Exide Technologies GB3914 User Manual

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

PLEASE READ BEFORE PLACING BATTERIES IN SERVICE

POW’R PAK VRLA

ELECTRIC VEHICLE 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 6).

2. PLACING IN SERVICE

All ELEMENT batteries must be given a freshening
charge prior to their use. To accomplish this, connect
the battery to the on-board SCR charger and commence
charging until the charger indicates that it is in the float
stage.

3. CHARGING

The charger is matched to the battery with respect to
voltage and ampere-hour capacity. The charger is a
GNB-approved high frequency charger with a CC-CV­CC profile which includes automatic charge control
features. The constant voltage portion of the curve is
set at 2.37 volts per cell.

The charger will automatically switch to float voltage of

2.28 volts per cell once the CC-CV-CC standard charge
has completed.

TO BEGIN CHARGING: ALWAYS CONNECT
THE BATTERY TO THE CHARGER PRIOR TO
CONNECTING THE CHARGER TO AC POWER.

TO STOP CHARGING: ALWAYS DISCONNECT
THE CHARGER FROM AC POWER PRIOR TO
DISCONNECTING THE BATTERY FROM THE
CHARGER.

FAILURE TO FOLLOW THIS SEQUENCE MAY
CAUSE CHARGER DAMAGE.

4. COOL DOWN

When the battery reaches an 80% depth of discharge,
disconnect battery from the lift truck and connect to
the on-board SCR charger. The battery will normally
reach full charge in 12 to 16 hours. Once the charge
is complete, the battery must be allowed to cool down.

BATTERY REQUIRES COOL DOWN PERIOD
FOLLOWING A CHARGE. FAILURE TO ALLOW
FOR COOL DOWN WILL SHORTEN BATTERY
LIFE.

5. OPPORTUNITY CHARGING

The ELEMENT battery is capable of being charged
during any breaks or downtime to provide additional
capacity within a given shift. Guidelines for opportunity
charging are as follows:

• Battery in the range of 30% - 60% depth of discharge

• Allow for full charge at least once per week

• Avoid duty cycle changes that would allow this
battery to sit discharged for periods greater than 24
hours

6. 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.

• 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.

• 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. However, normal
warehouse ventilation is adequate for normal usage.

• Lift batteries with hoist, crane, lift truck, or similar

equipment; move batteries on trucks, conveyors, or
rollers. Make sure equipment is of ample strength
and properly installed.

• 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.

POST THESE INSTRUCTIONS IN BATTERY MAINTENANCE AREA.

• Familiarize yourself with batteries and rules for

f technological innovation, the

®

FLOODED

CLASSIC

®

, TUBULAR-HP®, ELEMENT®, LIBERATOR®, GNB

®

FUSION™, ELEMENT®GEL, and SONNENSCHEIN®. 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
better environment. Its Total Battery Management program,
an integrated approach t

o manufacturing, distributing and
recycling of lead acid batteries, has been developed to help
ensure a safe and responsible life cycle for all of its products.

A Division of Exide Technologies

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.

7. 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. In a typical application, 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 multiplied by the number of cells, should be

set to avoid over discharge of the battery.

ADJUST LIFT INTERRUPT SETTING ON LIFT
TRUCK TO A MINIMUM INTERRUPT VOLTAGE
OF 1.86 VPC MULTIPLIED BY THE NUMBER OF
CELLS FOR ELEMENT BATTERIES

Since an ELEMENT battery has unremovable vent
caps, its state of charge cannot be approximated by
specific gravity measurement. 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 FIG. 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 VOLTS PER CELL
(80% DEPTH OF DISCHARGE)

8. TEMPERATURE

Normal operating conditions shall be between 60°F and
100°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.

FIG. 1 - ELEMENT DISCHARGE CURVE

2.2

2.1

2

1.9

1.8

AVE. VOLTS PER CELL (VPC)

1.7

1.6
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%0%

FULLY CHARGED

BATTERY DEPTH OF DISCHARGE (D.O.D.)

9. MAINTENANCE

Because this is a maintenance-free battery, there is
little to do regarding maintenance operations. The top
of the battery should be kept clean and dry and maybe
dusted to remove any accumulated foreign matter. In
the unlikely event of accidental contamination with
electrolyte, wash with a neutralizing solution (or one­gallon water mixed with one pound of baking soda or
commercial soda ash). Follow with a rinse using clear
water. Ensure waste water is disposed of in accordance
with Federal, State and Local regulations. Blow excess
water off the top of the battery using compressed air. In
the event of an accident involving a battery, notify your
local GNB representative who is equipped to handle
any environmental concern. 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.

10. 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 conditions, please contact your local GNB
representative immediately to ensure you are properly
equipped and are not affecting the life of the battery.

11. 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.

DO NOT OPERATE BATTERY

IN THIS REGION

80% DISCHARGED

VOLTAGE = 1.90 VPC

FULLY DISCHARGED

ELEMENT® and ABSOLYTE® are registered trademarks of Exide Technologies.

GNB Industrial Power

USA – Tel: [phone]
Canada – Tel: [phone]

www.gnb.com

GB3914 2013-03

36
2698