IOP-427 RNS-3-SS

TP-602 - SAFETY AND DE-ENERGIZATION PROCEDURES

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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.

• Follow all federal, state and local requirements for handling and treatment of battery wash cabinet effluent.

• Recirculation/Neutralization System (RNS) units are not designed to be shipped or transported after initial delivery.

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

• Perform system and safety check before operating.

• Failure to follow these instructions and warnings may result in property damage, personal injury or death.

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 BWC per your corporate policy, if damaged or not functioning properly. Lockout/tagout and deenergize 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.

BATTERY WASH WATER HAZARDS

HEAVY METALS:

Battery wash water contains heavy metals including (but not limited to) lead and antimony, which through prolonged exposure can lead to serious, long-term, adverse health conditions.

EXTREME pH LEVELS:

Highly acidic (low pH) as well as highly alkaline/ basic (high pH) solutions can cause severe burns, release toxic fumes, and cause violent chemical reactions when mixed with water or when mixed together.

• pH values outside of the BHS allowable range of 5 to 9 should be treated as “extreme” and caution should be taken to avoid direct contact with such solutions.

• Always wear appropriate PPE including rubber apron, gloves, boots and full face shield when working in contact with any battery wash water.

TREATMENT CHEMICALS:

Use of chemicals not approved by BHS to treat wash water may result in the release of toxic fumes.

OPERATIONAL SAFETY

OPERATIONAL SAFETY

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

• Operators shall wear appropriate PPE suitable for working with industrial lead-acid batteries while operating the RNS (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.

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

• Only use BHS approved chemicals in the RNS. Severe chemical and/or toxic reactions may result.

DO’s AND DON’T’s

• DO NOT overfill the RNS reservoir.

• DO NOT operate the RNS when reservoir is empty.

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

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

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

• DO NOT immerse any body part into the RNS holding tank water.

• DO NOT use any chemicals in the RNS that are not approved by BHS.

• DO NOT use the RNS to wash anything other than industrial lead-acid batteries.

• DO NOT use foaming type detergents in conjunction with the RNS.

• DO NOT use soda ash or similar types of neutralizers.

• Use only fully liquefi ed neutralizers.

• DO NOT spray personnel or electrical components with spray wand (if equipped).

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

 » As an emergency wash station 
 » As a parts washer 
 » As a battery room wash-down device 
 » As a battery acid disposal device

DE-ENERGIZATION

1. Turn off and disconnect power to the RNS. (Note: The green power light will go out). See Figures 1.1 & 1.2.
• 

  FIGURE 1.1

• 

  FIGURE 1.2

2. Open the control panel door and remove the 17.5A fuse (the left most fuse) from the control board. See Figure 2.
3. Reconnect power to and turn on the RNS.
4. Press the RECIRCULATE button to activate the recirculation cycle (default time is 20 minutes). Turn off the RNS after 10 seconds. See Figure 3.
• 

  FIGURE 2

• 

  FIGURE 3

5. If equipped with a spray wand, hold the trigger on the wand to release any residual pressure. If connected to a BWC, cycle the BWC through one complete wash to release residual water pressure. See Figures 4 & 5.
Failure to release any stored water pressure could result in an unexpected spray of wash water.
• 

  FIGURE 4

• 

  FIGURE 5

6. Disconnect electrical power to the RNS.
Failure to disconnect electrical power to the RNS could result in electrical shock.

GENERAL INFORMATION

INTRODUCTION

The RNS-3-SS is a closed loop system to supply and recycle the water used in cleaning forklift batteries.

The main objective of the RNS-3-SS is to:

1.) Remove contaminants associated with lead/acid batteries.

2.) Filter and reclaim water for multiple cycles.

3.) Keep contaminants contained until proper disposal method is obtained.

The basic mechanical operation includes: pumping water from the reservoir through the fi lters, into a battery wash unit, through the sump assembly, and back into the reservoir.

The system consists of the following major components and assemblies.

A.) Completely self contained cabinet with integral 200 gallon tank.

B.) Electrical component area.

C.) Water control solenoid valve

D.) Filters

E.) Water Pump

F.) Sump pump and fl oat switch (remote mounted to wash cabinet)

WATER MONITORING GENERAL DESCRIPTION

The pH level of the water stored in the RNS-3-SS is monitored by a hand held meter which is supplied from the factory. It is the user’s responsibility to keep the pH level within acceptable levels in order to avoid damage to components. See Section 4-3 for pH monitoring information.

LEADING PARTICULARS

FRONT & SIDE VIEW OF UNIT

INSTALLATION

GENERAL

The following paragraphs provide installation instructions for the RNS-3-SS. Instructions provided include: unpacking, positioning, power and water installation.

The following tools and materials will be required for system installation:

Channel Lock Pliers
Screw Driver (Standard, 1/4” Blade)
Adjustable Wrench (1/2”)
Measuring Tape (12’)
Level (12”)
Water Hose (length as required)
Liquid Neutralizing Conditioner (LNC) - one gallon supplied

Optional:
Heat Gun (to aid in hose attachment)

UNPACKING

A.) Place package system in general area of its operating location. Location considerations should be: within proximity to water supply, electrical power supply, vehicle entrance, and battery station locations.

B.) Cut wrapping bands and unstrap the system. Be careful not to scratch, cut or bend any components on system while unpacking.

C.) Inspect the system components for any signs of damage. Take particular note of any evidence of rough handling in transit. Immediately report any damage to shipping agent.

D.) Utilizing plant’s best technique, lift RNS-3-SS from its shipping skids and remove the skids from the area.

POSITIONING

The RNS-3-SS should be positioned where it will not interfere with the battery washing operation. Also, the distance from the battery wash unit should accommodate the interconnections between the system and the battery wash unit. The following paragraphs provide instructions for positioning of the system assemblies.

A.) Move RNS-3-SS into a position not further than 10 feet from the battery wash unit.

B.) Ensure that unit is level. If necessary, place shims under feet to level.

POWER CABLE

Unit is supplied with an AC line cord. A dedicated, 120 volt, 20 amp circuit with GFCI protection is required. The use of an extension cord is not recommended.

INNER CONNECTION TO WASH CABINET

There are 3 connections from the RNS-3-SS to a battery wash cabinet. (Typical BHS model number BWC-2).

A.) Attach the 3/4” I.D. hose from the water outlet of the RNS to the water inlet of the BWC-2. Note: This connection should be made AFTER completing procedures in 2-6.

B.) Attach the 1” I.D. hose from the sump pump outlet to the return inlet of the RNS.

C.) Connect the DC line cord from the sump pump to the 12 volt DC power outlet of the RNS.

SEE FIGURES 1-4 AND 2-1

FIGURE 2-1

FIGURE 2-3

INITIAL START UP PROCEDURE

A.) Prior to final hook up of the 3/4” pressure line to the wash cabinet, take the end of the hose and route it to the inside of the wash cabinet or a drain.

B.) Plug the RNS in to a 120 volt receptacle that is GFCI protected. See Section 2-4.

C.) Move the power toggle switch to the “on” position. The unit should start pumping immediately.

D.) Run the unit until all air is purged from the water circuit then turn the power switch to the “off” position and disconnect the power cord from the receptacle.

E.) Proceed with the connection of the pressure line to the wash cabinet. The RNS-3-SS is now ready for normal operation.

NOTE: If the RNS is being used with a manual wash unit, follow all the instructions above except the pressure line will have a spray wand attached. Air purging can be done by depressing the trigger of the wand while powering up the RNS as described above.

OPERATION

CONTROL CONSOLE

OPERATING INSTRUCTIONS

The RNS-3-SS is an automatic “ON DEMAND” water supply system. Once the unit has been set up and had the initial start up procedure completed, it is ready to operate with no further requirements.

Simply put the power switch in the “ON” position and when the pressure switch senses a drop in pressure or fl ow demand, it will start the pump system as needed and shut off automatically when the demand has ceased.

PLUMBING CIRCUIT THEORY OF OPERATION

REFERENCE FIGURE 3-3

Water is pulled from the bottom outlet port of water tank through the shut off valve and a 100 mesh strainer to the pump inlet.

The water from the pressure side (outlet side) of the pump fl ows through a reverse fl ow check valve, past the main system relief valve, pressure sensor, and gauge. The relief valve is activated if there is a failure in the pump or pressure switch that could cause over pressurization to occur.

Water is then pushed through the 5 micron filter assembly to the solenoid operated water valve.

Under normal operating conditions the solenoid operated valve for the recirculate mode is closed and is activated only when the recirculate function is actuated.

As demand/flow is required at the wash cabinet, the output water goes into the sump area of the wash cabinet base where a float switch is located.

When the water in the sump reaches a depth adequate to energize the float switch, it then energizes the sump pump mounted on the back of the wash cabinet that pumps the spent water back to the RNS return inlet.

As the water passes through the inlet it is dumped into a 50 micron bag filter to remove any debris larger than 50 microns.

The water is held in storage for recycling through the system