Exide Technologies GB3902 User Manual [en, es, fr]

THESE INSTRUCTIONS TO BE SHIPPED WITH BATTERY AND TO BE DELIVERED TO USER

PLEASE READ BEFORE PLACING BATTERIES IN SERVICE

MOTIVE POWER VALVE REGULATED

LEAD ACID (VRLA) BATTERIES

INSTALLATION AND OPERATING INSTRUCTIONS

1. RECEIVING BATTERIES

Immediately upon receipt of shipment, examine the outside of the packing for signs of rough handling before accepting battery from carrier. If there is evident 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 inspection by the carrier, arrangements should be made with the local representative to have the battery repaired before placing it in service.

BEFORE PLACING BATTERIES IN SERVICE,

REVIEW AND ADHERE TO THE SAFETY GUIDELINES (ITEM 7).

2. PLACING IN SERVICE

All ELEMENT®batteries must be given an equalizing charge prior to their use. To accomplish this, connect the battery to an approved GNB the automatic charge control terminates.

charger and commence charging until

3. CHARGING

The charger must be matched to the battery with respect to voltage and ampere-hour capacity. The charger must be an approved GNB voltage-constant current profile that has automatic charge control features and a nominal finish rate of 2 amps per 100 ampere-hours of rated capacity. The constant voltage portion of the curve is 2.37 volts per cell. Under no circumstances should you attempt to remove the safety relief-valve vent cap. Such removal shall void the battery’s warranty and seriously impair battery performance.

OPPORTUNITY CHARGING IS NOT PERMITTED, EXCEPT IN APPROVED AGV APPLICATIONS.

USE OF ANY CHARGERS OTHER THAN APPROVED GNB CHA RGERS CAN RESULT IN PERMANENT BATTERY DAMAGE. CONTACT YOUR LOCAL GNB POW ER REPRESENTATIVE TO VERIFY PRO PER CHARGING.

charger with a constant current-constant

INDUSTRIAL

4. COOL DOWN

When the battery reaches an 80% depth of discharge, disconnect battery from the lift truck and connect to an approved GNB charge in eight hours or less. Once the charge is complete, the battery must be allowed to cool down for eight hours. At a minimum, the battery must be allowed to cool down for a time period equal to the time period spent on charge.

charger. The battery will normally reach full

BAT TERY REQUIRES COOL DOWN PER IOD FOLLOWING A CHARGE EQUAL IN TIME TO CHARGE PERIOD. FAILURE TO ALLOW FOR COOL DOWN WILL SHORTEN BATTERY LIFE.

5. EQUALIZING CHARGE

Each cell of a ELEMENT®battery ma y have slight differences in uniformity of construction and content. These slight differences cause some cells to take less charge than the other cells in the battery. To bring the cells with a lower state of charge up to the same level as the others, the battery is given an “equalizing charge”. The battery should be given an equalizing charge after 50-100 hours of operation. If you are unsure of battery use hours, give the batteries an equalize charge every two weeks.

6. AGV CHARGING

The battery/charger systems are “BALANCED” on each AGV application to maintain a design operating “STATE OF CHARGE” within the battery. This state of charge is dependent on such factors as:

• AMP-HOUR USED

• CHARGE TIME ALLOWED

• CHARGE CURRENT

Any plant operations that will cause these factors to deviate significantly from the original design could cause sufficient battery/charger imbalance affecting the battery life and performance. Plant deviations such as:

• Plant Shutdowns • Extended Testing

• Duty Cycle Change • Vacations

have the poten tial to cau se these imbalances. In general, when opportunity charging is being used, any nonoperational period of greater than 24 hours should be controlled to prevent extended battery charging. This can be accomplished in an AGV application by using the vehicle

P O S T T H E S E I N S T R U C T I O N S I N B A T T E R Y M A I N T E N A N C E A R E A .

INSTALLATION AND OPERATING INSTRUCTIONS (continued)

supervisory controls. GNB recommends a 7 hours on-charge17 hours off-charge control for these 24-hour periods.

7. SAFETY

• Warning: Risk of fire, explosion, or burns. Do not disassemble, heat above 38 degrees Celsius, or incinerate.

• Wear appropriate safety equipment when working around electrically live batteries.

• The ELEMENT

battery can emit hydrogen gases under some abnormal charging conditions. Whenever possible, charge in a well-ventilated area and keep open flames away from batteries. Howe ver, n orma l ware house ventilation is adequate for normal ELEMENT

usage.

• Lift batteries with a hoist, crane, lift truck, or similar equipment; move batteries on trucks, conveyors, or rollers. Make sure equipment is of ample strength and properly installed. Be sure to place a rubber mat or similar insulating material across tops of batteries without covers when handling. This will prevent accidental shorts.

• Disconnect battery from the truck when performing maintenance and repair on motor or electrical system.

• Open, or “break” battery circuit before attempting repairs to charging plug or receptacles.

• Familiarize yourself with batteries and rules for charging and handling. Contact your local GNB representative for information.

• Assign battery and charger care to properly trained personnel. Review your company safety regulations, and familiarize yourself with industry and government guidelines (OSHA, ANSI, etc.) to help reduce personnel accidents and equipment damage.

8. OPERATION

Batteries are rated in ampere-hour and are selected to perform a specific workload within an established period of time. Increasing the work load or time period could result in over discharging, thus shortening battery life. In general, all lead-acid batteries should not be discharged to more than 80% of its six-hour rated capacity. ONE BATTERY IS REQUIRED PER TRUCK PER EIGHT-HOUR SHIFT. If a lift interrupt is used or installed on the lift truck, a minimum interrupt voltage of 1.86 VPC (under load), 2.02 VPC (open circuit) multiplied by the number of cells, should be set to avoid overdischarge of the battery.

ADJUST LIFT INTERRUPT SETTING ON LIFT TRUCK TO A MINIMUM INTERRUPT VOLTAGE OF 1.86 VPC (UNDER LOAD), 2.02 VPC (OPEN CIRCUIT) MULTIPLIED BY THE NUMBER OF CELLS FOR ELEMENT

Since ELEMENT

is a VRLA battery, it’s state of charge cannot be approximated by specific gravity. However, average cell voltage (Volts per Cell) with the battery under load can be used to approximate the battery depth of discharge as shown in Figure 1. Alternatively, the battery at 80% depth of discharge will have an open circuit voltage equal to 2.02 VPC multiplied by the number of cells in the battery.

THE ELEMENT®BATTERY SHOULD NOT BE DISCHARGED BELOW 1.86 VPC (UNDER LOAD), 2.02 VPC (OPEN CIRCUIT) (80% DEPTH OF DISCHARGE)

BATTERIES

IGURE 1 - ELEMENT

ISCHARGE CURVE

9. BATTERY DISCHARGE ALARM/MONITORS

Your ELEMENT®battery is equipped with a Battery Discharge Alarm to protect your ELEMENT An intermittent 80-db alarm will start to sound whenever the battery's voltage drops to or below the alarm reference voltage for a fixed period of time. The alarm will stop if and when the battery's voltage recovers to above the alarm reference voltage within a fixed period of time. The battery is at 80% depth of discharge when the alarm sounds continuously. As soon as the alarm begins to sound continuously, the battery should be completely recharged using an approved charger and proper charging procedures.

Batteries may be equipped with monitoring devices by GNB. Damage to or tampering with these devices shall void all warranties. Any addition of monitoring devices affixed to the battery, not authorized in writing by GNB, shall void all warranties.

battery from over-discharge.

10. 48 VOLT ELEMENT®BATTERIES

Your 48 volt ELEMENT®battery may be equipped with an active cooling system. This will be evident by two fan cutouts on the battery cover and by "81" at the end of the battery part number. The following special considerations apply:

1. The fans will only operate when the battery is on charge or during the cool-down period (at or above fully charged open circuit voltage). The fans will not operate when the battery is plugged into the lift truck. If the fans continue to operate when the battery is plugged into the lift truck, contact your local GNB service representative immediately at 1-888-563-6300.

2. 48 volt ELEMENT cooling system must be removed from the lift truck for charging, and have a minimum of 6 inches of clearance on all sides of the battery for proper airflow.

Deviations from the proper operating instructions for 48 volt ELEMENT

batteries will void the warranty. Additional information and assistance can be obtained by contacting your local sales representative by calling 1-888-563-6300.

batteries equipped with the active

11. TEMPERATURE

Normal operating conditions shall be between 60°F and 100°F. Operating temperature above 100°F will reduce the

attery’s service life. Operating temperature below 60°F

b results in less capacity and special charging is required.

12. MAINTENANCE

Because this is a ELEMENT®battery, there is little to do regarding maintenance operations. The top of the battery should be kept clean and dry and may be washed to remove any accumulated foreign matter. In the unlikely event of an accidental contamination with electrolyte or lead, contain the spill and notify your local GNB representative who is equipped to handle any environmental concerns. Spill kits are available from the GNB Parts Center by calling (800) 634-4462.

CES INSTRUCTIONS DOIVENT ETRE EXPEDIEES AVEC LA BATTERIE ET FOURNIES A L’UTILISATEUR.

Never attempt to add water to the battery - it has been designed to function without any such additions over its

entire life. As previously noted, any attempt to remove the vent caps shall void the warranty.

13. CHANGES IN OPERATIONS

If any time after initial purchase you have changes to your operating conditions, such as extended shifts, increased loads or other changes that alter your initial purchase

onditions, please contact your local GNB representative

c immediately to ensure you are properly equipped and are not affecting the life of the battery.

14. SERVICE

Additional information and assistance can be obtained by contacting your local sales representative or in the USA call toll free 1-888-563-6300.

À LIRE AVANT DE METTRE LA BATTERIE EN SERVICE.

BATTERIES D'ACCUMULATEUR À FORCE MOTRICE AU

PLOMB-ACIDE À RÉGULATION PAR SOUPAPE (VRLA)

INSTALLATION ET UTILISATION

1. RÉCEPTION DES BATTERIES

Immédiatement après avoir reçu une livraison et avant d’accepter la batterie du transporteur, vérifier que l’extérieur de l’emballage n’a aucun signe de manutention abusive. S’il y a évidence de dommage, il faut signer le récépissé et marquer “Livraison reçue endommagée” sur les deux copies, celle du transporteur et celle de réception. Il faut appeler transporteur immédiatement et demander un “Rapport d’inspection de dommage par le transporteur.”

Si des avaries non apparentes sont découvertes plus tard, il faut appeler le transporteur immédiatement et lui demander de faire un “Rapport d’inspection par le transporteur d’avaries non apparentes.” Après inspection par le transporteur, il faut faire des arrangements avec le représentant local pour faire réparer la batterie avant de la mettre en service.

IL F AUT EXAMINER ET RESPECTER LES DIRECTIVES DE SÉCURITÉ (ARTICLE 7) AVANT DE METTRE DES BATTERIES EN SERVICE.

2. MISE EN SERVICE

Toute batterie ELEMENT®doit recevoir une charge d’égalisation avant d’être mise en service. Pour cela, brancher la batterie sur un chargeur GNB jusqu’à la fin automatique du cycle.

approuvé et faire la charge

3. CHARGE

La tension et la capacité du chargeur doivent correspondre à celles de la batterie. Le chargeur doit être un chargeur approuvé par GNB constantes, avec des fonctions de commande de charge automatique et une intensité finale de 2 A par 100 Ah de capacité nominale. La portion de tension constante de la courbe est de 2,37 volts par cellule.

LA CHARGE D’OCCASION DES BATTERIES EST INTERDITE SAUF DANS LE CAS DES APPLICATIONS AGV APPROUVÉES.

L’UTILISATION DE TOUT CHARGEUR AUTRE QU’UN CHARGEUR APPROUVÉ PAR GNB PEUT CAUSER DES DOMMAGES PERMANENTS DE LA BATTERIE. CONTACTER LE REPRÉSENTANT LOCAL DE GNB POUR VÉRIFIER LA PROCÉDURE DE CHARGE APPROPRIÉE.

avec une tention et une intensité

CES INSTRUCTIONS DOIVENT ÊTRE AFFICHÉES

DANS L’AIRE D’ENTRETIEN DES BATTERIES

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