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GNB TUBULAR-LMX User Manual

GNB TUBULAR-LMX
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POST THESE INSTRUCTIONS IN THE BATTERY MAINTENANCE AREA
TUBULAR-LMX™ LOW MAINTENANCE 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 afxed 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, lling,
charging or repairing batteries.
1.4 Keep water readily available for ushing spilled electrolyte from eyes or skin. Use plain water
only and obtain medical attention immediately. Special deluge showers and eye washbasins
are required.
1.5 Batteries produce hydrogen and oxygen gas during charge. Keep open ames away. Do not
check electrolyte level with a cigarette lighter or match. Use a ashlight 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 certied/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.
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
oor. Check local regulations regarding the disposal of neutralized waste.
DO NOT USE CHAIN OR WIRE ROPE SLINGS.
Page 1
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GNB TUBULAR-LMX Specifications

General IconGeneral
BrandGNB
ModelTUBULAR-LMX
CategoryCamera Accessories
LanguageEnglish

Summary

Safety Instructions

General Safety Practices

Follow company safety instructions, observe caution labels, and familiarize with industry guidelines for battery handling.

Personnel Training

Assign battery and charger care only to properly trained personnel for safe operation and maintenance.

Electrolyte Handling PPE

Avoid contact with sulfuric acid electrolyte. Wear appropriate PPE like gloves, goggles, and apron during handling.

Emergency Flushing

Keep water readily available for flushing spilled electrolyte from eyes or skin. Obtain immediate medical attention.

Charging Hazards

Keep open flames away during charging due to hydrogen gas. Use flashlights, not matches or lighters.

Lifting and Moving

Use certified equipment for lifting and moving batteries. Place insulating material across tops of coverless batteries.

Tool Safety

Never lay metal tools, such as wrenches or screwdrivers, on top of a battery to prevent short circuits.

Maintenance Disconnection

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

Circuit Interruption

Open or "break" the battery circuit before attempting repairs to the charging plug or receptacles.

Spill Neutralization

Neutralize spilled electrolyte with baking soda or soda ash. Check local regulations for waste disposal.

Receiving and Placing Batteries

Inspection Upon Receipt

Examine packing for rough handling and wet spots indicating leaks before accepting shipment from the carrier.

Reporting Damage

Mark receipts as "Shipment Received Damaged" and call the carrier immediately to report any damage found.

Concealed Damage

Report "concealed" damage to the carrier immediately and arrange for an inspection and potential repair.

Initial Placement Checks

Verify battery weight, allow temperature adjustment, and ensure the charger is properly matched to the battery.

Electrolyte Level Check

Check electrolyte level is above plate separators. If low, replace with electrolyte of the same specific gravity.

Freshening Charge

Give the battery a freshening charge until there is no increase in specific gravity over three one-hour intervals.

Post-Shipment Recheck

Recheck electrolyte level after 3 hours of charging if low due to shipment. Add water or electrolyte if still below separators.

Normal Operating Gravity

The battery should reach its normal operating specific gravity of 1.295 to 1.345 at 77° F (25° C) after 90 days.

Operation and Charging

Discharge Limits

Limit discharging to 80% (specific gravity not below 1.180) to prevent over-discharging and shorten battery life.

Typical Operation Cycle

Batteries are designed for an 8-hour discharge, 8-hour charge, and 8-hour cool-down cycle.

Rated Capacity

Tubular-LMX™ batteries deliver 80% of their rated capacity at 77 °F (25 °C) per cycle.

Temperature Management

Maintain electrolyte between 60-100°F (15-38°C). Avoid exceeding 110°F (43°C) to preserve service life.

Post-Charge Cooling

Allow the battery to cool down for approximately 8 hours after charging before the next discharge cycle.

Hot Battery Handling

If a battery is hot to the touch, let it cool to room temperature before charging or discharging.

Charge Rate Taper

Starting charge rate is 3x finish rate, tapering down as battery reaches 85% charged.

Overcharging Indicators

High on-charge temperatures or frequent water additions may indicate overcharging.

Recharge Adequacy

Short running times or low end-of-charge specific gravities can indicate inadequate recharge.

Charger Rating Match

The charger's ampere-hour rating should be within 10% of the battery's ampere-hour rating.

Maintenance Schedule and Procedures

Record Keeping

Keep records of charging, watering, specific gravity, temperature, and open circuit voltages for warranty.

Temperature Monitoring

Maintain electrolyte between 60-100 °F. Operating above 100°F reduces service life; below 60°F reduces capacity.

Watering Intervals

Add water after 45/90 days or when specific gravity reaches 1.335-1.345, at the end of charging.

Equalization Charging

Equalize charge every 10 duty cycles to 80% DOD or bi-weekly, and after each water addition.

Depth of Discharge

Do not discharge beyond 80% of rated capacity; over-discharging voids warranty and shortens life.

Cleaning

Keep the top of the battery clean and dry.

Bi-Weekly Maintenance

Equalize charge the battery.

45/90 Day Maintenance

Check cell electrolyte levels and add water. Record gravities, temperatures, and voltages after watering.

Annual Maintenance

Inspect charger, check cables, connectors, and exterior for damage.

Troubleshooting and Water Additions

Trouble Signs

Monitor battery temperature, cell voltages, specific gravities, and top dryness for operational issues.

Maintenance Cleaning

Keep battery top clean and dry. Remove vent caps only for essential checks or additions.

Water Addition Procedure

Maintain level above separators, not above 1/8" from vent well bottom. Add water as needed, preferably at charge end.

Water Quality Requirements

Use only distilled water or water known to be free of impurities. Contact GNB for water quality concerns.

Electrolyte Level Sensor and Watering System

Sensor Installation

Acid resistant sensor installed in a central cell; lead wire attached to negative post of second cell.

Sensor Operation Indicator

Light ON and FLASHING indicates recommended electrolyte level. Light OFF means water addition is needed.

Sensor Troubleshooting

Check sensor operation by lifting it out. Verify lead wire connections if light remains ON or FLASHES.

Single Point Watering System

BWT system fills all cells to proper height efficiently with one connection.

Watering System Requirements

BWT Plug Assembly Function

Plug assembly controls watering to 1/8" below vent well at end of recharge, using a float and valve.

Filtration

Supply water should be filtered (20-micron or finer recommended) to remove particles and debris.

Pressure Requirements

Minimum reservoir height ten feet; 15 psi static system pressure recommended. Adjust for flow rate.

Fill Time

Connect system for 1-3 minutes until flow indicator stops. BFS recommends filling for two minutes with timer.

Water Quality Analysis

Use water meeting strict limits for total solids, fixed solids, organic material, iron, manganese, nitrates, etc.

Service, Parts, and Recycling

Watering Precautions

Disconnect from charging equipment, ensure battery is clean, and wear safety glasses before watering.

Service and Parts

Contact local GNB representative for maintenance, repair, and replacement parts for batteries and chargers.

Recycling Lead Acid Batteries

Follow U.S. Federal and State regulations for handling and disposal. GNB offers disposal service.

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