Modtech EM-100 Operator's Manual

OPERATO R’S MANUAL

EM-100

TM

Lithium Ion Battery Pack

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

TO REDUCE THE RISK O F 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/O R 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.

2

GENERAL S AFETY RULES

This manual contains important safety and operating information for t he
Modtech Corp. EM-100 24V Lithium-Ion battery pack. Before using the
battery pac k, r ead 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
EQUIPM ENT D A MA G E, CHARG E EM-100 LITHIUM ION BATT ERY
PACKS USING O NL Y MO DTECH CO RP. BATT ERY CHARGERS
DESIGNATED TO CHA RG E T HI S SPECIFIC BA TTERY PACK
MODEL. The use of other types of chargers may result in personal

injury or equipment damage. Under no circumstances attempt to
connect t he batter y pack t o 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 W ITH M ODTECH CO RP. EQUIPMENT SPECIFICALLY
AND EXPRESSLY DESIGNA TED FOR USE WITH THIS MODEL
BATTERY P ACK. 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 r ain or snow. Do not use the battery pack or
charger in the presence of explosive gases or flammable materials
because s p arks will be gener a ted w henever the battery pa c k is p lugged
or unplugged from chargers or other equipment.

4. AVOID USING OR STORING THE BATTERY PACK IN EITHER
EXTREME COLD OR EXT REME HOT TE M P ERATURE S. The battery

pack will disab le itself under c o ndit io ns of extre me heat (above 60 °C)
and may not function to full perfor mance under conditions of extreme
cold (below –20 °C). Storage at elevated temperatures (above 25 °C)
will shor ten the life o f your ba ttery pac k .

WARNING

READ AND UNDERSTAND ALL INST RUCTIONS

Failure t o follow all instruct ions may result in electrica l s hock , fire,

equipment damage, and/or serious personal injury.

SAVE THESE INSTRUCTIONS

3

5. DO NOT BURN OR INCI NE RATE BAT TE RY PACKS. Batter y packs
may explode causing personal injury, f ire, and/or damage. Fumes
resulting from burning of batter y packs may be toxic.

6. DO NOT DROP, CRUSH, IM PACT, OR M ECHANICALLY A BUSE
BATTERY P ACKS. Cease use of packs that have suffered a sharp

impact, been dropped, run over, or damaged in any other w ay. 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 t hat may lead to fire, per sonal injury, and or equipment damage.

7. DO NOT D ISASSEMBLE BATT ERY 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 CHEMI CALS. 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 ,
immediate l y c all for m edical he lp, a nd cont inue flushing f or 20 m inut es or
until medical help ar r ives .

9. AVOID SHORT CIRCUITS. A s hor t circ uit will res ult if conductive
materials such as wires, metal tools, coins, keys, salt water, or ot her
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 M I NI BLA D E 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 US E .

Failure t o follow all instruct ions may result in electrica l s hock , fire,

equipment damage, and/or serious personal injury.

4

FUNCTIONAL DES CRIPTION

TABLE 1 - TEST PUSH BUTTO N O PERATIO N

Press the push button firmly to a c tuate. T he LED will fla s h indicat ing
whether the pack is enabled and how much charge it contains. A very
short , single fla s h of the LED indicate s that t he pac k is d is a ble d a nd w ill
not provide any further power until re-charged. If the pack is enabled,
one flash w ill b e g iven fo r each 10% incr e ment o f charge . The flas hes
occur in groups of three for ease of counting. If t here 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

5

BATTERY PACK O PERATION

The EM-1 0 0 is a n intellige nt , lithium ion power pack. It pr otects itself
automatically in several ways:

1. High voltage conditi on: 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 dischar ging
(power output) and only allow charging (power input) in the case of low
voltage.

3. High temperat ur e condition: The EM- 1 0 0 will inhibit either c har ging
or discharging until the temperature is below satisfactory limits.

4. Low te mperatur e condit i on: T he EM - 1 0 0 will inhibit any charging
and only allow discharging until the temperature is above a satisfactor y
limit. In the case of extreme cold, d is c har g ing and char ging bo th will be
disabled.

5. High charge current: The EM-100 w ill inhibit char g ing momenta rily
in the case of high charge ( input) c urrent. Char ging will be re -enabled
aft e r a short time, but will b e d is ab le d again quickly if charge current
remains too high. In the case of extremely high charge current, the EM­100 w ill b ec o me d is a b led a nd must b e c o nnect ed to the c har ge r to re­enable. 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 - 1 0 0 will inhibit output cur r e nt
momentarily in t he cas e o f high discharge c urrent. Output w ill b e re­enabled af ter a s hor t time, but w ill be d is ab le d ag a in quickly if disc har ge
current remains too high. In the case of extremely high output current,
the EM-100 w ill b e c o me d is ab le d a nd must b e c o nnecte d to the char g er
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. In the 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.

6

8. Internal TCO fuse: The EM-100 includes a Temperature Cutoff Fuse
(TCO ) device internally. This de vice will open in the case of either
excessively high current or temperature. If this internal fuse opens, the
battery p ac k will output no po wer a nd an er ror will be indicated w hen
recharging is attempted. The pack must be removed from service in
this case. The TCO cannot be replaced or repair ed by t he user.

MAINTE NANCE AND STORAGE

Moisture and heat are deleterious to battery pack oper at ion and life.
Refrain from exposing the pack to rain, snow, or moisture of any kind.
When stor ing the pack, a cool, dry location is mandatory for good
preservation of capacity and life. I t 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 appr oximately 1 hour to r et urn it to 50%
charge le vel. If the pack is allo wed t o d is c har ge fully, it will beco me
disabled but not otherwise damaged. I n this case, a very short flash of
the LED w ill o c c ur when the test push button is presse d (see Ta ble 1 ). A
disabled pack should be charged at the user’s earliest convenience,
preferably f or at about one hour if it is t o be r et urned to storage.

If the pack is to be t r ansported for recycling or other purposes, or at time
of disposal or recycling, remove the external fuse. This w ill e le c trica lly
disconnect the pack contacts f r om the batter ies inside and provide a
safer st at e for avoiding short circuit conditions. The fuse may be simply
re-installed when the pack is to be ret urned to service.

DISPO SING OF BATTERY PACKS

Lithium ion battery packs are more environmentally friendly than many

other types of bat t er ies ( e. g. lead acid or nickel cadmium types). Always
dispose of battery packs accor ding to federal, st at e, and local
regulations. Contact a recycling agency in your area for r ecycling
instructions and locations.

Always treat battery packs w ith 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.

7

RBRC BATTERY RECYCLING

The RBRCTM Battery Recycling Seals indicate that the battery pack may
be recycled. When a spent pack is to be retired, ret urn it to Modtech
Corp. or a participating distributor for recycling. For more information,
visit the RBRC web site at www.rbrc.org.

SPECIFICATIONS

Battery Ce ll T y pe Lith ium Io n
Nominal Pack Voltag e 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] • [e-mail]

Copyright © 2008, Modtech Corp., All rights reserved

8

NOTES: