Genius LioGuard S-Box X1 User manual

V2.0 (15.06.2021)
Instruction Manual for Transport System
LioGuard
®
S-Box X1
M-Box X1
XXL-Box
S-Box X2
M-Box X2
LP1-Box
Read these instruction carefully before using the system,
and retain for future reference.

2
Contents
1Product Description......................................................................................................... 3
1.1 Technical data.............................................................................................................. 3
1.2 Components ................................................................................................................ 5
2Safety instructions........................................................................................................... 6
2.1 Intended use................................................................................................................ 6
2.2 Information about PyroBubbles® ................................................................................ 6
3Application ...................................................................................................................... 6
3.1 Storage......................................................................................................................... 6
3.1.1 Safety instructions ................................................................................................... 6
3.1.2 Storage instructions ................................................................................................. 7
3.2Transport ..................................................................................................................... 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 material............................................................................. 10
3.4.1 Safety instructions ................................................................................................. 10
3.4.2 Packing instructions ............................................................................................... 10
3.4.3 Work procedure..................................................................................................... 10
3.5 Sealing the transport container................................................................................. 11
3.5.1 Changing the clamping stroke of the the toggle catches ...................................... 11
3.5.2 Work procedure..................................................................................................... 12
3.6 Removing the hazardous material............................................................................. 14
3.6.1 Safety instructions ................................................................................................. 14
3.6.2 Work procedure..................................................................................................... 15
4Maintenance and Repair............................................................................................... 15
4.1 Maintenance.............................................................................................................. 15
4.1.1 Safety instructions ................................................................................................. 15
4.1.2 Maintenance instructions ...................................................................................... 15
4.2 Repairs ....................................................................................................................... 16
5Troubleshooting ............................................................................................................ 16
6Waste Disposal/Environmental Protection................................................................... 16
7Contact Information...................................................................................................... 16

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1Product Description
1.1 Technical data
S-Box
X1
S-Box
X2
M-Box
X1
M-Box
X2
XXL-Box
LP1-Box
Nominal outer dimensions in mm
(L x W x H)
800 x 600
x 750
800 x 600
x 1100
1200 x 800
x 800
1200 x 800
x 1250
2550 x 1550
x 1100
2840 x 1240
x 960
Nominal inner dimensions in mm
(L x W x H)
670 x 470
x 570
670 x 470
x 960
1070 x 670
x 640
1070 x 670
x 1100
2370 x 1360
x 840
2160-2700
x 1460-
2000 x 570
Maximum gross weight in kg
185
240
350
700
1530
2024
Container material
Stainless Steel
Galva-
nized
steel
Gasket material
Ethylene-Propylene-Diene-rubber (EPDM)
Chloro-
prene-
rubber
(CR)
Safety
valves
Quantity
2
4
5
Bolted joint diameter
in mm (inches)
25,4 (1‘‘)
50,8 (2‘‘)
63,5
(2,5“)
Opening pressure in
kPa
21 (0,21 bar, 3 psi)
7 (0,07 bar,
1 psi)
Filler material
PyroBubbles®-bulk

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S-Box X1
M-Box X1
S-Box X2
M-Box X2
XXL-Box
LP1-Box

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1.2 Components
fig. 1: example illustration
1 cover
2 safety valve
3 collision guard
4 guide (only at LP1-
Box also on the lid)
5 toggle catch
6 locking latch
7 locking lever
8 locking eyelet
9 locking hook
10 locknut
11 anchor point (only at
XXL-Box)
1
2
3
4
5
10
9
8
7
6

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2Safety instructions
2.1 Intended use
The transport container is used for transporting lithium-ion and lithium-metal cells and batter-
ies. 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 Information about PyroBubbles®
PyroBubbles® are multi-cellular hollow glass spheres, which are not dangerous (dust is not
respirable) in their solid form (delivery condition). If PyroBubbles® are ground or pulverized
mechanically, 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 respec-
tive nationally applicable technical rules for hazardous substances). If the dust concentration
at the place of work exceeds the specified occupational exposure limit values, approved 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 6) and shall not be used
further, because they no longer meet the requirements with respect to sorption capacity and
thermal insulation.
3Application
Attention
Before each use, check the integrity of the container and the other components such as the
rubber seal, the toggle catches and the safety valves.
3.1 Storage
3.1.1 Safety instructions
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 of the lifting gear.

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3.1.2 Storage instructions
PyroBubbles® must be stored in a dry location.
The transport container should be stored at temperatures between +5°C and +25°C, protected
from direct solar radiation and in a dry area, to maintain the sealing properties of the rubber
seal in accordance with DIN 7716 standard (Rubber products: Requirements for storage, clean-
ing and maintenance).
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 cell or battery suffers a thermal runaway, leave the danger
zone as quickly as possible.
Danger
Risk of explosion due to explosive gases
Injuries ranging from severe to fatal
In the event that the cell or battery suffers 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 of the lifting gear.
3.2.2 Transport instructions
During transport, observe the relevant legal regulations. This also applies to any additional
markings or labels.
Make sure that all the locking eyelets of the toggle catches are properly hooked onto the lock-
ing hooks, and that all toggle catches are closed.
Lift the transport container only by means of the guides provided, and use only appropriate
lifting gear.
When transporting dangerous goods, the space above the container must be kept free, so that
in the event of a thermal runaway the reaction gases have adequate space to vent via the
safety valves.

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To increase static friction, non-slip mats must be placed beneath the feet of the transport con-
tainer. The load is secured by lashing it down with tensioning straps, which are strapped across
the cover.
3.3 Opening the transport container
3.3.1 Work procedure
1. The transport container is delivered in a closed condition,
locked by means of the toggle catches.
Caution
There is a risk of squeezing or jamming fingers/hands in the toggle catches
Slight injuries to fingers and hands
Wear work gloves Do not insert your fingers or hands between the locking bolt
and the locking lever.
2. Press the locking bolt of the toggle catch downwards, and at
the same time move the locking lever upwards.
3. Remove the locking eyelet from the locking hook.

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4. Push the locking lever back downwards until the locking bolt
engages by itself.
5. Repeat steps 2 through 4 for all toggle catches.
6. Attach the lifting gear to all 4 anchor points on the cover. (only
at XXL box)
Use the guides on the cover. (only at LP1-Box)
7. Lift the cover off.
Caution
Risk of injury from falling parts
Injuries ranging from severe to fatal
When moving the cover, use only suitable lifting gear attached to the designated
lifting points. No person must be allowed to linger within the working area of
the of the lifting gear.

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3.4 Packaging the hazardous material
3.4.1 Safety instructions
Warning
Risk of poisoning due to toxic substances leaking from the battery
Injuries ranging from severe to fatal
Use protective equipment suitable for the hazardous material involved.
Warning
Hazards due to electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the battery with electrically insulating materials. Wear
adequately electrically insulating protective equipment.
Attention
Respiratory protection (filter type P2) is recommended, to prevent damage to the respiratory
organs by the dust that may be formed.
3.4.2 Packing instructions
The distances between the battery and the walls of the container depends on the respective
battery (design, energy content, condition, etc.).
3.4.3 Work procedure
1. Open the transport container (see section 3.3.1).
2. Fill a minimum layer of 20 cm (or distance according to
transport specifications) of PyroBubbles® into the transport
container.

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3. Place the hazardous material into the container in such a way
that the minimum distance is ensured.
Minimum distance S-Box X1 – M-Box X2: 12cm to all sides of
the container walls and 20 cm to the container bottom and
cover (or distance according to the transport permit)
XXL-Box & LP1-Box: 20cm all around (or distance according to
the transport permit)
4. Fill PyroBubbles® into the transport container, up to the top
edge. Pay particular attention to ensure that the transport
container is completely filled up to the top edge and in the
corners.
Attention
Only when the transport container is completely filled with
PyroBubbles® is an adequate level of protection ensured.
5. Close the transport container (see section 3.5.2).
3.5 Closing the transport container
3.5.1 Changing the clamping stroke of the the toggle catches
1. Loosen the locknut.
12/20 cm
12/20 cm
12/20 cm
12/20 cm

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2. Turn the locking eyelet counterclockwise to reduce the
clamping stroke. Turn the locking eyelet clockwise to increase
the clamping stroke.
3. Now tighten the locknut.
3.5.2 Work procedure
1. Throw the locking eyelets in such a way, that they form a right
angle with the container wall.
Caution
Danger of pinching between cover and transport container
Slight injuries to fingers and hands
Wear work gloves Do not insert your fingers or hands between the cover and
the transport container.
2. Attach the lifting gear to all 4 anchor points on the cover.
(only at XXL box)
Use the guides on the cover. (only at LP1-Box)
approx. 90°

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3. Place the cover centrally on the transport container.
Caution
There is a risk of squeezing or jamming fingers/hands in the toggle catches
Slight injuries to fingers and hands
Wear work gloves Do not insert your fingers or hands between the locking bolt
and the locking lever.
4. Press the locking bolt of a toggle catch downwards, and at the
same time move the locking lever upwards.
5. Place the locking eyelet over the locking hook.
6. In the unclamped condition, the locking lever should be at an
angle of approximately 45° to the container wall. It may be
necessary to alter the clamping stroke of the toggle catch (see
section 3.5.1).
approx. 45°

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7. Repeat steps 3 through 5 for all toggle catches.
8. Push the locking levers of all toggle catches downwards until
the locking bolt engages by itself.
3.6 Removing the hazardous material
3.6.1 Safety instructions
If the transport container shows any signs of deposits, discoloration 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 cell or battery, or a thermal runaway,
the transport container must be opened only by personnel wearing protective
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 cell or battery, or a thermal runaway,
the transport container must be opened only by personnel wearing protective
equipment appropriate to the type of hazardous substance involved.
Warning
Risk of explosion due to explosive gases
Injuries ranging from severe to fatal
In the event that the cell or battery suffers a thermal runaway, avoid ignition
sources. If possible, provide sufficient ventilation.

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Warning
Hazards due to electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the battery with electrically insulating materials. Wear
adequately electrically insulating protective equipment.
3.6.2 Work procedure
Variant 1
1. Open the transport container (see section 3.3.1).
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 3.3.1).
2. Use a forklift truck equipped with a fork rotator to lift the container between its guides
and hold it over a grating.
3. Slowly rotate the transport container until the battery slides up against the walls of the
container.
Attention
If the container is rotated too quickly, the battery could slam against the wall of the con-
tainer and damage it severely.
4. Continue rotating the transport container to a total of 180°. The battery will fall out on to
the top of the grating, while the PyroBubbles® will fall through the grating.
Attention
The mechanical stress to which the battery is subjected in this way could cause a thermal
runaway.
4Maintenance and Repair
4.1 Maintenance
4.1.1 Safety instructions
Warning
Risk of poisoning due to toxic substances that have leaked from the battery
Injuries ranging from severe to fatal
In the event of contamination due to substances leaking from the battery, wear
protective equipment appropriate to the hazardous substances involved.
4.1.2 Maintenance instructions
Contamination by substances leaking from the battery on to the transport containers must be
removed. For this purpose, use only cleaning materials that do not attack the material of the

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transport container (stainless steel) or the sealing rubber (EPDM).
PyroBubbles® can generally be reused, provided that they show no visual changes and the
granules are odor-neutral.
The service life of the sealing rubber is approximately 8 years.
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.
5Troubleshooting
Even though the cover is mounted centrally, the locking eyelets cannot be engaged on the
locking hooks.
Rotate the cover horizontally by 180°. If the locking eyelets still cannot be engaged on the
locking hooks, it may be that the locking hooks are damaged.
6Waste 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 commonly available recycling programs.
Danger
Danger of poisoning by inhalation of contaminated dust
Injuries ranging from severe to fatal
Use protective equipment suitable for the type of contamination involved.
Contaminated PyroBubbles® must be properly disposed of in accordance with the applicable
national regulations and in accordance with their respective contamination.
7Contact Information
Genius Technologie GmbH
Am Theresenhof 2
15834 Rangsdorf
GERMANY
www.genius-group.de