GB4158 - Exide Technologies
Contents
1. GREEN et Timeout excess of the maximum allowed Verify the bat tery capacity Audible message Batten C rre i Loss of output Current control Failure of the con RED YELLOW flash y trol logic Audible message Battery Voltage Loss of output Voltage control Battery discon RED GREEN flash y g nected or failure of the control logic Audible message Saleciion An unavailable configuration has been selected YELLOW GREEN flash Verify the selector s position Audible message Thermal Overheating of semiconductors Verify the fan RED YELLOW GREEN flash operation When there is an alarm the charger stops supplying current to the battery Page 4 DO NOT INTERMITTENTLY CHARGE OPPORTUNITY CHARGE OR SHORT CYCLE THIS BATTERY 7 CONNECTIONS The battery cells are connected in series using welded lead connectors 8 MAINTENANCE KEEP RECORDS Showing charging dates and times After each watering record the specific gravity temperature and open circuit voltages for each cell of the battery These records are required to maintain your warranty TEMPERATURE Under normal operating conditions the electrolyte temperature should be between 60 100 F 15 38 C Operating temperatures above 100 F will reduce the battery s service life Operating temperatures below 60 F result in less capacity and special charging is required WATER ADDITIONS After each 5 calendar days of operation to 80 DOD or when the2. F 15 38 C Following charging the battery should be allowed to cool down or rest approximately 8 hours prior to another discharge cycle If a battery is ever hot to the touch allow it to cool to room temperature before charging or discharging If a battery consistently operates at high temperatures greater than 100 F 38 C contact your local GNB Industrial Power representative for service 6 CHARGING The battery should be charged exclusively with the charger provided with the system WHEN BATTERY RECHARGE IS REQUIRED PLUG THE BATTERY CABLE CONNECTOR INTO THE CHARGER CABLE CONNECTOR AND THEN PLUG THE 3 PRONG CHARGER POWER CORD INTO A GROUNDED 120 VOLT 15 AMP 50 HZ OR 60 HZ POWER OUTLET The charger is equipped with an LED indicator to show the progress of the charging cycle RED LED shows that the battery is in the initial charging phase YELLOW LED shows that the battery has reached 80 of charge GREEN LED shows that the battery has reached 100 of charge Page 3 The Tubular LM FP charging algorithm includes an unterminated Float Stage that begins automatically once full charge is complete The Float Stage holds the battery at 2 28 volts per cell VPC until the battery is required for service The result is that the battery is maintained at full state of charge which helps to prevent self discharge and sulfation WHEN IT IS TIME TO PUT THE BATTERY INTO SERVICE REMOVE THE BATTERY FROM THE CHARGER BY UNPLUGGING THE CHARGE
3. equipment is of ample strength and properly installed DO NOT USE CHAIN OR WIRE ROPE SLINGS Never lay metal tools such as wrenches or screwdrivers on top of a battery Disconnect the battery from the truck when performing maintenance and repair on motor or electrical system Open or break the battery circuit before attempting repairs to the charging plug or receptacles Apply a strong neutralizer such as baking soda or soda ash when electrolyte is spilled on the floor Check local regulations regarding the disposal of neutralized waste Page 1 2 RECEIVING BATTERIES Immediately upon receipt of shipment examine the outside of the packing for signs of rough handling before accepting the battery from the carrier Wet spots on the shipping pallet may be an indication of leaking jars broken in shipment If there is evidence of damage the receipt should be signed and both copies carriers and receiving copies marked Shipment Received Damaged The carrier should be called immediately and asked to make a Carrier s Inspection for Damage Report If concealed damage is later detected the carrier should be called immediately and requested to make a Carriers Inspection for Concealed Damage Report After inspection by the carrier arrangements should be made with the local GNB Industrial Power representative to have the battery repaired before placing it in service BEFORE PLACING BATTERIES IN SERVICE REVIE
4. specific gravity in the cells reaches 1 335 to 1 345 check the water level in each cell after the end of the charging period when the battery is fully charged and the charger has tapered to its finish rate and add water if necessary as specified in Section 10 in this manual The watering interval may increase depending on how you use the system DEPTH OF DISCHARGE Do not discharge the battery beyond 80 of the rated ampere hour capacity Over discharging shortens the battery life and voids the warranty CLEANING Keep the top of the battery clean and dry See Section 9 CHARGER Do not try to service the charger yourself Opening the cover may expose you to shocks or other hazards and will void the warranty PREVENTIVE MAINTENANCE SCHEDULE based on five 80 DOD duty cycles per week Check cell electrolyte levels and add water toeachcell 0 cell Check cell electrolyte levels and add water toeachcell 0 levels and add water to each cell Record cell electrolyte specific gravities temperatures and open circuit EVERY 45 DAYS voltages after watering Inspect the cables and charging plugs sis the cables and Inspect the cables and charging plugs sis plugs Clean the top of the cells Inspect the charger Confirm proper output voltage and current Check for ANNUALLY external damage frayed or cut cables or worn connectors Clean the exterior of the battery TROUBLE SIGNS The battery temperatur
5. OPERATION Batteries are rated in ampere hours Ahr and are selected to perform a specific workload within an established period of time Increasing the workload or time period could result in over discharging thus shortening battery life Limit discharging of the battery to 80 or less so that specific gravities do not go below 1 180 If truck operation results in only partial discharges 40 or less and specific gravities are 1 250 or more at the end of the shift recharging may be deferred and the battery used for another shift providing the workload is not expected to increase Hydrometer readings and experience will determine the frequency of charge intervals under these circumstances A battery should always be recharged immediately following a complete discharge Never allow it to remain in a discharged condition otherwise permanent damage may result A battery is designed to be operated as follows 8 hours discharge 8 hours charge 8 hours cool down Tubular LM Low Maintenance batteries are designed and built to deliver 80 of their rated capacity at 77 F 25 C each cycle 5 TEMPERATURE In the operation of motive power lead acid batteries the electrolyte temperature must not exceed 110 F 43 C If the battery is continuously operated at or above this temperature the service life of the battery will be severely diminished Under normal operating conditions battery electrolyte temperature should be maintained between 60 100
6. POST THESE INSTRUCTIONS IN THE BATTERY MAINTENANCE AREA INSTALLATION AND OPERATING INSTRUCTIONS FOR memene FP MOTIVE POWER BATTERY AND CHARGER SYSTEM SAFETY Follow your company s Safety Instructions when working with or near industrial truck batteries Observe the caution label affixed to the battery Thoroughly familiarize yourself with industry and government guidelines OSHA ANSI for charging handling and maintaining industrial batteries Assign battery and charger care to properly trained personnel This battery contains sulfuric acid electrolyte Avoid contact with skin eyes or clothing Wear rubber apron gloves boots and goggles or face shield when handling checking filling charging or repairing batteries Keep water readily available for flushing spilled electrolyte from eyes or skin Use plain water only and obtain medical attention immediately Special deluge showers and eye washbasins are required Batteries produce hydrogen and oxygen gas during charge Keep open flames away Do not check electrolyte level with a cigarette lighter or match Use a flashlight or permanent lights Switch on off away from the top of the battery Do not smoke or create sparks Lift batteries with a certified approved hoist crane lift truck or similar equipment Move batteries with trucks conveyors or rollers Be sure to place a rubber mat or similar insulating material across the tops of coverless batteries when handling Make sure
7. Power representative if you are not sure of your water quality VENT WELL COVER POST LOW WATERING LEVEL BATTERIES MUST BE VISUALLY INSPECTED PER THE ABOVE SCHEDULE EVEN WITH THE USE OF A WATERING SYSTEM Before watering e Make sure that the battery is disconnected from all charging equipment e Make sure that the battery is properly cleaned e Make sure that you are working with safety glasses WATER ONLY AFTER CHARGING Page 6 11 SERVICE AND PARTS Your local GNB Industrial Power sales representative has more information regarding the full range of maintenance and repair service available GNB Industrial Power can also supply all of your battery charger and accessory device replacement part needs For more information in the U S A and Canada call 1 888 563 6300 All others please contact your local GNB Industrial Power battery sales representative 12 RECYCLING U S Federal and State Regulations require that lead acid batteries be handled and disposed of in compliance with strict guidelines GNB Industrial Power offers disposal service for lead acid batteries Call 1 888 438 5865 to arrange a pick up or to get additional information Page 7 GNB Industrial Power The Industry Leader bg dl Gap TAR ELE Platinum GNB Industrial Power a division of Exide Technologies is a global leader in motive power battery and charger systems for electric lift trucks and other material handling equipment With a st
8. R POWER CORD FROM THE POWER OUTLET AND THEN DISCONNECT THE CHARGER CABLE FROMTHE BATTERY CABLE High on charge temperatures or frequent need for water additions are indications of overcharging Short running times and or low end of charge specific gravities may indicate inadequate recharge Consult your local GNB Industrial Power representative on specific charging problems If the charger does not work correctly or if it has been damaged unplug it immediately from the power outlet and contact your local GNB Industrial Power service representative The charger may be provided with a thermal sensor connected to the top of the battery With this sensor the charging profile will automatically compensate for variable battery temperatures Do not disconnect the sensor from the top of the battery or the charger The charger is equipped with a two tone audible alarm In the event of an alarm condition the audible alarm will sound and the LED indicator will flash Possible alarm conditions are Condition Alarm Type Description Action Audible message Batten Preseic Battery disconnected or not in conformity Verify RED flash y the connection and the nominal voltage The thermal sensor is disconnected during the Audible message recharge or it is out working range Verify the Thermal Sensor YELLOW flash connection of the sensor and measure the tem perature of the battery iabe message Phase 1 and or Phase 2 have a duration in
9. W AND FOLLOW THE SAFETY GUIDELINES LISTED IN SECTION 1 3 PLACING IN SERVICE Verify that the battery weight meets or exceeds the minimum truck weight requirements Allow the battery to cool or warm to room temperature before charging or adding water Open the vent caps from each cell and check to see that the electrolyte level is above the plate separators If it is obvious that the electrolyte has spilled out of any cells replace it with electrolyte of the same specific gravity as found in the other cells of the battery 1 280 1 290 Close the vent caps and give the battery a freshening charge until there is no increase in specific gravity for three hydrometer readings taken at one hour intervals During shipment of the battery low temperatures and or normal shock and vibration often results in a drop in the electrolyte level If the level is below the plate separators recheck it after 3 hours of charging If the level remains below the plate separators add water or electrolyte to the proper level at the end of charging Following the first 90 days of service the battery should reach its normal operating specific gravity of 1 285 to 1 345 at 77 F 25 C IF BATTERIES ARE NOT IN REGULAR USE KEEP THEM CHARGED CHECK THE SPECIFIC GRAVITIES MONTHLY AND GIVE THE BATTERY A FRESHENING CHARGE 3 OR 4 HOURS AT THE FINISH RATE IF THE GRAVITIES HAVE FALLEN 0 030 OR MORE OTHERWISE GIVE A FRESHENING CHARGE EVERY THREE MONTHS Page 2 4
10. e rises more than 25 F 14 C during a normal charge The cell open circuit voltages vary by 0 15 volts or more The top of the battery is always wet or one cell requires excessive watering Page 5 9 MAINTENANCE CLEANING The top of the battery should be kept clean and dry Keep the vent caps in place during use and charging Remove the vent cap only to observe electrolyte levels make water additions take temperatures or take specific gravity readings with a hydrometer If the battery requires cleaning contact your local GNB Industrial Power servicing representative The solution used to clean and neutralize the outside of the batteries should be disposed of in an environmentally safe manner 10 WATER ADDITIONS Maintain electrolyte levels above the plate separators but no higher than 1 8 from the bottom of the vent well Check the electrolyte level quarterly or as necessary depending on battery use prior to charging If the level is not visible below the plate separators add just enough water to cover them and then proceed with charging the battery Otherwise defer watering the battery until the end of the charging period when the battery is fully charged and the charger has tapered to its finish rate At that time add enough water to bring the electrolyte level to 1 2 of the top of the cover Always use distilled water or water that is known to be free of abnormally high amounts of impurities Contact your local GNB Industrial
11. rong manufacturing base in both North America and Europe and a truly global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy your power needs locally as well as all over the world Based on over 100 years of technological innovation the Motive Power group leads the industry with the most recog nized global brands such as GNB FLOODED CLASSIC GNB Industrial Power USA Tel 877 462 4636 Canada Tel 800 268 2698 www gnb com For alternative language versions of this document visit www gnb com GB4158 2013 06 eet 2 6NB Fusion 7 Hemet EY oca Iitencly etticieat energy GNB FLOODED CLASSIC PLATINUM TUBULAR HP HIGH PERFORMANCE TUBULAR LM LOW MAINTE NANCE ELEMENT and GNB FUSION They have come to symbolize quality reliability performance and excellence in all the markets served GNB Industrial Power takes pride in its commitment to a bet ter environment Its Total Battery Management program an integrated approach to manufacturing distributing and recy cling of lead acid batteries has been developed to help ensure a safe and responsible life cycle for all of its products GNB npustRIAL POWER A Division of Exide Technologies
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