ATEX Certified Cells Owner's Manual

Introduction

This document provides essential information for the safe handling and proper use of ATEX-certified cells. It includes general system specifications, related safety measures, operating instructions, commissioning guidelines, and recommended maintenance procedures. This document should be retained and kept accessible to users working with or responsible for the battery. All users are responsible for ensuring the system is used appropriately and safely, based on anticipated or encountered conditions during operation.

This owner's manual contains important safety instructions. Chapters concerning battery safety and use must be read and understood before using the battery or equipment fitted with it.

It is the owner's responsibility to ensure that the use of this documentation and all related activities 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 cells if national laws and/or industry standards require it. Before handling the battery system, ensure all users receive adequate guidance and training.

For service, please contact your sales representative or call:

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

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

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

www.enersys.com

Ensuring your own and others' safety is extremely important.

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

Specifications

EU Declaration of Conformity

EnerSys® hereby confirms that these cells (see description below for EC Type-Examination Certificate serial number and number, SIRA certification service, 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. Basic health and safety requirements are met by complying with the following standards: DIN EN 60079-0, DIN EN 60079-7, DIN EN 60079-31, IEC 61241-0, and IEC 61241-1.

Signed: ________________________________________________ (ATEX/IECEx Authorized Manager)

Serial Number: ___________________________________________________

Ex Cell Type: _________________________________________________

EC Type-Examination Certificate: SIRA 01 ATEX 30 ________ U

IECEx Certificate of Conformity: IECEx SIR 07.006 ________ U

This declaration confirms that the aforementioned directives are met, but does not constitute a warranty of characteristics in a legal sense. Safety instructions in the accompanying product documentation must be followed.

This owner's manual contains instructions for the installation and safe use of Ex cells for vehicle batteries. Ex cells are components defined in Directive 2014/34/EU (ATEX/IECEx). Other directive requirements, not included in the cell component certification or the content of this owner's manual, must be followed during battery manufacturing and use.

Safety and Markings

Safety Instructions

The use of different cell models together in one battery is not permitted. This also applies to models similar in dimensions, performance, and capacity.

Ex cells meet safety requirements for their intended use.

Specific conditions for safe use according to EC Type-Examination Certificate numbers: SIRA 01ATEX3016U, SIRA 01ATEX3019U, SIRA 03ATEX3087U, SIRA 03ATEX3090U and IECEx Certificate of Conformity numbers: IECEx SIR07.0061U, IECEx SIR07.0062U, IECEx SIR07.0063U, IECEx SIR07.0064U must be met.

If cells are assembled into a battery, at least the requirements of standards DIN EN 60079-7 must be followed, including:

• General
• Battery casing
• Cells
• Terminal
• Cell charging
• Cell discharging
• Including other types of ignition protection
• Switching off and transport
• Standby batteries
• Insulation resistance
• Impact test
• Ventilation

Markings and Area of Use

This owner's manual covers cells according to the following EC Type-Examination Certificate and IECEx Certificate of Conformity numbers:

• IECEx SIR07.0061U-SIRA 01ATEX3016U: Type B open lead-acid motive power cells (PzB, PzMB)
• IECEx SIR07.0062U-SIRA 01ATEX3019U: Type D open lead-acid motive power cells (PzS, PzM)
• IECEx SIR07.0063U-SIRA 03ATEX3087U: Type B Evolution® valve-regulated lead-acid motive power cells (PzVB)
• IECEx SIR07.0064U-SIRA 03ATEX3090U: Type D Evolution® valve-regulated lead-acid motive power cells (PzV) and NexSys® TPPL cells (NxS)

The 'U' mark following the certificate number indicates that this certificate may not be cited as proof of conformity of the equipment or protective system. This component certificate may only be used as a basis for the certification of the equipment or protective system. The notified certificates refer only to the design and type-testing of the specified individual cells in accordance with Directive 2014/34/EU. For the manufacture and recycling of cells, the manufacturer must meet other directive requirements not covered by these certificates.

Therefore, the final installation must meet the requirements of ATEX and IECEx certified companies and qualified personnel.

The following ATEX/IECEx markings apply:

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 Ex 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)]

Installation and Commissioning

Installation

When installing cells, always lift them by all terminals simultaneously using insulated lifting devices.

Ex cells must only be connected in series (series connection). Parallel connection is not permitted. Ensure correct polarity during installation.

Only EnerSys® approved components may be used for electrical wiring. Optional watering systems and electrolyte circulation must be connected according to EnerSys requirements, e.g., "follow electrical wiring instructions." Request corresponding information if needed.

IMPORTANT NOTE: Connection technology, watering systems, and electrolyte circulation are part of the cell component testing and approval, and therefore must not be modified!

All components must be sourced from EnerSys.

End connections and intermediate outlets may also be made using only approved components. Use new, unused M10 x 20 screws with the specified thread locker: tightening torque 25 ± 2 Nm! Ensure absolutely good contact and secure tightening of the threads.

The sealing of connection cable covers must be ensured. For IP protection, use a cover without holes.

When using a terminal cover with a hole (only for the negative pole for voltage measurement), the terminal chamber must be filled with grease (e.g., Berutox M 21 KN).

Electronic components must not be used in the vicinity of the ATEX/IECEx battery (e.g., under any cover or near the cell).

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

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

Commissioning

For commissioning Ex cells, follow the owner's manuals for Perfect Plus™, Water Less®, Evolution®, or NexSys® TPPL cells (see www.enersys.com). Additionally, the manual for the equipment or protective system into which these Ex cells are integrated applies.

Lead-acid cells, especially flooded 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 every 3 months.

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

Use and Maintenance

Use and Charging

Never charge an Ex battery or cell in a classified area.

For charging and use, the owner's manual for the standard battery model can be used (see www.enersys.com). Additionally, the manual for the equipment or protective system into which these Ex cells are integrated applies.

Ex Cell Specifications:

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

Specifications

Only approved charging devices and approved charging characteristics may be used. When integrating the charging device into the equipment and charging batteries in hazardous areas, the charging system must be integrated according to the conformity assessment according to standard DIN EN 60079-7.

Batteries whose temperature exceeds 40 °C at the end of charging must be cooled to 40 °C before use in hazardous areas.

Maintenance and Repair

Only original EnerSys spare parts and components may be used. Replacement cells must have the manufacturer's ATEX marking and be equivalent in type, size, and capacity.

Additionally, the manual for the equipment or protective system into which these Ex cells are integrated applies.

Work performed must comply with the regulations of standard EN 60079-19. Repair work may only be carried out by appropriately qualified personnel and must be documented. The equipment or protective system must be marked with the corresponding R marking.

Notes and Disposal

Applicable Standards and Notes (Excerpt)

Directive 1999/92/EY

Directive 2014/34/EU

DIN EN 1127-1: Explosive atmospheres – Explosion prevention and protection – Part 1: Basic concepts and methods

DIN EN 1175-1: Industrial trucks – 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: Equipment repair, refurbishment and reuse

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: Protection type "tD"

DIN EN 62485-3: Safety requirements for secondary batteries and battery installations – Part 3: Traction batteries

Disposal

The battery must be recycled.

♻️ Dispose and return to manufacturer! Dispose of battery casings and cells only through a local service provider. Do not attempt to disassemble the battery or cells in any way. If a product is damaged and cannot be repaired, store it outside a classified area until it can be returned. Batteries marked with this symbol must be recycled. Batteries not returned for recycling must be disposed of as hazardous waste!

When using motive power batteries and chargers, the user must comply with applicable national standards, laws, regulations, and ordinances.

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). In case of discrepancies between this version and the original version, the English version shall prevail.

www.enersys.com

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EMEA-FI-OM-ATEX-CELL-0725