Exide Technologies GB4103 User Manual

™

PLEASE READ BEFORE PLACING BATTERIES IN SERVICE

RECYCLE

THESE INSTRUCTIONS TO BE SHIPPED WITH

BATTERY AND TO BE DELIVERED TO USER

FLOODED FLAT-PLATE AND TUBULAR-PLATE FAST CHARGE

AND OPPORTUNITY CHARGE MOTIVE POWER BATTERIES

INSTALLATION AND OPERATING INSTRUCTIONS

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.

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.

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.

P O S T T H E S E I N S T R U C T I O N S I N TH E BATT E RY MA I N T E N A N CE A R E A .

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 requires the use of a GNB Fusion with GNB FusionTMbatteries.

Remove the vent caps from each cell and check to see that the electrolyte level is above the plates. 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. Replace 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 element protector, recheck it after 3 hours of charging. If the level remains below the element protector, add water or electrolyte to the proper level at the end of charging.

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;

charger

diligent to "plug in" at all opportunities throughout the

ay, including breaks, meals, and shift changes. Care

d must be taken to ensure specific gravity readings in

he battery cells do not go below 1.160 at any time.

GNB Fusion, Tubular-HP, Tubular-LM, and

NB Flooded Classic Platinum Batteries are designed

G for opportunity charging during breaks, meal times, and shift changes. When not being used, the battery should always be connected to the Charger.

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.

Flooded flat-plate and 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 and opportunity charge leadacid batteries, the electrolyte temperature must never exceed a maximum of 140°F, with a maximum average temperature of 125°F when measured over one week of operation. Following the end of the day full charge, the battery should be allowed to cool to ambient temperature prior to the next discharge.

If a battery consistently operates at temperatures close to the allowable maximums, contact your local GNB Industrial Power representative for service.

6. CHARGING

The start rate of a fast or opportunity 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 Industrial Power representative on specific charging problems.

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 and opportunity charge systems are designed to return a significant amount of ampere-hours in short periods of time, these batteries are capable of delivering 160% of their rated capacity within a 24-hour period. To achieve such high levels of usage, operators must be

7. MAINTENANCE

• KEEP RECORDS… Showing specific gravities,

equalizing, charging, temperature, and voltages on a monthly basis. These records are required to maintain your warranty.

• TEMPERATURE… Under normal fast charge and

opportunity charge operating conditions, the electrolyte temperature shall be between 60140°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.

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