EnerSys NexSys CORE ATEX User manual

Instruction Manual NexSys®CORE ATEX batteries for use in hazardous areas ENGLISH
Introduction
Valve regulated lead acid (VRLA), Thin Plate Pure Lead (TPPL)
NexSys®CORE batteries are certied to ATEX standards
(increased safety concept Ex e) for use in hazardous areas
where there is a risk of explosion, due to gas or dust. These
batteries are part of the following equipment groups and
categories:
• Group I, category M2/Mb
• Group II, categories 2 and 3 (Zone 1 2G/Gb, Zone 2 3G/Gc)
• Group III, categories 2 and 3 (Zone 21 2D/Db and Zone 22
3D/Dc)
Relative to conventional ATEX batteries, the patented
ventilation design of EnerSys battery trays may make it
possible for a higher capacity battery to be selected for a given
truck manufacturer’s available battery compartment.
Unlike conventional batteries with liquid electrolyte,
NexSys®CORE ATEX batteries are valve-regulated lead-acid
batteries with immobilised electrolyte. Instead of a vent plug, a
valve is used to regulate the internal gas pressure, preventing
the ingress of oxygen from the air and allowing the escape of
excess charging gasses.
Operating VRLA batteries require similar safety precautions
as vented batteries, specically there are risks associated
with electrical, corrosive and explosive hazards. Battery
valves must never be removed. These batteries do not require
topping up with distilled or demineralised water.
This manual should be used in conjunction with the manual
for standard NexSys®CORE batteries which is available on
www.enersys.com.
Upon receipt, batteries should be in perfect condition and free
from any damage. If any damage is noted or accessories are
missing, please contact your supplier immediately.
ATEX-certied NexSys batteries are designed for use in
battery-powered applications (such as electric counterbalance,
reach and pallet trucks) within hazardous areas. EnerSys cells
and connectors have an IP (ingress protection) of 65; creates
of 23 (when lids tted).
The use of electrical equipment, such as DC-DC convertors,
low voltage alarms and EnerSys’ Wi-iQ units, is prohibited
unless certied for use in hazardous areas and tted outside
the battery.
Conformity
NexSys®CORE ATEX batteries conform with the relevant
provision of ATEX Directive 2014/34/EU.
Conformity has been demonstrated with reference to the
following documentation:
ATEX IECEx Certicate
Description
SIRA 01ATEX3022X SIRA IECEx 07.0065X Batteries up to
68.8 kWh
SIRA 03ATEX3090U SIRA IECEx 07.0064U DIN-size NexSys
(and Gel) cells
Notes:
• ATEX certicates apply to the EU whilst IECEx certicates relate to the
rest of the world (except North America).
• Quality assurance notication: SIRA 01 ATEX M103.
The applicable rating data for NexSys®CORE ATEX batteries is
as follows:
1. Nominal capacity C5: See type plate
2. Nominal voltage: See type plate
3. Discharge current: C5 /5h
4. Rated temperature: 30°C
These cells comply with the following clauses:
EN/IEC 60079-0 clause 23.3 (Cell types), 23.6 (Interchangeability),
23.8 (Leakage)’ 23.9 (Connections), 23.10 (Orientation) and 23.11
(Replacement of cells or batteries), and EN/IEC 60079-7 clause
5.6 (classication), 5.6.3.1 (Types of permissible batteries),
5.6.3.3 (cells), 5.6.3.4 (connections) and 6.6.3 (shock test).
When they are assembled into a battery, the remaining
clauses of EN/IEC 60079-7 need to be addressed with
particular reference to clauses EN/IEC 60079-0 clause 23.2
(Batteries), 23.4 (Cells in a battery), 23.5 (Rating of a battery),
23.11(Replacement of cells or batteries), and EN/IEC 60079-7
clause 5.6.3.2 (Battery containers), 5.6.4 (Charging of cells and
batteries), 6.6.2 (insulation resistance) and 6.6.4 (ventilation).
The cells covered by this certicate shall be installed in series,
in a suitable battery enclosure, together with cells of the same
electrochemical system, cell design and rated capacitance
that is manufactured by EnerSys. The battery enclosure shall
provide protection from mechanical impact;
The cells shall be installed in a vertical orientation, with the
electrical connectors at the top.
This equipment includes non-conducting parts that may
generate an ignition-capable level of electrostatic charges
under certain extreme conditions. The user shall ensure that
the equipment is not installed in a location where it may be
subjected to external conditions (such as high-pressure steam)
which might cause a build-up of electrostatic charges on non-
conducting surfaces. Additionally, cleaning of the equipment
shall be done only with a damp cloth;
The cells shall have a certied service temperature range of
-20°C to +60°C, which shall be taken into account when used in
a battery. Battery operating conditions take precedence.
Condition of use
Do not charge in a hazardous area
An example of NexSys®CORE ATEX label

• Pay attention to the operating instructions and
keep them close to the battery.
• Work on batteries must only be carried out by
skilled personnel!
• Use protective glasses and wear safety
clothing when working on batteries.
• Adhere to the current accident prevention
rules in the country where the battery is used or
EN 62485-3, EN 50110-1.
• No smoking!
• Do not expose batteries to naked ames,
glowing embers or sparks, as it may cause the
battery to explode.
• Avoid sparks from cables or electrical apparatus
as well as electrostatic discharges.
• Acid splashes into the eyes or on the skin
must be washed immediately with an abundance
of clean water. After abundant ushing
consult a doctor immediately!
• Clothing contaminated by acid should be
washed in water.
• Risk of explosion and re.
• Avoid short circuits: do not use non-insulated
tools, do not place or drop metal objects on
top of the battery.
• Remove rings, wristwatches and articles of
clothing with metal parts that might come into
contact with the battery terminals.
• Electrolyte is highly corrosive.
• In the normal operation of this battery a
contact with acid isn’t possible. If the cell
containers are damaged, the immobilized
electrolyte (absorbed in the separator) is
corrosive like the liquid electrolyte.
• Batteries are heavy. Ensure secure installation!
Use only suitable handling equipment.
• Lifting hooks must not damage the cells,
connectors or cables.
• Do not place batteries in direct sunlight
without protection. Discharged batteries can
freeze. For that reason, always store in a
frost-free zone.
• Dangerous electrical voltage!
• Avoid short circuits: NexSys batteries are
capable of high short circuit currents.
• Caution – metal parts of the battery are always live:
do not place tools or other objects on the battery!
• Pay attention to the hazards that can be
caused by batteries.
1. Safety
Any work carried out on the battery must comply with
EN 60079-19 and EnerSys®operating instructions. All defective
parts must be replaced by EnerSys supplied parts. No attempt
should be made to repair faulty parts. Failure to adhere to this
will render the warranty and certication null and void.
Always remember that the battery is a source of power. Even
when fully discharged, sucient energy remains in the battery
to cause serious damage.
The battery is designed to be used within the intended
surrounding area conditions.
The materials used are not known to react with any of the
explosive atmospheres with which they may come in contact
with. If unsure, please contact EnerSys.
The apparatus does not cause injury or harm when used as
specied in this manual and the standard NexSys®CORE
battery manual.
The apparatus does not produce ignition-capable electrical
sparks or arcs when used in compliance with this instruction
manual. The apparatus has been designed not to produce
potential ignition sources from electromagnetic, acoustic,
optical or other external energy sources.
Individual cells contain sulphuric acid. These cells are
constructed from materials that are resistant to acid attack.
Follow the safety practices below:
• Never charge NexSys®CORE ATEX battery in a zoned
controlled area unless special conditions, dened by
equipment manufacturers, are met.
• Never disconnect a battery under load in a zoned area.
• Never open the battery cover (if present) in a zoned area.
• Always use certied DC plugs for connection to the battery.
• Never use the battery if damaged or bare cables are visible.
• Never use the battery if the DC plugs are damaged.
• Never attempt to service the battery: call your
recommended authorised service centre.
• Any servicing carried out must be in accordance with ATEX
directives.
• Never mix cells of dierent types or capacities within one
battery.
2. Service
Your local authorised service engineer provides help and
support. This handbook gives guidelines of a general nature;
the engineer will help you to interpret your needs in relation
to your particular requirements. Your engineer can answer the
questions that are beyond the scope of this manual. Please do
not hesitate to call your local service centre if you have any
questions relating to your battery.
3. Handling
As NexSys®CORE ATEX batteries are heavy, always use the
appropriate equipment when attempting to handle batteries.
When lifting and handling NexSys®CORE ATEX batteries,
use the appropriate, approved lifting equipment and keep
the battery in an upright position. Due to the wide range of
types of electric vehicles, of designs of battery containers,
of equipment used and in methods of battery changing, it is
not possible to give detailed instructions on the procedures
to be followed when changing the batteries on a specic
electric vehicle. The manufacturer of the vehicle or the battery
changing equipment must supply the correct method and
procedure.
4. Taking delivery of your battery
Remove all packaging and carefully examine the complete
battery to ensure that there is no physical damage. Should
the battery not be put in service immediately, please refer to
storage guidelines (section 9).

5. Commissioning
NexSys®CORE ATEX batteries are supplied in a charged
condition. Check the following:
1. The cleanliness of the battery and the vehicle’s battery
compartment.
2. Ensure systems are in place to prevent your battery being
connected to the improper charging equipment. Ensure
all connections are correct and that positive and negative
polarities, which are clearly indicated on plugs, are
respected. Improper connection may result in damage to
the battery, vehicle or charger.
3. Ensure that any charging equipment is suitable for use with
NexSys®CORE ATEX batteries.
4. Charge the battery before rst use.
5. Should there be any uncertainty regarding the nature
of the hazardous area, please contact the equipment
representative.
6. Operation
6.1 Operational safety
Batteries should be used in accordance with the EN 62485-3
standard (“Safety requirements for secondary batteries and
battery installations - Part 3”) and Directive 1999/92/EC
(“Minimum requirements for improving the health and
safety protection of workers potentially at risk from explosive
atmospheres”).
6.2 Operating conditions
The ATEX-approved operating temperature range is -20°C to
40°C.
The lifetime of the battery depends on a number of operating
conditions, in particular the operating temperature and depth
of discharge. Optimal battery life is obtained with the battery
at a temperature between +15°C and +35°C to maximise
performance and battery life. High temperatures shorten
the life of the battery, low temperatures reduce the available
capacity.
Operating at a depth of discharge of 60% or less will maximise
the battery lifetime. The maximum permissible discharge is
80% of C5nominal capacity. From new, the battery reaches
its full capacity after approximately three charge/discharge
cycles.
6.3 Discharging
The valves on the top of the battery must not be sealed or
covered. Electrical connections (e.g. plugs) must only be
connected or disconnected in the open circuit condition
(without load). Discharges over 80% of the rated capacity are
categorised as deep discharges and are not acceptable as
they signicantly reduce the life expectancy of the battery.
Discharged batteries MUST be recharged immediately and
MUST not be left in a discharged condition.
Note: The following statement only applies to partially
discharged batteries.
Discharged batteries can freeze. Limit the discharge to
a maximum of 80% depth of discharge (DOD). The cycle life of
the battery will depend on the DOD; the higher the DOD, the
shorter the cycle life. The presence of a discharge limiter on
the vehicle is necessary.
When discharged with currents in the range of I1to I5, the
following energy cut-o settings must be used:
• 60% DOD 1.96V
• 80% DOD 1.92V
At lower currents please seek advice from EnerSys.
6.4 Charging
Note: Never recharge a NexSys®CORE ATEX battery in
a zoned area unless special conditions, dened by equipment
manufacturers, are met.
NexSys®CORE ATEX batteries must be charged using
appropriate EnerSys chargers. Using non-specied
chargers will invalidate the warranty. NexSys®CORE
ATEX batteries are suitable for both standard duty and
heavy-duty applications. In standard duty applications the
charger (0.2-0.25 charging rate) will recharge the battery
from 80% depth of discharge in approximately six hours.
Short opportunity charges are allowed (one opportunity
charge is permitted between main charges with a maximum
energy throughput of 100% C5)
Charging
Rate
From 80%
Depth of
Discharge to
Full Charge
From 60%
Depth of
Discharge to
Full Charge
From 40%
State of
Charge to
80% State of
Charge
0.25 C55.5 hours 4.75 hours 1.6 hours
0.20 C56.25 hours 5.25 hours 2 hours
Under normal circumstances NexSys®CORE ATEX batteries
have extremely low gas emissions. For safety purposes, when
calculating gas emission levels, use 1.5A / 100Ah C5. Provision
must be made for venting of the charging gases. When
charging, doors, battery container covers (when present)
and the covers of battery compartments must be opened or
removed. Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be connected
or disconnected under open circuit condition. To charge
the battery, connect it to the charger ensuring the charger
is switched o. Ensure positive and negative polarities are
correct. NexSys®CORE ATEX batteries must receive their full
charge at least once a week.
6.5 Equalising charge
NexSys®, NexSys®+ and Lifespeed iQ™ chargers will
automatically provide an equalising charge, following
a normal full charge (conditions embedded into the charging
prole).
7. Maintenance
As the electrolyte is immobilised its density cannot be
measured. Never remove safety valves from cells. In case
of accidental damage to valves, contact EnerSys®for
replacement.
7.1 Daily
Recharge the battery after every discharge. Check the
condition of the plugs, cables and that all insulation covers
are in place and in good condition. If any damage is visible,
take the battery out of service immediately and place it in
a safe area outside the hazardous zone. Do not attempt to
repair NexSys®CORE ATEX battery unless qualied to do so.
Call EnerSys or your authorised service representative for
assistance.
7.2 Weekly
Visually inspect the battery for signs of dirt and mechanical
damage to all component parts. Pay attention to the battery
charging plugs and cables.
7.3 Quarterly
It is recommended to carry out voltage readings at the end of
charge as well as to measure and record:
• The voltage of the complete battery
• The voltage of each cell
If signicant changes from earlier measurements or dierences
between cells are found, please contact EnerSys service.
If the runtime of the battery is not as expected, check the
following:
• That the required application matches the battery capacity
• The settings of the charger
• If necessary, the settings of the discharge limiter on the
vehicle.

7.4 Annually
Remove dust from the battery. Test all connections (sockets,
cables and contacts). The insulation resistance of the truck
and the battery must be checked by an electrical specialist
in accordance with EN 1175-1 at least once per year. Tests on
the insulation resistance of the battery must be conducted
in accordance with EN 1987-1. The minimum insulation
resistance must be 50Ωper Volt of nominal voltage and the
minimum battery resistance must not be below 1kΩregardless
of voltage (ref. EN 62485-3 standard).
The integrity of crates should also be monitored to ensure that
lifting equipment has not caused any damage. Any lifting hole
present on the tray must be checked for potential damage. No
sign of any deformation should be visible.
8. Care of the battery
The battery should always be kept clean and dry to prevent
tracking currents. Cleaning must be done in accordance with
the ZVEI code of practice “The Cleaning of Vehicle Traction
batteries”. Any liquid in the battery tray must be extracted
and disposed of in the correct manner. Damage to the
insulation of the tray should be repaired after cleaning, to
ensure that the insulation value complies with EN 62485-3
and to prevent tray corrosion.
Should it be necessary to remove cells, please contact EnerSys
service.
9. Storage
Batteries are dispatched from the manufacturer in a fully
charged condition. The state of charge will decrease with the
storage time. Due to parasitic chemical reactions all batteries
lose their stored energy when allowed to stand on open circuit.
The rate of self-discharge is non-linear and increases with
decreasing state of charge. High temperatures greatly reduce
storage life as they increase the rate of self-discharge. If the
truck/vehicle is not going to be used for periods in excess of
48 hours, the ignition key must be removed and any auxiliary
equipment (such as lights, beacons, on-board computer, etc)
must be switched o.
The standard storage time for a battery not installed on a truck
is one month without the need to recharge. The maximum
storage time is 6 months at 20°C provided the battery is fully
charged when put into storage and that other equipment that
could cause the battery to discharge is disconnected. It is
advisable to conduct an inspection and open circuit voltage
check after three months and implement a refresh charge if
necessary.
10. Faults
If faults are found on the battery or the charger,
EnerSys service should be called in without delay.
The measurements taken in point 7.3 will facilitate fault nding
and their correction. A service contract with EnerSys will make
it easier to detect and correct faults and ensure the battery
performs at its best.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste! Pb
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Subject to revisions without prior notice. E.&O.E.
EMEA-EN-IU-NEX-ATEX-0222