EnerSys ATEX Certified Cells User Manual

Introduction

This document provides essential information for the safe handling and correct use of ATEX certified cells. It includes a comprehensive system overview, safety measures, usage procedures, and guidelines for commissioning and recommended maintenance. The document must be kept accessible to all personnel working with and responsible for the battery. Users must ensure that all system applications are appropriate and safe based on established or encountered operating conditions.

This user manual contains important safety instructions. Read and understand the safety and battery operation sections before using the battery and the equipment it is installed in.

The owner is responsible for ensuring that the use of this documentation and all related activities comply with applicable legal requirements in their respective countries.

This user manual does not replace any required training on the handling and use of ATEX certified cells mandated by local laws and/or industrial standards. Before coming into contact with the battery system, ensure all users receive adequate training and instruction.

Your safety and the safety of others are very important. Failure to observe these instructions may cause death or serious injury.

Information

CE Declaration of Conformity

Subject: Ex Cells for Vehicle Traction Batteries

EnerSys® confirms that these cells (see below for serial number and CE type examination certificate details, certification service SIRA, notified body number 2813) comply with the provisions of Directive 2014/34/UE concerning devices and protective systems intended for use in potentially explosive atmospheres. Fundamental health and safety requirements are met by compliance with the following standards: DIN EN 60079-0, DIN EN 60079-7, DIN EN 60079-31, IEC 61241-0, and IEC 61241-1.

Signed: ________________________________________________ (Authorized ATEX/IECEx Representative)

Serial Number: ______________________________________________

Ex Cell Type: _________________________________________

CE Type Examination Certificate: SIRA 01 ATEX 30 U

IECEx Conformity Certificate: IECEx SIR 07.006 U

This declaration certifies conformity to the above directives but does not contain any legal property guarantees. Please observe the safety warnings in the attached product documentation.

This User Manual provides instructions for the safe assembly and operation of Ex cells in vehicle batteries. Ex cells are components defined by Directive 2014/34/UE (ATEX/IECEx). For battery production and use, further requirements of the Directive must be met, which are not covered by the cell component certification or this User Manual.

Therefore, the final installation operation must satisfy the ATEX and IECEx certification requirements for qualified companies and personnel.

Safety and Labeling

Safety Warnings

It is not permitted to use different types of cells within the same battery, nor cells with different dimensions, performance, or capacity.

Ex cells meet safety requirements when used as intended. Special terms and conditions for safe application must be met according to the CE type examination certificate numbers: SIRA 01ATEX3016U, SIRA 01ATEX3019U, SIRA 03ATEX3087U, SIRA 03ATEX3090U, and IECEx conformity certificate numbers: IECEx SIR07.0061U, IECEx SIR07.0062U, IECEx SIR07.0063U, IECEx SIR07.0064U.

When assembling cells into batteries, at least the conditions established by DIN EN 60079-7 must be observed, including:

• General Information
• Battery Container
• Cells
• Connector
• Cell Charging
• Cell Discharging
• Other types of fire protection
• Shut-down and Transport
• Auxiliary Batteries
• Insulation Resistance
• Impact Resistance Test
• Ventilation

Labeling and Field of Application

This User Manual applies to cells matching the CE type examination certificate and IECEx conformity certificate numbers:

• IECEx SIR07.0061U - SIRA 01ATEX3016U: Lead-acid traction cells of type B (PzB, PzMB)
• IECEx SIR07.0062U - SIRA 01ATEX3019U: Lead-acid traction cells of type D (PzS, PzM)
• IECEx SIR07.0063U - SIRA 03ATEX3087U: Lead-acid traction cells of type B Evolution® (PzVB)
• IECEx SIR07.0064U - SIRA 03ATEX3090U: Lead-acid traction cells of type D Evolution® (PzV) and NexSys® TPPL cells (NxS)

The 'U' character after the certificate number indicates that this certificate must not be confused with one intended for a device or protective system. This component certificate can only be used as a basis for certifying a device or protective system. The indicated certificates therefore refer only to the design and type testing of the component cells specified, in accordance with Directive 2014/34/UE. For manufacturing and marketing the cells, the producer must meet other requirements of the Directive, which are not covered by these certificates.

For this reason, the final installation operation must satisfy the ATEX and IECEx certification requirements for qualified companies and personnel.

These Ex cells can be used in the following areas:

• Explosion Group I, Mining Activity Category M2/Mb
• Explosion Group II, Categories 2 and 3 [Zone 1 2G/Gb, Zone 2 3G/Gc (gas)]
• Explosion Group III, Categories 2 and 3 [Zone 21 D/Db, Zone 22 3D/Dc (dust)]

Hazardous Area Classifications:

M2 Ex eb I

II 2G Ex eb IIC T6

II 2D Ex IIIC T80 °C

Ex eb I

Ex eb IIC T6

Ex tb IIIC T80 °C

Assembly and Commissioning

Assembly

During assembly, cells must always be lifted by all mounting points simultaneously using insulated suspension equipment.

Ex cells can only be connected in series (series connection). Parallel connection is not permitted. Pay attention to correct polarity during assembly. For electrical wiring, use only EnerSys® authorized components. The optional aquamatic system and electrolyte circulation must be wired in accordance with EnerSys requirements, e.g., "electrical wiring conformity." Request corresponding information if necessary.

NOTE: The connection technique, aquamatic system, and electrolyte circulation are part of the cell component testing and approval and must not be modified.

All components must be purchased from EnerSys.

Terminal and intermediate connections must also be made only with approved components. Use new, unused M10 x 20 screws with the specified threadlocker: torque wrench 25 + 2 Nm. Correct contact and thread engagement must be guaranteed.

Cover connections must be tightened. To ensure IP protection, a hole-free cover must be used.

If connector plugs with holes are used (only on the negative pole for voltage measurement), the connector chamber must be filled with grease, e.g., Berutox M 21 KN.

Electronic components must not be used in proximity to an ATEX/IECEx battery, for example, under a cover or near the cell.

Only Ex cells of the same type, size, and capacity can be connected together.

Ex cells must be securely installed in the battery container. Any gaps must be filled with stable, acid-resistant filler material. The use of cell boxes or foam filler material is not permitted.

Commissioning

For commissioning Ex cells, refer to the User Manual for Perfect Plus™, Water Less®, Evolution®, or NexSys® TPPL (see www.enersys.com). Additionally, the User Manual for the device or protective system in which these Ex cells are integrated applies.

Lead-acid cells, especially vented cells, can only be stored for a limited period without regular recharging. New cells must be fully charged upon delivery. Perfect Plus™ and Water Less® cells must be recharged at the latest every 6 weeks, while Evolution® and NexSys® TPPL cells must be recharged within 3 months.

When reassembling batteries, connect only cells with the same charge state and ATEX marking. The open-circuit voltage of the cells must be at least 2.13 V/cell under full charge conditions.

Operation and Maintenance

Operation and Charging

Never charge a battery or Ex cells in an area subject to environmental control.

For charging and operation, you can use the User Manual for the standard battery model (see www.enersys.com). Additionally, the User Manual for the device or protective system in which these Ex cells are integrated applies.

Identification Values of Ex Cells:

• Maximum nominal voltage in battery system: 500 V
• Ambient temperature range: -20 to 40 °C
• Maximum allowed battery cell temperature: 55 °C
• Nominal current: 0.2 C5

Activities:

Use only approved charging devices and charging functions. When integrating charging devices into vehicles and charging batteries in explosive risk areas, the charging system must be integrated with a conformity assessment based on DIN EN 60079-7.

Batteries that reach a temperature above 40 °C at the end of charging must be cooled to 40 °C before being used in explosive risk areas.

Maintenance and Repair

Only approved original EnerSys spare parts and components may be used. Only cells bearing an ATEX label from a manufacturer of the same type, size, and capacity can be used as replacements.

Additionally, the User Manual for the device or protective system in which these Ex cells are integrated applies.

To perform this work, it is necessary to comply with the rules prescribed by standard EN 60079-19. Interventions must be carried out exclusively by adequately qualified personnel, must be documented, and the device or protective system must be identified with a corresponding 'R' label.

Notes and Disposal

Regulatory Indications to Respect (Extract)

• Directive 1999/92/CE
• Directive 2014/34/UE
• DIN EN 1127-1: Explosive atmospheres - Prevention and protection from explosions - Part 1: Basic concepts and methodology
• DIN EN 1175-1: Industrial truck safety - Electrical requirements Part 1: General requirements for battery-powered trucks
• DIN EN 60079-0: Explosive atmospheres - Part 0: Equipment - General requirements.
• DIN EN 60079-7: Explosive atmospheres - Part 7: Equipment protection by increased safety "e"
• DIN EN 60079-31: Explosive atmospheres - Part 19: Repair, overhaul, and reclamation of equipment
• DIN EN 61241-0: Electrical apparatus for use in the presence of combustible dust - Part 0: General requirements
• DIN EN 61241-1: Electrical apparatus for use in the presence of combustible dust - Part 1: Type of protection "tD"
• DIN EN 62485-3: Safety requirements for secondary batteries and battery installations - Part 3: Traction batteries

Disposal and Return to Manufacturer!

Always dispose of the battery container and cells at a local service center. Do not attempt to disassemble the battery or cells in any way. Once the product has failed and is no longer repairable, keep it outside the controlled environmental area until it is removed for disposal.

Batteries marked with this symbol [♻️] Pb must be recycled.

Batteries not returned for recycling must be disposed of as hazardous waste.

When using traction batteries and chargers, comply with the standards, laws, regulations, and ordinances in force in the country of use.

This document is a translation of the original version published in English (https://www.enersys.com/4ace61/globalassets/documents/product-documentation/_enersys/emea/legacy/batteries/hawker/atex/emea-en-iu-haw-atex-0522.pdf). In case of inconsistencies between this version and the original, the English version shall prevail.

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Document Code: EMEA-IT-OM-ATEX-CELL-0725