Enersys ATEX-Certified Batteries Owner Manual

Overview

ATEX-Certified Batteries are maintenance-free, valve-regulated traction batteries designed for battery-powered equipment used in explosive atmospheres. They are intended for applications such as electric counterbalance trucks, reach trucks, pallet trucks, floor sweepers, and other cleaning equipment operating in hazardous gas or dust zones.

This guide covers the practical use of ATEX-Certified Batteries, including safe handling, charging, storage, maintenance, and fault response. It is written for operators, supervisors, and service personnel who work with explosion-protected battery systems.

Specifications

• Battery type: valve-regulated lead-acid, maintenance-free traction battery
• Electrolyte: immobilized gelled sulfuric acid
• Nominal voltage: 2.0 V per cell
• Nominal discharge current: C5/5h
• Nominal electrolyte specific gravity: 1.29 kg/l for Type PzV
• Rated commissioning temperature: 30°C
• Operating temperature range: +5°C to +35°C
• Maximum surface temperature in explosive areas: 80°C
• Typical service life: up to 4 years
• Ingress protection: cells and connectors IP65; crates IP23
• Compliance: ATEX Directive 2014/34/EU
• Use categories: Group I M2/Mb mining, Group II 2G/Gb and 3G/Gc gas zones, Group III 2D/Db and 3D/Dc dust zones

Detailed description

ATEX-Certified Batteries use a sealed design with a valve that regulates internal pressure. Instead of free liquid electrolyte, the battery contains gelled sulfuric acid, which helps prevent routine water loss and removes the need for topping up. The battery valves must remain in place, and the battery should always be kept upright during handling and installation.

The battery system is built for hazardous-area traction use and includes certified terminals, plugs, cables, and ventilation features. The patented ventilation design allows the battery to fit within existing DIN and British standard crate sizes while maintaining the capacity specified by the truck manufacturer. The crate, cells, and connectors are designed to work as a complete system in ATEX-protected environments.

These batteries are intended for use in electrically powered industrial vehicles and cleaning machines where explosive gas or dust may be present. They are not general-purpose starter batteries and should be treated as critical safety equipment rather than simple energy storage.

Safety

Only trained and skilled personnel should work on ATEX-Certified Batteries. Protective glasses, safety clothing, and standard accident-prevention rules should always be used. Smoking, open flames, sparks, and glowing embers must be kept away from the battery at all times.

Short circuits must be avoided because battery metal parts remain live. Tools and other metal objects should never be placed on the battery. Certified DC plugs must be used, and damaged plugs, bare cables, or visible wear are grounds for immediate removal from service.

The battery must never be charged in a hazardous zone. It must also never be disconnected or opened in a zoned area. If acid contacts skin or eyes, flush immediately with plenty of clean water and obtain medical help without delay. Acid-contaminated clothing should be washed thoroughly.

The electrolyte is highly corrosive if the cell container is damaged. Heavy batteries and cells must be moved only with approved lifting and handling equipment that does not damage the cells, connectors, or cables.

Setup and operation

When the battery is received, remove packing materials and inspect the battery container, cells, connectors, and accessories for damage. If anything is missing or damaged, it should be reported promptly. Before installation, confirm that the battery compartment is well drained, well ventilated, and free from loose metal objects that could fall into the ventilation openings.

Connect charger cables with the correct polarity and make sure the contact is secure. The pole screws require a torque of 25 +2 Nm for M10 hardware. Cables should be flexible, long enough to prevent strain, and protected from abrasion. Markings should clearly identify positive and negative connections to reduce the chance of wrong-polarity connection.

Charging should always be done with an approved charger, and the charger must be switched off before the battery is connected. The battery should not remain in a closed compartment during charging; ventilation covers or compartment lids must be opened or removed so charging gases can disperse safely. After the charger is switched off, the battery may be disconnected.

ATEX-Certified Batteries are designed for daily use patterns up to one cycle per day at a maximum depth of discharge of 80% C5, with use limited to six days per week. Deep discharge should be avoided because it shortens service life. The battery should be discharged evenly; using taps from only part of the battery is discouraged because it can create imbalance. If auxiliary loads must be supplied, a certified D.C.–D.C. converter should be used.

Equalizing charges are used to maintain capacity and battery life. A weekly equalization cycle is automatically performed with a high-frequency charger, but only outside hazardous areas. Full charging is expected every working day when the battery is in normal service.

The temperature range for use is +5°C to +35°C, with best life performance around 25°C to 30°C. If the battery becomes hot during use or charging, it should be removed from the controlled zone and allowed to cool before returning to service. Performance drops in colder environments, so extra capacity may be needed for low-temperature work such as cold storage applications.

Cleaning and maintenance

Keep the battery top, sides, and container clean and dry. Dust, water, and debris can create tracking paths that increase spark risk in hazardous areas. A damp cloth is recommended for routine cleaning of the battery surfaces.

Because the electrolyte is immobilized, no water filling is required. The battery must never be refilled with water, and the safety valve must never be removed. If a valve is damaged, it should be replaced by qualified service personnel.

Weekly checks should include cable insulation, connectors, vent plugs, insulators, and overall cleanliness. Frayed wires, worn insulation, or damaged parts require immediate removal from service outside the zoned area. Corrosion on metal parts should be cleaned, neutralized, and protected with suitable acid-resistant coating.

Monthly, end-of-charge voltage readings should be taken and recorded for the battery and each cell. If the battery does not deliver the expected runtime, the workload, charger settings, and discharge limiter settings should be reviewed.

Yearly inspections should include the plugs, output cables, and battery insulation resistance. The battery and truck insulation must be checked by a qualified electrical specialist using the relevant safety standards.

Troubleshooting

If the battery shows frayed wires, worn insulation, damaged plugs, or bare cables, it should be taken out of service immediately and moved to a safe area outside the hazardous zone. Repairs should not be attempted by the operator.

If the battery runs hot, the cause should be investigated before the unit is returned to service. Common causes include faults in the powered equipment or an internal battery problem. If the battery does not provide enough discharge time, check capacity match, charger settings, and discharge limiter configuration.

If connections are loose or corrosion is found, service should be arranged promptly. Malfunctions in the battery, charger, or accessories should be reported without delay so that fault finding can begin with the recorded maintenance data.

Storage

When ATEX-Certified Batteries are stored for a long period, they should be fully charged first and kept in a dry, frost-free room. Long-term storage should not be done in a discharged state, and the battery should not remain connected to a truck for extended periods.

To keep the battery ready for use in storage, either give it a monthly equalizing charge or maintain it on float charge at 2.27 V per cell. Storage duration should be considered part of the battery’s usable life.

Warranty and service life

The battery is designed for up to 4 years of use when handled and charged correctly. Warranty protection can be affected by ignoring operating instructions, using non-original parts, or making unauthorized modifications to charging arrangements.

If a battery or accessory fails, service should be handled by qualified EnerSys personnel or an authorized service representative. The battery should never be repaired by the user.

Pros & Cons

• Pros: Maintenance-free design, sealed gel electrolyte, strong hazardous-area certification, and no routine water topping-up.
• Pros: Suitable for industrial trucks and cleaning equipment used in explosive gas or dust zones.
• Pros: Clear inspection and charging rules that support predictable operation and longer service life.
• Cons: Charging is restricted and cannot be done in a hazardous area.
• Cons: Performance drops in cold conditions and battery life is reduced by deep discharge or excessive heat.
• Cons: Requires careful handling, certified accessories, and trained personnel for safe use.