Exide Technologies GB4146 User Manual

PLEASE READ THESE INSTRUCTIONS BEFORE PLACING BATTERIES INTO SERVICE.

™

THESE INSTRUCTIONS MUST BE SHIPPED WITH THE BATTERY AND

MUST BE DELIVERED TO THE USER.

INSTALLATION AND OPERATING INSTRUCTIONS

FOR FLOODED TUBULAR-HP®AND TUBULAR-LM™ FAST CHARGE

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.

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.

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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.

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.

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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 condition; 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.

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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… U nder normal fast cha r ge opera ting cond itions, t he
electrolyte temperature shall be between 60-140° F. 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… 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

• Check electrolyte levels (see water additions).

• Equalize charge.

MONTHLY

• Record electrolyte specific gravities.

• Visual inspection and confirmation that the battery-mounted monitor is
functioning properly.

• Inspect the cables and charging plugs.

• Clean the top of the cells.

SEMI-ANNUAL

• Inspect the charger. Confirm proper output voltage and current. Check for
external damage, frayed cables, or worn connectors.

• Clean the exterior of the battery.

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TROUBLE SIGNS

JAR

HIGH
WATERING
LEVEL

LOW
WATERING
LEVEL

COVER

VENT WELL

POST

1.25”

2.0”

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.

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 ABOVE SCHEDULE EVEN WITH THE USE OF A WATERING SYSTEM.

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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.

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A Division of Exide Technologies

GNB Industrial Power –

™

The Industry Leader.

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

GNB
HIGH PERFORMANCE, TUBULAR-LM™ LOW MAINTE­NANCE, ELEMENT
symbolize quality, reliability, performance and excellence in

all the markets served.
countries) in sales and service, GNB Industrial Power is best
positioned to satisfy your power needs locally as well as all
over the world.

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 recy­Based on over 100 years of technological innovation, the
Motive Power group leads the industry with the most recog­nized global brands, such as GNB

®

FLOODED CLASSIC®,

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: [phone]
Canada – Tel: [phone]

®

®

FLOODED CLASSIC PLATINUM™, TUBULAR-HP

®

and GNB®FUSION™. They have come to

®

www.gnb.com

GB4146 2013-06