EnerSys Perfect Plus & Water Less ATEX UKEX Certified Batteries

Standard, Data, & Condition

These ATEX UKEX-certified batteries are certified for use in areas with risks of explosion due to gas or dust:

• Explosion group I Category M2/Mb mining
• Explosion group II Category 2 and 3 [Zone 1 2G/ Gb, Zone 2 3G/Gc (Gas)]
• Explosion group III Category 2 and 3 [Zone 21 2D/ Db, Zone 22 3D/Dc (Dust)]

Batteries must be in perfect condition and free from damage. If any damage is noted or accessories are missing, contact your supplier within 24 hours of receipt. Traction batteries are designed for use in battery-powered applications within hazardous areas, such as electric counterbalance, reach, and pallet trucks, as well as floor sweepers and other cleaning equipment. The cells and connectors comply with IP (ingress protection) 65, and the crates with IP23.

The patented ventilation design allows these traction batteries to fit within existing DIN and British standard crate sizes, offering the same capacity as specified by the truck manufacturer.

Standard

Motive power ATEX UKEX-certified batteries comply with the ATEX 2014/34/EU and UKEX UKSI 2016:1107 UKEX Directive. Conformity has been demonstrated with reference to the following documentation:

EC type-examination certificates:

• UKEX: CSAE 23UKEX1000X (Batteries up to 98.8 KWh), CSAE 23UKEX1001X (Batteries above 68.8KWh up to 153.6 KWh)
• ATEX: SIRA 01ATEX3016U, SIRA 01ATEX3019U, SIRA 01ATEX3022X, SIRA 01ATEX3025X
• IECEx: SIRA IECEx 07.0061U, SIRA IECEx 07.0062U, SIRA IECEx 07.0065X, SIRA IECEx 07.0066X

Description:

• Flooded BS cell
• Flooded DIN cell
• Batteries up to 68.8 kWh
• Batteries above 68.8 up to 153.6 kWh

ATEX UKEX certificates apply to EEx and IECEx certificates apply to the rest of the world except North America (USA and Canada). Quality Assurance Notification: Sira 01 ATEX M103.

Rating Data

1. Nominal capacity C₅: See type plate
2. Nominal voltage: 2.0 V x No of cells
3. Nominal discharge current: C₅ / 5h
4. Nominal S.G. of electrolyte*: 1.29 kg/l (Will be reached within the first 10 cycles)
5. Rated temperature: 30°C
6. Nominal electrolyte level: up to electrolyte level mark "max."

Example of battery labeling:

The label includes the Hawker logo, type, capacity, nominal voltage, number of cells, CE and UKCA markings with notified body numbers, ATEX/UKEX/IECEx certifications, battery tray number, reference, serial number, service mass, and manufacturer details.

Safety Precautions

• Pay attention to the operation instructions and fix them close to the battery.
• Work on batteries must be carried out by skilled personnel only.
• Wear protective glasses and safety clothing when working on batteries.
• Adhere to accident prevention rules and standards EN 62485-3 and EN 50110-1.
• No smoking!
• Do not expose batteries to naked flames, glowing embers, or sparks, as this may cause the battery to explode.
• Acid splashes into eyes or on skin must be washed immediately with abundant clean water. After flushing, consult a doctor immediately.
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire! Avoid short circuits.
• Caution: Metal parts of the battery are always live. Do not place tools or other metal objects on the battery.
• Electrolyte is highly corrosive.
• Batteries and cells are heavy.
• Ensure secure installation! Use only suitable handling equipment (e.g., lifting gear) in accordance with VDI 3616.
• Dangerous electrical voltage!
• Be aware of the hazards that can be caused by batteries.

Ignoring operating instructions and repairing with non-original parts will void the warranty. All failures, malfunctions, and default codes of the battery, charger, or accessories must be communicated to EnerSys^® Service immediately.

Safety, Service, & Handling

Safety

Remember that the battery is a power source; even when fully discharged, sufficient energy remains to cause serious damage. Always follow these safety rules:

• Never charge an Ex battery in a zoned area.
• Never disconnect the battery in a zoned area. Isolate circuits before disconnecting the battery outside a zoned area.
• Never open the battery cover in a zoned area.
• Always use certified DC plugs for connection to the battery.
• Never use the battery if damaged or bare cables are evident.
• Never use the battery if the DC plugs are damaged.
• Never attempt to repair the battery. Call your recommended authorized service center.
• Close vent plug lids firmly after topping up the battery's electrolyte.

Service

Your local authorized service engineer provides local help and support. This handbook offers general guidelines; your engineer can help interpret your specific needs. They can answer questions beyond this manual's scope and obtain specialist help if required. Your battery is an expensive investment for use in a zoned area; EnerSys aims to help you achieve the best possible results. Contact your local service center with any battery-related questions.

Handling

Lead-acid Ex batteries are very heavy. Always use approved moving equipment when changing batteries. Use correct approved lifting equipment and keep the battery upright when lifting and handling. Due to variations in electric vehicle types, battery container designs, equipment, and changing methods, detailed instructions for battery changes on electric vehicles cannot be provided. The vehicle manufacturer or battery-changing equipment supplier must supply the correct method and procedure.

Taking Delivery of Your Battery

Do not perform any procedures in a zoned area. Polarity is marked with identification colors (Positive: Red, Negative: Blue) adjacent to the connection plug to prevent incorrect polarity connection. Cable retention material (e.g., spiral wrap) sleeves the insulation on overall battery voltage leads to prevent conductor exposure.

Ensure battery containers remain upright to prevent electrolyte spillage. Remove all packing material and carefully examine containers for physical damage. If the battery is not used upon receipt, refer to the Storage section on page 13.

Commissioning

For commissioning of unfilled batteries, refer to separate instructions. Check the electrolyte level. If it is below the anti-surge baffle or the top of the separator, top up to this level with purified water (IEC 62877-1:2016). Connect charger cables for good contact, ensuring correct polarity to avoid damage to the battery, vehicle, or charger. Wipe cell tops and container sides with a damp cloth to remove dust, water, or spilled sulfuric acid. Cell cleanliness is crucial. Check that all connections are tight. The specified torque for pole screws (M10) is 25 ± 2 Nm. Ensure cells are accessible for testing and topping up if the automatic watering facility is not fitted.

Verify the battery compartment is well-drained and ventilated, with no risk of metal objects falling through the top ventilation. Ensure the battery sits firmly and securely in its housing, using suitable packing to prevent movement. Cables should be flexible and long enough to prevent strain on the cable or certified terminals. Smear steel runners or supports with petroleum jelly to reduce rust and acid corrosion.

If a new Ex battery is used in an area with uncertainty about its zoned status, contact your local factory inspector. Never directly connect an electrical appliance (e.g., a warning beacon) to some cells; this can cause cell imbalance, insufficient discharge time, or cell damage, potentially affecting the warranty.

The battery is then charged as described in the Recharge section. Top up the electrolyte to the specified level with purified water as per the Water Topping-Up Interval section.

Maintenance

Daily

• Recharge the battery after discharge.
• Never charge an Ex battery in a zoned area, even with approved charging equipment. Always check charger operation.
• Check electrolyte levels at the end of charge and top up if necessary (respecting the max level). The correct level is at the top of the level indicator.

Overfilling with water can cause electrolyte overflow during recharge, weakening the electrolyte. Insufficient water exposes the top of the plates, reducing performance and battery life. Use only approved distilled or demineralised water conforming to IEC 62877-1:2016 purity standards.

Perfect Plus^®

Topping-up water, devices, or automatic water filling systems are available from your local supplier or service depot. Use only non-metallic containers for topping-up water. Never top up with acid; consult your local service depot if acid adjustment is needed.

Diagram shows electrolyte level indicator with 'Min' and 'Max' marks.

Weekly

• Note cells taking excessive or insufficient water; contact your local service depot if this occurs.
• Check all connections and leads for frayed or worn insulation. If found, remove the battery from service immediately and place it in a safe area outside the zoned area. Do not attempt to repair an Ex battery; call your local EnerSys^® Service Representative.
• Ensure all insulators and vent plugs are in place and battery plugs are sound.
• Keep the battery top clean and dry to prevent tracking paths for electricity that could cause a spark in a zoned area.
• If metal container corrosion occurs, scrape it off, neutralize the area with a water/baking soda solution or diluted ammonia, and protect the area with acid-proof paint.

Monthly

At the end of charge (with charger on), measure and record the voltages of all cells. After charging, measure and record electrolyte density, temperature, and filling level for all cells. If significant changes or differences between cells are found, request further testing and maintenance from EnerSys^® Service. Perform these checks after a complete charge and at least 2 hours of rest time.

Measure and record:

• Total voltage
• Voltage per cell
• If voltage readings are irregular, check the S.G. of each cell (see Water Topping-Up Interval section).

Contact an EnerSys^® Service Representative if significant changes or differences are found between cells or bloc batteries.

Figure 1 shows a battery cell with electrolyte level marks.

If battery discharge time is insufficient, check:

• Work required is compatible with battery capacity.
• Charger settings.
• Discharge limiter settings.

Check the electrolyte level and top up if necessary (respecting the maximum level according to Figure 1).

Annually

At least annually, following EN 1175-1, an electrical specialist must check the insulation resistance of the truck and battery according to EN 1987 part 1. The battery's insulation resistance must not be below 50 Ω/Volt of nominal voltage, as per EN 62485-3. For batteries up to 120 V nominal voltage, the minimum value is 1000 Ω.

Perform maintenance, including measuring electrolyte S.G. at the end of charge. Check the air pump filter during annual maintenance; clean or replace it if necessary. Earlier replacement is needed if a defect signal for the air mixing system (on the charger or battery) illuminates without apparent cause (e.g., no leaks). During annual maintenance, verify the air pump's correct operation.

Diagram compares 'Perfect Plus' and 'Water Less' battery cells, indicating 'Larger electrolyte capacity' and 'Reduced prism height' for Water Less.

Water Less^® Topping-Up Intervals

* +/- 1 week in most common applications at 20°C.
** This number of cycles can be reduced with high battery temperatures during 3-shift operation.
*** Electrolyte Circulation

Table details topping-up intervals based on PzM variant, conditions, and shift operation.

Discharge

Ensure all ventilation holes are not sealed or covered. Electrical connections (e.g., plugs) must only be made or broken in the open circuit condition. To optimize battery life, avoid discharges exceeding 80% of rated capacity (deep discharge). This corresponds to an electrolyte specific gravity of 1.14 kg/l at 30°C at the end of discharge.

Discharged batteries must be recharged immediately and not left discharged, including partially discharged batteries.

It is recommended that the battery is discharged evenly, and the use of tappings across part of the battery is discouraged. Use a D.C.-D.C. converter for auxiliary loads supplied from the whole battery.

NOTE: The D.C.-D.C. converter and auxiliary equipment must be certified for use in a zoned area.

Battery performance is related to temperature. Batteries are rated at 30°C. Lower temperatures reduce available performance. Additional capacity is required for use in low ambient temperatures (e.g., cold stores).

Recharge

NOTE: Never recharge an Ex battery in a zoned area.

Only direct current must be used for charging. Charging procedures following DIN 41773-1 and DIN 41774 are permitted. Connect the battery only to a charger suitable for its size to avoid overloading cables and contacts, unacceptable gassing, and electrolyte escape. Do not exceed current limits in EN 62485-3 during the gassing stage. If the charger was not purchased with the battery, have its suitability checked by the manufacturer's service department.

Ensure proper venting of charging gases. Open or remove doors, battery container lids, and battery compartment covers. Remove the battery from the closed battery compartment on the truck during charging. Ventilation must comply with EN 62485-3. Keep vent plugs on cells closed.

With the charger switched off, connect the battery, ensuring correct polarity (positive to positive, negative to negative). Switch on the charger. Electrolyte temperature rises by about 10°C during charging; begin charging only if the electrolyte temperature is below 43°C. The electrolyte temperature must be at least +10°C before charging to achieve a full charge.

Charging is complete when the electrolyte specific gravity and battery voltage remain constant for two hours.

Batteries fitted with electrolyte mixing (option): If the pump controller warning light is illuminated or a defect signal for the electrolyte circulation system appears, check piping system connections and examine for leaks or defects (see Maintenance section). Never remove the air pipe during charging. Excessive charging reduces battery life, increases water loss, and wastes electricity. Consult your supplier before extending charger gassing times.

The DC cable length between the charger and battery affects the voltage drop back to the charger's control unit. Do not extend the cable without consulting the charger manufacturer and your Ex battery supplier.

For batteries with light discharge, consider recharging at less frequent intervals (e.g., every second day). Seek advice from your local service engineer in such circumstances.

Do not disconnect the battery until the charger is switched off. Any managing charging system must be approved by your local area service center, or the warranty may be invalidated.

Equalising

Some chargers have an equalising facility (manual or automatic). Refer to the manufacturer's instructions for full operational procedures. Never charge an Ex battery in a zoned area.

Equalising charges safeguard battery life and maintain capacity. They are necessary after deep discharges, repeated incomplete recharges, and charges to an IU characteristic curve. Equalising charges follow normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge). Monitor the temperature!

Measurement of Specific Gravity

To take a hydrometer reading, squeeze the bulb, dip the rubber tube end into the electrolyte, and gently release the bulb to draw up enough liquid for the float to move freely. Hold the hydrometer vertically and do not apply pressure to the rubber bulb. Read the specific gravity from the scale on the float. Squeeze the bulb to return the electrolyte to the cell after reading.

The rated specific gravity (S.G.) is related to 30°C and the nominal electrolyte level in a fully charged cell. Higher temperatures reduce S.G., while lower temperatures increase it. The temperature correction factor is -0.0007 kg/l per °C. For example, an electrolyte S.G. of 1.28 kg/l at 45°C corresponds to 1.29 kg/l at 30°C. The electrolyte must conform to purity regulations in IEC 62877-2:2016.

Temperature

The rated electrolyte temperature is 30°C. Higher temperatures shorten battery life; lower temperatures reduce available capacity. The upper temperature limit is 55°C, which is not acceptable as an operating temperature.

The surface temperature must never exceed 80°C in the explosive area. Charging should only begin if the electrolyte temperature is below 43°C. If the electrolyte temperature reaches 55°C during charging, wait for it to cool before using the battery in the explosive area. If a hot battery is detected, remove it from the controlled zoned area and allow it to cool to ambient temperature.

Investigate why the battery is overheating before returning it to service. Possible causes include a fault in the powered equipment or a fault within the battery cells. Contact your local service center if a battery problem is suspected.

Surrounding Area Conditions

The apparatus is designed to cope with the intended surrounding area conditions.

Effect of Explosive Atmosphere on Materials

The selected materials are not known to react with any explosive atmospheres to which the apparatus may be subjected.

Protection Against Other Hazards

The apparatus does not cause injury or harm when used as specified in the installation and operation manual.

Withstanding Attack by Aggressive Substances

The individual cells contain sulfuric acid. These cells and the enclosures that make up the apparatus are constructed from acid-resistant materials. Refer to the manufacturer's data sheet.

Hazards From Different Ignition Sources

The apparatus does not produce ignition-capable electrical sparks or arcs. It is also designed not to produce potential ignition sources from electromagnetic, acoustic, optical, or other external energy sources.

Care of the Battery

Keep the battery clean and dry to prevent tracking currents. Extract and dispose of any liquid in the battery tray as prescribed. Repair any damage to the tray insulation after cleaning to ensure insulation value compliance with EN 62485-3 and to prevent tray corrosion. If cell removal is necessary, contact the service department.

Storage

If batteries are taken out of service for extended periods, store them fully charged in a dry, frost-free room. To ensure readiness for use, choose one of these charging methods:

1. A monthly equalizing charge (See Equalising in the Recharge section).
2. Float charging at a charging voltage of 2.27 V x the number of cells.

Consider the storage time when evaluating battery life.

Malfunctions

If malfunctions are found on the battery or charger, contact the service department immediately. Measurements taken in the Monthly Maintenance section facilitate fault finding. A service contract can help detect and correct faults promptly.

Aquamatic Water Refilling System (Optional Accessory)

Application

The water refilling system automatically maintains nominal electrolyte levels. Charging gases escape through the vent on each cell. The system uses a valve and float to control topping-up, allowing water flow into each cell and closing the valve when the correct level is reached. Follow instructions for fault-free operation.

Diagram illustrates the Aquamatic Water Refilling System components connected to a battery and charger.

Manual or Automatic Connection

Top up the battery shortly before completing a full charge, when it has reached a defined operational state for satisfactory electrolyte mixing. Filling occurs when the connector (7) from the tank connects to the coupling (6) on the battery.

For manual connection, connect the Perfect Plus^® battery to the filling system once a week. For automatic coupling (magnetic valve controlled by charging apparatus), the charger main switch selects the filling time. It is recommended to refill water at least once a week to ensure the correct electrolyte level.

In multi-shift operations and warm ambient temperatures, shorter topping-up intervals may be necessary.

Filling Time

Filling time depends on utilization rate and battery temperature. The topping-up process generally takes a few minutes and can vary by battery range. If using manual filling, turn off the water supply to the battery afterward.

Working Pressure

Install the water refilling system to achieve a water pressure of 0.2 to 0.6 bar (with at least a 2 m height difference between the battery's upper edge and the tank's lower edge). Deviations will cause improper system function.

Purity

Topping-up water must be purified, with a conductance not exceeding 30 μS/cm. Clean the tank and pipes before operating the system.

Pipe System on the Battery

The pipe system to individual battery cells must follow the battery's electrical circuit. This minimizes the risk of current leakage causing an explosion in the presence of electrolytic gas (DIN EN 50272-3). A maximum of 10 cells may be connected in series. Do not modify the system.

Working Temperature

In winter, batteries with the Aquamatic Water Refilling System should only be charged or refilled at room temperatures above 0°C.

Flow Control

A flow indicator in the water supply pipe monitors the filling process. During filling, the water flow turns a built-in disc. When all plugs are closed, the disc stops, indicating completion.

Electrolyte Circulation System (Optional Accessory)

Application

The electrolyte circulation system pumps air into individual battery cells to prevent electrolyte stratification and optimize battery charge with a charge factor of 1.07. This system is beneficial for heavy-duty use, short charge times, boost or opportunity charging, and high ambient temperatures.

Function

The system consists of a pipe system within the cells. An aeromatic diaphragm pump, fitted in the charger or mounted separately, sends a low-rate airflow into each cell, creating a circulating air stream. The air stream can be continuous or pulsed, depending on battery voltage and pump type. Air supply is adjusted based on the number of cells. The pipe system to individual cells must follow the existing electrical circuit to reduce the risk of current leakage causing an explosion (EN 62485-3).

Maintenance of Air Filter

Depending on working conditions, the pump air filter should be changed at least annually. In high air pollution areas, check and replace the filter more frequently.

Repair and Maintenance

Check the system for leakage; the charger will display an error message. Sometimes, the charging curve switches to the standard curve (without electrolyte circulation) in case of leakage. For faulty parts, contact EnerSys^® service. Use only EnerSys original spare parts, as they are designed for the pump air supply and ensure correct pump function.

Diagram shows a battery with electrolyte circulation pipes.

Disposal

Always dispose of the battery container and cells through your local service depot. Do not attempt to dismantle the battery or cells. Store failed, unrepairable products outside the zoned area until removed for reclaim. Batteries marked with the recycling symbol must be recycled. Batteries not returned for recycling must be disposed of as hazardous waste!

When using motive power batteries and chargers, the operator must comply with current standards, laws, rules, and regulations in force in the country of use!

Symbols indicate a crossed-out waste bin with 'Pb' and a recycling symbol. Text reads 'Battery must be recycled'.