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Installation, commissioning and operating instructions

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1. Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 37 6 Battery operation A Attention DIN VDE 0510 Part 1 and EN 50272 2 and IEEE 484 apply for the operation of stationary battery systems The recommended operating temperature for lead acid batteries is between 10 C and 30 C Technical data is valid for the nominal temperature of 20 C The ideal operating temperature range is 20 C 5 K Higher temperatures shorten the service life of the battery Lower tempe ratures decrease battery capacity Exceeding the limit temperature of 55 C is not permissible The operating temperature has to be kept above the freezing point when using the HOPPECKE AquaGen recombination system Thereby you avoid icing of the internal ceramic component and assure an optimal recombination 6 1 Discharging A Attention Never allow the final discharge voltage of the battery to drop below the voltage corresponding to the discharge current Unless the manufacturer has specified otherwise no more than the nominal capacity is to be discharged Immediately after discharge including partial discharge charge the battery comple tely 6 2 Charging general Depending on how the batteries are used charging is to be carried out in the operating modes described in Chap 6 2 1 to Chap 6 2 4 Attention Attention All c
2. Installation commissioning and operating instructions for vented stationary lead acid batteries Sewers N Wa 7140203152 V1 1 02 2014 POWER FROM INNOVATION 25 5 3 Conducting an open circuit voltage measurement Before installing the batteries conduct an open circuit voltage measurement of the individual cells or monobloc batteries to determine their state of charge and to make sure that they are functioning properly Fully charged cells with an electrolyte temperature of 20 C should have an open circuit voltage as listed in Tab 5 3 The open circuit voltages of the individual cells of a battery must not differ more than 0 02 V from one another C OOH USV bloc Be 2 13 0 01 V c Tab 5 4 Open circuit voltages for different cells monobloc batteries The following open circuit voltage deviations are acceptable for monobloc batteries 4 V monobloc 0 03 V block 6 V monobloc 0 04 V block 12 V monobloc batteries 0 05 V block High temperatures decrease the open circuit voltage while lower temperatures increase it A deviation of 15 K from the nominal temperature changes the open circuit voltage by 0 01 V cell Please consult your local HOPPECKE representative regarding larger deviations 5 4 Installation tools and equipment The batteries are delivered on pallets and the required accessories are located in separate packaging units Observe all information from the previous sections For the installation
3. 5 Attach safety marking signs these include Danger batteries Smoking prohibited and for battery volta ges gt 60 V Dangerous voltage Attach further marking signs according to local requirements 6 Attach the safety notices see Chap 0 7 If necessary Clean the batteries the racks and the installation room A WwW Never clean batteries using feather dusters or dry towels Danger of electrostatic charging and gas explosion We recommend cleaning the batteries using damp cotton cloths or paper towels Danger Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 35 8 Connect the battery system to the charging rectifier UPS using the end connections plus to plus and minus to minus and proceed as described in Chap 5 12 The connection cables between the end connections of the battery and the charging rectifier or UPS should be flexible conductors Inflexible wires could transfer vibrations which could loosen the connection under certain circum stances The cables must be supported so that no mechanical load can be transferred to the connection terminals cable trays cable ducts cable clamps 5 12 Commissioning charge initial charge Normally by the time of installation batteries are no longer fully charged This applies especially to batteries that have been in storage for
4. If the battery casing is destroyed leaked bonded electrolyte is just as corrosive as liquid electrolyte Leaking electrolyte is harmful to the eyes and skin Refer also to chap 2 3 Safety precautions Incomplete or insufficient maintenance can lead to unexpected battery failure or reduction of bat tery power Maintenance work must be completed once every six months by authorized technical specialists in accordance with the instructions in this documentation Work on batteries especially installation and maintenance should be performed by trained HOPPECKE specialists or by personnel authorized by HOPPECKE only personnel must be familiar with battery handling and the required precautionary measures Unauthorized persons must keep away from the batteries Without proper and regular maintenance of the batteries by HOPPECKE specialists or personnel authorized by HOPPECKE the safety and reliability of the power supply during operation cannot be ensured Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 5 HOPPECKE offers the following type ranges as vented lead acid VLA batteries GroE OSP HC OSP XC OPZS OPZS solar power max power power bloc OPZS OPZS bloc solar power OGi bloc OGi bloc HC USV bloc Following symbols and pictograms are pictured on each battery cell or on each battery block Ma Read
5. E E EE EE E RE 5 0 2 Safety instructions for working with lead acid batteries snesenseresnnreresrrrnrrnrerrsrrrrrrsrerrrrrrrrnrne 7 1 General information scsic tic oesiecer ees etac senile cccas dicen beck sccectatanaicucveces siinsesdsces occa blac sasicssticcastlcoesdaciessaslesoans 11 L Safety precautioiS csore ee REE e EE E E AREE E EEEE ORERE ern ere oe 11 1 2 Technical IDAs sses ec erccccacesdageetathscestticenetectctonaceddeusies tstancedawsetcencsesaceedutsecnnAscantecseratsaneteencetvones 11 Ne as Example for single Celleretesi ne ee ee E E OAE E 11 1 2 2 Identification plate battery cccccccceceececncecceeecneensecnsecescececnsseanceceeaeceauensaeeecnsaeenseseeanseanaas 12 1 3 ON arene O E E E E E saa aiacaceseess 12 1 4 Disposal and PECYCUING se cccsccenedeseecsecestvvsedesesceascheueetdeseicaede scuenedssdeceneceiuesedessadensettecsedescecesecteueses 12 1 5 SENICE mear ee e E E E ane ea eo een E eeenss 12 2 Safely eee E E E E canes cetonten toccamah na seei dace sandsiaenet tana ciamaseasstess 13 2 1 General eee en e E e e a eee E a e 13 2 2 Personal safety equipment protective clothing CQUIPMENT ccccccecesececececesesesesesesesesesesees 14 2 3 Safety precautions we ccs edie tancceccuasseuetctdsmeccsessbcestebosesesteacendoadevedaseshodetiasaceuass casndseddsendaseseonentevaes 14 29k SUUN GONG ee e E E EE E E E E E E E E E E 14 2 3 2 Explosive gases n nnnnnnnnnernnnnrnnrnrnrrnrnrnnrnrnrrnrnnnnr
6. ISO 9001 processes and procedures DIN EN ISO 14001 environmental audit and specialist disposal regulations covering specialist disposal with all associated waste codes for storage treatment and recycling For further information 49 0 2963 61 280 1 5 Service HOPPECKE has a worldwide service network that you should take advantage of HOPPECKE service is there for you whenever you need specialist consultation for installation of the battery system parts and accessories or system maintenance Contact us or your local HOPPECKE representative HOPPECKE service Email service hoppecke com Refer to the HOPPECKE website for contact data of all international HOPPECKE branches Internet www hoppecke com me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 12 2 Safety 2 1 General If the container of a filled lead acid battery is damaged electrolyte acid mist or hydrogen gas may escape Always take the normal safety precautions when working with lead acid batteries Procedure for handling acid spills Fix acid using a binding material such as sand and neutralize it using calcium carbonate sodium carbonate or sodium hydroxide Dispose of the acid according to the official local regulations Do not allow acid to escape into the sewage system soil or water The following table contains a list of chemicals recom
7. Threshold value on workplace 0 1 mg m Hazard symbol Personal protective equipment C corrosive Rubber PVC gloves acid proof goggles acid proof clothing safety boots 0 5 mg m3 at the lead battery production 9 Physical and chemical properties Lead Appearance form solid colour grey odour odourless Safety related data Solidification point 327 C Boiling point 1740 C Solubility in water 25 C low 0 15 mg l density 20 C 11 35 g cms vapour pressure 20 C Sulphuric acid 30 38 5 form liquid colour colourless odour odourless Solidification point 35 bis 60 C Boiling point ca 108 114 C Solubility in water 25 C complete density 20 C 1 2 1 3 g cm vapour pressure 20 C 10 Stability and reactivity of sulphuric acid 30 to 38 5 Corrosive inflammable liquid Thermal decomposition at 338 C Destroys organic materials such as cardboard wood textiles Reacts with metals producing hydrogen Vigorous reactions with lyes and alkalis 11 Data on toxicology of the constituents Sulphuric acid acts intensely corrosive on skin and mucous membranes The inhalations of mists may cause damage to the respiratory tract Lead and lead containing battery paste may cause damage to the blood nerves and kidneys when taken in Lead containing battery paste is classified as toxic for rep
8. and adhere to them strictly If you have not understood the information contained in this documentation or if local regulations and conditions apply which are not covered by the documentation or run contrary to the information in this documentation please contact your local HOPPECKE representative You can also contact us at our head office directly Danger If you are conducting any work on or with the battery system it is essential that you familiarize yourself with the installation operation and maintenance of lead acid batteries Attention 1 2 Technical Data 1 2 1 Example for single cell Each battery cell or bloc contains an identification plate on top of the cell bloc lid Refer to the example below 5 OPzS 250 2V 250Ah C 266 Ah C U 2 23 V cell Leese L24 kg Made in Germany float Example The information on the identification plate is as follows 5 OPzS 250 5 number of positive plates OPzS battery type 250 nominal capacity C capacity during discharge with ten hours current l over a discharge time of 10 h t 266 actual capacity C capacity of discharges with 10 h current Installation commissioning and operating instructions for vented stationary lead acid batteries ami HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 11 1 2 2 Identification plate battery id HOPPECKE amp R The identification plate of the entire battery system can be found on the Po ba
9. can be reduced by 50 m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 24 Technical ventilation increased ventilation using fan generally extractor fans air flow rate according to air volume flow Q air drawn in must be clean if large amounts of gas are released during charging continued ventilation is required for 1 h after charging is complete for multiple batteries in one room required air flow JQ avoid a ventilation short circuit by ensuring that there is sufficient distance between the intake and exhaust opening In case of a technical forced ventilation the charger shall be interlocked with the ventilation system or an alarm shall be actuated to secure the required air flow for the selected charging mode Another sample calculation for battery room ventilation is available in Required ventilation for hydro gen generated by batteries Chap 10 Required ventilation for hydrogen generated by batteries 5 2 2 Filling the cells Filling acid with a density according to Tab 5 3 must comply with the purity specifications according to DIN 43530 Part 2 IEC 60993 3 or IEEE 450 2002 The cells must be filled to the lower electrolyte level mark Use acid resistant filling devices funnels do not use Stainless steel Transport plugs are not to be used when operating the battery The p
10. explosion or at least minimize the impact of an explosion Development of electrostatic discharges on the battery or on your body or on clothes can be avoided if you consider the information below Do not wipe the battery with an arid fabric especially made of synthetic material Rubbing on surfaces of plastic material battery jars are typically made of plastic materials causes electro static charges Clean the surface of batteries with water moistened cotton fabric only By using a water moiste ned cotton fabric you avoid the buildup of electrostatic charges While working on batteries do not rub your clothes e g made of wool on the battery Thereby electrostatic charges could build up on the battery jar your body or on your clothes Wear Suitable shoes and clothing with special surface resistance that avoid the buildup of electro static charge Thereby the buildup of electrostatic charge on the body and clothing can be avoided Do not remove self adhesive labels from the battery without special safety measures Removing plastic labels can build up electrostatic charges which can ignite oxyhydrogen gas Before pulling off the label wipe the battery moist 2 3 4 Electric shock and burns Batteries can cause severe electric shock If there is a short circuit very strong currents may be present Do not touch any bare battery components connectors clamps or terminals Note for batteries with voltages over 1 500 V DC In batt
11. maximum of 45 C terminate the charge or switch to float charge to allow the temperature to drop HOPPECKE IU recharge with IU characteristic recharge I part recharge U part constant current constant voltage max 20 Ampere per 100 Ah 2 35 2 40 V per cell Y recharge current A time t h Fig 9 1 IU characteristic W and characteristic curves are also possible The charge voltages then increase to 2 60 to 2 75 V x number of cells Therefore the consumers are normally switched off With the W or I characteristic curves the charge currents are not limited until the charge voltage reaches the gassing voltage of 2 40 V x number of cells At this point the following limit values apply Charge current limit values above the gassing voltage of 2 40 V cell per 100 Ah Charging procedure Charge current Cell voltage characteristic curve 5 0 A 100 Ah 2 60 2 75 V cell W characteristic curve 7 0 A 100 Ah at 2 40 V cell 3 5 A 100 Ah at 2 65 V cell Tab 9 1 Charge current and cell voltage in relation to charging procedure me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 54 While charging up to 2 40 V the effective value of the superimposed alternating current is permitted to reach up to 10 A 100 Ah nominal capacity for a short time up to 20 A 100 Ah nominal capacity After recha
12. n number of cells __ current per 100 Ah gas C nominal capacity of the battery Sum of factors xgxes 0 05 ee C Q O05 xn Las 1O0Ah with Q in m h lia nA R lloat Beeps Thoost x fy x f Parameter Lead acid batteries vented cells Sb lt 3 f Gas emissions factor f Safety factor for gas emissions 5 includes 10 faulty cells and aging Float charge voltage V cell float Typical float charge current mA per Ah Laat Current float charge mA per Ah used only for calculating the air volume flow for float charge Boost charge voltage V cell U oost Typical boost charge current mA per Ah ee lee Current boost charge mA per Ah used only for calculating the air volume flow for boost charge Tab 5 2 Recommended current values recommendation for European standards Extract from the DIN EN 50272 2 If designing the ventilation in battery rooms depending on the structural conditions either natural ventilation or technical ventilation can be used Observe the following points Natural ventilation intake and exhaust openings required minimum cross section free opening in wall A gt 28 x Q A in cm Q in m h given that v 0 1 m s increased ventilation through chimney effect air routing exhaust released outside not into air conditioning systems or surrounding rooms 1 If AquaGen recombination systems are applied Mea
13. the charger is in a switched off state by measu ring the voltage e Secure the charger to prevent it from being switched back on again Heed the instructions given in the operating manual provided by the manufacturer of the battery charger Under certain conditions there is a risk caused by electrical battery voltage and in the event of a short circuit extremely high short circuit currents may flow There is a risk of explosion and fire due to explosive gas Observe the following regulations IEEE standards valid for USA only ZVEI publication Instructions for the safe handling of electrolyte for lead acid accumulators VDE 0510 Part 2 2001 12 in accordance with EN 50272 2 2001 Safety requirements for secondary batteries and battery installations Part 2 Stationary batteries DIN EN 50110 1 VDE 0105 1 Operation of electrical installations German version EN 50110 1 2004 IEEE Standard 485 1997 Recommended Practice for Sizing Large Lead Acid Storage Batteries for Generating Stations IEEE Standard 1187 2002 Recommended Practice for Installation Design and Installation of Valve Regulated Lead Acid Storage Batteries for Stationary Applications IEEE Standard 1188 2005 Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid VRLA Batteries for Stationary Applications IEEE Standard 1189 2007 Guide for Selection of Valve Regulated Le
14. the erection site When renewing old batteries ensure that all electrical loads are switched off before removing the old battery separator fuses switches This must be carried out by qualified personnel Danger If you have questions regarding battery system installation please contact your local HOPPECKE representative You can also contact us at our head office directly If choosing an installation location determining space requirements and performing the installa tion observe the relevant installation drawing if it is available The floor must be suitable for battery installation it must have a suitable load carrying capacity have an electrolyte resistant installation surface or acid collection tanks must be used be sufficiently conductive be at ground level max thickness of backing elements under racks and cabinets 6 mm be as free of vibration as possible otherwise a special rack is required Within the EU follow VDE 0510 Part 2 2001 12 in accordance with EN 50272 2 2001 Safety requirements for secondary batteries and battery installations Part 2 Stationary batteries me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 20 Ventilation source Sufficient room ventilation is absolutely required in order to limit the hydrogen concentration H concentration in the am
15. the instruction for installation commissioning and operation carefully p Always wear protective goggles and cloths Avoid naked flames and sparks General danger warning Risk of electrical voltage Risk of chemical burns through electrolyte Risk of explosion avoid short circuits electrostatic charge and discharge sparks Battery with low concentration of antimony Used batteries with this symbol have to be recycled Used batteries which are not sent for recycling are to be disposed of as special waste under all relevant regulations m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 6 0 2 Safety instructions for working with lead acid batteries working with lead acid batteries Danger When working on batteries always observe the safety regulations documented in DIN EN 50110 1 VDE 0105 1 Operation of electrical installations Always proceed in the correct order when installing and removing the battery and when connec ting it to the charger e Pay attention to the polarity Make sure the connections are tight e Use only battery charger leads that are in perfect technical condition and that have adequate cross sections Batteries must not be connected or disconnected while current is flowing or while the charger is switched on Before opening the load circuit make sure that
16. to a pallet There are no dangerous traces of acids lye etc on the outside of the packaging It is essential that loads on road vehicles are properly secured Danger Monobloc batteries battery cells are very heavy depending on type between ca 10 kg and max 1100 kg per cell bloc Wear protective shoes Use only the appropriate transportation equipment for transport and installation Attention 3 2 Delivery completeness and externally visible damage Check immediately upon delivery while the carrier is still present to make sure that your shipment is complete compare with the delivery note In particular check the number of battery pallets and the number of boxes with accessories Then inspect the goods for possible shipping damage Note all damages to the outer packaging visible stains or moisture that might indicate electrolyte leakage If the delivery is incomplete or damaged as a result of shipping Write a short defect notice on the delivery note before signing it Ask the carrier for an inspection and note the name of the inspector Compose a defect report and send it to us and to the carrier within 14 days 3 3 Defects Observe all required safety measures to avoid electric shock Keep in mind that you are handling live batteries Observe all instructions in Chap 2 Safety Unpack the goods as soon as possible upon delivery the sooner the better and inspect them
17. 10 2 Type of connection cable The battery system that you received is designed for a certain period standby time to produce a specified amount of power kW or current A at a particular voltage U for a certain period of time standby time You should be familiar with these parameters U kW A If this is not the case please contact your local HOPPECKE representative The battery system was designed so that the electrical energy is available at the battery terminals Limit voltage drop between the battery terminals and electrical loads to an absolute minimum If the voltage drop is too large the standby time of the battery system may be reduced Observe the following information 1 Keep the cable length between the batteries and the charging rectifier USV as short as possible 2 The cable cross section should be calculated so that voltage drop is negligible even at a high current flow Use the cross section of the cable provided to calculate the voltage drop at the nominal current If in doubt use cable with a cross section that is one size larger The connection cable must be short circuit proof or double wall insulated That means The insulation strength of the cable is higher than the max system voltage or there is a distance of at least 100 mm between wiring and electrically conductive parts or Danger connectors must be furnished with additional insulation Avoid mechanical stress on the cell battery termin
18. 12 1 Commissioning charge with constant voltage IU characteristic curve A Charge voltage of 2 35 2 40 V per cell is required The charge current should be at least 5 A per 100 Ah C at the beginning of charging The electrolyte density increases slowly during charging so a charge time of several days may be required before the minimum elec trolyte density reaches the nominal density 0 01 kg I Then switch to the float charge voltage as specified in the operating instructions The electrolyte density increases to the nominal value during operation The end of commissioning charge is reached when the cell or bloc voltage no longer rises for a period of 2 hours me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 36 5 12 2 Commissioning charge with constant current 1 characteristic curve or decreasing current W characteristic curve The maximum permitted currents can be obtained from Tab 5 6 Characteristic curve Charge Current characteristic 5A Tab 5 6 Max permitted charge currents in A per 100 Ah C battery capacity for and W charging Charging must continue until all cells have reached a minimum of 2 6 V the electrolyte density ceases to rise over a further period of 2 hours Then switch to the float charge voltage as specified in the operating instructions 5 12 3 Extende
19. 40203152 V1 1 02 2014 16 A If an additional ground connection is made by some cells within the grounded battery system there is a risk of short circuit fire and explosion If a battery system is not grounded A A If an accidental ground connection is made by some cells within the battery system voltage is created between the ground and the ungrounded terminal The voltage can be dangerously high risk of fatal injury due to electric shock If a second accidental ground connection is made there is a risk of short circuit fire and explo sion If you have questions about these instructions or any other questions regarding safety when working with a battery system please contact your local HOPPECKE representative You can also contact us at our head office directly Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 17 3 Transportation 3 1 General We take great care in packaging the batteries that we send to you so that they arrive without damage We strongly recommend that you inspect the delivery for possible shipping damage as soon as it arrives For road transportation filled lead acid rechargeable batteries are not treated as dangerous goods if They are undamaged and sealed They are protected from falling shifting and short circuit They are firmly secured
20. 5 4 Components of HOPPECKE hoisting belt Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION Fig 5 11 POWER FROM INNOVATION 7140203152 V1 1 02 2014 30 The procedure is as follows T Lay the belt sling over the battery from above so that the sewn end of the belt lies on the long side of the battery and faces upwards Fig 5 5 Tilt the battery to the side slightly and push the hoisting belt underneath the battery positioning it in the center Fig 5 6 Use only the HOPPECKE hoisting belt When using a normal rope sling there is a risk that the battery could slide in the sling or fall out of the sling Pull the end of the belt upwards through the loop Fig 5 7 Fig 5 13 Both ends of the belt must be at the same height over the battery Slide both ring eyelets into the ends of the hois ting belt Fig 5 8 Make sure that the opening in the ring eyelet is at the top and that the ring eyelet is not bent open Otherwise there is a risk that the battery could fall Avoid short circuits caused by the metallic conductive auxiliary equipment e g cross beam ring eyelets chain snap hooks Do not allow the auxiliary equipment to come in contact with the battery terminals Attach the cross beam to the hoist e g crane or forklift truck using the chain and the snap hooks Take the necessa
21. 50 Ls Time of recharge to 90 SOC Time inh 5 6 T 9 10 i 12 13 14 15 Charging Current in A 100 Ah Battery Capacity C 16 17 20 Fig 7 13 Time of recharge depending on depth of discharge start of charge between 55 and 100 DoD Installation commissioning and operating instructions for vented stationary lead acid batteries 7140203152 V1 1 02 2014 HH HOPPECKE POWER FROM INNOVATION 8 Battery maintenance To ensure the reliability and longevity of your battery system regular maintenance is required Document the type and scope of maintenance work performed as thoroughly as possible These records can be very helpful if troubleshooting is required and are a prerequisite for making war ranty claims 8 1 Work to be performed every six months Take the following measurements and record the measurement values 1 Voltage of the complete battery system on float charge 2 Individual voltage of selected cells or monobloc batteries on float charge 3 Electrolyte density of selected cells or monobloc batteries approx 20 4 Electrolyte temperature of selected cells or monobloc batteries 5 Electrolyte level of the cells 6 Ambient temperature 8 2 Work to be performed annually Take the following measurements and record the measurement values 1 Voltage of the complete battery system on float charge 2 Individual voltage of all cells or monobloc batteries on float charge 3 El
22. 70 75 20 Depth of discharge DoD Fig 7 11 Electrolyte freezing point as a function of depth of discharge DoD Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 49 7 11 Remarks to warranty management Above mentioned information about battery performance and lifetime particularly concerning the charging pro cedure and the influence of temperature and cycling affect terms of warranty as well In case of a warranty claim the customer battery operator needs to prove the compliance of above mentioned parameters with the allowed recommended limits Corresponding measurement logs have to be sent to the battery manufacturer These protocols shall clearly demonstrate that the lifetime of the affected battery has not been shortened by the application and associated parameters The expected service life mentioned by the battery manufacturer is valid for operation under optimal conditions only Therefore it is not possible to solely derive warranty claims from information on the expected service life provided by the manufacturer For special demanding operational conditions as well as for solar and off grid applications the expected battery service lifetime is heavily influenced by above mentioned operational conditions In order to decide whether a battery failure was caused by manufacturing defects or operational conditions above men
23. 9 i i i i i i i 0 I i 1 2 5000 N AERE ak Rs Sel ele Lappe Gs tee Re Selina i i i L i i i i 1 i t a 1 5 i I gt L i 1 f I h E i L o 4000 So ee Le a a te ee Le Te en E z I 1 F i i O I a E i 1 A i i i i i i i S i L i i i i J j 1 i L i 3000 E ees Mee a Oa cei e an A ee eed E EE EA i r i i i i i i i i i i i i I 1 L I I i i 2000 Cotto itn os LET oo E ma J CE E E E oS i i i i I i a L i i i i E i i i i li i i i I a C i i i E i E i i i i i i i i i i i i L I i i 1 I i F I E I J F 1 oa aoo re Depth of discharge DoD in 0P bolar power bei 20 C 0P solar power bei 25 C DPI solar power bei 30 C DFS solar power bei 40 C OFPz5 solar power bel 46 C OPz5 solar power bel 36 C Fig 7 10 Cycle lifetime of OPzS solar power depending on DoD and temperature 7 10 3 Electrolyte freezing point depending on depth of discharge DoD The freezing point of the electrolyte sulfuric acid rises with increasing depth of discharge In case the battery is exposed to cold ambient temperatures lt 5 C the maximum depth of discharge has to be decreased in order to avoid electrolyte freezing and potential damages of the cell jar Fig 7 11 shows an example for this relation Example If depth of discharge is below 60 the operating temperature must not be below 18 4 C 0 0 0 4 10 0 150 4 Freezing Point in C 50 55 60 86
24. FNE ANE ceS e E A A ee E E eee ee 25 5 23 dde TIME eirean a re E E a an a Eae aaa eraa a E a D EON Eaa aE FEEN Eea IAEE 25 5 3 Conducting an open circuit voltage measurement ss sssrsrrsrrrrrrrrrrrrrrrrrrsrrrrnrnrrrrnrnernrrrrsrnrnnne 26 5 4 Installation tools and CQUIPMENTL ccccceseeensececeaeeeeseseccnseceanaeeseseaensnseanaeeceseaeasnseaeanseeseaeas 26 5 5 RACK ions Fe 1d ee eee E E ERE EEE EEE ee ee E EE AT EEA eee 27 5 6 Cabinet installation socc sccsctescccecsssescescedcssecatsescebced sesecsesaccascecchaesstnaedacdesseeadscnencestedaesecelsessabsedasas 28 5 Handling the pDatterleS csrsieriariarias ren in e EEE EE AAE A EEE AE TEE EES 29 5 8 General information on connecting the batteries ccccccsesecesnceccesecnesecncnceceeseceenssnensnseeenes 31 5 9 Putting th c lls blocks Into the TACK Sie ates deta etr eee sesce scot at ote aaa a a E aa a EER 31 5 10 Connecting the batteries cccccecscceesssecesecesceceennsecncnceeceoecnensaecncesaeeeseensaconcneneenseseennseonaes 33 5 10 41 OMe COR eM NGS essre e EE E EEEE EEE EAEE EEE EE EEEE esac 33 5 10 2 Type of connection cable ss ssssesssnsrrsrrrrrrrrrrrsrnrrrrsrnrrnrnrrrrnrnnrnrnrrnrnrnnrurnnrnrunrnnnnrnrnrnnnnnnnnnnan 33 5 10 3 Clamping batteries using battery ConnectorS s ernrer1n11rnrrnrnnnnrnrnnrnrnnnnrnrnnrnnnnnnnnnrnrnnnnnnn nenne 34 5 10 4 Installing the screwed connectors cccccsccececsesesecnesececececceoecn
25. H HOPPECKE POWER FROM INNOVATION Installation commissioning and operating instructions for vented stationary lead acid batteries Similar to the illustration AquaGen optional Installation commissioning and operating instructions for vented stationary lead acid batteries Type Design Print Koerdt Promo4you GmbH 59929 Brilon 2013 HOPPECKE Batterien GmbH amp Co KG P O Box 1140 D 59914 Brilon All rights reserved even for patent and utility patent applications The distribution and duplication of this document and the use and disclosure of its contents are prohibited unless written permission is granted by HOPPECKE Batterien GmbH amp Co KG Noncompliance will result in a claim for damages af HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 Preface Valued customer Thank you for choosing a HOPPECKE product Please read this documentation carefully and completely before performing any tasks using the lead acid batteries This documentation contains important information regarding safe and correct unpacking storage installation commissioning operation and maintenance of lead acid batteries Non compliance with these safety instructions can lead to severe personal injury and material damage HOPPECKE is not responsible or liable for direct or indirect injury or damage resulting from improper use of t
26. No sources of ignition e g open flame glowing objects electrical switches sparks near to the cell openings Ambient temperature The recommended operating temperature is between 10 C and 30 C The optimal temperature is 20 C 5 K Higher temperatures shorten the service life of the battery All technical data is valid for the nominal temperature of 20 C Lower temperatures decrease battery capacity Exceeding the limit tem perature of 55 C is not permissible Avoid operating at temperatures in excess of 45 C for long periods of time Batteries should not be exposed to direct sunlight or near heat sources Ambient air The air in the battery room must be free of impurities e g suspended matter metal particles or flammable gases The humidity should be at a maximum of 85 If you ground the racks or battery cabinets make sure that you use a connection to a reliable grounding point Battery installation We recommend that batteries are properly installed in HOPPECKE battery racks or cabinets The use of other operator specific solutions may render the warran ty for the batteries null and void Country specific Some countries require batteries and racks to be installed in collection tanks regulations Please observe all local regulations and contact your local HOPPECKE repre sentative if necessary Tab 5 1 Demands on the erection site Installation commissioning and operating instructions for vented stationary lea
27. a long period of time See Chap 4 In order to charge the cells to the optimum level as quickly as possible you must first perform an initial charge The initial charge time restricted is a boost charge 1 Familiarize yourself with the maximum voltage that the charge rectifier can deliver without damaging the peripherals 2 Divide this maximum value by the number of battery cells not batteries connected in series This is the maximum cell voltage for the initial charge 3 Set the voltage so that average cell voltages are at a max of 2 40 V per cell The initial charge can take up to 72 hours It is important for this initial charge to be carried out completely This is only possible with a charge voltage greater than 2 35 V per cell Avoid interruptions if at all possible Log the commis sioning in the commissioning report See Inspection record 4 During commissioning measure the cell voltage of the pilot cells and after commissioning measure the cell voltage and surface temperature of each cell and log this data in the commissioning report along with the time A The electrolyte temperature must not exceed 55 C if necessary the charge operation must be interrupted until the electrolyte temperature drops below 45 C Danger The AquaGen premium top recombination systems are resistant to overload and may remain on the cells during commissioning charge Several types of commissioning are possible 5
28. ad Acid VRLA Batteries for Stationary Applications IEEE Standard 1375 1998 Guide for Protection of Stationary Battery Systems Batteries contain corrosive acids which can lead to chemical burn on skin and eyes if the battery is damaged You must wear safety goggles while handling the battery Wear all the intended personal safety clothing while handling the batteries Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 7 1 When renewing old batteries ensure that all electrical loads are switched off before remo ving the old battery Separators fuses switches This must be carried out by qualified per sonnel 2 Remove all wrist watches rings chains jewelry and other metal objects before working with batteries A Danger 3 Use insulated tools only 4 Wear insulating gloves and protective shoes refer to also to Chap 2 2 5 Never place tools or metal components on top of the batteries gt Danger 6 Make sure that the battery or batteries are not mistakenly grounded If the system is grounded terminate the connection Touching a grounded battery by mistake can result in severe electric shock The risk caused by an incorrect connection can be significantly reduced by terminating the ground connection gt Danger 7 Before establishing connections make sure to
29. als Protect cables with large cross sections using cable ties and cable clamps The connection cables between the main connection terminals and the charging rectifier or UPS should be flexible conductors Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 33 5 10 3 Clamping batteries using battery connectors There are screwed row step and tier connectors see Fig 5 22 Row connectors are used to con nect the individual cells monobloc batteries step connectors are used to connect the individual steps to one another for use with step racks and the tier connectors are used to connect the tiers for use with tier racks In addition there are welded connectors special design for individual cells of types GroE OPzS OSP HC OSP XC max power Fig 5 16 Using row connectors and step connectors Row step tier and end connectors are designed as screwed connectors After loosening a con nection the assembly screws must always be replaced Attention 5 10 4 Installing the screwed connectors 1 The batteries are connected using the insulated row connectors Fig 5 17 When establishing the serial connection the batteries are arranged so that the negative terminal of one battery is connected to the positive terminal of the next battery until the entire system has reached the necessary voltage Make sure th
30. and cell block voltage and discharge time at intervals of 10 of the discharge time At least record these values at 10 50 80 and 95 of the discharge time Terminate the discharge when the battery voltage has reached the value n x U where n is the number of cells and Uf is the selected final discharge voltage per cell Also terminate the discharge when a cell has reached a voltage of U U 200 mV or a monobloc battery with n cells has reached a voltage of U U J n x 200 mV Example 13 cells 12 GroE 300 5 h capacity test End voltage of the battery 23 40 V for 13 cells Average voltage per cell 1 80 V minimum end voltage of individual cells 1 60 V m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 56 Tab 9 3 Measured cell voltages and total voltage after 95 of the discharge time has elapsed Case A a weak cell passed capacity test battery okay Case B a faulty cell failed capacity test battery not okay Case C all cells okay failed capacity test battery not okay The battery must be charged immediately following the capacity test The measured capacity C Ah at the average start temperature is calculated as a product of the discharge current in A and the discharge time in hours As the battery capacity is dependent on the temperature the measured battery capacity needs to
31. at you do not cause mechanical damage to the terminals Attention 2 Attach the connectors as shown in Fig 5 15 First attach the screws by hand only so that you can make final adjustments to the cells and connectors 3 Tighten the screws using a torque wrench The recommended torque is 20 Nm 1 Nm Exception 3 OSP HC 105 with max torque of 15 Nm It is very important to tighten screws thoroughly as a loose con nection can become very hot and result in ignition or explosion Screws are approved for single use only Attention 4 If necessary fit the connectors and end terminals connection plates with insulating covers Fig 5 17 Screwed connector installation a HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 34 5 10 5 Clamping connection plates onto the batteries A We strongly recommend that you use original HOPPECKE connection plates when connecting There are a total of 11 different types of connection plates see Fig 5 16 Connection plates are always used when wires must be connected to cells with multiple battery terminals wires to cells with multiple battery terminal pairs Using other solutions may lead to overhea ting risk of fire and increased electrical contact resistance Attention Installation of standard connection plates 1 Screw the connection brackets onto the
32. ax All details in this brochure are based on state of the art technology Our products are subject to constant development We therefore reserve the right to make changes Printed in Germany 7140203152 EN 02 14 2 K 49 0 2963 61 270 www hoppecke com
33. be adjusted for temperature At temperatures higher than 20 C nominal temperature the battery capacity increases whereas the capacity decreases at lower temperatures If the average start temperature deviates 20 C from the reference tempe rature the capacity must be corrected The start temperature is used to carry out the temperature correction in accordance with the standard DIN EN 60896 11 using the equation 1 E C C I A S 20 00 1 measured capacity correction factor with 0 006 for discharges gt 3 h and 0 01 for discharges lt 3 h start temperature corrected capacity Ogre o II Installation commissioning and operating instructions for vented stationary lead acid batteries ami HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 57 According to the DIN EN 60896 11 standard the battery has passed the capacity test when 95 of the requi red power is attained in the first capacity test After the 5th discharge 100 of the required power must be attained After discharging a log must be made see Inspection record When handling batteries e g performing capacity tests you must observe the safety require ments in accordance with DIN EN 50272 Part 2 insulated tools protective eyewear protective clothing gloves ventilation etc Attention 10 Troubleshooting If malfunctions occur in the battery or charger contact customer service immediately Measured data as describ
34. bi ent air of the battery room to a value of lt 2 by volume Hydrogen is lighter than air Make sure that hydrogen does not accumulate e g in the ceiling area Ventilation and deaerati on openings should be placed near the ceiling See also Chap 5 2 1 1 and Chap 5 2 1 2 The ambience should be clean and dry Water oil and dirt must be kept away from the cell surface Passageway width in Europe Passageway width 1 5 x cell width installation depth at least front of and between the 500 mm see also EN 50272 2 battery racks USA 36 or 915 mm and cabinets HOPPECKE recommendation Danger If possible at the installation location 1 m Otherwise In accordance with local regulations Minimum distances Rack to wall 50 mm Battery to wall 100 mm Conductive parts to ground 1500 mm for Unom Or Usa gt 120 V DC between non insulated and grounded parts e g water lines Battery ent terminals 1500 mm for Unom gt 120 V DC Battery to sources of ignition See calculation of safety distance in Chap 5 1 1 Upper surface of battery to 250 mm It must be possible to measure the voltage and density and to next tier of rack or bottom add water of the next cabinet Lockable and fire retardant T90 Lighting Recommend at least 100 Ix Labeling Warning signs in accordance with EN 50272 2 Warning sign depicting risk of electrical volta 4 ge only necessary if battery voltage exceeds 60 V DC Risk of explosion
35. ceesesascasdedencecebe aeelassenccedeasacacdsdencetacaedcenaece 61 m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 10 1 General information Vented lead acid batteries contain liquid electrolyte Due to the electro chemical potential oxyhydrogen gas is continuously generated Decomposed water needs to be refilled from time to time Using the HOPPECKE AquaGen recombination system optional accessory can drastically extend water refilling intervals Due to the liquid electrolyte vented lead acid batteries can only be operated in upright position The HOPPECKE product range comprises several vented lead acid batteries like single cells nominal voltage 2 V or blocs nominal voltage of 6 V or 12 V for different applications For example GroE OSP HC OSP XC OPzS OPzS solar power OGi bloc OGi bloc HC power bloc OPzS und OPzS bloc solar power 1 1 Safety precautions Read this documentation carefully and completely before performing any tasks using the batteries This documentation contains important information regarding the safe and correct unpacking storage installation commissioning operation and maintenance of filled lead acid batteries Danger To ensure your own Safety as well as the safety of your colleagues and the system it is essential that you have read and understood all instructions in this documentation
36. charging Float charging is used to keep the battery or batteries in a fully charged state and corresponds to a large extent to the charge type as described in Chap 6 2 1 Use a charger that complies with the specifications described in DIN 41773 IU characteristic curve Set the charger to yield the following average cell voltages OSP XC cells and USV bloc monobloc batteries 2 25 V 1 other HOPPECKE vented product series 2 23 V 1 6 2 5 Equalizing charge correction charge Under normal circumstances equalizing charges are not required If there are unacceptably large discrepancies between the cell voltages of the individual cells at float charge see Tab 6 3 an equalizing charge must be performed Float charge GroE OSPHC OPzS power bloc OPZS OGi bloc OGi bloc HC 2 20 2 1 max power OPZS solar power OPZS bloc solar power Gee XC USV bloc 2 Ca _ a Voltage per unit per unit Tolerance float charge voltage for single cells 0 05 V 0 10 V 0 07 V 0 14 V 0 09 V 0 17 V 0 12 V 0 25 V Tab 6 3 Float charge voltage Equalizing charges are necessary after exhaustive discharge after inadequate charging if the cells have been held at different temperatures for long periods of time or if the electrolyte density temperature adjusted differs from the target value by 0 01 kg l in one or more cells the voltage in one or more cells has dropped below the critical threshol
37. check the correct polarity better one too many times than one too few gt Attention 8 Filled lead acid batteries contain highly explosive gas hydrogen air mixture Never smoke handle open flames or create sparks near the batteries Always avoid electrostatic discharge wear cotton clothing and ground yourself if necessary A Danger 9 Use only suitable hoisting devices with sufficient carrying capacity If lifting the battery use the hoisting belt specified by HOPPECKE Hook the belt sling onto to the battery so that the battery cannot fall out of the belt if necessary get help from another person Wear the appropriate safety clothing and safety equipment o 10 Never carry batteries by the battery terminals gt Danger 11 These batteries contain lead and cannot under any circumstances be disposed of with household waste or at a waste dump at the end of their service life for more information Attention refer to Chap 1 4 A m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 8 Table of contents Preface eae Re E eR ROT ee E Te WE NTE eee aOR Ie 3 Used Symbols ks ere e e E E e a e e E e E E SS 4 O Safety notices 2 0 0 0 cece cece nce c cece ceca ceca ca ceca ca ceca case cacacacasesaeasaceeaseeeeeeaeaeceeeeeseseeeseeeeeseseseseeeeees 5 0 1 Gonerakintonmnatioks essre e E EE
38. d as defined in Tab 6 2 during operation As the max permitted load voltage might be exceeded it must be clarified in advance whether the loads can be disconnected for the duration of the equalizing charge Attention Perform the equalizing charge as follows 1 Charging with IU characteristic up to max voltage U 2 4 V cell up to 72 hours 2 Should the max temperature exceed 55 C interrupt the charging process or continue with reduced current You can also temporarily switch to float charging to allow the temperature to drop 3 The end of the equalizing charge is reached when the cell voltage do not rise for a period of 2 hours Required process for charging the batteries by achievement of max storage duration Refer to Chap 4 m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 42 7 Settings for charging HOPPECKE OPzS solar power batteries This chapter contains instructions for charging of HOPPECKE OPzV solar power battery cells and battery blocks in solar applications 7 1 General charging characteristic The chart below refer to figure 7 1 demonstrates the OPZS solar power recharge characteristic IU characteristic after discharge with 50 DoD Depth of Discharge Parameters example e Charging voltage 2 4 V cell Charging current 10 A 100 Ah battery capacity C Charging
39. d acid batteries ami HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 21 5 1 1 Calculation of safety distance In close proximity of the batteries the dilution of explosive gases is not always given Therefore a safety distance has to be realized by a clearance in which there must not be any sparking or glowing equipments max surface temperature 300 C The diffusion of the oxyhydrogen depends on the gas release and the ventilation close to the battery For the following calculation of the safety distance d it can be assumed that the oxyhydrogen expands spherical Figure 5 1 depicts a graphic approximation of the safety distance d depending on the battery capacity Subsequently a detailed calculation is shown Safety clearance Required safety clearance needs to be calculated according to formula stated in EN 50272 2 Volumes of a hemisphere 2 3 Vi xntxd en Air volume flow required to reduce the concentration of generated hydrogen H in the air to 4 max Qas 0 05 n x1 xCx 10 9 5 y apal Qos z i Required radius of me hemisphere d 28 8 x 3 n x afi a i mm 10000 pusr TH 1000 oe tte m AI F eo H map A RRES eee mili Ml Safety distance d mm 10 1 100 10000 Battery capacity C Ah VRLA battery float change mode VLA battery float charge mode e VELA battery boost charge mode VLA battery boost charge mode Fig 5 1 Safety distance based on batter
40. d batteries Part 11 Vented types General requirements and methods of tests In addition note special test instructions e g in accordance with DIN VDE 0100 710 and DIN VDE 0100 718 The following is the short form of the procedure for testing the actual capacity of your battery system Also observe all instructions in Chap 9 2 We recommend performing an equalizing charge on the battery system as described in Chap 6 2 5 before performing this test Perform the equalizing charge no more than 7 days in advance and no less than 3 days in advance 1 Make sure that all connections are clean secure and noncorroded 2 During normal battery operation measure and record the following parameters Electrolyte density Voltage of each cell or monobloc battery Temperature of at least one out of every ten cells monobloc batteries Voltage of the complete battery system 3 Interrupt the connection between the battery system that you wish to test and the charger and all consumers Prepare an adjustable load that you can connect to the battery system The load current must correspond to the maximum permitted current for which the battery is designed Prepare a shunt that you can connect in series with the load Prepare the voltmeter so that you can test the total voltage of the battery Connect the load the shunt and the voltmeter Simultaneously start a time measurement Keep the load current constan
41. d commissioning charge Extended storage or climatic influences humidity temperature fluctuations reduce the charge state of the cells This makes an extended commissioning charge necessary Conduct the extended commissioning charge according to the following procedure 1 Charge at 15 A per 100 Ah C until 2 4 V cell is achieved approx 3 5 hours 2 Charge at 5 A per 100 Ah C for 14 hours cell voltage will exceed 2 4 V cell 3 Interrupt for an hour 4 Charge with 5 A per 100 Ah C for 4 hours Repeat items 3 and 4 until all cells have reached a minimum of 2 6 V the electrolyte density in all cells has risen to the nominal value of 0 01 kg l and these values cease to rise for a further 2 hours Subsequently switch to the float charge voltage as set out in Chap 6 2 4 5 13 Electrolyte level check If the electrolyte has been set below the upper level before commissioning top up with sulfuric acid to bring electrolyte level to the upper electrolyte level mark 5 14 Electrolyte density adjustment After commissioning is complete if the electrolyte density is too high replace a portion of the electrolytes with demineralized water according to DIN 43530 Part 4 or IEC 60993 1 The electrolyte density in the individual cells must not differ more than 0 01 kg l between cells In case of large deviations conduct an electrolyte density adjustment and subsequent equalizing charge according to the operating instructions
42. der the warranty Attention 4 2 Storage time If the cells batteries are to be stored for a long period of time store them fully charged in a dry frost free location Avoid direct sunlight To prevent damage to the batteries an equalizing charge must be performed after a maximum storage period of three months see Chap 6 2 5 Calculate this exact time starting on the day of delivery By the end of the max storage time charge acceptance might be declined during battery recharge Hence HOPPECKE recommends a suitable process of charging which assures a gentle full charge of the battery refer to chap 6 2 5 If storage temperatures exceed 20 C more frequently equalizing charges may be neces sary at temperatures around 40 C monthly charges Refer also to figure 4 1 to retrieve max storage times for different storage temperatures Failure to observe these conditions may result in sulfating of the electrode plates and significantly reduced capacity and service life of the bat tery Battery recharge during storage time should be carried out max twice The battery should be operated in continuous float charge mode thereafter Battery service life commences with delivery of the battery or batteries from the HOPPECKE plant Storage times have to be added completely to the service life Unfilled blocks cells have to be stored in a dry frost free location Avoid direct sunlight Storage time should not exceed 24 months Attention R
43. e wall make sure to maintain a distance of at least 2 m between the openings Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 59 Cell voltage U V block voltage U V Order number Department W D gt pee Oo 5 1O o pa ee e o Q0 fmd 2 gt Battery Number of the battery Checked by Equipment of testing Discharge time Min Discharge current A Discharge capacity P Temperature T C Q 4 hn a 2 J S a 2 HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 01 2013 60 ZVEIl ZVEI information leaflet No 1e Edition September 2012 Batterien Instructions for the safe handling of lead acid accumulators lead acid batteries The REACH regulation 1907 2006 EC has replaced the directive on safety data sheets 91 155 EC REACH describes the setting up and updating of safety data sheets for substances and preparations For articles like lead acid batteries safety data sheets are not required This leaflet addresses manufacturers of batteries and is meant to apply voluntarily The notes are meant to help to comply with legal require ments but do not replace them 1 Substances for
44. ectrolyte density of all cells or monobloc batteries 4 Electrolyte temperature of all cells or monobloc batteries 5 Electrolyte level of all cells or monobloc batteries 6 Ambient temperature 7 Perform a visual check of all screwed connectors 8 Check all screwed connectors to make sure that they are firmly secured 9 Visual check of battery racks or battery cabinets 10 Check to make sure that the battery room is properly ventilated and deaerated Should the float charge voltage of any cell vary by more than 0 1 V or 0 05 V from the average value refer Chap 6 2 5 perform an equalizing charge as a control measure or contact customer service HOPPECKE recommends the use of a stationary battery monitoring system for the inspection of relevant data Please contact your local HOPPECKE representative for further information 8 3 Cleaning of batteries accident prevention regulations Batteries should be cleaned at least once per year Note the following points Danger While cleaning the batteries you must wear safety goggles and saftey clothes To avoid electro static charges while handling the batteries your clothes safety shoes and saftey gloves must have a surface resistance of lt 10480hm A Do not use dry cleaning cloth Danger A Cell plugs or AquaGen recombination system must not be taken of or opened for cleaning Attention h Cleaning the batteries on a regular basis is necessary to ma
45. ed in Chap 8 1 simplifies fault detection and elimination A service contract with us facilitates the timely detection of faults 11 Required ventilation for hydrogen generated by batteries Compliance with VDE 0510 Part 2 or DIN EN 50272 Part 2 is required to ensure safe ventilation and prevent dangerous mixtures of hydrogen and oxygen gases hydrogen approx 4 Two values form the basis of the equation the maximum permissible hydrogen concentration in the air is 4 and the safety factor is 5 The equation can be derived accordingly 100 4 er ve Attenuation factor at maximum permissible hydrogen concentration wo A q 0 47 x Di Quantiy of accumulated hydrogen per actual Ah capacity 5 safety factor m vxgxs 0 05 q Ah This results in the total equation for the necessary ventilation in m h Q 0 05 xn x la x C x 10 h E leat x f x f resp lag loosi x t x f Q Necessary ventilation air flow rate m h n Number of cells l Proportion of charge current in mA Ah used for water dissociation on boost charge per 1 Ah nominal capacity of the battery 1 mA Ah loo Proportion of charge current in mA Ah used for water dissociation on boost charge per 1 Ah nominal capacity of the battery 4 mA Ah C Nominal capacity of the battery C capacity N l Gas emissions factor Proportion of the charge current responsible for hydrogen accumulation 1 f Safety factor which includes the p
46. ed to be observed Listed symbols are used multiple times for safety relevant information Danger Attention Personal health batteries or the environment are at risk Failure to observe this hazard notice can lead to severe or fatal injury Batteries materials or the environment are at risk Personal safety is not at risk Failure to observe this notice can lead to malfunction or damage to the batteries In addition material and environmental damage may occur Risk of explosion or blast splashing of hot or molten substances Explosion and fire hazard avoid short circuits Avoid electrostatic charge and discharge sparks Failure to observe this hazard notice can lead to severe or fatal injury Risk of corrosion caused by leaking electrolyte Electrolyte is strongly corrosive Electrical voltages hazardous to health may cause fatal injury Metal parts of the battery are always alive therefore do not place items or tools on the battery Failure to observe this hazard notice can lead to severe or fatal injury Warning Risks caused by batteries Do not smoke Do not use any naked flame or other sources of ignition Risk of explosion and fire General prohibition Observe these instructions and keep them located near the battery for future reference Work on batteries only after instruction by qualified personnel Wear protective goggles and clothing while working on batteries Observe the accident preventi
47. ee EA E EEE E E E e S 38 6 2 Charging general sc sccccscenccctnescescedacteccesescassedataccnlsaccabselasxetscztecis sadecndeccteacetde daszacsestecasseieinsesses 38 6 2 1 Standby parallel operation ccicccasiccrerntacinecdsacdiinentaieeseaoeevadseeernduendtewendsdcashtandeeradackeaskandieventnucase 40 6 2 2 Floating operation ch cctevescceustscantscuesmeceiasenssstehsacatcadeousilenicnadcsenceiasnetcanesssacsedussedasdcenetecemsatcaberes 41 6 2 3 Switch mode operation charge discharge Operation c cccecccececececesececesesecesecesesesenenecesenes 41 6 2 4 Float charging wocncscs cecssesnazescesebaascennseccneseccesedcounccce savcesadeaencecescedadsedacneccesepaesedsstedcarsadeisisiwescseoes 42 6 2 5 Equalizing charge correction CHAVIS caciccscuc Sceeedetce docu reeenewereraredeee ie aiaa a aini EEEE aaa 42 7 Settings for charging HOPPECKE OPzS solar power batteries ccccceceeceeeeeeeeeeeeeeeeeeeeeeeneneeaees 43 7 1 General charging Characteristic cccccsescsecnesececececescecncneeecnsnsaeenseseeessecnaneassesecnnseonaneneeeas 43 2 General hints for battery charging in solar or Off Srid applications ccceeeeeeceeeeeeeeeeeeeeeeaeeeeeeaees 43 13 Standard charge procedures c2c cecszecesdecentsdsesecense cneodctecesieasdetancheveimteedeecansesdonssennecaniicbsieicesdsbe 44 1 4 eo Ore r a rekon 4 ro 2 Seines ee ee ee eee ee ee ee eee eee eee 44 1 5 Charging procedure for Cyclic applicationS s
48. end terminals of the battery see Fig 5 18 a z a m j i y j h j a j Make sure that you do not cause mechanical damage to the terminals Attention l 2 First attach the screws by hand only so that you can make final adjustments T to the cells connection brackets and connection plates 3 Fix the connection plate to the connection bracket of the battery with a torque of 20Nm 4 Afterwards tighten the pole screws using a torque wrench The recommen Fig 5 18 ded torque is 20 Nm 1 Nm Exception 3 OSP HC 105 with max torque Installing the end terminals of 15 Nm connection plates It is very important to tighten screws thoroughly as a loose con nection can become very hot and result in ignition or explosion Attention 5 11 Connect the battery system to the DC power supply Make sure that all installation work has been performed properly before connecting the battery system to the charging rectifier or UPS Attention 1 Measure the total voltage target value sum of open circuit voltages of the individual cells or monobloc batteries 2 If necessary label the cells or monobloc batteries visibly with continuous numbers from the positive terminal to the negative terminal of the battery HOPPECKE includes number stickers in your shipment Attach polarity labels for the battery connections Complete the identification plate in this documentation see Chap 1 2 bk
49. ensaececesaecesesnsseoecneneenseseennseonaes 34 5 10 5 Clamping connection plates onto the batteries ccccccecececececececesecececesesececesesecesenenenesenenes 35 Installation commissioning and operating instructions for vented stationary lead acid batteries Sewers 8 Bee 7140203152 V1 1 02 2014 POWER FROM INNOVATION 9 5 11 Connect the battery system to the DC power SUDDI ccccececececececececesecececeseneceseseneeesenes 35 5 12 Commissioning charge initial Charge c cscsesccesececececesseceeeesecesecesceoeensseaecnsneesseseentenenens 36 5 12 1 Commissioning charge with constant voltage IU characteristic curve cccececececececeeeeeeeeeees 36 5 12 2 Commissioning charge with constant current I characteristic curve or decreasing current W characteristic CUVE asic wah cies encase views aa xc dled a ae be eA EEE EE aia ai ence aiaa stat 37 5 12 3 Extended commissioning charge sevesssceicccesttcssevacendadecieedontacasdetecttalenetcndessecssedsnezeeniccsaticcwiaecestsds aT oe BS A Electrolyte level Chet cae en eee ee ee een ae ene er ee ee ee eer eer eee er ere of 5 14 Electrolyte density adjustment soc cece cece ss celeced ext ccca cs ccccten sececececeescbdesedcce st ccc iecscace ce eececseddcedcctask of 6 Battery operation 0c c cece cece cece ceca ca ceca ca ceca ca ceca cacacasecacacaeceeaseeeeeeesecesececeeeeeseseeeeeeeseees 38 6 1 DISCMANS ere eaaa e AE E EE n
50. equired process for charging the batteries by achievement of max storage duration Charge with constant power of 1 A or 2 A per 100 Ah C battery capacity Interrupt charging when all cell voltages have rised to min 2 6 V cell refer also to Chap 6 2 Attention 4 3 Preparing for a several month storage period If the storage time extends over a period of several months make sure to provide an appropriate charger so that the charging tasks can be performed promptly as previously described For temporary storage arrange the blocks cells so that they can be temporarily connected in series for charging The batteries should remain on their pallets until final installation To avoid having to perform the previously described work we strongly recommend that you con nect the battery or batteries to the regular charging voltage supply within three months Failure to observe the recharging intervals will render the warranty null and void Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 19 A Observe ventilation requirements refer to chap 5 2 1 1 even for charging of temporarily connec ted cells Attention available capacity C 012 3 4 5 amp Ff 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 storage time t months Fig 4 1 Available Capacity vs storage time 5 Installation 5 1 Demands on
51. ery systems with a nominal voltage of over 1 500 V DC you must provide equipment for splitting the batteries into cell groups with voltages lower than 1 500 V DC In order to prevent serious injury as a result of electric shock or burns be very cautious when performing any work on the battery system Always wear the recommended protective clothing insulated rubber gloves and rubber shoes etc and always use insulated tools or tools made of non conductive material Remove all wrist watches rings chains jewelry and other metal objects before working with batteries Danger Before conducting work on the battery system Determine whether the battery system is grounded We do not recommend this If the system is grounded terminate the connection Touching a grounded battery by mistake can result in severe electric shock This risk can be significantly redu ced by removing the ground connection However the racks or cabinets used to hold the batteries do need to be well grounded or completely insulated If a battery system is grounded There is a voltage between the ground and the ungrounded terminal If a grounded person touches this terminal there is risk of fatal injury There is also a risk of short circuit if dirt or acid on the ungrounded terminal come in contact with the battery rack me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 71
52. factor 120 The development of the state of charge SoC parameter is represented by the blue line charging current by red line and charging voltage by the green line Although 100 SoC are reached after approx 5 hours a total recharge time of ca 12 5 hours is needed in order to reach the charging factor here 120 Charging shall generally be performed according to IU or IUI characteristic u annie ae ee ae 24 o D xX l i I i S A TO et m sie mmm dencceneiemnnmm 5 O l l I I 2 ao i gt l I I Z Dq eo qr T 3 2 q 22 pe l i i OD Ser I 1 i i S oO L 50 L mla e m e e e Jo O O e 5 I i i gt o I I V 2 40 i i i t 2 0 o Z T l i i 5 Jesaja 5 30 it a ie et oe re une Pn ee ee praia Tes pee anes l 1 I I 20 L 4 4 4 4 4 1 8 1 l l 10 1 1 T I I l l l l Q 1 6 0 0 2 0 40 6 0 8 0 10 0 12 0 14 0 Time h Fig 7 1 Charging characteristic of OPzS solar power cell at 50 DoD 7 2 General hints for battery charging in solar or off grid applications Charging procedure shall be compliant to IU or IUl characteristic refer to example fig 7 1 Recommended charging voltages for cyclical applications are depicted in fig 7 2 1 Available battery capacity depends on discharge current for lead acid batteries This effect is caused by different material utilization 2 Every battery dischar
53. following could act as sources of ignition for gas explosions open flames flying sparks electrical sparking equipment mechanical sparking equipment electrostatic charge Observe the following measures to prevent gas explosions sufficient natural or technical ventilation no heating using open flames or glowing objects T gt 300 C separate battery compartments with individual ventilation anti static clothing shoes and gloves according to applicable DIN and EN regulations surface conductivity resistance lt 10 and insulating resistance 10 Q hand held lights with power cable without switch protection class II hand held lights with battery protection category IP54 warning and regulatory signs The ventilation requirements for battery rooms cabinets or compartments are based on the required reduction of the concentration of hydrogen generated during charging and safety factors which include battery aging and the potential for fault worst case Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 23 5 2 1 2 Ventilation calculation for ventilation requirements of battery rooms Air volume flow Q C Q vxaxexnx igas TDDAR v dilution factor 96 air 4 H 24 q quantity of hydrogen generated 0 42 10 m Ah s safety factor 5
54. for any defects in case commissioning should be carried out promptly The batteries can be delivered filled or unfilled If you have received filled batteries check the electrolyte level in the cells The electrolyte level should be adjusted only after commissioning the cells float charge If you have received unfilled batteries wait to fill the batteries until they have reached their final destination m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 18 Check the entire scope of delivery to make sure that it matches the detailed delivery note or the packing list Failure to promptly inform the carrier of defects or incompleteness could result in the loss of your claims If you have questions regarding incomplete shipments or damage to the delivered products please contact your local HOPPEKKE representative You can also contact us at our head office directly 4 Storage 4 1 General After receiving the batteries you should unpack install and charge them as soon as possible If this is not possible store the batteries fully charged in a dry clean cool and frost free location Excessively high storage temperatures may result in accelerated self discharge and premature aging Do not expose the batteries to direct sunlight Do not stack the pallets with the batteries as this can cause damage which is not covered un
55. g and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 55 9 3 Capacity test of the battery Necessary accessories Suitable electronic load or electrical resistance with adjustable resistance value to adjust the discharge Current or discharge load Suitable current probe with sufficient precision for measuring the DC current or shunt for measuring the discharge current Voltage measuring device for measuring the electrical voltage Thermometer for measuring the battery temperature Clock for measuring the discharge time Project planning data table for selecting the correct discharge current or the correct discharge power Acid density measuring device for vented batteries with a measuring range of 1 10kg I 1 29 kg l Carry out the battery discharge in accordance with the regulations on performing capacity tests EN 60896 11 The discharge current and the discharge power are selected according to the project planning data tables up to a given final discharge voltage and the given potential of the existing loads Minimum precision requirements for the measuring devices precision class For temperature measurement Acid density for vented batteries only 0 005 g l Tab 9 2 Precision requirements for the measuring devices During the capacity test record the discharge current or discharge power temperature battery
56. ge phase followed by a battery charge phase is referred to as a battery cycle Installation commissioning and operating instructions for vented stationary lead acid batteries HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 43 7 3 Standard charge procedures U characteristic Used for regular recharge after every battery discharge The charging procedure shall comply to U characteristic with 2 4 V cell refer to curve A in fig 7 2 Note Up to 2 4 V C the charging current is theoretically not limited However the recommended charging current is 5 A to 20 A 100 Ah nominal battery capacity C Ul_ characteristic Charge with U characteristic as described above Keep the charging current at 5 A 100 Ah nominal battery capacity C as soon as the current has dropped to this value during constant U phase During la phase the charging voltage ranges between 2 6 to 2 75 V C refer to curve B in fig 7 2 la phase should last either 2 or 4 hours refer also to chapter 7 5 Charging procedure for cyclic applications If the battery is fully charged the charging voltage needs to be adjusted to normal float charge voltage for standby batteries as given in the HOPPECKE operating instructions 2 23 V cell at temperature between 10 C and 30 C refer to fig 7 1 7 4 Equalizing charge Equalizing charges are required after deep discharges with depth of discharge DoD of gt 80 and or ina dequate charges They ha
57. hange to LWA HE ai h I Chega to MTA SDC ake No Charge to LOUPE WE ser Me T Charge bo LOS SOC ace Mn 1 Fig 7 4 Phases with more than one battery cycle per day Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 45 20 21 az Cyc arfa D il 12 14 16907 He mja na 24S hpn s mja a ss s ae ae ao 1 27 3 4 5 F F BY So 15 11 Ley as bays Charge te 308 S00 acc Ho 1 Change to Ss SE aes Ho L Charges bo 100 MHE aor Ain F Charge ts 100M DOC aor Me I Charge to IIE SOC anc Ma T Fig 7 5 Battery cycles ranging longer than one day 7 6 Charging currents Recommended DC charging current range for boost and equalization mode is 5 to 20 A 100 Ah nominal capacity C 7 7 Alternating currents Depending on the charging equipment its specification and its characteristics Superimposed alternating currents may contribute to battery charging current Alternating currents and the corresponding reaction by the connected electrical loads may lead to an additional battery temperature increase and consequently to a shortened battery service life as a result of stressed electrodes micro cycling The alternating current must not exceed 5 A RMS 100 Ah nominal capacity In order to achieve the optimum service life for vented lead acid batteries on float charge a maximu
58. harging procedures may be used with their limit values as specified in DIN 41773 IU charac teristic curve DIN 41774 W characteristic curve and DIN 41776 I characteristic curve Superimposed alternating currents Depending on the charger type and charging characteristic curve alternating currents flow through the battery during charging and are superimposed onto the charging direct current These superim posed alternating currents and the reaction of the loads lead to additional heating of the battery or batteries and create a cyclical strain on the electrodes This might result in premature aging of the battery For a charge voltage over 2 4 V cell do not exceed 10 A per 100 Ah nominal capacity In a fully charged state float charge with a charge voltage of 2 23 to 2 25 V cell the effective value of the alternating current must not exceed 5 A per 100 Ah nominal capacity In order to achieve the optimum service life for vented batteries on float charge a maximum effective value of the alternating current of 2 A per 100 Ah nominal capacity is recommended Temperature related adjustment of the charge voltage Operating temperature between 10 C and 30 C No adjustment necessary Operating temperature lt 10 C or gt 30 C Adjustment necessary Correction factor O 004 V cell per K Operating temperature constantly gt 40 C Adjustment necessary Correction factor O 003 V cell per K HOPPECKE Installation commissioning a
59. he attached ZVEI publication Instructions for the safe handling of lead acid accumulators lead acid batteries Danger The battery room must be equipped with the following Emergency kit to absorb leaked electrolyte The following materials listed for use in an emergency situation Danger If sulfuric acid comes in contact with the skin Remove contaminated clothing immediately Dab off acid using a cotton or paper towel do not rub Rinse affected area of skin carefully using plenty of water After rinsing wash the area using soap Avoid making contact with the affected areas of the skin If necessary contact a doctor me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 14 If sulfuric acid comes in contact with your eyes Carefully wash the affected eye with large quantities of water for 15 minutes using running water or eye rinsing bottle Avoid using high water pressure Always contact an eye doctor immediately If electrolyte is ingested Immediately drink plenty of water Consult doctor or contact a hospital immediately Before the doctor arrives if available swallow activated carbon If sulfuric acid comes in contact with clothing or other material immediately Remove contaminated clothing Wash clothing in sodiu
60. he individual strings between the cells should be avoided because strings could be very long Cross connec tions mask bad cells and blocks and could cause individual battery strings to overload 2 Only batteries of the same type and same state of charge should be connected same battery type plate size and plate design 3 The environmental conditions should be the same for each string connected in parallel In particular avoid temperature discrepancies between the individual strings batteries 4 In order to ensure consistent current distribution make sure that the connectors and end connections are set up so that the individual supply lines connected to the consumer have the same electrical resistance ratio 5 The commissioning date of the batteries should be the same batteries of the same age identical storage time and same state of charge If the installation does not comply with all of the above mentioned guidelines you have to charge each string separately and connect them in parallel afterwards In general connect the batteries using the shortest possible cables Normally cells are connected in series with alternating polarity resulting in the shortest possible connector length 5 9 Putting the cells blocks into the racks 1 Apply some soft soap to the profiles of the rack so that the batteries can be adjusted sideways more easily once they have been placed onto the rack Fig 5 12 Lubricated support profiles 2 Positi
61. his product all warranty claims become null and void HOPPECKE reserves the right to make changes to the contents of this documentation HOPPECKE Batterien GmbH amp Co KG is not responsible for errors in this documentation HOPPECKE is not liable for direct damage related to the use of this documentation Our products are undergoing constant development For this reason there may be discrepancies between the product that you have purchased and the product as represented in this documentation Please keep this documentation so that it is immediately available for all personnel who must perform work in connection with the batteries If you have questions we would be happy to help you You can reach us via e mail info hoppecke com or by phone on working days between the hours of 8 am and 4 pm CET at the following number Phone 49 0 2963 61 0 Fax 49 0 2963 61 481 Your team from HOPPECKE Batterien GmbH amp Co KG Postal address HOPPECKE Batterien GmbH amp Co KG P O Box 1140 D 59914 Brilon Germany Head office address HOPPECKE Batterien GmbH amp Co KG Bontkirchener Stra e 1 D 59929 Brilon Hoppecke Phone 49 0 2963 61 0 Fax 49 0 2963 61 449 Internet www hoppecke com Email info hoppecke com Installation commissioning and operating instructions for vented stationary lead acid batteries E HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 3 Used Symbols The following safety notes ne
62. ing By no means may the electrolyte the diluted sulphuric acid be emptied in an inexpert manner This process is to be carried out by the processing companies 14 Transport instructions 14 1 Batteries wet filled with acid Land transportation according to ADR RID e Special Provision 598 no transport as dangerous goods new spent batteries are not subject to other requirements of ADR RID if they meet the requirements according to Special Provision 598 If the requirements of Special Provision 598 are not fulfilled the transport of new and spent batteries has to be declared as dangerous goods as follows Hazard class 8 e UN no 2794 Naming and description BATTERIES WET FILLED WITH ACID e Packing group none e Hazard label 8 e ADR Tunnel restriction code E Sea transportation according to IMDG Code e Hazard class 8 e UN no 2794 e Proper shipping name BATTERIES WET FILLED WITH ACID e Packaging group none e EmS F A S B e Packaging Instruction P 801 Hazard label 8 Air transportation according to IATA DGR e Class 8 e UN no 2794 e Proper shipping name BATTERIES WET FILLED WITH ACID e Hazard class 8 e Packaging Instruction 870 14 2 Batteries wet non spillable Land transportation according to ADR RID e Un no 2800 Hazard class 8 Proper shipping name BATTERIES WET NON SPILLABLE Packing group none Packaging Instruction P 003 e Haza
63. installation location must fulfill the conditions described in Chap 5 1 Comply with the minimum distances listed in Tab 5 1 Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 27 1 If the installation drawing is available mark the outlines of the racks on the installation surface using chalk 2 The installation surface must be level and rigid If backing elements are used make sure that the thickness does not exceed 6 mm 3 Carefully set up the racks and arrange them horizontally 4 The distances of the support profiles must correspond to the dimensions of the cell or monobloc battery 5 Check rack stability and ensure that all screwed and clamp connectors are firmly secured 6 If necessary ground the racks or rack parts A If using wooden racks you must fit a flexible connector between each rack joint Attention 5 6 Cabinet installation Alternatively you may choose to install the batteries in HOPPECKE cabinets The cabinets can be delivered with batteries already installed or battery installation can take place on site HOPPECKE provides different types of cabinets A The installation location must fulfill the conditions described in Chap 5 1 Comply with the minimum distances listed in Tab 5 1 Danger Fig 5 3 Battery cabinet mi HOPPECKE Installation commissioning and operating in
64. intain battery availability and to meet a HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 52 The AquaGen recombination system has to be cleaned like the batterie cell block by using a moist cotton or paper towel Note While charging especially boost charge the AquaGen recombinationsystem will heat up Therefore do not clean the AquaGen recombination systems during boost charge Danger Plastic parts of the batteries especially the cell container have to be cleaned with water or water moistened cleaning cloth without additives After cleaning the battery surface has to be dried with appropriate measures like moist antista tic cleaning cloth e g cotton Note In OSP HC and OSP XC battery cells deposits streak formations might buildup on the inner surface of the cell jar This occurs mainly in the area of the electrolyte level surface These deposits are caused by additves in the separators which are used as antioxidant to protect the plastic material of the separator Light washouts of this additives over battery service life cannot be avoided This fact has neither negative impact on the electric performance of the battery nor on battery service life 9 Testing the battery system 9 1 Performing the capacity test short form Perform tests in accordance with EN 60896 11 Stationary leadaci
65. irect current source and battery are connected in parallel The charge voltage is the operating voltage of the battery and the system voltage at the same time The direct current source charging rectifier is capable of supplying the maximum load current and the battery charge current at any time The battery only supplies current when the direct current source fails The charge voltage should be set at see Tab 6 2 x number of cells in series measured at the battery s terminals To reduce the recharging time a charging stage can be applied in which the charge voltage is 2 33 V to 2 4 V x number of cells Standby parallel operation with recharging stage Automatic changeover to the charge voltage of see Tab 6 2 x number of cells in series occurs after charging i HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 40 Battery type Float charge voltage OPzS 2 23 1 V cell power bloc OPzS 2 23 1 V cell OPzS solar power 2 23 1 V cell OPzS bloc solar power 2 23 1 V cell max power 2 23 1 V cell GroE 2 23 1 V cell OGi bloc 2 23 1 V cell OGi bloc HC 2 23 1 V cell OSP XC 2 25 1 V Cell OSP HC 2 23 1 V cell USV bloc 2 25 1 V cell Tab 6 2 Float charge voltage adjustment in standby parallel operaion 6 2 2 Float operation The following is characteristic for
66. ist material Identification requirement C corrosive Causes severe burns Keep locked up and out of reach of children In case of contact with eyes rinse immediately with plenty of water and seek medical advice Never add water to this product In case of accident or if you feel unwell seek medical advice immediately show the label where possible applies for concentrated acid only and not for refilling the battery with water To be observed in case of storage German Water Resources Act Notes Installation commissioning and operating instructions for vented stationary lead acid batteries er HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 69 Notes i HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 70 Notes Installation commissioning and operating instructions for vented stationary lead acid batteries Fr HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 71 POWER FROM INNOVATION erating instr seis for vented stationary lead acid batteries gt SS eee HOPPECKE Batterien GmbH amp Co KG HOPPECKE P O Box 1140 D 59914 Brilon Germany POWER FROM INNOVATION Bontkirchener Stra e 1 D 59929 Brilon Hoppecke Phone 49 0 2963 61 0 Email info hoppecke com F
67. lugs which came fitted on top of the batteries are HOPPECKE Labyrinth plugs These plugs have to remain on the batteries after refilling and during operation of the battery To increase safety and reduce maintenance costs we recommend the use of HOPPECKE AquaGen premium top recombination systems High temperatures decrease the electrolyte density while lower temperatures increase it The correction factor is 0 0007 kg l per K Example An electrolyte density of 1 23 kg l at 35 C corresponds to a density of 1 24 kg l at 20 C 5 2 3 Idle Time After filling allow every cell an idle time of 2 hours Immediately after the idle time depending on the total number of cells measure the electrolyte temperature and density in 4 to 8 of the cells pilot cells and note this in the commissioning report If the temperature rise is lower than 5 K and the electrolyte density has not decreased to more than 0 02 kg l less than the density of the filling acid then a simplified commissioning charge as described in Chap 5 12 1 and Chap 5 12 2 is sufficient If the discrepancy is larger then an extended commissioning charge as described in Chap 5 12 3 is required Commissioning charge has to be performed immediately after idle time of the final filled cell Attention GroE max power OGi OGi bloc OGi bloc HC OPZS OPZS bloc OPZS solar power OPZS bloc solar power OSP HC OSP XC USV bloc Tab 5 3 Electrolye density in kg l at 20 C
68. m bicarbonate solution bicarbonate of soda or baking soda When bubbles stop forming rinse using clean water 2 3 2 Explosive gases Danger Danger Danger Lead acid batteries can release an explosive mixture of hydrogen and oxygen gases Severe per sonal injury could occur in the event of an explosion of this mixture Always wear the recommended protective clothing protective goggles insulated gloves and protective shoes etc Use the correct tools only znon sparking with insulated grips etc Eliminate all potential sources of ignition such as sparks flames arcs Prevent electrostatic discharge Wear cotton clothing and ground yourself when you are working with the batteries directly In case of fire extinguish using water or CO extinguisher only Do not point the fire extinguisher directly at the battery or batteries to be extinguished There is a risk that the battery casing may break as a result of thermal tension In addition there is a risk of static charging on the surface of the battery This could result in an explosion Switch off the charging voltage of the battery If extinguishing a fire use a breathing apparatus with a self contained air supply If using water to extinguish a fire there is a risk that the water foam could react with the electrolyte and result in violent spatter For this reason wear acid resistant protective clothing Burning plastic material may p
69. m effective value of the alternating current of 2 A per 100 Ah battery capacity C is recommended 7 8 Water consumption Every lead acid battery decomposes certain amounts of water into hydrogen and oxygen gas This effect rises with increasing amount of charge discharge cycles charging voltage and battery temperature as well 4 Je gr er der Ladestrom Im Bereich von 5 A bis 20 A 100 Ah umso k rzer ist die ben tigte Ladezeit mi HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 46 7 9 Temperature influence on battery performance and lifetime 7 9 1 Temperature influence on battery capacity Battery capacity depends significantly on ambient temperature Lead acid batteries loose capacity with decre asing temperature and vice versa as shown in fig 7 6 This should be considered when sizing the battery Temperature range for OPZS solar power batterie Possible temperature range 20 C to 45 C Recommend temperature range 10 C to 30 C 110 Battery Capacity in S86 amp BS BS s a 2 a5 10 5 0 5 10 15 20 25 30 35 40 Temperature in C Fig 7 6 OPZS solar power Dependency of battery capacity on temperature 7 9 2 Temperature influence on battery lifetime As corrosion processes in lead acid batteries are significantly depending on battery temperature the battery design lifetime is directl
70. mended for neu tralizing electrolyte in an approved system Observe the safety measures even when neutralizing small amounts of electrolyte Danger Mix the required quantities of the chemicals See Tab 2 1 with the electrolyte in small portions Take special care when adding sodium carbonate as this results in intense foaming Danger Neutralization is complete when a pH value between 6 and 8 has been reached If there is no suitable mea suring device available the degree of neutralization can be checked using common pH paper Neutralization is complete when the pH paper turns olive green to yellow in color If the pH paper is blue this indicates that the neutralization point has been exceeded Acid must be added to neutralize the mixture again Gel electrolyte from damaged or used batteries can be disposed of in the same way The following quantities of any these chemicals can be used to neutralize 1 liter of electrolyte with the listed nominal density Calcium Sodium Sodium hydroxide I carbonate kg carbonate kg NaOh NaOH CaO Na CO 20 concentration 45 concentration Tab 2 1 Chemicals for neutralizing 1 liter of electrolyte Nominal density Observe all regulations documentation and standards as described in Chap 0 2 Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 13 2 2 Pe
71. mulation and company name Data on the product Trade name Lead acid battery filled with diluted sulphuric acid Data on the manufacturer Telephone Facsimile 2 Hazardous substances CAS No Description 7439 92 1 blue lead 7439 92 1 traces of As Sb Battery paste 7664 93 9 sulphuric acid 3 Potential hazards No hazards in case of an intact battery and observation of the instructions for use Lead acid batteries have significant characteristics They contain diluted sulphuric acid which may Cause servere acid burns During the Charging process they develop hydrogen gas and oxygen which unter certain circumstances may turn into an explosive mixture Content lead containing 31 Weight R phrases lead alloys with 34 Weight R 61 20 22 33 62 52 53 34 Weight R35 They have an internal voltage which depending on their level can be dangerous to the human body when touched Standard EN 50272 2 includes safety requirements for batteries and battery installations and describes the basic precautions to protect against dangers deriving from electric currents leaking gases or electrolytes This leaflet was prepared by the Working Group on Environment and Occupational Health of the ZVEI German Electrical and Electronic Manufacturer s Association Batteries are marked with the following hazard symbols The meaning of the hazard symbols is No smoking no ope
72. n flames no sparks Wear safety goggles Sulphuric acid Observe operating instructions Explosive gas mixture 4 First aid measures General Information Sulphuric acid after contact with skin after inhalation of acid mist after contact with the eyes after swallowing Lead containing battery paste after contact with skin acts corrosive and damages tissue rinse with water remove and wash wetted clothing inhale fresh air rinse under running water for serveral minutes drink a lot of water immediately and swallow activated carbon classified as toxic for reproduction clean with water and soap seek the advice of a doctor 6 Measures to be taken in case of unintentional release Cleaning take up procedures Use a bonding agent such as sand to absorb split acid Use lime sodium carbonate for neutralisation dispose with due regard to the official local regulations do not permit penetration into the sewage system the earth or water bodies AEU EUCRCEC Store frost free under roof prevent short circuits Protect plastic housings against exposition to direct sun radiation Seek agreement with local water authorities in case of larger quantities If batteries have to be stored in storage rooms it is imperative that the instructions for use are observed 5 Fire fighting measures Suitable extinguishing agents When electrical devices a
73. n in fig 7 2 Operating temperature Voltage adjustment per cell Between 10 C to 30 C No Adjustment Between 30 C to 40 C 0 004 V K Voltage needs to be decreased 7 5 Charging procedure for cyclic applications HOPPECKE recommends battery recharging according to the following guideline 1 After every discharge recharge battery to at least 90 state of charge according to these figures Depth of Discharge 2 4V C 15 50 DoD Fig 7 12 55 100 DoD Fig 7 13 2 After every 5 nominal throughputs 10 cycles or 10 days whatever occurs first recharge battery with IUI characteristic phase with 5 A 100 Ah nominal battery capacity C for two hours 3 After every 10 nominal throughputs 20 cycles or 20 days whatever occurs first recharge battery with IUI characteristic phase with 5 A 100 Ah nominal battery capacity C for four hours The following figures depict examples for battery cycles eee CTT Charge be BOS Oe ace Mg L Charge be As HPD ace Ma L aa a0 en az cycies h Duna Charge to 100 LDE ax ic 2 Change to 10 IOE ex Ha 2 Ohanga te JON Ce ee Hin J Charge tn LDN S e Ae F Fig 7 3 One battery cycle per day 1j fy a ape ey Py E a a eae a eS ee ee y any ee ae ee es ee ee ee 1 F a7 475 L FY a ajin i DE 24 5 169 17 18 19 Bo 21 22 23 249 25 Be 2 30 31 32 33 Hj Dora Charge ba Se H perc Mi Charge on Gai 00 mre ir i C
74. nd operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 38 245 j 240 235 230 2 25 Charging Voltage in V 2 20 z15 09 20 10 o 10 2 a0 40 So Temperature in C Fig 6 1 Temperature related float charge voltage adjustment Maximum charge currents Up to 2 4 V cell the battery is able to absorb the maximum current the battery charger provides Using the IU characteristic according to the DIN 41773 a charging current of 10 A to 20 A per 100 Ah rated capacity C is recommended If charge voltages of 2 4 V cell are exceeded this leads to higher water dissociation and electrode stress The charge currents per 100 Ah nominal capacity shown in Tab 6 1 must not be exceeded when charging with a charge voltage of over 2 4 V cell Attention Charging Cell rocedure Voltage OPzS OPzS OPZS bloc E power bloc solar power solar power OGi bloc OSPXC OSPHC USV bloc Oooo characteristic 5 0A 6 5A 2 6 to curve DIN 41776 2 75 V W characteristic T OA 9 0A for 2 40 V curve DIN 41774 35 A flee for 2 65 V Tab 6 1 Charge currents Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 39 Dependency of electrolyte density on temperature The electrolyte is diluted sulfuric acid The nominal density of the electro l
75. nrnnrnrnnnnnnntnrnnnnrananrnrnnnnnnnrnrnnannnnnnenrnnann nnana 15 233 MCU ee diSchal acetic rece E A E E E E nse meee E 15 2 3 4 Electric shock and uUrnS sssssnssrerrsrsrrrrrrrrrrrrrrsrrrrrrsrerrnrnrrrrnrnnrnrnrrnrurnnrurnnrnrannnnnnrnrnrnnnnnnn ennan 16 3 Transport aeee e canes e e a e e E e a a 18 3 1 General eere E E a e 18 3 2 Delivery completeness and externally visible damage s sssresnsrsrrsrrrrrrrrrrrsrrrrrrsrrrrnrnrrrrnrnenne 18 3 3 DECIS ee E E uate 18 4 Storage o E E E eee E a ee 19 4 1 Generali aesrrersee eA rE E ea A R E Ed 19 4 2 Storage UME e area E E E E E E 19 4 3 Preparing for a several months storage period cccccececeeeeceeeeeeeeeeeeeneeeeseeeeeeeeeeeeneeeeeeseneneneenes 19 5 Installation a tensiesc sens sciscevssarccorsmerstevsseactipescatiesaiediatere seis ievsreicbepeimcseiatadeiiyssnieiasveicbipeimatieinieceierereiatenses 20 5 1 Demands othe erection SHE sce see seen ec css EEEE EEEE TE AiE EEEE aE ENEE EATE E a 20 5 1 1 Calculation of safety distance s s ssessererrsrrrrsrrrrrrsrerrnrnrrrrnrnnrrrnrrsrnrrnrurnrrnrurrnrnrrernrnnrnrnrnnnan 22 5 2 FIDE tE CEIS arcee A A EE EEA EE E EEA AE EE eee eee 23 CONG ee eee E S EE E EEES e 23 5 2 1 1 Ventilation preventing explosions s snssnasnnnrnrrrsrrrrrrrnrrnrrnrrrrrnrrnrrnrrnrrnrrnrrnrrnrrnrrnrrurrnrnnrenrnnnn 23 5 2 1 2 Ventilation calculation for ventilation requirements of battery roOMS s ssssesssrerrsrsrerrerernersre 24 5 227
76. on A 67 no transport as dangerous goods non spillable batteries are not subject to other requirements of IATA DGR if they meet the requirements of Special Provision A 67 Provided that poles are secured against short circuit An appropriate manufacturer s confirmation is necessary Batteries which do not meet the requirements according to Special Provision A 67 have to be packed as listed in 14 1 Air transportation IATA DGR according to Packing Instruction 870 and carried as dangerous goods according to UN 2794 14 3 Batteries damaged Land transportation according to ADR RID e Hazard class 8 e UN no 2794 e Proper shipping name BATTERIES WET FILLED WITH ACID e Packing group none 4 5 e Packing Instruction P 801 a transport as dangerous goods packing in accu boxes or Special Provision VV 14 transport as dangerous goods in bulk In accordance with the German law governing the sale return and environmentally sound disposal of batteries and secondary cells Batteries Act PAZA TEBENG o Batteriegesetz BattG from 25 e ADR Tunnel restriction code June 2009 national E transposition of directive e Note these references canbe 2006 66 EC battery directive applied by transportation of lead acid batteries have to be Lead acid batteries of UN no marked with a crossed out 2800 as well wheelie bin with the chemical symbol for lead Pb shown below 7 Pb In addition the ISO return rec
77. on rules as well as EN 50272 2 und EN 50110 1 Wear conductive shoes General order HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 4 xi 9 Any acid splashes on the skin or in the eyes must be rinsed with plenty of clean water immedia tely Then seek medical assistance Spillages on clothing should be rinsed out with water Recycling Spent batteries have to be collected and recycled separately from normal household wastes General notice or tip for better understanding and optimum use of the battery or batteries O Safety notices 0 1 General Information A Danger gt p gt Attention gt Danger gt Incorrect use of the products described here can lead to personal and material damage HOPPECKE is not responsible or liable for direct or indirect personal and material damages which occur as a result of handling the products described here Risk of explosion and fire avoid short circuits Attention Metal parts of the battery or batteries are always live so never place foreign objects or tools on top of the batteries Electrostatic discharges can ignite oxyhydrogen gas and therefore cause an explosion of the battery Exploding parts can lead to heavy injuries Electrolyte is highly corrosive In normal operation it is not possible to come into contact with electrolyte
78. on the batteries one after another into the racks so that they are angled and level with the correct polarity Remove all transportation and hoisting equipment Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 31 D A Attention ZN Danger A Attention For large batteries it is required that you begin installation in the center of the rack When using tier racks install the batteries on the bottom rack first When handling the batteries observe the instructions in Chap 5 7 Place the batteries carefully onto the profiles of the rack otherwise the battery casing could be damaged When placing the batteries on the rack do not allow the batteries to knock up against one ano ther This could destroy the batteries and result in an acid leak The battery connection terminals and must under no circumstance be short circuited This applies also to the plus and minus pole of the entire battery string Be very careful when using step racks 3 Slide the blocks or cells to either side until the distance between the batteries is approx 10 mm Fig 5 20 If connectors are used these determine the distance between the batte ries When sliding the batteries sideways in the racks do not push them at the middle instead push them at the corners as these are stronger Push batteries using your hands onl
79. operating conditions The cycle life refers to one discharge per day Cycle life cannot exceed stated service life under float charge conditions S000 Epig TDO Cycle number n o 10 20 30 40 50 Ba 70 ad 90 Depth of discharge DoD in Fig 7 8 Cycle lifetime of OPzS solar power as a function of DoD at 20 C 7 10 2 Cycle life time depending on ambient temperature Since design life mainly depends on temperature the cycle lifetime is affected by temperature as well Fig 7 9 depicts this relation for a regular battery depth of discharge of 80 1600 1400 1200 1000 800 Cycles n 600 400 Ambient temperature in C Fig 7 9 Cycle lifetime of OPZS solar power as a function of ambient temperature HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 48 The following figure refer to fig 7 10 depicts dependency of cycle life on depth of discharge and tempera ture it fe T see ee qe ee eee ee SS eee ee eee ee Pree eee ee eee 1 i i i i I L L L I L L I F I I L 1 i i i i 8000 a a a ee ee eee ee eee docccsasc ee chee basnsssssasi I I L I F i i I i i i i i i i i I I I J TT Ae eee ee Ok a ee eee eae eae ee aa k i i i i i i i i i i L i i i E i I E i I E000 oe a are belie uneaatenG Scie ease nai een ii 1 F S i E i i i f i E i i i
80. otential for faults resulting from a damaged cell possible short circuit and battery aging 5 me HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 58 Beispiel 1 A battery with 2 x 60 V 60 V nominal voltage 4 OPzS 200 200 Ah is equivalent to 2 x 30 cells The battery is on float charge at 2 23 V per cell Nominal capacity of the battery 200 Ah Gas emissions factor 1 Ca n Number of cells 2 x 30 Cells l f Safety factor 5 lot 2 MA Ah Q 0 05 m x 2 x 30 Cells x 1 mA x 200 Ah x 1 x 5 x 10 Ah Ah Qui 3 m Ah Result For a 60 V battery composed of 2 x 30 cells 4 OPzS 200 operating on float charge an airflow of 3 m h is required for proper ventilation What is the appropriate diameter for intake and exhaust openings with natural ventilation The necessary cross section for ventilation openings can be calculated using the following formula A Q X28 Q Necessary ventilation air flow rate m h A Necessary cross section for ventilation openings cm A 3m x 28 84cm h Result Ventilation openings intake and exhaust with a cross section of 84 cm ensure ventilation with an airflow of 3 m h What factors must be considered when installing a natural ventilation system If possible the ventilation openings should be positioned on opposite walls If they must both be on the sam
81. rd label 8 Special Provision 238 para a b no transport as dangerous goods non spillable batteries are not subject to other requirements of ADR RID if they meet the requirements according to special provision 238 An appropriate manufacturer s confirmation is necessary Batteries which do not meet the requirements according to Special Provision 238 have to be packed and carried as listed in 14 1 Land transportation ADR RID according to Special Provision 598 Sea transportation according to IMDG Code e Hazard class 8 e UN no 2800 e Proper shipping name BATTERIES WET NON SPILLABLE e Packing group none Packaging Instructions P 003 and PP 16 e Hazard label 8 e EmS F A S B e Special Provision 238 no 1 2 no transport as dangerous goods non spillable batteries are not subject to other requirements of IMDG Code if they meet the requirements according to Special Provision 238 An appropriate manufacturer s confirmation is necessary Batteries which do not meet the requirements according to Special Provision 238 have to be packed as listed in 14 1 Sea transportation IMDG Code according to Packaging Instruction P 801 and carried as dangerous goods according to UN 2794 Air transportation according to IATA DGR e Hazard class 8 e UN no 2800 e Proper shipping name BATTERIES WET NON SPILLABLE Packing group none Packaging Instruction 872 Hazard label 8 Special Provisi
82. re set in fire in general water is the suitable extinguishing agent For incipient fires COzis the most effective agent Fire brigades are trained to keep a distance of 1 m when extinguishing an electrical fire up to 1 kV with spray jet and a distance of 5 m with full jet For electrical fires in electrical installations with voltages gt 1 kV other distances are applicable depending on the respective voltage For fires in photovoltaic installations other rules apply Unsuitable extinguishing agents Powder fire extinguishers are not suitable amongst others because of only minor efficiency possible risks or collateral damages Special protective equipment For larger stationary battery installations or larger stored quantities protective goggles respiratory and acid protective equipment acid proof clothing 2 5 8 Exposure limits and personal protective equipments 8 1 No exposure caused by lead and lead containing battery paste 8 2 Possible exposure caused by sulphuric acid and acid mist during filling and charging CAS Nr 7664 93 9 R phrases R 35 S phrases S 1 2 Causes severe burns Keep looked up and out of reach of children In case of contact with eyes rinse immediately with plenty water and seek medical advice Never add water to this product applies for concentrated acid only In case of accident or if you feel unwell seek medical advice immediately show the label where possible
83. rging when in standby parallel operation and floating operation the effective value of the superim posed alternating current is not permitted to exceed 5 A 100 Ah nominal capacity The recharging time is 6 8 hours Charging must be monitored and terminated or switched to float charge voltage when charging is complete The state of full charge is reached when the charge currents charge voltages depending on the charging pro cedure and the electrolyte densities no longer increase within a period of 2 hours HOPPECKE IUla recharge with IUla characteristic recharge U part constant voltage 2 35 2 40 V per cell max Voltage 2 75 V per cell voltage U V recharge current A recharge I part recharge la part constant current constant current i max 20 Ampere per 100 Ah 5 Ampere per 100Ah time limited to max 3 hours time t h Fig 9 2 IUI characteristic The IUI charging method is an even better method for preparing the batteries it is a charge with an additional constant current at the end of the charging In contrast to the charge with constant voltage in the last step after IU charging a constant charge current with 5 A 100 Ah is applied for 3 hours The charge voltage can then increase up to 2 60 V to 2 75 V per cell The W and Ula characteristic curves result in increased gas generation when using these characteristic curves increased ventilation is required Installation commissionin
84. roduce toxic fumes If this should occur leave the location as quickly as possible if you are not wearing the breathing apparatus described above If using CO fire extinguishers there is a risk that the battery could explode as a result of static charging Note also the information in the attached ZVEI leaflet Instructions for the safe handling of lead acid accumulators lead acid batteries 2 3 3 Electrostatic discharge All lead acid batteries produce hydrogen and oxygen while operating particularly during charging These gases leak from the battery in the ambience Based on the mandatory natural or technical ventilation it can be assu med that a flammable oxyhydrogen concentration exists only in the close proximity of the battery A flammable mixture of oxyhydrogen always exists inside the battery cells This effect does not depend on the battery tech nology design or manufacturer it is rather a specific characteristic of all lead acid batteries Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 15 The energy needed for an ignition of oxyhydrogen is quite low and can be caused differently Examples Open flame fire glowing sparks or flying firebrands from grinding electric spark from switches or fuses hot surface areas gt 200 C and an underestimated cause electrostatic discharge Measures to avoid an
85. roduction 12 Data on the ecology of the constituents Preliminary remark Relevant only if release is caused by destruction of the battery Sulphuric acid Water polluting liquid within the meaning of the German Water Resources Act WHG Water pollution class 1 mildly water polluting As described in section 6 use a bonding agent such as sand to absorb spilled acid or neutralise using lime sodium carbonate Dispose of under the locally applicable provisions Dispose with due regard to official local regulations Do not allow progression into the sewage system soil or bodies of water Lead and lead containing battery paste are hardly soluble in water Lead can be dissolved in an acidic or alkaline environment Chemical and physical treatment is required for elimination from water Waste water containing lead must not be disposed of in untreated condition 3 5 13 Recycling information The points of sale the manufacturers and importers of batteries respectively the metal dealers take back dead batteries and render them to the secondary lead smelters for processing Spent lead acid batteries are not subject to accountability of the German Waste Prove Ordinance They are marked with the recycling return symbol and with a crossed out roller container cf chapter 15 Marking Spent lead acid batteries are not allowed to be mixed with other batteries in order not to compliance the process
86. rsonal safety equipment protective clothing equipment If working with lead acid batteries the following equipment must be provided at the very least Insulated tools Rubber gloves Protective shoes Fire extinguisher Rubber apron Protective goggles Face shield Face mask Emergency eye wash To avoid electrostatic charging all textiles protective shoes and gloves worn while working with batteries must have a surface resistance of lt 108 ohm and an insulation resistance of 210 ohm refer EN 50272 2 and DIN EN ISO 20345 2011 Personal protective equipment Safety footwear If possible wear ESD shoes Remove all wrist watches rings chains jewelry and other metal objects before working with batteries Never smoke handle open flames or create sparks near the batteries Never place tools or metal components on top of the batteries Danger The use of proper tools and safety equipment can help to prevent injury or reduce the severity of injury in case of an accident 2 3 Safety precautions 2 3 1 Sulfuric acid Batteries are safe when used properly However they contain sulfuric acid H SO which is extremely corrosive and can cause serious injury Further information to sulfuric acid can be found in the attached material safety data sheet Always wear protective gloves and use the proper tools when working with lead acid batteries Observe the following instructions and read t
87. ry precautions to make sure that the chain does not slide off of the forklift Hang both ring eyelets with the hoisting belt in the cross beam Fig 5 14 Always position the eyelets in the notches on the cross beam Pull the hoisting belt slowly and guide the battery manually The battery must always be transported in a vertical position Fig 5 10 Transport the battery to the installation location e g step rack or tier rack Lubricate the profiles of the rack slightly with soft soap 10 Carefully place the battery onto the rack 11 Remove the hoisting belt from the battery Fig 5 5 to Fig 5 11 show an example for OPzS battery handling Installation commissioning and operating instructions for vented stationary lead acid batteries 5 8 General information on connecting the batteries If connecting the batteries always establish the serial connections first followed by the parallel connection Do not reverse this procedure Before connecting check to make sure that the batteries have the correct polarity Attention To establish the serial connection arrange the batteries so that the positive terminal of one bat tery is positioned as near as possible to the negative terminal of the next battery If sealed stationary batteries are connected in parallel observe the following 1 Only battery strings with the same length and voltage may be connected with one another Cross connecting t
88. shing agent Threshold value on workplace 0 1 mg m8 Personal protective equipment Rubber PVC gloves acid proof goggles acid proof clothing 6 Measures to be taken in safety boots case of unintentional release 0 5 mg m at the lead battery production Cleaning take up procedures 9 Physical and chemical properties Use a bonding agent such as sand to absorb spilt acid use Appearance lime sodium carbonate for neu form liquid tralisation dispose with due colour colourless regard to the official local regu odour odourless lations Safety related data solidification point 35 60 C boiling point approx 108 114 C Solubility in water complete Store frost free under roof Seek flash point N A agreement with local water ignition temperature N A authorities in case of larger quan lower explosive limit N A tities Observe VAWS densitiy 20 C 1 2 1 3 g cm vapour pressure 20 C 14 6 mbar bulk density N A pH value lt 1 at 20 C dynamic viscosity approx 2 8 mPa s at 20 C 10 Stability and reactivity 12 Data on the ecology of the sulphuric acid of the constituents 30 38 5 Water polluting liquid within Corrosive inflammable liquid the meaning of the German Thermal decomposition at Water Resources Act 338 C Water pollution class 1 Destroys organic materials ray water Pann such as cardboard wood In order to avoid damage
89. ssssrsnssrernrrsrrrrnrrrrrrnrrsrnrrnrsrrrrnrnrrrrnrnrnrnrenrernnne 45 7 6 Charging NS ennen gic ese aan ese E A EE E ee EE E E E 46 Cal Alternating currents oa cccvede ccohcctenccevescuc apescedcecvesencsacsdeacecveeaecancededcecdedescstecdescesseaec aascedlectenencescees 46 7 8 Water CONSUMDPUO eae eee ene ae ne ee ec ne ae eS ne ee eee een eee ee 46 7 9 Temperature influence on battery performance and lifetime cccceeeeceeeeeeeeeeeeeeeeeeeeneseeaenenenees 47 7 9 1 Temperature influence on battery capacity sescncacsicsececceiecesticnreceastvecsecnesnsatecseanedansseeinacccesneeseeke 4T 7 9 2 Temperature influence on battery lifetime ccccccecececeeseeceeeeeecececeesesecnssecncncesossesnentenenans 47 7 10 Influence of cycling on battery behavior ndcspccesenesesscdesectesniiccnccwunsncindecsehenduiuctncestscasiecnecsdcdeacessndes 48 7 10 1 Cycle life time depending on depth of discharge DOD ccccccccececececececesesecesesesecesesesesenens 48 7 10 2 Cycle life time depending on ambient temperature cscccceceecececececcesecnsseencnsscessecnensenenees 48 7 10 3 Electrolyte freezing point depending on depth of discharge DOD ccccccesecececececeseeesesesesenens 49 LEL Remarks to warranty management cae ie cee ett a eh ces eee eae ert eos eet ete 50 7 12 Rechare time diagrams cccccceecececessecncncecsesecneneancncncascesecneneancusecenseseensssoncnceeaesesnensenenans 50 8 Batter
90. structions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 5 7 Handling the batteries Be very careful when lifting and moving the batteries as a falling battery could cause personal injury or material damage Always wear protective shoes and safety goggles The battery attached to a rope sling must be guided manually by one person so that it remains in a horizontal position and so that it does not slide out of the rope sling If guiding the battery hooked to a rope sling make sure to wear acid resistant non slip gloves Always lift batteries from below and never lift batteries using the terminals as this can destroy the battery Before installing the battery visually check to make sure that it is in perfect condition Install the battery in accordance with VDE 0510 Part 2 2001 12 in accordance with EN 50272 2 2001 For example you must cover conductive parts using insula ting mats Make sure that all terminals are covered with insulating caps If lifting the battery use the hoisting belt specified by HOPPECKE as shown in Fig 5 4 Note that the hoisting belt sling needs to be adjusted with the Velcro for different battery cell dimensions Use the auxiliary equipment shown in Fig 5 4 cross beam chain snap hooks ring eyelets The maximal bearing capa city of the hoisting belt amounts to 340 kg Please contact your local HOPPECKE representative in case of questions Fig
91. t and measure the voltage of the battery system in regular time intervals Check the row connectors block connectors step connectors and tier connectors for excessive heating 10 Calculate the capacity of the battery system using the following formula Capacity at 20 C T_ T x 100 T actual discharge time until the permitted minimum voltage is reached T theoretical discharge time until the permitted minimum voltage is reached 11 Reconnect the battery system as originally connected and perform a boost charge see Chap 5 13 D O ON O Ol Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 53 9 2 Performing the capacity test extended version Preperation The best and quickest method for preparing batteries for testing is the IU charge method also used for equa lizing charges Because it is possible to exceed the permitted load voltages appropriate measures must be taken e g disconnection of the consumers The IU characteristic curve with increased voltage 2 33 2 40 V x number of cells is the most common char ging characteristic used for commissioning the batteries The charge is performed with a constant voltage of max 2 33 V 2 40 V cell for up to 48 hours The charge cur rent should not be higher than 20 A per 100 Ah nominal capacity If the elcetrolyte temperature of the cells blocs exceeds the
92. this operating mode Consumers direct current source and battery are connected in parallel The charge voltage is the operating voltage of the battery and the system voltage at the same time The direct current source is not able to supply the maximum load current at all times The load current inter mittently exceeds the nominal current of the direct current source During this period the battery supplies power The battery is not fully charged at all times Therefore depending on the number of discharges the charge voltage must be set to approx 2 25 to 2 30 V x the number of cells connected in series 6 2 3 Switch mode operation charge discharge operation DC Power Supply Electrical Load Battery Charger Fig 6 4 Switch mode operation The following is characteristic for this operating mode When charging the battery is separated from the consumer Towards the end of charging the charge voltage of the battery is 2 6 2 75 V cell depending on the depth of discharge and number of cyclical loads The charging process must be monitored On reaching a state of full charge terminate charging or switch to float charging as described in Chap 6 2 4 The battery may be connected to the consumer if required Installation commissioning and operating instructions for vented stationary lead acid batteries FE HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 41 6 2 4 Float
93. tioned parameters need to be monitored and registered on a regular basis These data have to be forwarded to the manufacturer for further analysis HOPPECKE recommends the usage of a battery monitoring system for monitoring and logging of critical data Please contact your local HOPPECKE representative for information on HOPPECKE battery monitoring equipment and accessories 7 12 Recharge time diagrams The following diagrams depict approximately necessary recharge times with U characteristic as a result of the maximum possible charging current and the actual depth of discharge DoD at begin of the recharge phase Time for recharging battery with 2 4 V C to 90 SoC Starting recharge at 15 50 DOD 10 0 Example for recharge parameters 8 0 Battery has been discharged to 50 DoD With a 7 max possible recharge current of 10 AM00Ah Ci a recharge time of ca 4 6 his needed in order to recharge the battery to a state of charge of 90 Time in h 4 4 A 4 H 4 5 6 7 g 4 10 11 12 13 14 15 16 17 18 19 20 Charging Current in A 100 Ah Battery Capacity C 1ss 20 2s IO 3S OH OCU C O Fig 7 12 Time of recharge depending on depth of discharge start of charge between 15 and 50 DoD mi HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014
94. to textiles the sewage system the acid has to be neutralised by means of lime or sodium carbonate before disposal Reacts with metals producing hydrogen Vigorous reactions with lyes and alkalis Ecological damage is possible by change of pH 11 Data on the toxicology 13 Instructions for of the constituents processing disposal acts intensely caustic on skin The batteries have to be pro and mocous membranes in cessed disposed of with re low concentration already gard to the official local regu The inhalation of mists may lations cause damage to the respiratory tract 14 Transport regulations Land transport Description of the goods Sea transport Air transport Other data ADR RID Battery fluid Acid Danger number UN number IMDG Code IATA DGR Dispatch per mail service chapter 3 2 UN 2796 chapter 3 2 UN 2796 80 2796 chapter 3 2 UN 2796 chapter 3 2 sulphuric acid impermissible 15 Regulations Marking according to Danger symbol R phrases S phrases National regulations Water pollution class Other regulations 16 Miscellaneous data The data rendered above are ba sed on today s knowledge and do not constitute an assurance of properties Existing laws and regulations have to be observed by the recipient of the product in own responsibility German Regulations on Hazardous Materials 35 1 2 26 30 45 1 l
95. ttery rack or inside the battery cabinet se o The nominal voltage the number of cells blocks the nominal capacity Ogi bloc 80 l H Cio C and the battery type are listed on the identification plate of o the system ie Seed a OF EN Fig 1 1 Example for type plate on battery rack 1 3 CE Mark Effective as of 1 January 1997 the EC declaration of conformity 2006 95 EC Low Voltage Directive and the corresponding CE marking for the battery system are required for batteries with a nominal voltage between 75 V and 1500 V DC The installer of the battery system is responsible for displaying the declaration and affixing the CE label on or next to the battery s identification plate 1 4 Disposal and recycling h LRY Used batteries with this marking are recyclable goods and must be sent for recycling Attention Used batteries which are not sent for recycling are to be disposed of as special waste under all relevant regulations Pb We offer our customers our own battery return system All lead acid batteries are taken to the secondary lead smelting plant at our HOPPECKE site observing the provisions of the German recycling and waste law battery regulations transport approval regulations together with the general principles of environmental protection and our own corporate guidelines The HOPPECKE smelting plant is the only lead smelter in Europe certified under DIN EN
96. ve to be executed as follows Max 2 4 V Cell up to 72 hours refer to curve A in fig 7 2 Note Up to 2 4 V C the charging current is the oretically not limited However a restriction of max charging current to 20 A 100 Ah nominal battery capacity Cio is reasonable In case of charging voltages above 2 4 V C the charging current needs to be restricted to 5 A 100 Ah battery capacity C Resulting voltage range is 2 6 to 2 75 V C refer to curve B in fig 7 2 The cell bloc temperature must never exceed 55 C If it does stop charging or revert to float charge in order to allow temperature to fall Avoid operating temperatures in excess of 45 C for long periods of time The end of equalization charge is reached when the cell voltages and electrolyte densities do not increase during a period of 2 hours 2 80 2 70 265 gt 260 S 2 55 S aso f No adjustment TD 248 o I lt S O 2 40 i i 235 I I i 230 i H I 2 25 A xe 20 10 10 20 Temperature in C Fig 7 2 Charging voltage as a function of temperature in solar cycling operation 3 The higher the charge current in the range of 5 A to 20 A 100 Ah the shorter the required charging time i HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 44 Temperature dependent voltage adjustment as show
97. vei org Information Leaflet Safety data sheet on accumulator acid diluted sulphuric acid in compliance with EC Directive 91 155 EU 1 Substance formulation and company name Data on the product diluted sulphuric acid 1 22 1 29 kg l Trade name accumulator acid Data on the manufacturer Telephone Facsimile 2 Composition data on the constituents Chemical characteristics Sulphuric acid 30 38 5 ig densitiy 1 22 1 29 kg l CAS Number 7664 93 9 EU Number 016 020 00 8 UN Number 2796 EINECS Number 231 639 5 Diluted sulphuric acid may cause General instructions Remove soiled wetted clothing severe acid burns immediately after contact to skin Rinse with a lot of water immediately after contact to skin after inhalation of acid mist Inhale fresh air after contact with the eyes Rinse under running water for several minutes after swallowing 2 Drink a lot of water immediately and swallow activated carbon Seek the advice of a doctor This leaflet was prepared within the Committee on Environmental Affairs of the Division Batteries of the German Electrical and Electronic Manufacturers Association ZVEI Revised Edition November 2003 5 Fire fighting measures 8 Exposure limits and personal protective equipment Suitable extinguishing agents Possible exposure caused by sulphuric acid and acid mist during filling in case of surrounding fires and charging COz and solid existingui
98. y never use a tool Fig 5 13 10 mm clerance between the batteries 4 After the batteries have been placed in the racks you can replace the Labyrinth plugs with other plugs if you have ordered them These plugs could be ceramic plugs ceramic funnel plugs AquaGen premium top H AquaGen premium top V recombination systems Please refer to the manual for the AquaGen recombination system Fig 5 14 Labyrinth plugs left and AquaGen recombination system right 5 Final step Count all cells blocks and check for completeness i HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 32 5 10 Connecting the batteries The batteries are in their final position and can now be connected 5 10 1 Connection terminals For GroE batteries 5 GroE 500 to 26 GroE 2600 only The battery terminals have been greased at the factory using battery terminal grease Inspect each terminal for visible damage or oxidation If necessary clean the terminal using brushes with hard plastic bristles Re grease by using the above mentioned terminal grease For batteries without rubber molded terminals use the red and blue touch protection rings to avoid contact The little clearance hast to face downwards The red one is used for the positive terminal and the blue one for the negative terminal Fig 5 15 Touch protection ring 5
99. y capacity m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 22 5 2 Filling the cells If the cells or batteries were delivered unfilled dry they have to be filled now Empty but not fully emptied and cleaned acid tanks have to be handled as filled according to the regulation of dangerous goods for street transport If acid tanks should be disposed assure to meet the local legal requirements Pay also attention to the disposal and operating recommen dations in the material safety data sheet for sulfuric acid 5 2 1 Check Before filling the cells make sure that the installation and ventilation requirements according to EN 50272 2 2001 are met Should commission charging be carried out using higher amperage than you established for the type of ventilation equipment then you must increase the ventilation in the battery room e g using additional portable fans according to the amperage applied Increased ventilation has to be applied during com missioning and for one hour afterwards The same applies for occasional special battery charging processes 5 2 1 1 Ventilation preventing explosion It is impossible to stop gases from being generated while charging batteries therefore the hydrogen concen tration in the air must be reduced with sufficient ventilation Do not use sparking equipment near batteries The
100. y maintenance 0c cece cece cece cece cece cece ceca ceca ca casa ca ceca cacacacasacacacaeaceeaeaseseeeceeeeeseceeeceeeceeseenes 52 8 1 Work to be performed every six MOMUNS sepccciecnencksidenncccswadetncechedss oesiebaddaaecerswaccanieeheadcncemencacdad 52 8 2 Work to be performed annually ccccececcececsceccececnssecncneneasceseeneseancncneesoesnensanencnsesenseenenss 52 8 3 Cleaning of es SS Sierro rE EEEE E EE E EE E EEEE OERE Er E EE EEEE 52 9 Testing the batt ry SySte mM cscssccsris neinei e a aa A aE EE i Ea PE a a E 53 9 1 Performing the capacity test short Orm 1 2 2 c 262c0 cc scescacacecscccassedeeecccceeccatseceniecacsescassedesscceces 53 9 2 Performing the capacity test extended version ccccccccecececenecececenecesesesesenesenesesesesesenenenenees 54 9 3 Capacity test of the DAW SN cscsnccsscncscesdecentsseeneseonetoeusddeetecesdensotcdssoescrecncsacctdaseacns ssadidewsatcebedec 56 10 Troubleshooting nnnanennennnnenenrnrnrnnrnrarrrrrrrrrrrnsrnrnnrsrarnnrnrrrrnrnnrnrnnrnrarrntnrnnrnrnnrnnnnrnrnnnn unnn rannat 58 11 Required ventilation for hydrogen generated by batteries cccccccceececeeeeeeeeeeeeeeeeeeeeeeneneeeeaenes 58 INSPECTION PIOtOCOl iiss icceccscsescacsecacedcasseteedsaicsaacassevcasiedcndeabaedeaksolouaacesnendattedesnicdestccassblestecasstacasseceetdedeaas 60 Safety data SHGCU ss cccsocicc ns hc ce cecek scales encccdistecacicencetecsnacekessan
101. y related to the ambient temperature As rule of thumb it can be stated that the speed of corrosion doubles per 10 K increase rule by Arrhenius Thus battery service life will be halved in case the temperature rises by 10 K The following graph refer to fig 7 7 shows this relationship The diagram depicts operation in float charge mode Additionally the cycling lifetime has to be taken into account 120 0 100 0 Design life in PEE ES 15 p 35 30 35 40 45 Operating Temperature in C Fig 7 7 Design life of OPZS solar power cell as a function of ambient temperature standby application in float charge operation with 2 23 V cell Installation commissioning and operating instructions for vented stationary lead acid batteries i HOPPECKE 7140203152 V1 1 02 2014 POWER FROM INNOVATION 47 7 10 Influence of cycling on battery behavior 7 10 1 Cycle life time depending on depth of discharge DoD Cycle lifetime is defined as number of discharging and charging cycles until the actual remaining battery capacity drops below 80 of the nominal capacity C The cycle lifetime of a lead acid battery is directly depending on the regular depth of discharge DoD during these cycles Depending on different types of batteries and the design of the plates and electrodes the cycle lifetime may vary significantly The following chart fig 7 8 shows the cycling behavior of a HOPPECKE OPZS solar power under ideal
102. ycling symbol is rendered amp The manufacturer respectively the importer of the batteries shall be responsible for the attachment of the symbols In addition a consumer user information on the significance of the symbols has to be attached which is required by the German Battery Ordinance quoted above as well as by the voluntary agreement of the battery manufactures concluded with the German Federal Minister of the Environment in September 1988 LVEl Batherien Editor ZVEI Zentralverband Elektrotechnik und Elektronikindustrie e V Fachverband Batterien Lyoner Stra e 9 60528 Frankfurt Fon 49 69 6302 283 Fax 49 69 6302 362 Mail batterien zvei org ZVEI 2012 In spite of all due care however we cannot accept any liability that the information is complete or correct or up to date The manufactures and sellers of the batteries subject to identification requirements packaging technical instructions leaflets shall be responsible for this information 16 Other information The data rendered above are based on today s knowledge and do not constitute an assurance op properties Existing laws and regulations have to be observed by the recipient pf the product in own responsibility 5 5 ZVEI Fachverband Batterien 7 Battenen Postfach 70 12 61 60591 Frankfurt am Main Lyoner Stra e 9 60528 Frankfurt am Main Tel 0 69 63 02 209 Fax 069 63 02 279 e mail batterien z
103. you will require your personal safety equipment protective clothing safety tools and other equipment as described in Chap 2 2 Danger m HOPPECKE Installation commissioning and operating instructions for vented stationary lead acid batteries POWER FROM INNOVATION 7140203152 V1 1 02 2014 26 Available Lifting conveyor forklift truck lift truck or small mobile crane or similar device to aid in battery installation Chalk line and chalk optional Le Plastic spirit level optional as Torque wrench Backing elements max 6 mm for installing the racks cabinets optional Ratchet set optional Wrench and ring wrench set with insulated grips Screwdriver with insulated grip Paper towels or cloths made of cotton do not use cloths made out of synthetic fibers as there is a risk of static charging moisturised with water Tab 5 5 Equipment for installation 5 5 Rack Installation Danger Danger We recommend that batteries are properly installed in HOPPECKE battery racks or HOPPECKE battery cabinets The use of other operator specific solutions may render the warranty for the batteries null and void HOPPECKE produces different types of racks For installation information see the separate docu mentation included with each rack Fig 5 2 Step rack left and tier rack right Observe the special requirements and regulations when installing battery racks in seismic areas The
104. yte is based on a temperature of 20 C and nominal electrolyte level in fully charged condition The maximum permitted deviation is 0 01 kg l High temperatures reduce the electrolyte density while lower temperatu res increase electrolyte density The correction factor is 0 0007 kg l per K Example Electrolyte density 1 23 kg l at 35 C corresponds to a density of 1 24 kg l at 20 C and electrolyte density 1 25 kg l at 5 C corresponds to a density of 1 24 kg l at 20 C Measuring electrolyte density prerequisites The electrolyte density decreases during discharging and increases during charging Because electrolyte density is also dependent on temperature See above and on the fill level of the battery when measuring the den sity both values should be determined and documented Prerequisites for measuring electrolyte density using a hydrometer No water has been added to the battery over the last few days electro Fig 6 2 Hydrometer lyte layering Water has a lower density than sulfuric acid it is lighter so mixing requires time The battery has been charged for at least 72 hours The electrolyte level in the battery is correct The temperature is 20 C If this is not the case recalculate accordingly see above 6 2 1 Standby parallel operation DC power supply Electrical Load Fig 6 3 Standby parallel operation The following is characteristic for this operating mode Consumers d

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