Exide Technologies FLOODED FLAT-PLATE FAST CHARGE MOTIVE POWER BATTERIES GB4145 2011-10 - Manual (Page 2)

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 Titan 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 perforated,
plastic element protector. 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 (25˚C).
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 Titan 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.
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 motive power batteries are designed
and built to deliver 80% of their rated capacity at
77˚ F (25˚C.)
5. TEMPERATURE
In the operation of fast charge lead-acid batteries, the
electrolyte temperature must not exceed a maximum of
140˚F (60˚C), and must maintain an average temperature
of 125˚F (52˚C). 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
representative for service.
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, and voltages
on a monthly basis. These records are required
to maintain your warranty.
• TEMPERATURE… Under normal fast charge
operating conditions, the electrolyte
temperature
shall be between 60-140˚ F (15-60˚ C). 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.
9. WATER ADDITIONS
Maintain electrolyte levels above the bottom of the
perforated, plastic element protector, but no higher
than 1/8" from the bottom of the cell cover 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 element protector) 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 between 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 representative if
you are not sure of your water quality.
10. SERVICE AND PARTS
Your local GNB sales representative has more
information regarding the full range of maintenance
and repair service available. GNB 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 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 offers disposal
service for lead acid batteries. Call 1-888-438-5865 to
arrange a pick-up or to get additional information.
• WATER ADDITIONS… GNB-approved fast
chargers have the capability for equalize charging
at specific times and days of the week (eg.
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.
TROUBLE SIGNS
• Battery temperature averages more than
125˚F (52˚C).
• 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
them 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 servicing representative.
The solution used to clean and neutralize the outside of
the batteries should be disposed of in an environmentally
safe manner.
BATTERIES MUST BE VISUALLY INSPECTED
PER THE ABOVE SCHEDULE EVEN WITH THE
USE OF A WATERING SYSTEM.
BEFORE PLACING BATTERIES IN SERVICE,
REVIEW AND FOLLOW THE SAFETY
GUIDELINES LISTED IN ITEM 1. SAFETY.
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.
VENT WELL
HIGH
COVER WATERING
LEVEL
1.2”
2.2”
ELEMENT
PROTECTOR
LOW
JAR WATERING
LEVEL