Genius LioGuard XS-Box 1 Basic User manual

V3.0 (17.06.2021)
Instruction Manual for Transport System
LioGuard
®
XS-Box 1/2 Basic/Advanced/Premium
S-Box 1/2 Basic/Advanced/Premium
Safety system for storage and transport in compliance with the ADR for
lithium-ion and lithium-metal cells and batteries
Please read these instructions before use and keep them in a safe and accessible place.

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Contents
1Product Description......................................................................................................... 3
1.1 Technical Data ............................................................................................................. 3
1.2 Components ................................................................................................................ 4
2Safety Instructions........................................................................................................... 5
2.1 Proper intended use.................................................................................................... 5
2.2 Hazard potential of lithium ion cells and batteries..................................................... 5
2.3 Information about PyroBubbles® ................................................................................ 6
3Use................................................................................................................................... 6
3.1 Storage......................................................................................................................... 6
3.1.1 Safety instructions ................................................................................................... 6
3.1.2 Storage instructions for storage without hazardous content ................................. 7
3.1.3 Storage instructions for the storage of cells and batteries ..................................... 7
3.2 Transport ..................................................................................................................... 7
3.2.1 Safety instructions ................................................................................................... 7
3.2.2 Transport instructions.............................................................................................. 7
3.3 Opening the transport container................................................................................. 8
3.3.1 Work procedure....................................................................................................... 8
3.4 Packaging the hazardous goods .................................................................................. 9
3.4.1 Safety instructions ................................................................................................... 9
3.4.2 Packaging instructions ............................................................................................. 9
3.4.3 Recommended Safety Distances ............................................................................. 9
3.4.4 Workflow................................................................................................................ 10
3.5 Sealing the transport container................................................................................. 12
3.5.1 Changing the clamping stroke of the toggle catches............................................. 12
3.5.2 Work procedure..................................................................................................... 12
3.6 Removing the hazardous goods ................................................................................ 14
3.6.1 Safety instructions ................................................................................................. 14
3.6.2 Work procedure for Basic and Premium ............................................................... 14
3.6.3 Work procedure for Advanced .............................................................................. 14
4Maintenance and Repair............................................................................................... 15
4.1 Maintenance.............................................................................................................. 15
4.1.1 Safety instructions ................................................................................................. 15
4.1.2 Maintenance and cleaning instructions................................................................. 15
4.2 Repairs ....................................................................................................................... 15
5Waste Disposal/Environmental Protection................................................................... 15
6Contact Information...................................................................................................... 16

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1Product Description
1.1 Technical Data
XS-Box 1
XS-Box 2
S-Box 1
S-Box 2
Outer dimensions in mm
(L x W x H)
400 x 300 x 235
400 x 300 x 285
600 x 400 x 295
600 x 400 x 441
Maximum gross weight PG I
(kg)
13
30
Maximum gross weight PG II
(kg)
45
Basic
Inner dimensions in mm
(L x W x H)
360 x260 x 195
360 x 260 x 245
556 x 356 x 276
556 x 356 x 422
Volume (l)
18
23
56
84
Net weight (kg)
1,9
2,0
3,4
4,7
Advanced
Inner dimensions in mm
(L x W x H)
298 x198 x 135
297 x 195 x 190
492 x 292 x 196
492 x 292 x 341
Volume (l)
8,0
11
28
49
Net weight (kg)
3,7
4,0
6,8
9,0
Premium
Inner dimensions in mm
(L x W x H)
302 x202 x 131
-
492 x 292 x 196
492 x 292 x 341
Volume (l)
8,0
-
28
49
Net weight (kg)
4,7
-
14,3
21,1

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1.2 Components
Fig. 1: transport container, Basic version
1 Cover
2 Toggle catch
3 Locking lever
4 Locking bolt
5 Locking lug
6 Locking hook
7 Belt fastener
8 Lifting harness
9 PE filler pads (only at Basic and Premium)
Fig. 2: transport container, Advanced version
10 Gitterkorb
11 Korbgriff
Fig. 3: transport container, Premium version
12 Einleger Griff
13 Einleger
5
6
4
2
3
1
7
8
9
6
11
10
12
13

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2Safety Instructions
2.1 Proper intended use
The transport container is used for transporting and storing lithium-ion and lithium-metal cells
and batteries. The transport container shall be used only in an undamaged and unmodified
condition. The integrity of the transport container shall be checked before each use.
2.2 Hazard potential of lithium ion cells and batteries
With today's manufacturing standards, it can be assumed that lithium-ion cells and batteries,
when properly used and handled, are safe. However, damage can lead to an irreversible, de-
structive reaction, a so-called thermal runaway. Such damage could be, for example:
•mechanical damage
•heat stress
•overcharging
•outer short circuit
•total discharge
•ageing (dendrite formation)
Such damage can cause the cell to heat up, resulting in a decomposition reaction of cell com-
ponents. This decomposition reaction in turn leads to further heating, which then causes the
decomposition process to accelerate uncontrollably. These reactions also lead to the for-
mation of large quantities of toxic and flammable gases, which in interaction with the high
temperatures of the cell can lead to severe fire events. This intense release of heat can conse-
quently cause thermal runaway in the adjacent cells, so that under certain circumstances the
entire battery reacts.
The escaping gases include carbon monoxide (CO), hydrogen (H2), carbon dioxide (CO2) and
oxygen (O2). It is also possible that hydrogen fluoride (HF) escapes, which can react with the
air humidity to form hydrofluoric acid. If the escaping reaction gas does not ignite, it can mix
with the air oxygen to form an explosive atmosphere.
Due to the high hazard potential ensuing from damage that may not always be visible from the
outside, we recommend that returned batteries should always be stored in corresponding
safety containers.

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2.3 Information about PyroBubbles®
PyroBubbles® are multi-cellular hollow glass spheres, which are not hazardous in their solid
form (delivery condition). Continuous contact with high concentrations of respirable dust can
impair lung functioning. The general dust limits of 1.25 mg/m3 for respirable (A dust) and 10
mg/m3 for inhalable (I dust) fractions must be observed. An individual time-weighted average
must not exceed the value of 3 mg/m3 for the A-dust fraction. For details, refer to TRGS 900
(or respective nationally applicable technical rules for hazardous substances). If the dust con-
centration at the place of work exceeds the specified occupational exposure limit values, ap-
proved and suitable respiratory protection must be used (filter type P2).
It is recommended to wear eye protection in the case of dust formation, and to wear gloves in
the case of skin contact.
PyroBubbles® that no longer correspond to their condition at the time of delivery, must be
disposed of in accordance with the disposal instructions (see section Fehler! Verweisquelle
konnte nicht gefunden werden.) and shall not be used further, because they no longer meet
the requirements with respect to sorption capacity and thermal insulation.
3Use
Caution
Before each use, check the integrity of the container and the other components.
3.1 Storage
3.1.1 Safety instructions
Danger
Danger of poisoning due to toxic, partially odourless gases
Injuries ranging from severe to fatal
In the event that the cells or batteries suffer a thermal runaway, leave the haz-
ardous area as quickly as possible.
Danger
Danger of explosion due to explosive gases
Injuries ranging from severe to fatal
In the event that the cells or batteries suffer a thermal runaway, avoid ignition
sources. If possible, provide sufficient ventilation.

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3.1.2 Storage instructions for storage without hazardous content
PyroBubbles® must be stored in a dry location.
The transport container must be stored protected from direct sunlight, to prevent ageing of
the plastic material. The recommended storage temperature range is +15°C to +30°C.
3.1.3 Storage instructions for the storage of cells and batteries
When storing cells and batteries, the lid of the container must be kept free, so that any reaction
gases that may develop can escape and a resulting pressure build-up inside the transport con-
tainer is avoided.
3.2 Transport
3.2.1 Safety instructions
Danger
Danger of poisoning due to toxic, partially odourless gases
Injuries ranging from severe to fatal
In the event that the cells or batteries suffer a thermal runaway, leave the haz-
ardous area as quickly as possible.
Danger
Danger of explosion due to explosive gases
Injuries ranging from severe to fatal
In the event that the cells or batteries suffer a thermal runaway, avoid ignition
sources. If possible, provide sufficient ventilation.
3.2.2 Transport instructions
During transport, observe the relevant legal regulations. This also applies for any additional
markings or labels.
Make sure that the transport containers are securely closed by means of the belt fasteners.
Lift the transport container only by means of the lifting harness provided.
When transporting dangerous goods, the space above the transport container must be kept
free, so that in the event of a thermal runaway the reaction gases have adequate space to
vent.

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3.3 Opening the transport container
3.3.1 Work procedure
1. The transport container is delivered in a closed condition, se-
cured by means of the belt fasteners.
2. Press the locking bolt of one toggle catch downwards, and at
the same time move the locking lever upwards.
3. Remove the locking lug from the locking hook.
4. Repeat steps 2 through 3 for all toggle catch.
5. Lift the cover off.

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3.4 Packaging the hazardous goods
3.4.1 Safety instructions
Warning
Danger of poisoning due to toxic substances leaking from the cells or batteries
Injuries ranging from severe to fatal
Use protective equipment suitable for the hazardous goods involved.
3.4.2 Packaging instructions
The required safety distances between the battery and the container walls, resp. the upper
edge of the container, depend on the respective battery (design, energy content, condition,
etc.). If the minimum distances are not defined in the transport specifications, then, depending
on the respective model design, the safety distances described in point 3.4.3 are recom-
mended.
3.4.3 Recommended Safety Distances
XS-Box 1
XS-Box 2
S-Box 1
S-Box 2
Container,
upper edge
6 cm
8 cm
Basic
Container base
4 cm
6 cm
Container,
side walls
Advanced
Container base
1 cm
2 cm
Container,
side walls
Premium
Insert base
1 cm
-
2 cm
Insert, side walls

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3.4.4 Workflow
1. Open the transport container (see section Fehler! Verweis-
quelle konnte nicht gefunden werden.).
2. At Basic: Remove all PE filler pads from the transport con-
tainer. Depending on the model, next insert the PE filler pads
flat out into the transport container up to the minimum
height recommended in point 3.4.3.
2. At Advanced: Enter an evenly distributed layer of PyroBub-
bles® with a minimum filling height of 1 cm above the grid
floor.
2. At Premium: Remove all PE filler pads from the transport con-
tainer. Depending on the model, you can then place the PE
filling pads flat in the transport container up to the minimum
height recommended in point 3.4.3.
3. Place the hazardous substance in such a way that the recom-
mended minimum distances are guaranteed. When loading
multiple batteries, there must also be a sufficient all-round
safety distance between the batteries.
SSsSsssed

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4. Enclose the hazardous goods with additional PE filler pads. If
you want to place several layers of hazardous goods into the
transport container, you need to make sure that there is a suf-
ficient padding thickness between the individual layers.
5. At Basic and Premium: Fill PE filler pads into the transport
container, up to approx. 2 cm below the top edge of the con-
tainer.
Caution
Only when the transport container is completely filled with
PE filler pads, is an adequate level of protection ensured.
5. At Advanced: Cover the introduced hazardous goods with the
PyroBubbles® supplied, filling them up to 2 cm below the up-
per edge of the container. If you want to place several layers
of hazardous goods into the transport container, you need to
make sure that there is a sufficiently thick padding of PyroB-
ubbles® between the individual layers.
Caution
Only when the transport container is completely filled with
PyroBubbles® is an adequate level of protection ensured.
6. Close the transport container (see section Fehler! Verweis-
quelle konnte nicht gefunden werden.).
Caution
Make sure that the container lid is resting firmly on top of the
upper edge of the container and is not tilted.
2 cm
2 cm

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3.5 Sealing the transport container
3.5.1 Changing the clamping stroke of the toggle catches
1. Turn the locking lug counter-clockwise to reduce the clamp-
ing stroke. Turn the locking lug clockwise to increase the
clamping stroke.
3.5.2 Work procedure
1. Place the cover on the container.
2. Place a belt fastener over the cover, using the corresponding
slots in the lid as a guide.
Caution
Make sure that the belt fastener is not twisted.
3. Press the locking bolt of the corresponding toggle catch
downwards, and at the same time move the locking lever up-
wards.

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4. Place the locking hook into the locking eyelet. It may be nec-
essary to alter the clamping stroke of the toggle catch (see
section Fehler! Verweisquelle konnte nicht gefunden wer-
den.).
5. Press the locking lever of the toggle catch downwards.
Caution
Make sure that the belt fastener is tightly strapped.
6. Repeat steps 2 through 5 for the other toggle catch.

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3.6 Removing the hazardous goods
3.6.1 Safety instructions
If the transport container shows any signs of deposits, discolouration or a piercing smell, you
must assume that the electrolyte has leaked or there has been a thermal runaway in the bat-
tery.
Danger
Danger of poisoning due to toxic, partially odourless gases and toxic substances
Injuries ranging from severe to fatal
In the event of electrolyte leaking from the cells or batteries, or a thermal runa-
way, the transport container must be opened only by personnel wearing protec-
tive equipment appropriate to the type of hazardous substance involved.
Danger
Danger of poisoning by inhalation of contaminated dust
Injuries ranging from severe to fatal
In the event of electrolyte leaking from the cells or batteries, or a thermal runa-
way, the transport container must be opened only by personnel wearing protec-
tive equipment appropriate to the type of hazardous substance involved.
Warning
Danger of explosion due to explosive gases
Injuries ranging from severe to fatal
In the event that the cells or batteries suffer a thermal runaway, avoid ignition
sources. If possible, provide sufficient ventilation.
3.6.2 Work procedure for Basic and Premium
1. Open the transport container (see section Fehler! Verweisquelle konnte nicht gefunden
werden.).
2. Remove the PE filler pads until the battery becomes visible.
3. Remove the battery.
3.6.3 Work procedure for Advanced
Variant 1
1. Open the transport container (see section Fehler! Verweisquelle konnte nicht gefunden
werden.).
2. Remove the PyroBubbles® by skimming or vacuuming them off until the batteries are vis-
ible.
3. Remove the batteries.
Variant 2
1. Open the transport container (see section Fehler! Verweisquelle konnte nicht gefunden
werden.).

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2. Use the basket handles to remove the mesh basket. The PyroBubbles® remain in the con-
tainer while the hazardous goods remain in the mesh basket.
3. Remove the batteries.
4Maintenance and Repair
4.1 Maintenance
4.1.1 Safety instructions
Warning
Danger of poisoning due to toxic substances that have leaked from the cells or
batteries
Injuries ranging from severe to fatal
Use protective equipment suitable for the hazardous goods involved.
4.1.2 Maintenance and cleaning instructions
Contamination by substances leaking from the cells or batteries on to the transport containers
must be removed. For this purpose, use only cleaning materials that do not attack the material
of the transport container (PP).
PyroBubbles® can generally be reused, provided that they show no visual changes and the
granules are odour-neutral. Damaged PE filler pads must be replaced.
4.2 Repairs
Do not use damaged transport containers; they no longer meet the requirements of the ap-
proved type. Repairs shall be made exclusively by the manufacturer or by a specialist author-
ized by the manufacturer.
5Waste Disposal/Environmental Protection
The materials used in manufacturing the transport container are recyclable and can be recy-
cled through commonly available recycling programs.
Uncontaminated PyroBubbles® can forwarded to recycling programs for building materials.
Danger
Danger of poisoning by inhalation of contaminated dust
Injuries ranging from severe to fatal
Wear protective equipment suitable for the respective contamination.
Contaminated PyroBubbles® must be properly disposed of in accordance with the applicable

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national regulations and in accordance with their respective contamination.
6Contact Information
Genius Technology GmbH
Am Theresenhof 2
15834 Rangsdorf
www.genius-group.de
Phone: [phone]
Fax: [phone]
Email: inf[email protected]