• 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! Do not remove the plugs.
• Electrolyte is highly corrosive. In the normal
operation of this battery contact with acid isn’t
possible. If the cell containers are damaged,
the immobilised electrolyte (gelled sulphuric
acid) is corrosive like liquid electrolytev
• Batteries and cells are heavy. Ensure secure
installation! Use only suitable handling
equipment. Lifting hooks must not damage the
cells, connectors or cables.
• 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.
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 service the battery:
Call your recommended authorised service centre.
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 and 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.
Use special coding systems for maintenance free batteries for
the charging plug- and- socket devices to prevent accidental
connection to a wrong type of charger.
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).
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 (16) storage.
5. Commissioning
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. 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.
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. 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).
6. Recommended maintenance
The electrolyte is immobilised in a gel. The density of the
electrolyte cannot be measured.
• Never refill with water!
• Never remove the safety valve from the cell In case of
accidental damage of the valve, contact our After Sales
Service for replacement.
(I) Every day:
Recharge the battery after discharge.
• Remember never charge an Ex battery in a zoned areaeven
if approved charging equipment is available. Always check
that the charger is operating correctly.
• Check that the plugs and sockets are in good condition.
(II) Weekly:
Check all connections and take off leads for any frayed or worn
insulation. If frayed wires or worn insulation is noted take the
battery out of service immediately and place in a safe area that
is outside the zoned area. DO NOT ATTEMPT TO REPAIR an Ex
battery. Call your local service depot Check that all insulators
and vent plugs are in place and that the battery plugs are of
sound condition.
Ensure that the top of the battery is clean and dry. Dirt and
moisture can provide tracking paths for the electricity and