HAWKER evolution ATEX-Certified Batteries

Introduction

The information contained in this document is of essential importance for the safe handling and proper use of ATEX-certified Evolution® batteries. The document includes general system specifications, system-related safety measures, operating instructions, commissioning instructions, and recommended maintenance procedures. This document should be retained and kept accessible to users working with and responsible for the battery. It is the responsibility of all users to ensure that the system is used appropriately and safely, based on anticipated or encountered conditions during operation.

This operating manual contains important safety instructions. Chapters concerning battery safety and use must be read and understood before using the battery and the equipment it powers.

The owner is responsible for ensuring that the use of this documentation and all related actions comply with applicable country-specific legal requirements.

This owner's manual is not intended to replace training related to the handling and use of ATEX-certified Evolution® batteries if national laws and/or industry standards require it. Before handling the battery system, it must be ensured that all users receive adequate guidance and training.

For service, contact your sales representative or call:

EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Phone: +41 44 215 74 10

EnerSys Headquarters
2366 Bernville Road
Reading, PA 19605, USA
Phone: +1-610-208-1991
+1-800-538-3627

EnerSys APAC
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
www.enersys.com

Ensuring your own and others' safety is extremely important.

⚠️ WARNING: Failure to follow these instructions can lead to death or serious injury.

Standards and Operating Conditions

These ATEX-certified Evolution® batteries are certified for use in areas with a risk of explosion due to gas or dust.

• Explosion group I class M2/Mb for mining
• Explosion group II class 2 and 3 [Area 1 2G/Gb, Area 2 3G/Gc (gas)]
• Explosion group III class 2 and 3 [Area 21 2D/Db, Area 22 3D/Dc (dust)]

They must be in perfect condition and intact. If you find damage or missing accessories, contact the supplier within 24 hours of receiving the product. Traction batteries are designed for use in battery-powered applications in hazardous areas: electric counterbalanced, reach trucks, sweepers, and other cleaning equipment. Cells and terminals meet IP rating 65, boxes IP23.

Thanks to the patented ventilation structure, these traction batteries fit existing DIN and BS size boxes and offer the same capacity as specified by the forklift manufacturer. Protection class 65, box protection class IP23.

Standard

ATEX-certified Evolution® batteries comply with ATEX Directive 2014/34/EU. Compliance is demonstrated by reference to the following documents:

EC Type-Examination Certificates:

ATEX certificates are valid in the EU area and IECEx certificates elsewhere in the world, excluding North America (USA and Canada). Quality Assurance Notification: Sira 01 ATEX M103.

Operating Conditions

Do not charge in a hazardous area.

Example of battery markings

Specifications and Safety

Specifications

• Nominal capacity C5: Refer to type plate
• Nominal voltage: 2.0 V x number of cells
• Nominal discharge current: C5/5h
• Nominal electrolyte specific gravity* Type PzV: 1.29 kg/l
• Nominal temperature for commissioning: 30 °C

*Achieved during the first 10 operating cycles.

ATEX-certified Evolution® batteries are valve-regulated, maintenance-free batteries. Unlike traditional batteries with liquid electrolyte, they have immobilized electrolyte (gel sulfuric acid). Instead of a vent plug, a valve is used to regulate internal gas pressure, preventing the ingress of airborne oxygen and allowing excess charging gases to escape. Safety requirements for valve-regulated lead-acid batteries are the same as for open cells. The user must protect themselves from hazards associated with electricity use, explosion hazards from electrolytic gas, and to some extent, hazards from corrosive electrolyte. The valves of ATEX-certified Evolution® batteries must not be removed. These batteries do not require the addition of distilled or demineralized water. ATEX-certified Evolution® batteries are designed for a service life of up to 4 years.

Safety Instructions

• Keep operating instructions near the battery.
• Only trained personnel should work with batteries.
• Always wear safety glasses and protective clothing when working with batteries.
• Follow accident prevention regulations and standards EN 62485-3 and EN 50110-1.
• No smoking! ?
• Do not expose batteries to open flames, glowing embers, or sparks, as these can cause the battery to explode.
• Acid splashes in eyes or on skin must be washed immediately with plenty of clean water. Seek medical attention immediately after thorough rinsing!
• Acid-stained clothing must be washed with water.
• Risk of explosion and fire! Avoid short circuits.
• Warning: Battery metal parts are always live. Do not place tools or other metal objects on top of the battery!
• Electrolyte is highly corrosive. Under normal use, there is no risk of contact with acid. If cell containers are damaged, the immobilized electrolyte (gel sulfuric acid) is as corrosive as liquid electrolyte.
• Batteries and cells are heavy.
• Ensure safe installation! Use only approved lifting equipment. Lifting hooks must not damage cells, terminals, or cables.

Safety, Maintenance, and Handling

Safety Instructions (cont.)

• Hazardous voltage! [High voltage warning]
• Be aware of potential hazards from batteries.

Failure to follow operating instructions and repairs using non-original parts will void the warranty. Report any battery, charger, or accessory defects, malfunctions, or error codes immediately to EnerSys® service.

Safety

Always remember that a battery is a power source. Even a fully discharged battery contains enough energy to cause serious damage.

Follow these safety instructions:

• Never charge an ATEX battery in a classified area.
• Never disconnect a battery in a classified area. Isolate circuits before disconnecting the battery outside a classified area.
• Never open the battery cover in a classified area.
• Always use a certified DC connector to connect the battery.
• Never use a battery with damaged or exposed wires.
• Never use a battery with damaged DC connectors.
• Never attempt to repair the battery. Contact an authorized service center.

Maintenance

A local authorized service technician can provide assistance and support. This manual provides general instructions, and the technician will help you interpret your needs according to your requirements.

The authorized service technician can answer questions not covered by this manual and provide expert assistance if needed. Your battery is an expensive investment and designed for use in classified areas. Our goal is to help you get the most out of it. If you have questions about your battery, contact your local service.

Handling

ATEX lead-acid batteries are very heavy. Always use approved lifting equipment when changing batteries. When lifting and handling ATEX batteries, use appropriate, approved lifting gear and keep the battery upright. As electric vehicles, battery boxes, equipment, and battery changing methods vary, detailed instructions for changing the battery of a specific electric device cannot be provided. The manufacturer of the vehicle or battery changing equipment must provide correct methods and procedures.

Battery and Commissioning

Receiving the Battery

Do not perform any of the following operations in a classified area. Use connectors and sockets with a special coding system designed for maintenance-free batteries to prevent accidental connection to the wrong charger. Incorrect battery polarity connection is prevented by marking the terminals visibly next to the connection socket with a color code (red for positive and blue for negative).

Accidental disconnection of battery wire insulation and exposure of wires is prevented by covering the wires with cable protection (e.g., spiral cable protection). Remove all packaging and carefully inspect the boxes for physical damage.

If the battery is not put into use immediately upon receipt, see Storage on page 11.

Commissioning

Charger cables must be connected to each other to ensure good contact. Check correct polarity. Otherwise, the battery, vehicle, or charger may be damaged. Wipe the tops and sides of the cells and the box with a damp cloth to remove dust and water. Cell cleanliness is extremely important. Ensure all connections are tightened.

The specified tightening torque for terminal bolts is 25 + 2 Nm (M10 screw).

Ensure cells are easily accessible for testing. This facilitates regular maintenance. Ensure the battery compartment is empty and ventilated and that no metal objects can fall through the battery's top ventilation opening. Ensure the battery is properly seated in its compartment and secured with suitable sealing to prevent movement during operation. Cables must be flexible and long enough so that no strain is placed on the cable or the certified connectors attached to them. If a new ATEX battery is used in an application where the classification of the area is uncertain, contact your local factory representative. Never connect electrical equipment (e.g., warning light) directly to any battery cells. This can lead to cell imbalance during charging, resulting in reduced capacity, insufficient discharge time, or cell damage, which CAN VOID THE BATTERY WARRANTY.

The battery will then be charged according to the Charging section on page 9.

Maintenance

Electrolyte is immobilized in a gel. Electrolyte density cannot be measured.

• Never add water!
• Never remove the safety valve from a cell. If a valve is accidentally damaged, contact customer service for replacement.

Daily

Recharge the battery after discharging.

• Remember that an ATEX battery must never be charged in a classified area, even if an approved charger is available. Always check that the charger is functioning correctly.
• Check that connectors and sockets are in good condition.

Maintenance and Discharging

Maintenance (cont.)

Weekly

Check all connection and wiring cables for frayed or worn insulation. If you find frayed wires or worn insulation, immediately remove the battery from service and place it in a safe area outside the classified area. Do not attempt to repair Ex batteries. Contact your local EnerSys® service representative.

Check that all insulators and vent caps are in place and that the battery terminals are in good condition.

Ensure the top of the battery is clean and dry. Dirt and moisture can cause leakage currents and potential sparks in a classified area. If the battery box has corrosion, scrape it off and neutralize the area with water and baking soda or a diluted ammonia solution. Protect the area from corrosion by painting it with acid-resistant paint.

Monthly

At the end of charging, check C5/100 voltages, measure, and record:

• battery voltage
• voltage of each cell

If you notice significant changes compared to previous measurements or deviations between cells or battery packs, contact EnerSys® service. If the battery discharge time is insufficient, check:

• compatibility of battery capacity with the intended use
• charger settings
• discharge limiter settings.

Annually

Check the following carefully:

• condition of connectors: ensure good contact between connectors without signs of overheating
• condition of output cables. If checking torque, use a torque wrench according to the recommended value: 25 + 2 Nm.

The insulation resistance of the forklift and battery must be checked at least once a year by an electrical expert according to EN 1175-1. Battery insulation resistance tests must be performed according to EN 1987 Part 1. Battery insulation resistance must not fall below 50 Ω/V per nominal voltage according to EN 62485-3. For batteries with a nominal voltage of up to 120 V, the minimum value is 1000 Ω.

Discharging

Ventilation openings must not be closed or covered. Electrical connections (e.g., connectors) may only be connected or disconnected when the circuit is open. To ensure optimal battery life, avoid operational discharges exceeding 80% of nominal capacity (deep discharge). They shorten battery life. Use only the battery manufacturer's recommended state-of-charge meter for measuring the state of charge (it is essential to use a discharge limiter with an energy cut-off of 1.83 VPC for operating voltage at 80% depth of discharge (DoD) C5, with a 12-hour charge, and 1.87 VPC for 60% DoD C5, with an 8-hour charge). Discharged batteries must be recharged and never left discharged for extended periods.

ATEX-certified Evolution® batteries can be used in normal operation for one shift per day, up to 80% DoD C5, and up to 6 days a week.

Avoid use in applications where:

• there is no rest time for battery cooling
• battery use causes a significant temperature increase during operation.

We recommend discharging the battery evenly; partial discharge with intermediate removal is not recommended. To solve this problem, a DC-DC converter must be used, which allows supplying additional loads from the entire battery.

NOTE: DC-DC converters and accessories must be certified for use in classified areas. Battery performance is directly dependent on temperature. The nominal temperature for batteries is 30 °C. If the battery temperature is lower than this, the available power decreases. Therefore, additional capacity is needed if batteries are used at low ambient temperatures (e.g., cold storage).

Charging and Temperature

Charging

NOTE: Never charge an ATEX battery in a classified area.

Full charge must be performed daily with an EnerSys®-approved charger. Charging time for an 80% discharged battery must be 12 hours, or for a 60% discharged battery, 8 hours with a properly specified high-frequency charger. If any charger cables are replaced, our technician must inspect the charger on-site.

ATEX-certified Evolution® batteries have low gas emissions. However, adequate ventilation for charging gases must be ensured during charging (EN 62485-3).

Battery box covers and compartment covers must be opened or removed. Connect the battery to a switched-off charger and ensure correct polarity. (Plus to plus, minus to minus.) Then switch on the charger.

If the charger was not purchased with the battery, it is recommended that the manufacturer's service checks its suitability. Due to charging gases, adequate ventilation must be ensured during charging.

PzV batteries (ATEX-certified Evolution® batteries) have low gas emissions, so some charging gases may form.

Battery box covers and compartment covers must be opened or removed.

During charging, the battery must be removed from the forklift's closed battery compartment. Ventilation must comply with EN 62485-3 requirements.

The length of the DC cable between the charger and the battery affects the charging voltage and the charger's control unit settings. Cables must not be extended without first consulting the charger manufacturer and the ATEX battery supplier. If the battery is only slightly discharged, it can be charged less frequently (e.g., every other day). In such situations, seek advice from a local service technician.

Disconnect the battery only after the charger has been switched off.

Local service centers must approve all charging systems used, otherwise the warranty may be voided.

Equalizing Charge

Equalizing charges optimize battery life and maintain its capacity. Individual equalizing charges are performed automatically weekly, 8 hours after the charging cycle with an HF charger is completed.

However, remember that an Ex battery must never be charged in a classified area.

Temperature

During battery operation, the temperature should be between +5 °C and +35 °C. Use outside this temperature range requires approval from an EnerSys® service technician. Optimal battery life is achieved when the battery is at 25-30 °C. High temperatures shorten battery life according to IEC 1431 standard technical report, while lower temperatures reduce available capacity.

Surface temperature must never exceed 80 °C in an explosive atmosphere. If the electrolyte temperature rises to 55 °C during charging, wait for it to cool down before using the battery in an explosive atmosphere. If a hot battery is detected, it must be removed from the classified area and allowed to cool to ambient temperature. The cause of overheating must be determined before the battery is put back into use.

Possible causes of battery overheating include a fault in the battery supply device or an internal fault in the battery cells. If you suspect a battery fault, contact your local service center.

Hazards and Care

Environmental Conditions

The battery is designed for use under specified environmental conditions.

Effect of Explosive Atmospheres on Materials

Selected materials are not known to react with explosive atmospheres to which the device may be exposed.

Protection from Other Hazards

The device does not cause injury or damage when used as described in this installation and operating manual.

Hazards from Ignition Sources

The device does not produce ignitable electric sparks or arcs. The device is also designed not to produce potential ignition sources from electromagnetic, acoustic, optical, or other external energy sources.

Protection from Corrosive Substances

Individual cells contain sulfuric acid. These cells and the casing form the device and are made of materials resistant to acid effects. Refer to manufacturer's technical specifications.

Battery Maintenance

The battery must always be kept clean and dry to prevent leakage currents. Any liquid in the battery box must be removed and disposed of properly.

Box insulation damage must be repaired after cleaning to prevent box corrosion and ensure the insulation value complies with EN 62485-3. If cells need to be removed, it is advisable to call service to do this.

Storage and Malfunctions

Storage

If the battery is taken out of service for an extended period, it must be stored fully charged in a dry and cool place, free from the risk of freezing. To ensure the battery is always ready for use, different charging methods can be followed:

1. Monthly equalizing charge (see section Equalizing Charge under Charging), or
2. Maintenance charge at a voltage of 2.27 V per cell.

Storage time must be considered when estimating battery life.

Never leave the battery connected to the forklift for extended periods. Storage in an open circuit is not permitted when discharged.

Malfunctions

If a malfunction is detected in the battery or charger, contact the service department immediately. Measurements taken in the Monthly Maintenance section on page 8 will help identify and correct faults. A service contract with us will facilitate fault detection and speed up their correction.

Battery to be recycled. Dispose of and return to manufacturer!

Always dispose of the battery box and cells through a local service center. Never attempt to disassemble the battery or cells in any way. If the product is damaged and can no longer be repaired, store it outside the classified area until it can be returned. Batteries marked with this symbol [Recycling symbol] must be recycled. Batteries not returned for recycling must be disposed of as hazardous waste!

When using traction batteries and chargers, the user must comply with applicable country-specific standards, laws, regulations, and directives.

Document Information

This document is a translation of the original English version (English Version Link). If there are discrepancies between this version and the original version, the English version applies.

www.enersys.com

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