ATEX Certified Cells User Manual

EnerSys

Introduction

The information contained in this document is critical for the safe handling and proper use of ATEX certified cells. It provides an overview of system requirements, related safety measures, codes of conduct, and guidelines for commissioning and recommended maintenance. This document must be kept and made accessible to users working with and responsible for the battery. Every user is responsible for ensuring that the system is used appropriately and safely, considering expected or encountered circumstances during operation.

This user manual contains important safety instructions. Before using the battery and the equipment into which the battery will be installed, carefully read the safety and operation sections contained in this manual.

It is the owner's responsibility to ensure that the use of this documentation and all related activities comply with the applicable legal requirements of the respective country.

This user manual does not replace training on the handling and operation of ATEX certified cells, which may be required by local laws and/or industry standards. Before handling the battery system for any purpose, all users must be adequately trained and instructed.

For servicing, please contact your regional representative or call the following numbers:

EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10
EnerSys Global Headquarters
2366 Bernville Road
Reading, PA 19605 USA
Tel: +1-610-208-1991
+1-800-538-3627
EnerSys APAC
85, Tuas Avenue 1
Singapore 639518
+65 6558 7333

www.enersys.com

Your safety and the safety of others are very important

⚠️ WARNING: Failure to follow instructions may result in death or serious injury.

EC Declaration of Conformity

Explosion-proof cells for vehicle propulsion batteries

EnerSys® hereby confirms that these cells (as described below by the EC type-examination certificate serial number and number, the SIRA certification body, and the notified body number 2813) comply with the provisions of Directive 2014/34/EU concerning equipment and protective systems intended for use in potentially explosive atmospheres. The essential 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.

Signature: ________________________________________________ (Authorized representative by ATEX/IECEx)

Serial Number: ___________________________________________

Explosion-proof cell type: _____________________________

EC type-examination certificate: SIRA 01 ATEX 30 U

IECEx conformity certificate: IECEX SIR 07.006 U

This declaration certifies compliance with the above directives but does not constitute a legal guarantee of characteristics. Observe the safety notes in the accompanying product documentation.

This user manual provides guidance for the installation and safe operation of explosion-proof cells in vehicle batteries. The explosion-proof cells are components as defined by Directive 2014/34/EU (ATEX/IECEx).

For manufacturing and use as a battery, further requirements of the directive must also be met, which are not covered by the cell's component certificate or by the content of this user manual.

Safety and Marking

Safety Notes

Mixing different cell types within a single battery is not permitted. This also applies to variants of the same type, performance, and capacity.

Explosion-proof cells meet safety requirements when used as intended.

The specific conditions for safe application must be observed according to the following EC type-examination certificates: SIRA 01ATEX3016U, SIRA 01ATEX3019U, SIRA 03ATEX3087U, SIRA 03ATEX3090U and the IECEx conformity certificates: IECEx SIR07.0061U, IECEx SIR07.0062U, IECEx SIR07.0063U, IECEx SIR07.0064U.

When assembling cells into a battery pack, the conditions specified in the DIN EN 60079-7 standard must be observed, including:

General information
Battery enclosure
Cells
Connections
Cell charging
Cell discharging
Inclusion of other types of ignition protection measures
Switching off and transport
Battery packs
Insulation resistance
Impact resistance test
Ventilation

Marking and Application Area

This user manual applies to cells with the following EC type-examination certificate numbers and IECEx conformity certificate numbers:

IECEx SIR07.0061U – SIRA 01ATEX3016U for Type B traction lead-acid batteries (PzB, PzMB)
IECEx SIR07.0062U – SIRA 01ATEX3019U for Type D traction lead-acid batteries (PzS, PzM)
IECEx SIR07.0063U – SIRA 03ATEX3087U for Type B Evolution® traction lead-acid batteries (PzVB)
IECEx SIR07.0064U – SIRA 03ATEX3090U for Type D Evolution® traction lead-acid batteries (PzV) and NexSys® TPPL cells (NxS)

The 'U' character following the certificate number indicates that this certificate is not to be confused with a certificate for a complete apparatus or protective system. This component certificate can only serve as a basis for a certificate for the apparatus or protective system. The specified certificates therefore relate only to the design and type examination of the specified component cells according to Directive 2014/34/EU.

For the manufacture and marketing of the cells, the manufacturer must comply with the other requirements of the directive, which are not covered by these certificates.

Consequently, the final installation must meet the requirements stipulated for the ATEX and IECEx certified entity and qualified personnel.

The explosion-proof markings are:

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

These explosion-proof cells may only be used in the following areas:

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

Assembly and Commissioning

Assembly

When assembling, always lift the cells by all poles simultaneously using insulated lifting equipment.

Explosion-proof cells must be connected in series only, not in parallel.

Ensure correct polarity during assembly.

Only use EnerSys® approved components for electrical connections.

The optional Aquamatic system and electrolyte circulation must be connected according to EnerSys requirements, e.g., 'in accordance with electrical connections'. If necessary, request further information.

NOTE: Connection technology, the Aquamatic system, and electrolyte circulation are part of the cell component inspection and approval process, and therefore must not be modified!

All components must be sourced from EnerSys.

Final connections and intermediate connections must only be made with approved components.

New, unused M10 x 20 screws must be used with the specified screw locking: torque wrench 25 + 2 Nm! Proper contact and thread engagement must be ensured.

The cover connections must be tightened. Use covers without holes to ensure protection against external influences.

If using vented connector caps (only on the negative pole for voltage measurement), fill the connector chamber with grease, e.g., Berutox M 21 KN.

Electronic components must not be used near ATEX/IECEx batteries, for example, under the cover or near the cell.

Only connect explosion-proof cells of the same type, size, and capacity.

Explosion-proof cells must be securely installed in the battery compartment. Any gaps must be filled with stable, acid-resistant sealant. Cell boxes or foam fillers are not permitted.

Commissioning

When commissioning explosion-proof cells, adhere to the instructions described in the user manuals for Perfect Plus™, Water Less®, Evolution®, or NexSys® TPPL (see: www.enersys.com).

Additionally, consult the user manual of the equipment or protective system into which these explosion-proof cells are installed.

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

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

Operation and Maintenance

Operation and Charging

Never charge an explosion-proof battery or cell in an area classified as a hazardous zone.

For charging and operation, the user manual for the standard design battery is applicable (see: www.enersys.com). Additionally, the user manual of the equipment or protective system into which these explosion-proof cells are installed must be taken into account.

Rating:	Nominal Capacity, C₅	Connector Cross-section	Nominal Current
max.	315 Ah	25 mm²	63 A
max.	440 Ah	35 mm²	88 A
max.	630 Ah	50 mm²	126 A
max.	880 Ah	70 mm²	176 A
max.	1550 Ah	95 mm²	310 A

Only use approved charging devices and charging curves.

When integrating charging devices into vehicles and charging batteries in hazardous areas, the charging system must be integrated with a conformity assessment according to DIN EN 60079-7.

Batteries that have reached a temperature above 40 °C at the end of charging must be cooled to 40 °C before use in hazardous environments.

Maintenance and Service

Only use genuine spare parts and components approved by EnerSys.

Only use replacement cells of the same type, size, and capacity, marked with the manufacturer's ATEX label.

Additionally, the user manual of the equipment or protective system into which these explosion-proof cells are installed must be taken into account.

The provisions of standard EN 60079-19 must be followed when performing this work. The subsequent work may only be carried out by properly qualified personnel, and the work must be documented, and the equipment or protective system must be marked with the appropriate "R" label.

Notes and Disposal

Notes on Normative Requirements (Extract)

Directive: 1999/92/EC

Directive: 2014/34/EU

MSZ EN 1127-1: Explosive atmospheres. Explosion prevention and protection – Part 1: Basic principles and methodology
MSZ EN 1175-1: Safety of industrial trucks. Electrical requirements. Part 1: General requirements for battery-powered industrial trucks
MSZ EN 60079-0: Explosive atmospheres – Part 0: Equipment. General requirements
MSZ EN 60079-7: Explosive atmospheres – Part 7: Equipment protection by increased safety “e”
DIN EN 60079-31: Explosive atmospheres – Part 19: Equipment repair, overhaul and marking
MSZ EN 61241-0: Electrical apparatus for use in the presence of combustible dust. Part 0: General requirements
MSZ EN 61241-1: Electrical apparatus for use in the presence of combustible dust. Part 1: Protection by enclosure “tD”
MSZ EN 62485-3: Safety requirements for batteries and battery installations. Part 3: Traction batteries

Disposal and Return to Manufacturer

[Pb] The battery must be recycled.

Dispose of the battery holder and cells at your local service center. Do not attempt to disassemble the battery or cells in any way. If the product is faulty and irreparable, store it outside the classified zone until it can be returned for disposal.

Batteries marked with this symbol must be recycled. Non-recycled batteries must be treated as hazardous waste!

When operating propulsion batteries and chargers, the standards, laws, regulations, and ordinances in force in the country of use must be observed!

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