The Hawker Evolution ATEX battery is designed for equipment operating in explosive atmospheres (ATEX/IECEx zones). Certified to ISO 7240-1 standards, it prevents ignition through spark-proof terminals and gas recombination technology. Used in oil/gas refineries, mining, and chemical plants, it powers EX-rated forklifts, lighting systems, and ventilation units where flammable gases/dust exist. Built with AGM VRLA construction, it maintains ≤0.5% hydrogen emission levels under load.
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What makes ATEX environments require specialized batteries?
ATEX zones contain flammable gases, vapors, or dusts where standard batteries risk sparks or surface heating. The Hawker Evolution ATEX battery’s hermetically sealed design suppresses arc formation during terminal disconnection. Exceeding EN 50272-2 venting requirements, it ensures <0.2mJ ignition energy.
In Zone 1/2 areas (continuous/intermittent explosive risks), even minor sparks from battery disconnects can trigger disasters. The Hawker battery employs dual-stage pressure relief valves and copper-cadmium terminals that resist corrosion-induced resistance spikes. Pro Tip: Always verify the battery’s “II2G Ex mb ib IIC T4” marking matches your zone classification. For example, petrochemical tanker loading docks mandate ATEX batteries for equipment like EX-rated reach trucks—using standard models risks $500K+ regulatory fines. But how do these batteries handle repeated charge cycles in high-risk areas? Advanced AGM separators minimize electrolyte stratification even during rapid charging at 0.25C rates.
How does the Hawker Evolution ATEX differ from industrial batteries?
Unlike standard Hawker models, the ATEX variant adds intrinsic safety barriers and thermal runaway prevention. It limits surface temps to 135°C (vs. 180°C+ in industrial batteries) via nickel-plated steel casings. Its electrolyte suspension system prevents spillage even at 45° tilt angles.
The Evolution ATEX series meets stricter IEC 60079-11 mechanical impact tests—withstanding 7J blows without casing fractures. Its terminals use triple-seal gaskets and torque-limited hardware requiring 15Nm tools, eliminating DIY modifications. A real-world comparison: In underground coal mines, standard Hawker batteries last 1,200 cycles, but ATEX versions achieve 1,500+ cycles due to reinforced plate alloys. However, they’re 18–22% heavier; a 48V/750Ah unit weighs 1,150kg versus 940kg for non-EX counterparts. Pro Tip: Pair these batteries with ATEX-compliant chargers—their current ramp-up curves prevent case deformation during gassing phase.
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| Feature | Hawker ATEX | Standard Industrial |
|---|---|---|
| Terminal Spark Resistance | Yes (0.1mJ max) | No |
| Hydrogen Emission | 0.45 L/Ah | 1.2 L/Ah |
| Operating Temp | -40°C to +60°C | -20°C to +50°C |
What industries rely on Hawker ATEX batteries?
Key users include pharmaceutical cleanrooms (powder handling), grain silos, and aviation fuel depots. They’re mandatory where hydrogen sulfide or methane concentrations exceed 10% LEL (Lower Explosive Limit).
In paint manufacturing, the ATEX battery’s non-static busbar covers prevent solvent vapor ignition during transfer pump operations. Offshore oil platforms use them in EX-rated communication hubs where battery replacements occur biannually due to salt corrosion. Did you know? A single Hawker ATEX 80D31R battery powers emergency lighting for 12+ hours in LNG carrier engine rooms—critical during gas detection system activations. Pro Tip: Schedule quarterly internal resistance checks; ATEX cells degrade 30% faster in high-humidity zones compared to controlled warehouses.
How are Hawker ATEX batteries maintained?
Maintenance focuses on terminal oxidation checks and equalization charging. Technicians use IR thermometers to verify terminal temps stay below 55°C during 8-hour discharges.
Unlike flooded batteries, the AGM design doesn’t require watering but needs bimonthly voltage balancing at 2.4V/cell. A 48V ATEX pack’s BMS disables discharge if any cell drops to 1.8V, preventing reverse charging. For instance, in ethanol distillation plants, crews use thermal imaging cameras weekly to detect abnormal cell heating >5°C above ambient. Pro Tip: Replace terminal boots every 18 months—silicone degrades in UV-rich environments, compromising spark containment.
| Parameter | ATEX Requirement | Hawker Performance |
|---|---|---|
| Maximum Surface Temp | ≤135°C | 127°C |
| Charge Voltage Tolerance | ±1% | ±0.8% |
| Short Circuit Current | <3000A | 2,750A |
Can Hawker ATEX batteries be recycled?
Yes—their lead-calcium grids and AGM separators meet EU Battery Directive 2006/66/EC. Certified recyclers recover 99% lead, 80% sulfuric acid (neutralized to sodium sulfate), and polypropylene casings.
Recycling involves crushing batteries in inert nitrogen chambers to prevent hydrogen explosions. A single Hawker Evolution ATEX 6DGAZ model yields 18.2kg reusable lead versus 16.5kg from standard auto batteries. However, cadmium-plated terminals require hazardous waste handling—contact licensed processors like Redux in Europe. Did you know? Improper ATEX battery disposal can incur penalties up to 4% of annual turnover under REACH regulations. Pro Tip: Always obtain a Waste Transfer Note specifying the battery’s EX certification level for compliant recycling.
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FAQs
Absolutely. Use only chargers with “Ex m” or “Ex ib” markings. Non-certified units lack current ramping to prevent gassing above 0.5L/Ah during CV phase.
Can I retrofit Hawker ATEX batteries into older equipment?
Only if the vehicle has EX rating documentation. Retrofit kits must include grounded cable conduits and BMS interlocks—expect 30+ hour labor costs.
How often should ATEX battery zones be inspected?
Weekly terminal checks and annual load bank testing. In Zone 0 areas, thermal scans are mandated every 72 operating hours by IEC 60079-17.
