4
1. Safety
Always remember that the battery is a source of power, even when
fully discharged there remains sufficient energy in the battery to cause
serious damage.
Follow these safety codes
• Never charge a Ex battery in the zoned controlled 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
authorised service centre.
• Close vent plugs lids firmly when topping the batteries electrolyte
has been completed.
2. Service
Your local authorised service engineer provides local help and support.
This handbook gives guidelines of a general nature; our engineer will
help you to interpret your needs in relationship to your particular
requirements.
Your authorised engineer can answer the questions that are beyond
the scope of this manual and obtain specialist help should it be
required. Your battery is an expensive investment and designed for use
in a zoned area, it is our aim to help you obtain the best possible results
from it. Please do not hesitate to call your local service centre if you
have any questions relating to the battery.
3. Handling
Lead acid Ex batteries are very heavy. Always use approved moving
equipment when attempting to change batteries. When lifting and
handling the Ex batteries use the correct approved lifting equipment
and keep the battery in an up right position. Due to the wide variation
in types of electric vehicles, designs of battery containers, equipment
used and methods of battery changing, it is not possible to give
detailed instructions on the procedures to be followed when changing
the batteries on an 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
Do not carry out any of the following procedures in a zoned area. The
possibility of the battery being connected in the wrong polarity is
prevented by visibly marking the polarities adjacent to the connection
plug with an identification colour (Positive Red and Negative Blue). The
possibility of the insulation on the overall battery voltage leads being
cut to expose the conductor is prevented by sleeving the insulation
with cable retention (i.e. spiral wrap).
Please ensure that the battery containers are always upright so that
the electrolyte is not spilled. Remove all packing material and carefully
examine the containers, etc. to ensure that there is no physical damage.
If the battery is not used at receipt, please refer to (17) storage.
5. Commissioning
For commissioning of unfilled batteries, see separate instructions. The
level of the electrolyte must be checked.
If it is below the anti-surge baffle or the top of the separator it must first
be topped up to this height with purified water (IEC 62877-1:2016). The
charger cables must be connected to ensure a good contact, taking
care that the polarity is correct. Otherwise battery, vehicle or charger
could be damaged. Wipe over the tops and sides of the cells and
container with a damp cloth to remove dust, water or spilt sulphuric
acid. Cell cleanliness can not be too highly stressed. Check that all
connections are tight.
The specified torque loading for the pole screws is 25 + 2Nm (screw
M10). Make sure that the cells are readily accessible for testing and
topping up if the automatic watering facility is not fitted. This will make
regular maintenance hassle free.
Check that the battery compartment is well drained and ventilated
and that there is no risk of metal objects dropping through the top
ventilation of the battery. Check that the battery sits quite firmly and
securely in its housing, use suitable packing to prevent any movement
when the vehicle is in motion. The cables should be flexible and of
sufficient length to prevent any strain being imposed either on the
cable or the certified terminals to which the cables are connected.
Smear any steel runners or supports, which support the battery
container with petroleum jelly. This will keep down the possibility of
rust and acid corrosion and extend the life of these components.
If a new Ex battery is to be used in an application where there is
uncertainty about the zoned area please contact your local factory
inspector.
Never directly connect an electrical appliance (for example: warning
beacon) to some cells of the battery. This could lead to an imbalance
of the cells during the recharge, i.e. a loss of capacity, the risk of
insufficient discharge time, damage to the cells and this may EFFECT
THE WARRANTY OF THE BATTERY.
The battery is then charged as in item (8). The electrolyte should be
topped up to the specified level with purified water (item 6.).
• 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 flames,
glowing embers or sparks, as it may cause the
battery to explode.
• Acid splashes in the eyes or on the skin must be
washed with water. In case of accident 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!
• Pay attention to the hazards that can be
caused by batteries.
Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. All the
failures,malfunctions or defects of the battery, charger any other accessories, must be notified to our After Sales Service.