Exide Technologies GB3979 User Manual

PLEASE READ BEFORE PLACING BATTERIES IN SERVICE

THESE INSTRUCTIONS TO BE SHIPPED WITH BATTERY AND

TO BE DELIVERED TO USER

INSTALLATION AND OPERATING INSTRUCTIONS

FOR FLOODED TUBULAR-HP MOTIVE POWER BATTERIES

1. SAFETY

1.1 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.

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1.2 Assign battery and charger care to properly trained personnel.

1.3 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.

1.4 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.

1.5 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.

1.6 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 equipment is of ample strength and properly installed.

DO NOT USE CHAIN OR WIRE ROPE SLINGS.

1.7 Never lay metal tools, such as wrenches or screwdrivers, on top of a battery.

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

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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
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. Use a charger with
automatic charger termination controls. GNB Industrial Power recommends the use of a

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GNB

SCR charger.

Open 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. 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 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.

Following the first week of service, the battery should reach its normal operating specific
gravity of 1.310 to 1.320 for 100T and 140T cells at 77° F (25° C).

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6. CHARGING

When recharging a fully discharged battery, the starting charge rate may be 3 to 5 times
higher than the finish charge rate. The charge rate should taper down to the finish rate
by the time the battery is 85% charged and may be even lower when fully charged. 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.

The ampere-hour rating of the charger applied to the battery should be within 10% of the
ampere-hour rating of the battery.

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 specific gravities, equalizing, charging, temperature, and

voltages on a monthly basis. These records are required to maintain your warranty.

TEMPERATURE… Unde r normal operating cond itions, the electr olyte
temperature shall be between 60-100˚ F (15-37˚ C). Operating temperature
above 100˚ F will reduce the battery’s ser vice life. Operating temperature below
60˚ F results in less capacity and special charging is required.

WATER ADDITIONS… Add water at the end of the charging period when the battery is
fully charged and the charger has tapered to its finish rate. See Item 9.

EQUALIZE… Once a week for heavy application (e.g., 80% daily discharge) to once a
month for light duty application (e.g., less than 50% daily discharge). If the Tubular-HP

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battery is charged with a GNB

EHF-series charger set for the Tubular-HP charge profile,

equalization should be performed every 12 weeks.

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 9.

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