IOP-425 RNS-1

TP-601 - 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 RNS 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 attempt to move the RNS using a pallet or lift truck with a capacity of less than 2,000 pounds.

• 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. Place the RNS power switch into the center or “OFF” position. See Figure 1


FIGURE 1

2. Place the pump circulation valve in the recirculate position.
Units built prior to 09/01/03:
• Rotate the valve handle to the “R” position and move the handle to the horizontal position. See Figures 2.1 & 2.2.
• 

  FIGURE 2.1

• 

  FIGURE 2.2

Units built from to 09/01/03 to present:

• Rotate the valve handle clockwise to the vertical position. See Figure 3.


FIGURE 3

3. Rotate the valve on the intake strainer counter 3. clockwise to the closed position. See Figure 4.


FIGURE 4

4. If connected to a BWC, unplug the RNS auto start cable from the BWC. See Figure 5.


FIGURE 5

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 6 & 7.
Failure to release any stored water pressure could result in an unexpected spray of wash water.
• 

  FIGURE 6

• 

  FIGURE 7

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-1 is a closed loop system to supply and recycle the water used in cleaning forklift batteries.

The main objective of the RNS-1 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 filters, into a battery wash unit, through the sump assembly, and back into the reservoir.

FUNCTIONAL DESCRIPTION

The following paragraphs provide the functional description of the RNS-1 system’s major components and assemblies. (See Figure 1-1, page 4)

A.)Reservoir - The reservoir is a 125 gallon polyethylene container that stores the battery cleaning water.

B.) Electrical Enclosure Assembly - The electrical enclosure houses the electrical control components and assemblies. The enclosure cover holds the Selector Control Switch and green power indicator lamp.

C.) Selector Control Switch - The Selector Control Switch provides “OFF”, “ON” and “AUTO” switch positions.

D.) Manually Operated pH Probe - The hand-held pH meter is used to monitor pH level of the water in the RNS unit. (See Section 1-3)

E.) Water Control Valve - The Water Control Valve directs the system’s water flow from the 5 micron filters to either the battery wash unit or back to the reservoir.

F.) Filters - There are two 5 micron filter cartridges, connected in parallel, to filter water contaminates in the system.

G.) Water Pump - The water pump circulates the water through the system.

H.) Sump Assembly - The sump assembly is located in the wash unit. The sump assembly receives the drained water from the battery wash unit and returns it to the RNS-1 reservoir. When the water in the sump pan reaches a certain level, the fl oat switch turns on the sump pump and water is pumped back to the reservoir.

I.) Reservoir Support - In addition to supporting the reservoir, the reservoir support also supports the water control valve, water pump, 5 micron filters, and the electrical enclosure.

pH LEVEL MONITORING

Consistent monitoring of pH levels in recirculation and neutralization systems is the single most important step in preventing part failures, insuring smooth operation and extending the life of the system. Failures due to improper pH levels will not be covered under warranty.

The pH level should never drop below 5.0 or rise above 9.0. Allowing the pH levels outside these parameters will result in premature failure of the sump pump and float switch in the battery wash cabinet. Left unchecked, further damage may be done to the relief valve and the system pump in the RNS.

It is recommended that pH levels are checked at least daily under normal conditions. If a large number of batteries are going to be washed or if batteries that have not been well maintained are going to be washed for the fi rst time, it is recommended that the pH be checked after every second or third battery and neutralizer added accordingly. Refer to Section 3-2C for neutralizing procedures. After several pH tests, adjust the frequency of testing accordingly.

The pH level should be checked at the start of each shift as a part of the daily checklist of the entire battery handling system.

pH LEVEL MONITORING PROCEDURE

pH Meter should be checked and calibrated (if required) prior to each test. Refer to Section 4-3 for calibration procedures.

1.) Remove a water sample from the reservoir for testing.

2.) Switch pH meter on and set selector switch to “pH”.

3.) Immerse the probe end of pH meter into the water sample. Allow the pH probe to sit in the water for approximately one minute to allow the reading to stabilize prior to recording the reading.

DO NOT immerse pH meter past line marked on meter or damage to the meter will result.

4.) If pH is between 5.0 and 9.0, the RNS can be used to wash batteries. If pH is out of range, refer to Section 3-2C for neutralizing procedures.

LEADING PARTICULARS

INSTALLATION

GENERAL

The following paragraphs provide installation instructions for the RNS-1 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 (12”)

Measuring Tape (12’ min)

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-1 from its shipping skids and remove the skids from the area.

POSITIONING

The RNS-1 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-1 into a position not further than 10 feet from the battery wash unit.

B.) Ensure the unit is relatively level.

POWER CABLE CONNECTION

A power line must be connected to the unit’s electrical enclosure assembly. The connection should be made by a certified electrician and any installed wiring shall meet all local electrical codes and requirements. See Section 1-4 for RNS-1 power requirements.

WASH CYCLE CONTROL CABLE CONNECTION

When the RNS-1 is connected to a Battery Wash Cabinet (Typical BHS model BWC-2), a wash cycle control cable from the RNS-1 must be connected to the BWC-2 control panel. See Figure 2-1.

INNER CONNECTION TO WASH CABINET

There are 3 connections from the RNS-1 to a battery wash cabinet. (Typical BHS unit model BWC-2).

A.) Attach the 3/4” I.D. hose from the water outlet of the RNS-1 to the water inlet of the BWC-2.

Note: This connection should be made AFTER completing procedures in Section 2-8.

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

C.) Connect the DC line cord from the sump pump of the wash unit to the 12 volt DC power outlet of the RNS-1.

SEE FIGURE 2-1

WATER INSTALLATION

Water can be hard piped to the reservoir or the unit can simply be filled using a water hose. The reservoir support is constructed to Water can be hard piped to the reservoir or the unit can simply be filled using a water hose. The reservoir support is constructed to facilitate usage of forklift or pallet truck to transport the unit to a water source. ( facilitate usage of forklift or pallet truck to transport the unit to a water source. (Note: Be sure to disconnect all hoses and electrical Note: Be sure to disconnect all hoses and electrical cables to wash unit prior to transporting RNS-1. cables to wash unit prior to transporting RNS-1.) ) Check that filter bowls are tight. Once filter bowls have been checked, open shut-off Check that filter bowls are tight. Once filter bowls have been checked, open shut-off valve beneath tank and partially fill. See Figure 2-2. Check for leaks under the tank. If no leaks are found, finish filling the tank with valve beneath tank and partially fill. See Figure 2-2. Check for leaks under the tank. If no leaks are found, finish filling the tank with approximately 110 gallons of water. approximately 110 gallons of water.

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 to a drain.

B.) Move the selector switch to the “ON” position. The unit should start pumping immediately.

3-Phase units are “phase sensitive”. If wired out of phase, the pump will run in reverse and must be corrected immediately or damage to the pump will occur.

C.) Run the unit until all air is purged from the water circuit then turn the selector switch to the “OFF” position.

D.) Proceed with the connection of the pressure line to the wash cabinet.

The RNS-1 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-1 as described above

OPERATION

CONTROLS

The RNS-1 system is controlled by a Selector Control Switch and a Water Control valve. The Selector Control Switch is located on the electrical enclosure assembly and provides the switch positions ON/OFF/AUTO. The Water Control valve is located above the two 5 micron fi lters and provides valve positions “C” and “R”. The following steps describe the operation of the controls:

A.) Selector Control Switch

The Selector Control Switch provides “OFF”, “ON” and “AUTO” switch positions. Functional descriptions for each of these three switch positions are as follows:

OFF In this position all functions are off.

ON The “ON” position allows continuous operation of the water pump. It is normally used when the battery wash unit is connected to a hand-held spray nozzle to clean batteries. This position also allows continuous operation of the water-pump motor to circulate the water when adding liquid neutralizing conditioner or when draining the reservoir. ( NOTE: This position may be marked as “MAN” for Manual on older units.)

AUTO The “AUTO” position is normally used when a BWC wash cabinet is used as the battery wash unit. It allows the wash cycle to be controlled by the wash cabinet timer.

WATER MONITORING GENERAL DESCRIPTION

The pH level of the water stored in the RNS-4-SS is monitored by a panel mounted pH meter / controller which is supplied data from an in-line pH probe. In the event the water reaches preset parameters, the pH metering system is designed to shut off the system until the problem can be rectified. The only active circuit will be the recirculation mode.

WATER NEUTRALIZATION SYSTEM

The unit is designed with an onboard, manually operated neutralizer injection system that, when activated, injects approximately 6-8 ounces of solution into the tank. Actuating the recirculation circuit allows the neutralizer to be circulated and dispersed into the water.

OZONE GENERATOR GENERAL DESCRIPTION

The ozone generator supplies ozone to the water in the storage tank of the RNS-4-SS. Its function is to aid in the neutralizing process and inhibit the growth of bacteria and algae in the tank. It is designed to operate only when the pressure switch is activated, either during the recirculation or battery wash cabinet demand for flow.

LEADING PARTICULARS

FRONT & SIDE VIEW OF UNIT