Packing Critical 12-Volt Lithium-Ion Battery

Courtesy of PORSCHE CARS NORTH AMERICA, INC.

Metal container for high-voltage modules

• Dimensions (length x width x height): approx. 1.8 x 1.4 x 1.4 m
• For transporting max. 8 HV modules
• Weight: ~ 1.6 t (incl. filling material and battery)

1. Open metal container.
2. Measure 25 cm from the floor inside the metal container -1-  and mark this on the container wall (inside) using a water-resistant marker -2-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Height marking (shown as an example)

3. Wear protective clothing, breathing mask as well as goggles and protective gloves.
4. Position air extraction hose -2-  in the metal container -1-  in order to extract the dust and switch on the device.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Extraction (shown as an example)

5. Fill hollow glass granulate (Extover® or PyroBubbles®) -2-  into the metal container -1-  to a height of 25 cm until the line marked on the inner wall of the container is completely covered by hollow glass granulate.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Filling hollow glass granulate

   Information 

   Several 12-volt lithium-ion batteries can be packed into the metal container. Note:

   • Minimum fill height from floor: 25 cm  .
   • Distance between 12-volt lithium-ion battery and metal container: 12 cm  .
   • mm fill height between the 12-volt lithium-ion batteries  .
   • The battery must be covered with at least 25 cm of hollow glass granulate from the top  .
6. Place battery on the hollow glass granulate in the metal container.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Placing battery in container

   1. 6.1
      IMPORTANT: The distance -A-  from the battery to the metal container must be at least 12 cm.
   2. 6.2
      IMPORTANT: It must be possible to cover the battery with at least 25 cm of hollow glass granulate from above.

   Information 

   IMPORTANT: The metal container must be completely filled with hollow glass granulate, right up to the top edge.
7. Fill the metal container up to the top edge with -1-  hollow glass granulate -2-  .

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Filled metal container (shown as an example)

8. Close the metal container and secure it with the tension locks.
   1. 8.1 Visually inspect the lid seal on the -2-  metal container -1-  .

      Courtesy of PORSCHE CARS NORTH AMERICA, INC.

      Visual inspection (shown as an example)

   2. 8.2 Fit lid on the metal container and lift it up again. Perform visual inspection. The cross on the inside of the lid must be visibly pressed down in the hollow glass granulate. If it is, the metal container is filled correctly.
   3. 8.3 If necessary, adjust the tension locks -2-  using a lock nut so that the metal container lid -1-  is firmly sealed.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Adjust tension locks.

9. Affix hazardous goods label -2-  in a clearly visible position on both  long sides of the metal container -1-  .

   Forms for the required hazardous goods stickers can be found in the HEOL Manual.

   Courtesy of PORSCHE CARS NORTH AMERICA, INC.

   Labels for damaged/defective lithium-ion batteries

10. Affix UN 3480 label -3-  on both  long sides of the metal container -1-  over the hazardous goods label -2-  .
11. Affix identification sticker -4-  for the battery on both  long sides of the metal container -1-  next to the UN 3480 sticker -3-  .
12. Attach document bag

    Information 

    The original test log for classification of the lithium-ion battery must be kept in the Porsche Centre.

13. Complete accompanying documentation and place it in the document bag together with another copy of the test log for classification of the lithium-ion battery.
14. Affix "Item number (large)" label on one short side of the transport box.