extronics iBATT5XX Installation instructions

Installation & Operating Manual
iBATT5XX

iBATT5XX Installation & Operating Manual
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Document Number 413017(7). For release status refer to Extronics DDM.
© 2023 Extronics Limited. This document is Copyright Extronics limited.
Extronics reserve the right to change this manual and its contents without notice, the latest
version applies.

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Contents
1Introduction.......................................................................................................... 4
2Safety Information and Notes .............................................................................. 5
2.1 Storage of this Manual................................................................................... 5
2.2 Certification Requirements ............................................................................ 5
2.3 Special Conditions for Safe Use .................................................................... 5
2.4 Warnings ....................................................................................................... 6
3Installation & Use................................................................................................. 7
3.1 Lifting............................................................................................................. 7
3.2 Mounting........................................................................................................ 7
3.3 Opening and Closing the Enclosure .............................................................. 7
3.4 Cable Entries................................................................................................. 7
3.5 Battery Wiring ................................................................................................ 7
3.6 Battery Charging............................................................................................ 8
3.7 Prevention of Electrostatic Charging ............................................................. 8
3.8 Authorized Persons ....................................................................................... 8
3.9 Transportation and Storage........................................................................... 8
3.10 Cleaning and Maintenance......................................................................... 8
3.11 Aggressive substances and environments ................................................. 8
3.12 Exposure to External Stresses ................................................................... 9
4Technical Data .................................................................................................. 10
4.1 Specification ................................................................................................ 10
4.2 Battery Information ...................................................................................... 11
5Certification ....................................................................................................... 12
5.1 Marking Information..................................................................................... 12
5.2 EU Declaration of Conformity ...................................................................... 13
5.3 UKEX Declaration of Conformity ................................................................. 14
6Type Codes ....................................................................................................... 15

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1 Introduction
The iBATT5XX is an ATEX/IECEx/UKEX/UKEX approved floor mount stainless
steel battery enclosure for use in Zone1 and Zone 2 hazardous areas. It is
designed to be used in conjunction with the iUPS1XX system & other products to
provide an uninterruptible power supply. The iBATT5XX can also be used
independently providing the special conditions for safe use are applied as
detailed on the ATEX/IECEx/UKEX certificates.
When used in conjunction with the Ex ‘e’ certified charge protection circuit
contained within the iUPS1XX system or other Extronics supplied product, users
are permitted to charge the internal batteries within a hazardous area.

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2 Safety Information and Notes
2.1 Storage of this Manual
Keep this user manual safe and in the vicinity of the device. All persons who have to
work on or with the device should be advised on where the manual is stored.
2.2 Certification Requirements
The battery enclosure main explosion protection concept is increased safety Ex ‘e’ for
zone 1 or zone 2 gas protection.
Certification options:
II 2 G Ex eb IIC T6 Gb Tamb -40°C to +55°C
Applicable certificates:
ExVeritas 15ATEX0001X, IECEx EXV 15.0007X, ExVeritas 23UKEX1575X
Applicable standards:
EN IEC 60079-0:2018, EN IEC 60079-7:2015/A1:2018
2.3 Special Conditions for Safe Use
•Refer to the installation and operating manual for cell charging conditions.
•The battery box shall not be exposed to mechanical shock.
•If the battery is to be disconnected from its associated equipment in the
hazardous area then a suitably approved disconnection device shall be used.
•When the battery box is fitted with external heating the method shall be
suitably approved for the area classification.
•The permitted cell types are lead-acid, nickel-iron and nickel-cadmium that are
constructed to comply with the relevant IEC standards as per the requirements
of table 11 of EN 60079-0:2012 for secondary cells.
•The cells used to form the battery shall only be connected in series.
•The battery shall be made from cells of the same type and from the same
manufacturer.
•The cells shall the operated within the allowable limits of the cell manufacturer.

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•To prevent faults from the charging devices causing over voltage or over
current of the cells voltage regulation and current limitation (fuses) will be
provided between the charger and the cells.
•The optional temperature probe if fitted shall be suitability ATEX and IECEx
approved apparatus and the electrical connections shall be external to the
battery box.
•Ex e glands shall be ATEX and IECEx approved.
•The cell interconnecting conductor sizing shall be in accordance with IEC
60364-5-52: 2009 Edition 3.0 and EN60079-14: 2014 with reference to the
maximum ambient temperature of + 55°C and the conductor not to exceed
70°C at the conductor branching point.
•The height of the battery enclosure can be reduced by up to 15% provided the
lid ventilation is increased by the same percentage.
•When the cell terminals are encapsulated the encapsulant material used shall
be suitable for a maximum service temperature of 85°C. The terminals shall
be fully encapsulated to ensure there are no bare electrical conductors.
2.4 Warnings
•Keep this user manual safe and in the vicinity of the device. All persons
required to work on or with the device should be advised on where the manual
is stored.
•Installation of the iBATT5XX must be performed in accordance with IEC
60079-14.
•Maintenance and inspection must be performed in accordance with IEC
60079-17.
•The iBATT5XX must only be fitted with suitably certified cable entry
components.
•In the event of battery charger failure, the maximum charge voltage and
current specified in the battery manufacturer’s instructions shall not be
exceeded.

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3 Installation & Use
3.1 Lifting
The iBATT5XX enclosure should be lifted into position carefully, ensuring that no
damage has been caused to the enclosure or any of the components installed onto
the outer faces such as certified vents, drains valves, cable glands, plugs etc.
Smaller & lighter enclosures (<25Kg) may be lifted by hand into position. Larger &
heavier enclosures (>25Kg) should be lifted into position by other means such as
cranes, hoists etc. If other means are used then straps should be fitted carefully to
the underside of the enclosure (Note, ensure any straps fitted DO NOT damage the
drain valve or lid gap spacers) & the enclosure lifted vertically into position.
3.2 Mounting
The iBATT5XX enclosure should be securely mounted to the floor with the fitted
brackets. Suitable fixings should be used with the fixing points to ensure no
movement or vibration on the enclosure.
3.3 Opening and Closing the Enclosure
The iBATT5XX enclosure is designed with a bolted or hinged lid which is secured
using retained bolts. Unscrew each lid bolt & remove the lid. When the lid is re-fitted,
place the lid onto the base & insert all the lid bolts into its threaded insert. Tighten
each lid bolt to 2Nm.
For certification compliance, the lid will have a specific gap between the base & the
lid for gas venting. When the lid is re-fitted, it must be ensured that the supplied
retained bolt spacers are used & in place before the lid is tightened down. There will
be certified drain valves fitted to bottom face of the enclosure, these drain valves
should be checked for any signs of damage or obstruction in the drain valve outlet. If
damage is found then the enclosure should be immediately removed from service
until the drain valve is replaced, contact Extronics for advice.
3.4 Cable Entries
Any cables fitted to the enclosure entries in the battery box must be via
ATEX/IECEx/UKEX approved Ex e cable glands. Customers fitting their own cable
glands should install them in accordance with the requirements EN 60079-14
‘Electrical Installations in Hazardous Areas (other than mines)’.
3.5 Battery Wiring
Some iBATT5XX enclosures are supplied with cable or connectors that are pre-wired
onto the battery terminals via certified cable entry devices. This is usually for IP56
supplied enclosures or bulkhead mounted connectors. If the enclosure is not supplied
pre-wired, then cable(s) needs to be installed & terminated onto the battery terminals
via suitably certified cable glands as described is 3.4. Ensure the cable(s) are
terminated onto the battery terminals using the correct cable lugs & tightened to the
correct torque, M6 bolts 7-9Nm, M8 bolts 10-12Nm. Take great care not to short out
the battery terminals during installation.

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3.6 Battery Charging
The iBATT5XX enclosure can be charged in hazardous or non-hazardous areas. The
battery should be charged in accordance with the battery manufacturer’s instructions,
see separate battery product information sheet.
When the enclosure is charged in the hazardous area, in the event of battery charger
failure, the maximum charge voltage and current specified in the battery
manufacturer’s instructions shall not be exceeded, it is the user’s responsibility to
provide additional protection for compliance with EN 60079-7.
3.7 Prevention of Electrostatic Charging
The iBATT5XX enclosure can build up electrostatic charge on its surfaces, so the
following steps are to be followed to reduce static charge build up:
Static charge build up should be reduced by:
•Connecting the enclosure to a suitable earth point
•Cleaning off surface dust using a damp cloth
•Not installing into areas where high airflow can occur
3.8 Authorized Persons
Only persons trained for the purpose are authorized to handle the iBATT5XX; they
must be familiar with the unit and must be aware of the regulation and provisions
required for explosion protection as well as the relevant accident prevention
regulations.
3.9 Transportation and Storage
The iBATT5XX enclosure must be transported and stored so that it is not subjected
to any excessive mechanical stresses.
3.10Cleaning and Maintenance
The iBATT5XX and its components maintenance intervals depend on the
environment where the enclosure is installed. Battery cells shall be maintained in
accordance with the cell manufacture’s maintenance documents. Refer to battery
manufacturer’s instructions.
3.11Aggressive substances and environments
The iBATT5XX enclosure is not designed to come into contact with aggressive
substances or environments, please be aware that additional protection may be
required.

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3.12Exposure to External Stresses
The iBATT5XX is not designed to be subjected to excessive stresses e.g. vibration,
heat, impact. Additional protection is required to protect against these external
stresses.
The iBATT5XX will require additional protection if it is installed in a location where it
may be subjected to damage.

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4 Technical Data
4.1 Specification
Maximum Voltage
Unlimited
Maximum Cells
36 (but can be increased, ask Extronics)
Maximum Capacity
2500Ah (but can be increased, ask Extronics)
Maximum Enclosure Size
1610 x 1810 x 700
Enclosure Material
316 Stainless Steel
Finish
180 grit dull polish or painted as required
Enclosure Ingress Protection
IP43 as standard
IP56 with encapsulated terminals (special option)
Environmental
Certification temperature: –40oC to 55oC
Operating temperature: dependant of installed batteries
Relative humidity; 0 to 95%, non-condensing
Certification
ATEX/IECEx/UKEX
II 2 G Ex eb IIC T6 Gb
ExVeritas 15ATEX0001X, ExVeritas 23UKEX1575X,
IECEx EXV 15.0007X
Options
Optional temperature sensor, RTD Ex’d/e’ certified, can be fitted for temperature
compensated charging
Optional enclosure heating, certified heat tracing can be fitted
Optional enclosure on external face, certified Ex’d/e’ enclosures can be fitted
Optional current measuring device, certified Ex’d/e’ current shunt resistors can be fitted

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4.2 Battery Information
See separate battery product information sheet supplied by Extronics.

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5 Certification
5.1 Marking Information

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5.2 EU Declaration of Conformity

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5.3 UKEX Declaration of Conformity

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6 Type Codes
See separate battery product information sheet supplied by Extronics.