IOP 404 BP-MS

TP-IOP 404 BP-MS - SAFETY AND DE-ENERGIZATION PROCEDURE

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GENERAL SAFETY

• Read and understand all instructions and warnings before using or servicing this equipment.

• Keep these instructions for future reference.

• Battery Extractor (BE) units shall only be operated by suitable persons of at least 18 years of age, who have been trained in the proper and safe operation of the BE and expressly certified/charged, in writing, by the user or their representative.

• Only one person is permitted to travel on the BE at any time.

• BE units shall only be used indoors in an industrial setting on a hard, nonslip, and level floor without defects including but not limited to holes, gouges, cracks, drains or obstacles comprised of concrete or other suitable industrial material meeting the minimum requirements specified by BHS as well as any local requirements.

• A licensed structural engineer should be consulted prior to installing a BE on any building level other than the ground floor.

• BE units are not designed to be shipped or transported after initial delivery.

WORK AREA

• Keep work area clean and well lit. Cluttered work areas and poor lighting can lead to accidents.
• Clean up/contain any fluid spills immediately to prevent slips or falls.
• Be aware of potential hazards when performing any service or maintenance to the unit.

SERVICE & MAINTENANCE

Service personnel shall wear Personal Protective Equipment (PPE) appropriate for the task being performed.

LOCKOUT/TAGOUT

Lockout/tagout the BTC per your corporate policy, if damaged or not functioning properly. Lockout/tagout and de-energize all systems prior to performing any maintenance or service to unit.

LEAD-ACID BATTERIES-EXPLOSION HAZARD

Do not allow open flames or sparks of any kind near a battery. Highly explosive gas is generated when charging a battery that can remain in battery cells for extended periods of time after charging is complete.

• Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when performing service or maintenance to any lead-acid batteries.

• Do not place metal or other conductive objects on top of battery. Arcing may occur causing damage to the battery and/or serious personal injury or death.

• Use only chargers matching the voltage and amperage of the battery being charged. Overcharging a battery can cause damage to the battery, charger and/or serious personal injury or death.

• Turn off charger before disconnecting battery from charger. Arcing between battery and charger connectors can cause damage to the connectors and/or serious personal injury or death.

HYDRAULIC HAZARD

AVOID HIGH PRESSURE FLUIDS-Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Keep hands and body away from pin holes which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand.

Any fluid injected into the skin under high pressure should be considered a serious medical emergency despite an initial normal appearance of the skin. There will be a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately.

OPERATIONAL SAFETY

OPERATIONAL SAFETY

• Only personnel trained in the proper and safe operation of BE units may operate or service the BE

• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the BE (see prior page).

• All data plates, warning labels, placards, etc shall be in place and legible at all times. Contact BHS for replacement data plates, warning labels, placards or instructions.

• All users and service personnel shall be familiar with the meaning and risks associated with all data plates, warning labels, etc.

• All operators and service personnel shall be aware of potential crush and shear points while operating or servicing the BE.

• Keep hands and arms out of the battery compartment while operating the BE.

• Remove BE from service if damaged, defective, or operating improperly (or becomes such while operating) until repairs can be made to correct any problem(s).

• All operators shall be aware of the location of the end stops in the travel path to prevent driving the BE into the end stops.

DO’s AND DON’T’s

• DO NOT exceed the maximum capacity of the BE.

• DO NOT modify or fit the BE with attachments without prior, written approval from BHS.

• DO NOT perform any maintenance or service to the BE with a battery loaded on the BE.

• DO NOT allow anyone to ride in or on the BE.

• DO NOT operate the BE with any guard or cover removed unless required for maintenance or repair.

• Disconnect the BE from all power sources before attempting to perform service or maintenance to the unit.

• DO NOT drive the BE into the end stops.

• DO NOT operate the BE if disengaged from the guidance track.

• DO NOT allow a battery to exit the BE when a lift truck or battery stand is not present to accept the battery.

• DO NOT use the BE in a manner for which it is not intended. Some examples of prohibited use are but not limited to:

           >>To transport people 
           >>As a vehicle jack
           >>To lift loads greater than its rated load capacity
           >>Where unintentional movement may exist
           >>Having direct contact with foodstuff
           >>In a potentially explosive atmosphere

DE-ENERGIZATION

1. Fully lower the BE roller bed.1.
Failure to lower the inner carriage when performing service to the BTC could result in injury from the roller bed lowering unexpectedly.


FIGURE 1

BTC-MPPEL/MPPEE/MPPAE:

1. Unplug the battery charger (if equipped).
2. Disconnect the positive cable from the battery post. Secure the positive cable so it cannot contact the positive battery post. See Figure 2.
Failure to disconnect electrical power to the BTC could result in electrical shock.


FIGURE 2

3. Cycle the manual valves several times to relieve stored hydraulic pressure. See Figure 3.
Failure to release any stored hydraulic pressure could result in injury from: Escaping hydraulic fluid under high pressure (see HYDRAULIC HAZARDS in the GENERAL SAFETY section). Unexpected movement of hydraulic components.


FIGURE 3

Pre-Installation

BATTERY ROOM CONSIDERATIONS

It is not permitted for unauthorized persons to enter the BE travel path and its approach areas or for persons to use it for access to other areas. Entry to these zones shall be restricted to specially authorized persons who have been properly informed on and use measures provided for their safety. Each person entering a machine operating area through an open door shall ensure that the main isolator remains disconnected by means of a personal locking device such as a padlock or an equivalent device. Refer to page A.1 for a list of general safety guidelines.

FLOOR CONDITIONS

The floor is the single most critical area of the battery room. A bad floor can cause significant issues with the installation as well as downtime and maintenance problems with the extractor. The floor should be verified as to its minimum thickness and strength with user. As noted on the drawing, the specific requirement of flatness for your particular type of system is listed. Below is a chart stating floor requirements. If possible, especially on double stack and higher systems, a digital level should be used to shoot the grade for compliance with the specification. The floor should also be inspected for severe cracks or excessively wide expansion joints in the travel path of the machine. If floor drains are present, they must not have a grade to the opening that encroaches into the travel pat

Prior to commissioning the battery extractor system into service, the "Battery Extractor System Start-up Check List" (IF-5025) shall be completed and submitted to Battery Handling Systems, Inc. A copy of this form can be found on the

Operation Overview

All operators should be familiar with the operator console of the extractor before performing any battery changes. The controls of the console are simple and well marked. It consists of four, manually operated, hydraulic control valves and a two position selector switch which controls the magnet.

• The operator shall make certain there are no persons or obstacles in the extractor path prior to traveling forward or reverse.
• The floor drive and magnet near/far valves are moved in the direction of the function travels which they control. The lift/lower valve is pulled toward the operator for “up” and pushed away for “down.” The arm left/right valve is pulled toward the operator to move the arm to the left and pushed away to move the arm to the right.
• In the event of any failure or malfunction, step off the foot switch and all functions will stop immediately, locking all hydraulics in place.
• To ensure smooth operation, all valve movements should be made in a slow, deliberate motion.
• Only one key should be provided to operate the extractor.
• When leaving the machine, the operator shall turn off the key switch and remove the key to prevent unauthorized use.
• Ensure all the batteries and cables are properly stored in the battery stands prior to moving the BE.
• The BE is designed to carry only one battery in each compartment on the carriage.
• When loading the BE, position the batteries in the center of the compartments to prevent any battery movement when transporting.
• Ensure there are no projections outside of the carriage before moving

Operating Instructions

PRE-CHANGE OUT PREPARATION

1. Position lift truck for change out in designated area.
2. Remove all battery restraints and disconnect battery cables following manufacturers guidelines. (Be sure to position battery cables so as not to be damaged by the battery during change out.)
3. Board battery extractor and depress foot pedal.
4. Turn key switch to “ON” position

DISCHARGED BATTERY REMOVAL

1. Move extractor forward or reverse to position center of empty compartment with center of lift truck battery compartment. (Lead roller of extractor is equipped with a centering groove. Users may find it beneficial to mark center of lift truck compartment to aid in alignment.)
2. Align extractor’s roller compartment height with lift truck’s battery compartment.
3. Rotate magnet to face lift truck.
4. Move extractor arm into battery compartment aligned in Step 2.
5. Move extractor arm toward battery until magnet contacts battery. DO NOT force cup/magnet to battery after initial contact with battery is made.
6. Energize magnet by turning selector switch on.
7. Move extractor arm away from lift truck toward center of extractor roller bed, removing discharged battery. (Battery should be pulled past the center friction stops and centered left to right in the compartment.)
8. Turn off magnet and move extractor arm away from battery 1” to 2” (25 mm to 50 mm).
9. Move extractor arm out of battery compartment into opposite compartment (if empty) and center arm in carriag

CHARGED BATTERY RETRIEVAL

1. Locate charged battery for appropriate type of lift truck being changed.
2. Disconnect desired battery from its charger and disengage battery safety stop. ALWAYS be sure charging has been completed and charger is not still charging battery. Dangerous sparking/arcing can occur if battery is unplugged from charger while charging.
3. Move extractor to appropriate rack position and align empty roller compartment with the center of the battery storage rack compartment. (The battery safety stop of each compartment is the center of that compartment and should be used for alignment with the groove in the lead roller of the battery extractor compartment.)
4. Rotate the magnet to face the battery to be retrieved.
5. Move arm into empty compartment (if not already positioned there.)
6. Move extractor arm toward battery until magnet contacts battery.
7. nergize magnet by turning selector switch on. DO NOT force cup/magnet to battery after initial contact with battery is made.
8. Move extractor arm away from battery rack toward center of extractor roller bed, removing charged battery. (Battery should be pulled past the center friction stops and centered left to right in the compartment.)
9. Turn off magnet and move extractor arm away from battery 1” to 2” (25 mm to 50 mm).
10. Move extractor arm out of battery compart

DO NOT drive the BE into the travel path end stops. The end stops are designed to prevent the BE from accidentally traveling beyond its designated travel path. Driving the BE into the end stops will cause the BE to stop suddenly, possibly causing damage to the end stop, the BE and/or personal injury.

DISCHARGED BATTERY RETURN

1. If required, adjust extractor compartment height to battery rack level with open battery compartment. Drive extractor to align roller compartment containing discharged battery with open battery compartment.
2. Return discharged battery to battery rack using powered rollers. NOTE: No magnet is necessary for pushing. DO NOT activate magnet switch. Slowly push battery into rack until fully into compartment.
3. Engage battery safety stop and connect battery to charger as required