 • 8,026,698

8,084,154 • D601,088 • D632,649 • 20100197222

20100248616 and others

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GENERAL SAFETY RULES

This manual contains important safety and operating information for the
Modtech Corp. CHG-50 24V Lithium-Ion battery charger. Before using
the charger, read this operator’s manual. Also, read and observe all
information on the labels attached to the charger.

1. CAUTION! TO REDUCE THE RISK OF INJURY AND/OR
EQUIPMENT DAMAGE, USE CHG-50 ONLY TO CHARGE MODTECH
CORP. EM-100 LITHIUM ION BATTERY PACKS. The use of other

types of batteries or equipment may result in personal injury or
equipment damage. Under no circumstances attempt to connect the
charger to any power supplies or other equipment that is not specifically
and expressly designated for use with this model charger.

2. AVOID DANGEROUS CONDITIONS AND ENVIRONMENTS. Do
not charge battery packs in damp or wet conditions. Avoid using the
charger 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 a battery pack is plugged or
unplugged from chargers or other equipment.

3. USE CHARGER IN WELL VENTILATED AREA. Do not block
charger air vents.

4. AVOID USING OR STORING THE CHARGER IN EITHER
EXTREME COLD OR EXTREME HOT TEMPERATURES. The charger

will not charge batteries under conditions of extreme heat (above 45 C)
nor will it charge batteries under conditions of extreme cold (below 0 C).

5. MAINTAIN CHARGER ELECTRICAL CORD. Unplug only by pulling
on the plug, not the cord. Do not use cord as carrying handle. Avoid
contact with oil, solvents, or sharp edges which may damage insulation.
Protect against stepping upon, driving over, or tripping upon cord. If cord
appears damaged in any way, retire charger from service immediately
until it can be repaired.

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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6. CHARGER IS RATED FOR 115 VAC OPERATION. Use charger
only with appropriate electrical outlets.

7. UNPLUG CHARGER WHEN NOT IN USE. Remove battery pack as
well.

8. TO REDUCE USE OF ELECTRIC SHOCK always unplug charger
before cleaning or maintenance. Use of a Ground Fault Circuit
Interrupter is recommended to reduce shock hazards.

9. DO NOT DISASSEMBLE. Charger contains no user serviceable
parts and should not be disassembled under any circumstances. If faulty
operation is suspected, return charger for inspection and service if
required.

10. 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 of the
charger at the same time. A short circuit may cause sparks, excessive
heat, fire, personal injury, or other equipment damage.

11. STORE CHARGER IN A COOL, DRY PLACE. Avoid leaving the
charger in direct sunlight, vehicle cabs, compartments, or unventilated
storage buildings during hot summer conditions. Under extreme
temperature conditions damage may occur. Avoid allowing charger to
become wet or damp. Allow damp or wet charger to dry thoroughly
before using.

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 – CHARGER LED OPERATION

If either the charger or battery pack is too hot (fast flashing) or too cold
(slow flashing), the charger will wait until the temperature is in the
acceptable range before charging. Once charging is underway, the LED
will be mostly on, blinking off for a short time at 5-second intervals.
When charging is complete, the LED will be mostly off, with only a brief
flash every 2 seconds. If an error is detected, the charger will flash a
dot-dash pattern. In this case the battery pack must be removed and
may be re-installed. If charging does not proceed normally when the
pack is re-installed, the battery pack may be damaged and should be
retired from service and sent for inspection and repair if needed.

VENTILATION

HOLES

LED

ELECTRIC

CORD

(NOT VISIBLE)

BATTERY

CONNECTOR

INFORMATION

LABELS

CHG-50

24 Volt

Lithium Ion

Battery Charger

CHARGE COMPLETE
CHARGING
TOO HOT
TOO COLD
BATTERY FAILURE

VENTILATION

HOLES

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CHARGER OPERATION

The CHG-50 is an intelligent, lithium ion battery charger. Operation is as
follows:

1. Battery packs may be charged whenever convenient: If a battery
pack is below 90% charge level, it may be placed on the charger at any
time to recharge to 100%. Modtech Corp. lithium ion battery packs
exhibit no memory effect and need not be completely discharged before
recharging. Battery packs that are already above 90% charge level
when placed on the charger will not be further charged. This is
normal and intentional operation aimed at maximizing the life of your
battery packs.

2. Only acceptable battery pack types will be charged: When a
battery pack is placed on the charger its type is detected automatically.
Only packs known and acceptable to the CHG-50 will be charged.

3. Charge temperature is controlled: The charger will measure its
own temperature and the temperature of the battery pack. Charging
proceeds only when both temperatures are within acceptable limits. The
CHG-50 uses a thermostatically controlled fan. The fan will be enabled
and operate at a speed needed to cool the charger. Fan speed will
generally increase as charging progresses and the charger warms
up. A slight “ticking” sound especially at low fan speeds is normal.

4. When charging is complete, removal of the battery pack and
unplugging the charger at your earliest convenience are recommended.
No damage will occur if a pack remains attached to the CHG-50 for an
indefinite period of time, however.

5. After unplugging the charger, the LED may continue to flash for 10
seconds. This is normal and not a cause for concern.

6. Charging time for a fully discharged EM-100 battery pack is
approximately 2-1/2 hours.

7. Storing batteries at 40% to 50% charge level is good practice to
maximize battery life. When preparing to store a pack for an extended
period of time, use the fuel gauge button to see the pack’s charge level.
If the pack is above 50% charge level, it may be used for a while to
decrease the level. If it is below 40%, it may be placed on the charger.
The charger will increase the packs charge level by 10% in
approximately 12 minutes. Charge accordingly to achieve 40% to 50%.

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8. Failure indication is a dot-dash pattern flashed by the LED. If the
failure indication occurs with a different battery pack, the failure may be
within the charger. There are no user serviceable parts within the
charger and it must be returned for inspection and repair if needed.

MAINTENANCE AND STORAGE

Moisture, extreme heat and extreme cold should be avoided when
storing (or using) the CHG-50. Refrain from exposing the charger
to rain, snow, or moisture of any kind. When storing the charger, a
cool, dry location is best. The charger should be unplugged and
the battery pack removed prior to storing

SPECIFICATIONS

Nominal Input Power 115 VAC, 1 A, 60 Hz
Pack Types Charged Modtech Corp. EM-100
Nominal Charging Voltage 24 VDC
Nominal Charging Current 2.4 A
Minimum Charging Temperature 0 C
Maximum Charging Temperature 45 C
Dimensions 6-1/4” x 3-1/4” x 2-3/4”

(159 x 83 x 70 mm)
Weight 29 oz. (822 g)

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CHG-50 Charger with EM-100 Lithium Ion Battery Pack

7136 Eagle Rd.  Willoughby, OH 44094-9636

Tel: [phone]  Fax: [phone]  [e-mail]

Copyright © 2008, Modtech Corp., All rights reserved

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NOTES: