INSTALLATION AND OPERATING INSTRUCTIONS FOR FLOODED
Contents
1. The top of the battery is always wet or one cell requires excessive water 8 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 9 WATER ADDITIONS Maintain electrolyte levels above the top of the separators but no higher than 1 8 from the bottom of the vent well Check the electrolyte level weekly or as necessary depending on battery use prior to charging If the level is not visible below the top of the separators add just enough water to cover it 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 2 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 Power representative if you are not sure of your water quality BATTERIES MUST BE VISUALLY INSPECTED PER THE ABOVE2. 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 REVIEW AND FOLLOW THE SAFETY GUIDELINES LISTED IN ITEM 1 SAFETY 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 Make sure the battery charger is properly matched to the battery and GNB approved for use with Tubular HP or Tubular LM Fast Charge batteries Use a charger with automatic charger termination controls Remove the vent caps from each cell and check to see that the electrolyte level is above the top of the 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 Insert 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 top of the separators recheck it after 3 hours of charging If the level remains below the top of the separators add water or electrolyte to the proper level at the end of charging Page
3. SCHEDULE EVEN WITH THE USE OF A WATERING SYSTEM VENT WELL COVER POST HIGH WATERING LEVEL ged dita tre Page 5 LOW WATERING LEVEL 10 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 11 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 6 This page left blank GNB Industrial Power The Industry Leader bg dl Gap teeta 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 strong 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 ove
4. 2 Following the first month of service the battery should reach its normal operating specific gravity of 1 305 0 005 at 77 F IF BATTERIES ARE NOT IN USE KEEP THEM CHARGED CHECK THE SPECIFIC GRAVITIES MONTHLY AND GIVE 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 4 OPERATION Batteries are rated in ampere hours Ah and are selected to perform a specific workload within an established period of time Because fast charge systems are designed to return a significant amount of ampere hours in short periods of time fast charge batteries are capable of delivering up to 160 of their rated capacity within a 24 hour period To achieve such high levels of usage operators must be diligent to plug in at all opportunities throughout the day including breaks meals and shift changes Care must be taken to ensure specific gravity readings in the battery cells do not go below 1 160 at any time A Tubular HP or Tubular LM Fast Charge Battery is designed for fast charging during breaks meal times and shift changes When not being used the battery should always be connected to the charger The battery must be limited to no more than twenty 20 hours of use per day six days per week and 50 weeks per calendar year A battery should always be recharged immediately following a complete discharge Never allow it to remain in a discharged c
5. PLEASE READ THESE INSTRUCTIONS BEFORE PLACING BATTERIES INTO SERVICE THESE INSTRUCTIONS MUST BE SHIPPED WITH THE BATTERY AND MUST BE DELIVERED TO THE USER TUBULAR Z P TUBULAR INSTALLATION AND OPERATING INSTRUCTIONS FOR FLOODED TUBULAR HP AND TUBULAR LM FAST CHARGE 1 2 1 3 1 4 1 5 1 6 MOTIVE POWER BATTERIES 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 wash basins 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 simi
6. g conditions the electrolyte temperature shall be between 60 140 F Operating temperature above 100 F will reduce the battery s service life Operating temperature below 60 F results in less capacity and special charging is required WATER ADDITIONS GNB approved fast chargers have the capability for equalize charging at specific times and days of the week e g Sunday 08 00 Water additions can be made the following day prior to use provided an equalization charge is confirmed to have been performed EQUALIZE Once a week DEPTH OF DISCHARGE Do not discharge the battery below 80 of the rated capacity Over discharging shortens the battery life and voids the warranty CLEANING Keep the top of the battery clean and dry See Item 8 PREVENTIVE MAINTENANCE SCHEDULE WEEKLY e Check electrolyte levels see water additions e Equalize charge MONTHLY e Record electrolyte specific gravities e Visual inspection and confirmation that the battery mounted monitor is functioning properly e Inspect the cables and charging plugs e Clean the top of the cells SEMI ANNUAL e Inspect the charger Confirm proper output voltage and current Check for external damage frayed cables or worn connectors e Clean the exterior of the battery Page 4 TROUBLE SIGNS Battery temperature averages more than 125 F Open circuit cell voltages vary by 0 15 volts or more and specific gravity varies by 0 020 or more during equalizing
7. lar 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 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 Page 1 1 8 Disconnect the battery from the truck when performing maintenance and repair on motor or electrical system 1 9 Open or break the battery circuit before attempting repairs to the charging plug or receptacles 1 10 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 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 carrier s 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 Carrier s Inspection for Concealed Damage Report After
8. ondition otherwise permanent damage may result Flooded tubular plate motive power batteries are designed and built to deliver 80 of their rated capacity at 77 F 5 TEMPERATURE In the operation of fast charge lead acid batteries the electrolyte temperature must never exceed 140 F or a 7 day average temperature of 125 F Following the end of the day full charge the battery should be allowed to cool to ambient temperature prior to the next discharge The average electrolyte temperature of the battery shall not drop below 60 F 15 C If a battery consistently operates at temperatures close to the allowable maximums contact your local GNB representative for service Page 3 6 CHARGING The start rate of a fast charge battery can be as high as 40 of the batteries rated capacity at the 6 hour rate During the end of the day full charge the charge rate should taper down to the finish rate approximately 5 of the rated capacity by the time the battery is 85 charged and may be even lower when the battery is fully charged Short running times and or low end of charge specific gravities may indicate inadequate recharge Consult your local GNB representative on specific charging problems 7 MAINTENANCE KEEP RECORDS Showing specific gravities equalizing charging temperature cleaning and voltages on a monthly basis These records are required to maintain your warranty TEMPERATURE Under normal fast charge operatin
9. r 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 leet Ee 6NB Fusion 7 Hiement EY oca tttencly 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 For alternate language versions of this document visit www gnb com GNB Industrial Power USA Tel 877 462 4636 Canada Tel 800 268 2698 www gnb com GB4146 2013 06 GNB npustRIAL POWER A Division of Exide Technologies
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