EnerSys NexSys® CORE ATEX Batteries for Hazardous Environments

Introduction

The NexSys® CORE ATEX batteries are Valve Regulated Lead-Acid (VRLA) Thin Plate Pure Lead (TPPL) batteries certified for use in potentially explosive atmospheres (increased safety, Ex e) where gas or dust may cause explosions. These batteries are categorized for Group I, Category M2/Mb, and Group II, Category 2 and 3 (Zone 1 2G/Gb, Zone 2 3G/Gc, Zone 21 2D/Db, Zone 22 3D/Dc).

Compared to conventional ATEX batteries, EnerSys' patented ventilation system allows for higher capacity within the same battery compartment size.

Unlike batteries with liquid electrolyte, NexSys CORE ATEX batteries use a sealed system with a working valve to regulate internal gas pressure, preventing oxygen ingress and allowing excess gas to escape. These batteries do not require refilling with distilled or demineralized water.

VRLA battery operation requires similar safety precautions as sealed batteries with vent plugs, including risks related to electrical hazards, corrosion, and explosion. Battery valves must never be removed.

This manual should be used in conjunction with the NexSys CORE standard battery manual, available at www.enersys.com.

Upon receipt, ensure batteries are undamaged and complete. Contact your supplier immediately if any damage or missing accessories are found.

The ATEX-certified NexSys batteries are designed for use in battery-powered applications such as electric counterbalanced and reach trucks, and pallet trucks in hazardous areas. EnerSys cells and connectors have an IP65 ingress protection rating, and battery containers have an IP23 rating when the lid is attached.

The use of electrical equipment such as DC-DC converters, low-voltage alarms, and EnerSys Wi-iQ battery monitoring devices is prohibited unless they are certified for hazardous areas and mounted externally to the battery.

Nominal Data for NexSys® CORE ATEX Batteries:

• Nominal Capacity C5: See type label
• Nominal Voltage: See type label
• Discharge Current: C5/5h
• Nominal Temperature: 30°C

These cells comply with the following clauses:

• Group II Components: DIN EN/IEC 60079-0 Clauses 23.3 (cell types), 23.6 (interchangeability), 23.8 (electrolyte leakage), 23.9 (connections), 23.10 (orientation), and 23.11 (replacement of cells or batteries); DIN EN/IEC 60079-7 Clauses 5.6 (classification), 5.6.3.1 (types of permissible batteries), 5.6.3.3 (cells), 5.6.3.4 (connections), and 6.6.3 (impact test).
• Battery Assembly: Remaining clauses of DIN EN/IEC 60079-7, with specific reference to DIN EN/IEC 60079-0 Clauses 23.2 (batteries), 23.4 (cells in a battery), 23.5 (dimensioning of a battery), and 23.11 (replacement of cells or batteries); DIN EN/IEC 60079-7 Clauses 5.6.3.2 (battery containers), 5.6.4 (charging of cells and batteries), 6.6.2 (insulation resistance), and 6.6.4 (ventilation).

Cells under this certification must be installed in series with cells of the same electrochemical system, cell construction, and nominal capacity from EnerSys, within a suitable battery enclosure that provides protection against mechanical impact.

Cells must be mounted vertically with electrical connections at the top.

These devices contain non-conductive parts that may generate ignitable electrostatic charges under certain extreme conditions. Users must ensure devices are not installed in locations exposed to extreme conditions (e.g., high-pressure steam) that could cause electrostatic charge buildup on non-conductive surfaces. Cleaning should only be done with a damp cloth.

Certified cells have an operating temperature range of -20°C to +60°C, which must be considered when used in a battery. Battery operating conditions take precedence.

Conditions of Use

Charging must not be performed in a hazardous area!

Conformity

ATEX-certified NexSys batteries comply with ATEX Directive 2014/34/EU. Conformity is demonstrated with reference to the following documentation:

Example of ATEX NexSys CORE label:

Type: XXXX

Nominal Voltage: XXXX V

Capacity C5: XXXX Ah

No. of Cells: XXXX

Battery Tray No.: XXXX

Service Mass: XX Kg

Serial No.: XXXX

CE2813

II 2D Ex to IIIC T80°C Db

II 2G Ex eb IIC T6 Gb

EN 60079-0, EN 60079-7, EN 60079-31

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www.enersys.com

MADE IN XXXX

Hawker GmbH, Dieckstrasse 42, 58089 Hagen, Germany

1. Safety

• Battery work must only be performed by qualified personnel.
• Keep the operating manual near the battery.
• Wear safety goggles and protective clothing when working on batteries. Comply with national accident prevention regulations and DIN EN 62485-3 and DIN EN 50110-1.
• No smoking. Keep open flames, embers, or sparks away from the battery due to explosion and fire hazards.
• Avoid sparks from cables, electrical equipment, and electrostatic discharge.
• Eye/Skin Contact: Flush eyes or skin with plenty of clean water immediately and seek medical attention. Wash acid-contaminated clothing with water.
• Explosion and Fire Hazard: Avoid short circuits. Use only insulated tools and do not place or drop metallic objects on the battery.
• Dangerous Electrical Voltage! Avoid short circuits: NexSys CORE batteries can withstand very high short-circuit currents. Metal parts of the battery are always live: do not place tools or other objects on the battery. Be aware of hazards from batteries.
• Remove rings, wristwatches, and metal clothing that could contact battery terminals.
• Electrolyte is highly corrosive. While normal operation should not involve acid contact, damaged cell containers will expose the electrolyte (absorbed in the separator) which is corrosive, similar to liquid electrolyte.
• Batteries are heavy. Ensure secure mounting. Use appropriate handling equipment. Lifting hooks must not damage cells, connectors, or cables.
• Do not expose batteries to direct sunlight without protection. Discharged batteries can freeze. Store batteries in a frost-free area.

All battery work must be performed according to DIN EN 60079-19 and the EnerSys operating manual. Replace defective parts only with genuine EnerSys parts. Do not attempt to repair faulty parts. Failure to comply voids the warranty and certification.

Remember that the battery is an energy source. Even when fully discharged, sufficient energy remains to cause severe damage.

The battery is intended for use within specified environmental conditions.

Reactions with materials in potentially explosive atmospheres are not known. Consult EnerSys if in doubt.

When used according to this manual and the NexSys CORE “Standard” Battery Manual, this equipment poses no risk of injury or damage. When used in accordance with this manual, the equipment does not generate ignitable electrical sparks or arcs. The equipment is designed not to generate potential ignition sources from electromagnetic, acoustic, optical, or other external energy sources.

Individual cells contain sulfuric acid. These cells are made of acid-resistant materials.

Follow these safety measures:

• ATEX/IECEx-certified NexSys CORE batteries must not be charged in a controlled hazardous zone area unless specific measures defined by equipment manufacturers are followed.
• Never disconnect a battery under load in a hazardous zone.
• The battery cover (if applicable) must never be opened in a hazardous zone.
• Always use certified DC connectors for battery connections.
• Do not use the battery if damaged or exposed cables are visible.
• Do not use the battery if DC connectors are damaged.
• Never attempt to service the battery; contact the recommended authorized service center.
• All maintenance must be performed in accordance with ATEX directives.
• Never mix cells of different types or capacities within a battery.

2. Maintenance

Your local authorized service technician can provide assistance. This manual provides general information; your technician can define your specific requirements and match them to battery configurations. Your engineer can answer questions beyond the scope of this manual. Contact your local service representative for any battery-related questions.

3. Handling

Always use appropriate equipment for handling ATEX/IECEx-certified NexSys CORE batteries, as they are heavy. ATEX/IECEx-certified NexSys CORE batteries must be lifted and handled in an upright position using suitable, approved lifting equipment. Due to the wide variety of electric vehicles, battery container designs, equipment used, and battery change procedures, detailed instructions for changing batteries on specific electric vehicles cannot be provided. The correct procedure and steps must be provided by the vehicle manufacturer or battery change equipment provider.

4. Receiving Your Battery

Remove all packaging material and carefully inspect the entire battery to ensure there is no physical damage. If the battery will not be put into immediate service, refer to the storage guidelines (Section 9).

5. Commissioning

ATEX and IECEx-certified NexSys CORE batteries are supplied in a charged state. Please check the following:

1. Cleanliness of the battery and the vehicle battery compartment.
2. Ensure a system is in place to prevent connecting your battery to an incorrect charging device. Verify all connections are correct and that positive and negative polarity is observed as clearly marked on the connectors. Incorrect connection can damage the battery, vehicle, or charger.
3. Ensure all charging equipment is suitable for use with NexSys CORE ATEX batteries.
4. Charge the battery before its first use.
5. If unsure about the type of hazardous area, consult the representative responsible for your equipment/vehicle.

6. Operation

6.1 Operational Safety

Battery usage must comply with EN 62485-3 (“Safety requirements for batteries and battery installations - Part 3”) and Directive 1999/92/EC (“Minimum requirements for improving the safety and health protection of workers potentially exposed to explosive atmospheres”).

6.2 Operating Conditions

The operating temperature range is between -20°C and +40°C as per ATEX approval. Battery lifespan depends on operating conditions, particularly operating temperature and depth of discharge. Optimal battery life is achieved by operating the battery in the temperature range of +15°C to +35°C for maximum performance and longevity. High temperatures shorten battery life, and low temperatures reduce available capacity.

Operating at a depth of discharge of 60% or less maximizes battery lifespan. The maximum permissible discharge is 80% of the nominal capacity C5. From new, the battery will reach its full capacity after approximately three charge/discharge cycles.

6.3 Discharge

The valves on top of the battery must not be sealed or covered. Connecting or disconnecting electrical connections (e.g., connectors) must only be done when de-energized (no load). Discharges exceeding 80% of nominal capacity are considered deep discharges and are not permitted, as they significantly reduce battery life. Discharged batteries MUST be recharged immediately and MUST NOT be left in a discharged state.

Note: The following applies only to partially discharged batteries.

Discharged batteries can freeze. Limit discharge to a maximum depth of discharge of 80%. Battery durability depends on the depth of discharge; the higher it is, the shorter the durability. A discharge limitation must be present in the vehicle.

For discharge currents from I₁ to I₅, use the following cutoff settings:

• Max. 60% Depth of Discharge, 1.96V
• Max. 80% Depth of Discharge, 1.92V

For lower currents, contact EnerSys.

6.4 Charging

Note: ATEX/IECEx-certified batteries must never be recharged in a hazardous zone area unless specific measures defined by equipment manufacturers are followed.

ATEX and IECEx-certified NexSys® CORE batteries must be charged with appropriate EnerSys chargers. Using non-specified chargers will void the warranty. NexSys CORE ATEX batteries are suitable for applications with normal and high duty cycles. In normal duty applications, the charger (charge current between 0.2 and 0.25 C5) will recharge the battery from 80% discharged in approximately six hours.

Short intermediate charges are permitted (an intermediate charge between main charges with an energy throughput of 100% C5 is permissible).

Under normal conditions, NexSys CORE batteries exhibit extremely low gas emissions. For gas emission calculations for safety purposes, use 1.5A/100Ah C5. Provisions must be made for venting charging gases. Doors, battery container lids (if applicable), and battery compartment covers must be opened or removed during charging. Valve openings must not be sealed or covered. Connecting or disconnecting electrical connections (e.g., connectors) must only be done when de-energized.

Connect the battery to the charger for charging, ensuring the charger is switched off first. Observe correct polarity at the positive and negative terminals. NexSys CORE batteries must be fully charged at least once a week.

6.5 Equalization Charge

Chargers from the NexSys, NexSys +, and Lifespeed iQ™™™ series automatically switch to equalization charge after the normal charging process (profile-controlled).

7. Maintenance

The electrolyte is fixed. Electrolyte density cannot be measured. Never remove the safety valves from the cells. If a valve is damaged, contact EnerSys for replacement.

7.1 Daily

Recharge the battery after every discharge. Check the condition of connectors and cables, ensuring all insulating covers are fitted and in good condition. If visible damage is present, immediately take the battery out of service and move it to a safe area outside the hazardous zone. DO NOT attempt any repairs on an ATEX/IECEx-certified battery. This is only permitted for qualified personnel. Contact EnerSys or your authorized service representative for assistance.

7.2 Weekly

Perform a visual inspection of all battery components for dirt and mechanical damage. Pay particular attention to the battery's charge connectors and cables.

7.3 Quarterly

It is recommended to perform voltage measurements at the end of the charging cycle and record the following:

• Voltage of the entire battery
• Voltage of each individual cell

If significant changes compared to previous measurements or differences between cells are detected, contact EnerSys customer service.

If battery runtime is insufficient, check the following:

• Whether the application can handle the battery capacity.
• Whether the charger settings are correct.
• If applicable, whether the vehicle's discharge limitation settings are correct.

7.4 Annually

Remove all dust from the battery. Inspect all connections (connectors, cables, and contacts). At least annually, the insulation resistance of the vehicle and the battery must be checked by an electrician according to DIN EN 1175-1. The insulation resistance test for the battery must be performed according to DIN EN 1987-1. The determined insulation resistance must be at least 500 Ω per volt of nominal voltage, and the battery resistance must not fall below 1 kΩ, regardless of voltage (see standard DIN EN 62485-3).

Check the integrity of the battery tray to ensure no damage has been caused by lifting equipment. All lifting openings on the battery tray must be checked for possible damage. There should be no visible deformation.

8. Battery Care

Keep the battery clean and dry to avoid creepage currents. Cleaning should be performed according to the ZVEI leaflet “Cleaning of Vehicle Traction Batteries”. Any liquid in the battery tray must be absorbed and disposed of properly. Damage to the inner lining of the battery tray must be repaired after cleaning the affected area to ensure insulation values according to DIN EN 62485-3 and to prevent tray corrosion.

If cells need to be replaced, contact EnerSys customer service.

9. Storage

Batteries are supplied by the manufacturer in a fully charged state. The battery's state of charge decreases with storage time. All batteries lose stored energy due to chemical side reactions, even when stored in an open circuit. The self-discharge rate is not linear and increases with decreasing state of charge. High temperatures significantly reduce storage capability by increasing self-discharge. If the vehicle will be unused for more than 48 hours, remove the ignition key and switch off any auxiliary equipment (e.g., lamps, displays, onboard computer).

The standard storage time for a battery not installed in a vehicle, without needing to be recharged, is one month. The maximum storage time without charging at 20°C is 6 months, provided the battery is fully charged at the beginning of storage and all other electronic devices that could discharge the battery are disconnected from the battery. However, it is recommended to perform an inspection after 3 months, measure the open-circuit voltage, and recharge if necessary.

10. Troubleshooting

If battery or charger malfunctions are detected, contact EnerSys customer service immediately. Measurement data as per Section 7.3 simplifies troubleshooting and fault resolution. A service contract with EnerSys facilitates timely detection and resolution of faults to ensure optimal battery performance.

Return to Manufacturer!

Batteries bearing this symbol must be recycled. Batteries not sent for recycling must be disposed of as hazardous waste!

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