potentially cause a spark in a zoned area. Should there be any
corrosion of the metal container, scrape this off and neutralise
the area with a solution of water and baking soda, or diluted
ammonia, and protect the part from further corrosion by
painting it with acid proof paint
(III) Monthly:
• Carry out end of charge voltage readings at C
5
/100, measure
and record:
• the voltage of the battery
• the voltages of each cell
If significant changes from earlier measurements or
differences between the cells or bloc batteries are found,
please contact EnerSys
®
Service.
• If the discharge time of the battery is not sufficient, check:
• That the work required is compatible with the battery
capacity
• The settings of the charger
• The settings of the discharge limiter.
(IV) Annually:
Check with attention:
• the state of the plugs :be sure to have a good contact
between the plugs without trace of overheating.
• the state of the output cables. If you check the torque
loading, you must use a torque wrench with respect of
recommended value : 25+2 Nm
In accordance with EN 1175-1 at least once per year, the
insulation resistance of the truck and the battery must be
checked by an electrical specialist. The tests on the insulation
resistance of the battery must be conducted in accordance
with EN 1987 part1. The insulation resistance of the battery
thus determined must not be below a value of 50 Ω per Volt of
nominal voltage, in compliance with EN 62485-3. For batteries
up to 120 V nominal voltage the minimum value is 1000 Ω.
7. Discharge
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be connected
or disconnected in the open circuit condition. To achieve
the optimum life for the battery, operating discharges of
more than 80 % of the rated capacity must be avoided (deep
discharge). They reduce the battery service life. To measure
the state of discharge use only the battery manufacturer’s
recommended discharge indicators (imperative presence of a
discharge limiter with an energy cut-off at 1.83 vpc operating
voltage at 80% DOD C
5
, when the recharging time is 12 hours,
and 1.87 vpc at 60 % DOD C
5
when the recharging time is 8
hours). Discharged batteries must be recharged and never be
left in a discharged state for a long time.
Hawker
®
Evolution ATEX certified batteries can be used in
normal duty applications one cycle per day at a max. DOD 80%
C
5
and a maximum 6 days per week.
Avoid applications where:
• no rest time is available allowing the battery to cool
• battery duty leads to a high increase of temperature during
operation.
It is recommended that the battery is discharged evenly and
the use of tappings across a part of the battery is discouraged.
To overcome this problem a D.C.- D.C. converter must be
used to allow auxiliary loads to be supplied from the whole
battery. NOTE: The D.C.-D.C. converter must be certified for
use in a zoned area as well as the auxiliary equipment. Battery
performance is directly related to temperature. Batteries are
rated at 30ºC. Where the battery temperature is lower than
this, the available performance is reduced. Additional capacity
is therefore required when the batteries are to be used in areas
of low ambient temperatures (e.g. cold stores).
8. Recharge
NOTE: NEVER RECHARGE A Ex BATTERY IN A ZONED AREA.
A full charge shall be carried out every working day with a
Hawker charger.
The charging time for a 80 % discharged battery shall be
12 hours, or 8 hours for a 60% discharged battery with the
appropriately assigned Hawker high frequency charger. After
any changing of cables on the charger, our technician must
visit the site to check the charger.
Hawker Evolution ATEX certified batteries have a low gas
emission. Nevertheless, when charging, proper provision shall
be made for venting of the charging gases (EN 62485-3).
Battery container lids and the covers of battery compartments
shall be opened or removed. With the charger switched off
connect the battery, ensuring that the polarity is correct.
(Positive to positive, negative to negative). Now switch on the
charger.
If the charger was not purchased together with the battery it
is best to have its suitability checked by the manufacturers
service department. When charging, proper provision must be
made for venting of the charging gases.
PzV batteries (Hawker Evolution ATEX certified batteries) are
low gas emission, so some charging gasses are evolved.
Battery container lids and the covers of battery compartments
must be opened or removed.
During the charge the battery must be removed from the
closed battery compartment on the truck. The ventilation must
comply to EN 62485-3 standard.
The length of the D.C. cable between the charger and battery
affects the voltage drop back to the control unit of the charger.
The cable should not be extended without prior consultation
with the charger manufacturer and supplier of your Ex battery.
In situations where the battery is generally only very lightly
discharged, it may be an option to recharge the battery at
less frequent intervals, perhaps every second day. In such
circumstances please seek the advice or your local service
engineer.
Do not disconnect battery until the charger has been switched
off.
Your local area service centre must approve any managing
charging system otherwise the warranty may be invalidated.
Equalizing
Equalising charges are used to optimise the life of the battery
and to maintain its capacity. A unique equalisation charge is
automatically carried out weekly 8 hours after the end of the
charge with a Hawker HF charger.
But remember never charge an Ex battery in a zoned area at
any time.
9. Temperature
The temperature range of use for the battery is b5°C
and + 35 °C. Any use outside of this range shall be approved by
a EnerSys service technician. Optimal battery life is obtained
for a battery temperature of 25-30°C High temperatures reduce
battery life according to IEC 1431 technical report, lower
temperatures reduce the capacity available.
The temperature on surface must never exceed 80°C in
explosive area. If electrolyte temperature reaches 55°C during
the charge, wait for the cooling before to use the battery in
the explosive area. If a hot battery is detected it should be
taken out of the controlled zoned area and allowed to cool to
ambient temperature. An investigation should be carried out
into why the battery is getting hot before it is placed back into
service.
Possible reasons why the battery might be getting hot is
that there might be a fault in the equipment that the battery
is powering or a fault could have occurred within the cells of
the battery. In the case of a suspected battery problem contact
your local service centre.
10. Surrounding area conditions
The apparatus is designed to cope with the intended
surrounding area conditions.
11. Effect of explosive atmosphere on materials
The materials selected are not known to react with any
explosive atmospheres to which the apparatus may be
subjected
12. Protection against other hazards
The apparatus does not cause injury or harm when used as
specified in the installation and operation manual.
13. Hazards arising from different ignition sources
The apparatus does not produce ignition capable electrical
sparks or arcs. The apparatus has also been designed not
to produce potential ignition sources from electromagnetic,
acoustic, optical or other such external energy sources.
14. Withstanding attack by aggressive substances
The individual cells contains sulphuric acid: These cells and
enclosure which make up the apparatus are constructed from
materials that are resistant to acid attack see manufactures
data sheet.