EnerSys Hawker Perfect Plus

This document describes the Hawker® Perfect Plus™/Water Less® ATEX certified batteries, which are motive power batteries designed for use in hazardous areas with risks of explosion due to gas or dust. These batteries are certified for increased safety "e" and comply with ATEX Directive 2014/34/EU.

Function Description:

Hawker ATEX certified batteries are designed to provide motive power in applications within hazardous areas, such as electric counter-balance, reach, and pallet trucks, as well as floor sweepers and other cleaning equipment. The patented ventilation design allows these traction batteries to fit within existing DIN and British standard crate sizes while offering the specified capacity. The cells and connectors comply with IP65, and the crates with IP23.

The batteries are certified for:

Explosion group I Category M2/Mb (mining)
Explosion group II Category 2 and 3 [Zone 1 2G/Gb, Zone 2 3G/Gc (Gas)]
Explosion group III Category 2 and 3 [Zone 21 2D/Db, Zone 22 3D/Dc (Dust)]

The electrolyte circulation system (optional accessory) is based on the principle of pumping air into individual battery cells. This system prevents electrolyte stratification and optimizes battery charge with a charge factor of 1.07. It is particularly beneficial for heavy-duty use, short charge times, boost or opportunity charging, and high ambient temperatures. The air stream is continuous or pulsed depending on the battery voltage and pump type, with the air supply adjusted according to the number of cells. The pipe system to the individual battery cells must follow the existing electrical circuit to reduce the risk of current leakage in the presence of electrolytic gas causing an explosion (EN 62485-3).

The Aquamatic water refilling system (optional accessory) automatically maintains nominal electrolyte levels. A valve and a float control the topping-up process, allowing water flow into each cell and closing the valve when the correct water level is reached. The charging gases escape through the vent on each cell.

Important Technical Specifications:

Certification: ATEX Directive 2014/34/EU, IECEx certified.
Ingress Protection: Cells and connectors IP65, crates IP23.
Temperature Range: Rated at 30°C. Upper temperature limit is 55°C for electrolyte, 80°C on surface in explosive areas. Charging should only begin if electrolyte temperature is below 43°C.
Electrolyte Specific Gravity (S.G.): Nominal S.G. of 1.29 kg/l at 30°C in fully charged condition. Temperature correction factor is -0.0007 kg/l per °C. Electrolyte must conform to IEC 62877-2:2016 purity regulations.
Water Purity for Topping Up: Must be purified water with a conductance of not more than 30 µS/cm, conforming to IEC 62877-1:2016.
Insulation Resistance: Must not be below 500 per Volt of nominal voltage (EN 62485-3), with a minimum of 1000Ω for batteries up to 120V nominal voltage.
Pole Screw Torque: 25 + 2Nm (M10 screw).
Discharge: Avoid discharges of more than 80% of rated capacity (electrolyte S.G. of 1.14 kg/l at 30°C).
Charging: Only direct current, in accordance with DIN 41773-1 and DIN 41774. Gassing stage current limits must not be exceeded (EN 62485-3).
Aquamatic System Working Pressure: 0.2 to 0.6 bar (at least 2m height difference between battery and tank).
Maximum Cells in Series (Aquamatic): 10 cells.

Usage Features:

Safety: Always follow safety codes. Never charge or disconnect in a zoned area. Isolate circuits before disconnecting outside a zoned area. Use certified DC plugs. Do not use if damaged. Do not open battery cover or attempt repairs in a zoned area. Close vent plug lids firmly after topping up.
Handling: Batteries are heavy; use approved moving and lifting equipment, keeping batteries upright. The manufacturer of the vehicle or battery changing equipment must supply correct procedures for battery changes.
Commissioning: Check electrolyte level, top up with purified water if below anti-surge baffle or top of separator. Ensure correct polarity when connecting charger cables. Wipe cells and container clean. Check all connections are tight. Ensure battery compartment is well drained and ventilated, and battery sits firmly. Cables should be flexible and of sufficient length.
Discharge: Discharged batteries must be recharged immediately. Avoid deep discharges. Use D.C.-D.C. converters for auxiliary loads to prevent tappings across parts of the battery.
Recharge: Always recharge after discharge. Never charge an Ex battery in a zoned area. Ensure charger is operating correctly. Ensure proper ventilation during charging. Do not disconnect until the charger is switched off.
Equalizing Charges: Used to safeguard battery life and maintain capacity, necessary after deep discharges, incomplete recharges, and charges to an IU characteristic curve. Charging current must not exceed 5 A/100 Ah of rated capacity.
Storage: Store fully charged in a dry, frost-free room. Options include monthly equalizing charge or float charging at 2.27 V x number of cells.

Maintenance Features:

Daily: Recharge after discharge. Check electrolyte levels at the end of charge and top up with purified water to the max level indicator.
Weekly: Check for cells taking too much or too little water. Check all connections and leads for frayed or worn insulation. Check that all insulators and vent plugs are in place. Ensure battery top is clean and dry. Scrape off and neutralize corrosion on metal containers.
Monthly: Measure and record cell voltages (charger on), electrolyte density, temperature, and filling level (charger off, after 2 hours rest). If significant changes or irregularities are found, contact EnerSys Service.
Annually: Check insulation resistance of truck and battery by an electrical specialist (EN 1175-1, EN 1987 part1). For electrolyte circulation systems, check and clean/replace the air pump filter. Check correct operation of the air pump.
Aquamatic System Maintenance:
- Manual Connection: Connect to filling system once a week.
- Automatic Connection: Water refilling at least once a week.
- Filling Time: Varies, supply should be turned off after filling is complete.
- Working Temperature: Charge or refill above 0°C.
- Flow Control: Monitor filling process via flow indicator; disc stops turning when complete.
Electrolyte Circulation System Maintenance:
- Air Filter: Change at least once a year, more frequently in high air-pollution areas.
- Repair: Check for leakage (Hawker charger displays error message). Contact EnerSys service for faulty parts, use only original spare parts.
Malfunctions: If malfunctions occur, contact EnerSys service department immediately.
Disposal: Dispose of battery containers and cells through a local service depot. Do not dismantle. Store failed products outside the zoned area until removed for reclaim. Recycle batteries.