Genius LioGuard M-Box Advanced User manual

V3.0 (17.06.2021)
Instruction Manual for Transport System
LioGuard
®
M-Box 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 carefully before use and keep them
in a safe and accessible place.

2
Contents
1Product Description......................................................................................................... 3
1.1 Technical data.............................................................................................................. 3
1.2 Components ................................................................................................................ 3
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 goods .................................... 7
3.1.3 Storage instructions for cells and batteries............................................................. 7
3.2 Transport ..................................................................................................................... 7
3.2.1 Safety instructions ................................................................................................... 7
3.2.2 Transport instructions.............................................................................................. 8
3.3 Opening the transport container................................................................................. 9
3.3.1 Work procedure....................................................................................................... 9
3.4 Inserting and removing the mesh basket (only at Advanced)................................... 10
3.4.1 Workflow................................................................................................................ 10
3.5 Packaging the hazardous goods ................................................................................ 12
3.5.1 Safety instructions ................................................................................................. 12
3.5.2 Packaging instructions ........................................................................................... 12
3.5.3 Recommended safety distances ............................................................................ 12
3.5.4 Workflow................................................................................................................ 13
3.6 Sealing the transport container................................................................................. 15
3.6.1 Work procedure..................................................................................................... 15
3.7 Removing the hazardous goods ................................................................................ 17
3.7.1 Safety instructions ................................................................................................. 17
3.7.2 Work procedure for Advanced .............................................................................. 17
3.7.3 Work procedure for Premium................................................................................ 18
4Maintenance and Repair............................................................................................... 18
4.1 Maintenance.............................................................................................................. 18
4.1.1 Safety instructions ................................................................................................. 18
4.1.2 Maintenance and Cleaning Instructions................................................................ 18
4.2 Repairs ....................................................................................................................... 18
5Waste Disposal/Environmental Protection................................................................... 18
6Contact Information...................................................................................................... 19

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1Product Description
1.1 Technical data
M-Box Advanced
M-Box Premium
Exterior / Interior dimen-
sions
L x W x H (mm)
1230 x 1030 x 835
966 x 766 x 404
1106 x 906 x 600
1106 x 906 x 600
Basket dimensions
L x W x H (mm)
-
981 x 788 x 400
Volume (l)
299
Empty weight (kg)
83
max. gross weight VG II
(kg)
456
1.2 Components
Fig. 1: M-Box in closed state
1 Tie-down strap
2 Locking lever
3 Lock slide
4 Rotary shaft
5 Hasp
6 Staple
7 Handle
8 Guide
5
6
4
2
3
1
7
8

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Fig. 2: M-Box Advanced in open state
Fig. 2: M-Box Premium in open state (top layer of PE bags removed)
9 Locking slide
10 Suspension bolts
11 Lifting eye
12 Lid holder
14 Basket handle
15 Mesh basket
16 insert
17 PE filler pads
13 Lid holder pivot

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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 (recommended protection class
FFP2).
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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Warning
Risk of injury from falling parts
Injuries ranging from severe to fatal
When moving transport containers, use only suitable lifting gear attached to the
designated lifting points. No person must be allowed to linger within the working
area of the lifting gear.
3.1.2 Storage instructions for storage without hazardous goods
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 is +15°C and +30°C.
3.1.3 Storage instructions for 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.
Warning
Risk of injury from falling parts
Injuries ranging from severe to fatal
When moving transport containers, use only suitable lifting gear attached to the
designated lifting points. No person must be allowed to linger within the working
area of the lifting gear.

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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 tie-down straps.
Lift the transport container only by means of the guides provided and use only appropriate
lifting gear.
When transporting hazardous 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.
To increase static friction, non-slip mats must be placed beneath the bearing surface of the
transport container. The load is secured by lashing it down with tie-down strap, which are
strapped across the lid.

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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,
secured by means of the tie-down straps.
2. Press the lock slide of a toggle catch in the direction of the
locking lever. At the same time, pull the locking lever up-
wards and move it approximately 180° around the rotary
shaft.
3. Pull the tie-down strap out from the rotary shaft of the
toggle catch. Next, pull the tie-down strap out from the
guides and store the tie-down strap outside of the work
area.
4. Repeat steps 2 through 3 for all tie-down straps.
5. Open the lid using the handles of the lid.
Caution
Make sure both lid holders snap into place on the lid
holder pivot.

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3.4 Inserting and removing the mesh basket (only at Advanced)
3.4.1 Workflow
1. Open the transport container (see section Fehler! Verweis-
quelle konnte nicht gefunden werden.).
2. Push the locking slide on a lid holder downwards.
3. Pull the lid holder from the suspension bolt. Carefully put
down the lid holder.
4. Repeat steps 2 and 3 for the other lid holder.
Caution
Securely hold the lid with one hand.
5. Open the lid more than 90°.
Caution
Support the lid to prevent damage to the lid hinges.

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6. Remove the mesh basket or place the mesh basket into the
transport container with the help of the basket handles pro-
vided.
7. Close the lid so that a lid holder can be attached to the corre-
sponding suspension bolts.
8. Push the locking slide into the groove of the suspension bolt.
9. Repeat steps 7 and 8 for the other lid holders.

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3.5 Packaging the hazardous goods
3.5.1 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.
Warning
Danger due to high electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the batteries with electrically insulating materials. Wear
adequate electrically insulating protective equipment.
Caution
Due to dust formation, the use of respiratory protection is recommended to avoid damage to
the respiratory organs (recommended protection class FFP2).
3.5.2 Packaging instructions
The required safety distances between the battery and the mesh basket, 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 3.5.3 are recommended.
3.5.3 Recommended safety distances
M-Box
Container, upper edge
10 cm
Advanced
Basket, base
6 cm
Basket, side walls
Premium
Insert, base
1 cm
Insert, side walls
4 cm

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3.5.4 Workflow
1. Open the transport container (see section Fehler! Verweis-
quelle konnte nicht gefunden werden.).
2. At Advanced: Evenly distribute a layer of PyroBubbles® to a
minimum fill height of 6 cm above the bottom of the mesh
basket.
2. At Premium: Remove all PE filler pads from the transport con-
tainer. Place at least one layer of PE filling pads into the insert.
The insert always remains in the container.
3. At Advanced: Place the hazardous substance in such a way
that the recommended minimum distances are guaranteed.
When loading multiple batteries, there must also be a suffi-
cient all-round safety distance between the batteries.
3. At Premium: Place the hazardous substance in such a way
that a minimum distance of 4 cm to the insert side walls and
10cm to the upper edge of the container is guaranteed. When
loading multiple batteries, there must also be a sufficient all-
round safety distance between the batteries.
4 cm
4 cm
4 cm
4 cm

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4. At Advanced: Cover the introduced hazardous goods with the
PyroBubbles® supplied, filling them up to the upper 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 sufficient padding thickness between the indi-
vidual layers.
Caution
Only when the transport container is completely filled with
PyroBubbles® is an adequate level of protection ensured.
4. At Premium: Enclose the dangerous goods with additional PE
filler pads. If you want to place several layers of dangerous
goods into the transport container, you need to make sure
that there is a sufficient padding thickness between the indi-
vidual layers. Also, place the dangerous goods into the con-
tainer in such a way that a minimum distance of 4 cm is en-
sured to all sides of the insert walls and 10 cm to the con-
tainer lid.
5. At Premium: Fill the transport container up to the top edge
with PE filler pads.
Attention
Only when the transport container is completely filled with
PE filler pads, is an adequate level of protection ensured.
6. Close the transport container (see section Fehler! Verweis-
quelle konnte nicht gefunden werden.).
Attention
Make sure that you do not damage the PE filler pads with the
lid holder.
4 cm
4 cm
4 cm
4 cm

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3.6 Sealing the transport container
3.6.1 Work procedure
1. Hold the lid with one hand and release the catch of the lid
holder pivots by gently pulling it toward the front of the con-
tainer.
2. Close the lid using the handles of the lid and place the hasp
over the staple on the front side of the container.
3. Pass a tie-down strap through a front and rear guide, beneath
the transport container, and run the tie-down strap into and
along the recess provided in the lid.
Caution
Make sure that the tie-down strap is not twisted.
4. Pass the loose end of the tie-down strap through the rotary
shaft of the toggle catch and pull the tie-down strap tight.

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5. Press the lock slide of the toggle catch in the direction of the
locking lever. At the same time, move the locking lever by ap-
proximately 90° around the rotary shaft.
6. Move the locking lever without pressing the lock slide up and
down several times until the tie-down strap is firmly clamped.
7. Press the locking lever downwards.
8. Repeat steps 3 through 7 for the remaining tie-down straps.

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3.7 Removing the hazardous goods
3.7.1 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.
Warning
Danger due to high electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the batteries with electrically insulating materials. Wear
adequate electrically insulating protective equipment.
3.7.2 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 battery is visible.
3. Remove the batteries.
Variant 2
1. Open the transport container (see section Fehler! Verweisquelle konnte nicht gefunden

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werden.).
2. Use a suitable lifting device to remove the mesh basket from the container (see steps Feh-
ler! Verweisquelle konnte nicht gefunden werden. 1 through 9). The PyroBubbles® re-
main in the container while the hazardous goods remain in the mesh basket.
3. Remove the batteries.
3.7.3 Work procedure for 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. The insert must remain in the
transport container.
3. Remove the battery.
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 (HDPE).
PyroBubbles® can generally be reused, provided that they show no visual changes and the
granules are odour-neutral.
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.

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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
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]