Genius PyroBubbles Storage Box 30 User manual

V1.3 (2019-06-05)
Instruction Manual for
PyroBubbles ® - Storage Box 30
PyroBubbles ® - Storage Box 90
PyroBubbles ® - Storage Box 220
PyroBubbles ® - Storage Box 280
PyroBubbles ® - Storage Box 520
for lithium-ion and lithium-metal cells and batteries
Read these instructions carefully before use and retain for
future reference.

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Contents
1Product Description......................................................................................................... 3
1.1 Technical data.............................................................................................................. 3
1.2 Construction ................................................................................................................ 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® ................................................................................ 5
3Use................................................................................................................................... 6
3.1 Storage......................................................................................................................... 6
3.1.1 Safety Instructions ................................................................................................... 6
3.1.2 Instructions for storage without hazardous content............................................... 7
3.1.3 Instructions for storage with hazardous content .................................................... 7
3.2 Packaging the hazardous goods .................................................................................. 7
3.2.1 Safety Instructions ................................................................................................... 7
3.2.2 Workflow.................................................................................................................. 8
3.3 Removing the hazardous goods .................................................................................. 9
3.3.1 Safety Instructions ................................................................................................... 9
3.3.2 Work procedure....................................................................................................... 9
3.4 Transporting the container........................................................................................ 10
3.4.1 Safety Instructions ................................................................................................. 10
3.4.2 Transport instructions............................................................................................ 10
4Maintenance and Repair............................................................................................... 11
4.1 Maintenance.............................................................................................................. 11
4.1.1 Safety instructions ................................................................................................. 11
4.1.2 Maintenance and Cleaning Instructions ................................................................ 11
4.2 Repairs ....................................................................................................................... 11
5Waste Disposal/Environmental Protection................................................................... 11
6Spare Parts .................................................................................................................... 12
7Contact Information...................................................................................................... 12
8Customer Service........................................................................................................... 12

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1Product Description
1.1 Technical data
Storage Box
30
Storage Box
90
Storage Box
220
Storage Box
280
Storage Box
520
Article Number
2306
2307
2308
2309
2310
External
dimensions of
container in mm
(L x W x H)
600 x 400
x 800
800 x 600
x 800
1200 x 800
x 800
1200 x 1000
x 800
1665 x 1480
x 910
Internal
dimensions of
container in mm
(L x W x H)
363 x 213
x 395
563 x 413
x 395
1013 x 563
x 395
1013 x 743
x 373
1245 x 1045
x 400
Ground clear-
ance in mm
150
120
Content of inner
containers in L
30
90
220
280
520
Load capacity in
kg
100
200
400
400
400
Net weight in kg
(including
PyroBubbles®)
Painted/galva-
nized
71 / 86
115 / 122
196 / 206
234 / 247
300 / 315
Stackable
triple
no
Outer container
Steel
Inner container
Steel
Filler material
PyroBubbles® bulk
PyroBubbles® PE filler pads
PyroBubbles®
weight in kg (±
10%)
15
29
56
72
220

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1.2 Construction
Fig. 1: Storage Box 220 in opened state (as an example)
1 Outer container
2 Inner container
3 Cover with PyroBubbles® PE filler pads
4 Stacking corner
5 Interspace with PyroBubbles® fill
6 Toggle catch (lockable)
7 lifting grip
8 Helical torsion spring (not at Storage Box
520)
9 Lid support (only for Storage Boxes 220,
280 and 520)
10 Bracket for lid support (only for Storage
Boxes 220, 280 and 520)
1
2
3
4
5
10
9
8
7
6

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2Safety Instructions
2.1 Proper intended use
The storage container is used for storing lithium-ion and lithium-metal cells and batteries. The
storage container shall be used only in an undamaged and unmodified condition. The integrity
of the storage 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 in an uncontrolled manner. In combination with the high
temperatures of the cell, the large quantities of toxic and flammable gases formed can lead to
severe fire events. This intense release of heat can consequently 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 batteries with unknown condition should always be stored in
corresponding safety containers.
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.

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For details, refer to TRGS 900 (or respective 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 5) 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 storage container and the filler material.
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.
Warning
Risk of injury from falling parts
Injuries ranging from severe to fatal
When moving storage containers, do so only with suitable forklifts / pallet trucks
and using the designated lifting points. No person must be allowed to linger
within the working area of the forklift / lift truck.

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3.1.2 Instructions for storage without hazardous content
PyroBubbles® must be stored in a dry location.
The storage containers should be set up on a flat surface, under a canopy.
3.1.3 Instructions for storage with hazardous content
When storing cells and batteries, the lid of the storage container must be kept free, so that
any reaction gases that may occur can escape freely and there is no pressure build-up inside
the storage container.
3.2 Packaging the hazardous goods
3.2.1 Safety Instructions
Danger
Risk of poisoning due to toxic substances escaping from cells or batteries
Injuries ranging from severe to fatal
Wear protective equipment suitable for the respective hazmat.
Warning
Hazards due to electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the battery with electrically insulating materials. Wear
adequate electrically insulating protective equipment.
Caution
Risk of pinching between the lid and container
Slight injuries to fingers and hands
Wear work gloves. Do not insert your fingers or hands between the lid and the
container.
Caution
To prevent a short circuit via the inner container, cover the contacts on the batteries with elec-
trically insulating materials.

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3.2.2 Workflow
1. The lid of the storage container is delivered from the factory with at least one of the
toggle catches (6) locked. Pull this toggle catch upwards and remove the screw hooks
from the lid.
2. Model Storage Box 30 – 280: using the lifting grip (7), open the cover.
Model Storage Box 520: using suitable lifting devices and the lifting grip (7), open the
cover.
3. Model Storage Box 220, 280 and 520: hold the lid with one hand and snap the lid sup-
port (9) into the bracket (10).
4. The lid remains standing in its open state.
5. Place the hazardous substance into the inner container.
Optional: Fill all cavities in the inner container with PE filler pads.
Caution
The hazardous substance placed into the container must not protrude beyond the edge
of the inner container.
6. Model Storage Box 220, 280 and 520: firmly hold the lid with and remove the lid sup-
port (9) from the bracket (10).
7. Model Storage Box 30 – 280: Close the lid using the lifting grip (7), place the screw hook
of the toggle catch (6) over the edge of the cover and then tighten the catch.
8. Model Storage Box 520: Close the lid using suitable lifting devices and the lifting grip
(7), place the screw hook of the toggle catch (6) over the edge of the cover and then
tighten the catch.

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3.3 Removing the hazardous goods
3.3.1 Safety Instructions
If the storage container shows any signs of deposits, discolouration or a piercing smell, you
must assume that the electrolytes have leaked or there has been a thermal runaway in the
battery.
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 storage 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 storage 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
Hazards due to electric voltage
Injuries ranging from severe to fatal
Cover the terminals of the battery with electrically insulating materials. Wear
adequate electrically insulating protective equipment.
3.3.2 Work procedure
1. Open the storage container (see section 3.2).
2. Optional: Remove the PE filler pads until the battery is visible.
3. Remove the battery. The inner container must remain in the outer container.

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3.4 Transporting the container
3.4.1 Safety Instructions
Warning
Risk of injury from falling parts
Injuries ranging from severe to fatal
When moving storage containers, use only suitable lifting gear acting at the des-
ignated lifting points. No person must be allowed to linger within the working
area of the lifting gear.
3.4.2 Transport instructions
Make sure that the storage containers are properly closed by means of the toggle catches.
To increase static friction, non-slip mats must be placed beneath the feet of the storage con-
tainer. The load is secured by lashing it down with tie-down straps, which are strapped across
the lid.
Caution
The storage container is not suitable for transporting lithium-ion batteries in the sense of
transport for dangerous goods.

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4Maintenance and Repair
4.1 Maintenance
4.1.1 Safety instructions
Warning
Risk of poisoning due to toxic substances that have escaped from cells and bat-
teries
Injuries ranging from severe to fatal
Wear protective equipment suitable for the respective hazardous substance.
4.1.2 Maintenance and Cleaning Instructions
Contamination by substances leaking from the cells or batteries on to the storage containers
must be removed. For this purpose, use only cleaning materials that do not attack the material
of the storage container (steel) or the sealing rubber (chloroprene rubber).
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 continue using damaged storage containers. Repairs shall be made exclusively by spe-
cialists authorized by the manufacturer.
5Waste Disposal/Environmental Protection
The materials used in manufacturing the storage container are recyclable and can be recycled
through commonly available recycling programs.
Uncontaminated PyroBubbles® can be forwarded to a construction-material recycling process.
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.

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6Spare Parts
All the information you need for ordering spare parts can be found in the spare parts list. For
fast order processing, we need the following information:
•Our article number of the spare part
•Our article designation of the spare part
•Order quantity
•Designation of the container, the manufacturing number and year of manufacture
Store the spare parts in a dry and dust-free environment and protect them from frost and heat.
We also recommend setting up a manual store for these parts.
We expressly point out that we have neither tested nor approved any spare parts that have
not been supplied by us. The installation or attachment as well as the use of such parts may
under circumstances influence the specified design features of the container.
We neither assume nor accept any warranty and/or liability for any damages whatsoever aris-
ing from the use of non-original parts and accessories.
7Contact Information
Genius Technology GmbH
Am Theresenhof 2
15834 Rangsdorf
[phone]
[e-mail]
www.genius-group.de
8Customer Service
The customer service is provided within the framework of the warranty. The warranty period
is up to 1 year after the initial commissioning, for all parts except consumables. Customer ser-
vice beyond this period requires a separate agreement, or, if necessary, it can be agreed with
us and provided to the customer at the customer’s expense.
For all technical problems, please contact us at the above address.
Please observe all current legal regulations relating to the above points.