DOWNLOAD PDF CAT BUCYRUS MINE POWER STORAGE BATTERIES INSTALLATION, USE, MAINTENANCE & REPAIR MANUAL
THIS GUIDE CONTAINS IMPORTANT OPERATION AND SAFETY INFORMATION AND SHOULD BE KEPT AVAILABLE TO THOSE PERSONNEL INSTALLING AND OPERATING THIS EQUIPMENT.
P/N A6474X26
Revision 11, January 09
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PREFACE
This manual is intended to provide GENERAL product information for Bucyrus America, Inc. mine power storage batteries. The illustrations, descriptions and procedures contained in this publication apply only to Bucyrus America, Inc. mine power storage batteries. Bucyrus America, Inc. reserves the right to revise models and designs without prior notice.
This Bucyrus America, Inc. mine power storage battery was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.
At the completion of the manufacturing process, the battery was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of the battery, without the consent of Bucyrus America, Inc. and these regulatory agencies, or any repair or replacement of parts contrary to Bucyrus America, Inc.’s instructions, may invalidate these approvals and render the battery unsafe to operate.
Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this battery.
While this manual attempts to anticipate the most important operations and maintenance needs for this battery, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Bucyrus America, Inc. Service Representative immediately
This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is nontransferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.
Bucyrus America, Inc. All rights reserved.
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SYMBOLS AND SPECIAL NOTATIONS
Throughout this manual there are specific notations that are either UPPERCASE BOLD, UNDERLINED or ITALICIZED for the primary purpose of emphasis Please pay special attention to such statements as they regard safety or critical maintenance installation information.
You will also see the following:
NOTICE: THIS NOTATION DENOTES A REFERENCE TO PREVIOUSLY STATED INSTRUCTIONS
IMPORTANT: THIS SYMBOL DENOTES THAT SPECIAL ATTENTION MUST BE ADHERED TO IN THE ATTACHED STATEMENT.
CAUTION: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A CUT, BRUISE OR ABRASION.
WARNING: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A LOST TIME ACCIDENT.
DANGER: THIS SYMBOL DENOTES THAT FAILURE TO COMPLY WITH THE ATTACHED STATEMENT COULD RESULT IN A SERIOUS INJURY OR FATALITY.
DANGER
ONLY TRAINED AUTHORIZED PERSONNEL SHOULD OPERATE OR PERFORM MAINTENANCE ON THE BATTERY.
FAILURE TO ADHERE TO DANGERS, WARNINGS AND CAUTIONS, NOTED IN THIS MANUAL, COULD RESULT IN SERIOUS INJURY OR DEATH.
FAILURE TO OPERATE OR MAINTAIN THIS BATTERY IN STRICT ADHERENCE TO THESE INSTRUCTIONS AND WARNINGS IN THIS MANUAL COULD VOID THE WARRANTY.
MAJOR HAZARDS
AREA
HAZARD
SAFEGUARDS WHERE HAZARD CAN OCCUR
WHAT CAN HAPPEN IF PRECAUTIONS AND SAFEGUARDS ARE NOT OBEYED
HOW TO AVOID THE HAZARD
ENTIRE BATTERY
ELECTRICAL
EXPLOSIVE GASES
Mine service batteries can weigh several thousand pounds and could cause severe injury or death should the battery fall on persons or body parts
Electrical shock could cause death or serious injury. The battery produces lethal amounts of current whether connected to a machine or not.
Batteries produce explosive gases that could be ignited causing burns or explosions.
Batteries must be resting securely in a machine, on battery tables, or platforms capable of supporting the weight while performing maintenance or service on battery.
Batteries should be maintained and serviced by qualified personnel. The battery should be disconnected before servicing.
CORROSIVE ACIDS
COVERS
Batteries contain strong acid that could cause severe burns if spilled or splashed on body parts or in the eyes.
Battery covers could fall, crushing hands, arms, or fingers.
Batteries should be well vented before servicing, particularly if welding or burning on the battery. Batteries should be maintained by qualified personnel.
Protective clothing, gloves, and eyewear must be worn when working on batteries. Batteries should be maintained by qualified personnel.
Battery covers must be secured with the cover supported when working under the covers.
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SAFETY PRECAUTIONS AND GUIDELINES
OVERVIEW
Before you install, maintain or repair a mine service battery -
READ and STUDY this guide. KNOW how to safely use the battery and what you must do for safe maintenance.
ALWAYS wear or use the proper safety items required for your personal protection.
If you have ANY QUESTIONS about the safe use or maintenance of this unit: ASK YOUR SUPERVISOR - NEVER GUESS - ALWAYS CHECK
MAINTENANCE
AVOID, whenever possible, servicing, cleaning or examining the battery in congested areas.
ALWAYS replace damaged or lost decals or metal instruction plates. Refer to the Parts Manual for the proper location and part number of decals and plates.
DISCONNECT the battery when servicing or when welding on the battery.
BE SURE the battery area is well ventilated (clear of fumes) when it is necessary to connect battery charger. Fumes from the battery could ignite by a spark and explode.
It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.
Chapter 4 of this guide is dedicated to safety procedures that MUST be followed when using or servicing lead-acid batteries. It is important that you read and understand the procedures outlined in this guide, particularly those in Chapter 4.
CHAPTER 1 - INTRODUCTION
Section I. General
1-1. Scope
This guide contains information concerning the theory, construction, installation, use, maintenance, repair, and hazards of lead-acid storage batteries used to power mine tractors, scoops, locomotives, and coal haulers.
1-2.
Forms, Records and Reports
The following form will be used by personnel responsible for the receipt, storage, operation, charging, and maintenance of lead-acid storage batteries.
a. Monthly Storage Battery Record - The Monthly Storage Battery Record is to be used to record the services performed on motive power batteries. This record should be prepared and maintained by the using operator and should accompany the battery at all times. (See Figure 1 for a typical "Monthly Storage Battery Report" form.)
FIGURE 1 – MONTHLY STORAGE BATTERY RECORD
Section II. Definitions
1-3. Standards
Those definitions referenced throughout this manual generally agree with accepted industry standards. For a more complete listing of "Definitions for Lead-Acid Industrial Storage Batteries" see NEMA Standards publication No. 1B 1-1971.
Copies of NEMA standards may be obtained at nominal cost by writing to: National Electrical Manufacturers Association, Department of Engineering and Safety Regulations, 2101 L Street, N.W. Washington, D.C. 20037.
Section III. Description and Construction
1-4.
Battery
Mine power lead-acid batteries for electric vehicles typically consist of of: (1) a steel tray into which the cells are assembled; (2) a battery terminal connector; and (3) other components necessary to secure and protect the cells and provide the necessary electrical interconnections.
a. Battery Identification and Data - The essential information necessary for proper care of an industrial motive power battery appears on the battery, either stamped into one of the intercell connectors or on a name plate affixed to the tray. This information usually includes the manufacturer's name and model, number of plates per cell, battery capacity, battery voltage, serial number, suggested charging rate, and fully charged specific gravity of electrolyte.
If vital information is missing, or is no longer legible, such information can be obtained by contacting your nearest BUCYRUS AMERICA, INC. representative.
Some manufacturers list, as a part of the model or type designation, the rated ampere-hour capacity of a single positive plate, such as "SS75". As an alternate means of determining rated battery capacity, this number should be multiplied by the total number of positive plates in one cell. To find the number of positive plates in a cell, subtract one from the total number of plates and divide by two. To find the capacity of a battery designated "SS75-19," therefore: 19 - 1 = 18; 18 divided by 2 = 9; 9 x 75 = 675 Ah battery capacity.
b. Cell Arrangement - The individual cells, which contain the energy generating components of the battery, may be arranged slightly differently for various types of equipment. The cells of all motive power batteries are, however, always connected in series to produce the required voltage. Cell and battery capacity, which is the available ampere-hours or watt-hours, is a function of the total number and size of plates within each cell. Voltage, though, is the same for all cells regardless of size. Each lead-acid cell yields a nominal 2 volts.
c. Connector Arrangement - Connections between cells are made by intercell connectors which may be lead-coated copper straps or be cast of solid lead. These connections are always welded, in proper sequence, by the application of heat to the terminals of the cells. Energy from the battery is drawn off by terminal cables which extend beyond the steel tray wall and are in turn permanently joined to the battery terminal connector.
1-5. Cell
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This is the basic unit of any battery. It is a galvanic cell which produces electrical energy when connected to an electrical load and, after being discharged, may be restored to its original fully charged condition. It has a nominal voltage of 2 volts and consists of an element, from which the energy is derived, and the electrolyte; both are contained by an impact resistant, molded plastic jar. The element is prevented from contacting the bottom of the jar by means of a high impact bridge, which consists of a series of support ribs. These ribs provide sediment space below the bottom of the element to accommodate particles of active material, shed by the positive plates during normal operation of the battery. (See Figure 2.)
FIGURE 2 – TYPICAL BUCYRUS AMERICA, INC. CELL
Cover - With lead insert bushing prevents leakage and voltage to ground.
Post - Special alloy for increased strength and conductivity.
Post Plate Strap - Extra heavy to insure a permanent connection between post and plates.
Positive Grid - A non-porous lead alloy casting, designed for maximum current carrying capacity, capable of many years of service.
Active Material - Specially formulated and uniformly applied under rigid laboratory control to insure maximum efficiency throughout long battery life.
Jar - Molded of high-impact material to remain leak free under rough treatment.
Bridge - Provides firm element support and ample sediment space.
Vent Cap – Quarter turn bayonet type simplifies watering and inspection.
Separator Guard – White in color to increase visibility for fast electrolyte check.
Negative Plate – Designed to compliment positive plate performance.
Vertical Mat - Laminated construction compromised of uniformly spaced fine glass tape that imbed into the active material and an interwoven glass fiber mat wrapped vertically around the positive plate insuring optimum activematerialretention.
Horizontal Mat - Made of glass fibers with an insoluble binder. Breaks up gas bubbles and increases positive plate insulation.
Retainer and Bottom Shield - A high porosity perforated envelop that encases positive plate and glass mats to prevent shorts and insure maximum performance and life.
Separator - Deep channeled, microporous, impervious to heat, acid and corrosion: provides insulation between positive and negative plates while allowing the free flow of electrolyte throughout the cell.
Bucyrus America, Inc. mine batteries incorporate every feature required by today’s mines. They are designed by engineering technology and built by master battery craftsmen according to strict quality control guidelines. DBT America Inc. batteries are the finest available to meet today’s mining requirements, and our precision construction provides new equipment performance throughout a long life.
The top of each cell is fitted with a molded rubber plastic cover sealed to the jar at the edges. A vent or filler cap is located in the center of the cover. This vent permits the escape of hydrogen and oxygen while the cells are gassing and, when removed, provides an opening through which water may be added
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