Table of Contents
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Executive
Responsible
department:
department:
SVA
SVA
Created/changed (current Index):
2019-05-16, W. Pickart
Checked (current index)
2019-06-13, I. Fuhrmann
Approved (current index)
2019-11-13, Dr. K. Gutzeit
grid|power FNC
Fibre Nickel Cadmium Batteries for Standby
Applications
Manual
Revision
Date
001
2015-07-22
002
2017-10-24
003
2019-05-16
Manual_Grid_Power_FNC_en_V3_0
Document type:
Technical Documentation
Operation and Installation Manual
File name:
Manual_Grid_Power_FNC_en_V3_0.doc
x
®
Batteries
Name
Chapter
I. Fuhrmann
I. Fuhrmann
7.1
W.Pickart
All
State of
confidentiality:
External
Document state
Approved
Revision:
Language:
03
EN
Reason for Changes
Initial version
Notes for recommissioning
Changes in structure chapters 2-7
Page:
1
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Summary of Contents for Hoppecke grid power FNC Series
- Page 1 Executive Responsible Document type: State of department: department: Technical Documentation confidentiality: External Created/changed (current Index): Document state 2019-05-16, W. Pickart Operation and Installation Manual Approved Checked (current index) 2019-06-13, I. Fuhrmann Approved (current index) File name: Revision: Language: Page: 2019-11-13, Dr. K. Gutzeit Manual_Grid_Power_FNC_en_V3_0.doc ®...
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Page 2: Manual_Grid_Power_Fnc_En_V3
All rights reserved including those of patent and utility model applications. Disclosure of as well as copying this documentation and using or revealing its contents are not permissible unless this has been expressly approved in writing by HOPPECKE Batterie Systeme GmbH. Infringements will lead to liability for damages. -
Page 3: Table Of Contents
Table of Contents USING THIS MANUAL 1.1. Target group of this document 1.2. Means of Representation 1.3. Notation of Nominal Data 1.4. Abbreviations and Definitions SAFETY 2.1. General Safety Instructions 2.2. Personal Protective Equipment 2.3. Specific Safety Instructions for grid|power FNC ®... - Page 4 Using this manual 7.1. Storage of Filled and Charged (FC) Cells 7.2. Storage of Unfilled and Uncharged (UU) and Filled and Uncharged (FU) grid|power ® Cells INSTALLATION 8.1. Mounting a Rack or Cabinet 8.1.1. Before Mounting a Rack or Cabinet 8.1.2.
- Page 5 Using this manual DISASSEMBLY, DISPOSAL AND RECYCLING APPENDIX 13.1. Commissioning Record 13.2. Maintenance Log 13.2.1. Six-monthly Maintenance Interval 13.2.1.1. Visual Inspection and Checking Electrolyte Level 13.2.1.2. Measuring battery system voltage 13.2.2. Annual Maintenance Interval 13.2.2.1. Cleaning the battery system 13.2.2.2. Insulation testing 13.2.2.3.
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Page 6: Using This Manual
This operating and installation manual is intended to assist with the optimal operation of the HOPPECKE nickel-cadmium batteries used, as well as their installation and maintenance. This is the only way in which a maximum service life can be achieved. -
Page 7: Notation Of Nominal Data
Using this manual 1.3. Notation of Nominal Data Nominal battery data is used in accordance with the following notation in this operation and installation manual: Notation Meaning Value Nominal voltage 1.2 V multiplied by the number of cells connected in series Nominal capacity available capacity at discharge at I... -
Page 8: Safety
Safety Safety Observe the safety instructions while handling the battery system and its components. 2.1. General Safety Instructions DANGER! Caused by: Explosions Pressure waves Flying hot or molten substances Avoid: Short-circuits Electrostatic charges and discharges ... -
Page 9: Personal Protective Equipment
Safety 2.2. Personal Protective Equipment Always wear the following personal protective equipment when working on the batteries or their components: Safety glasses Safety gloves Protective clothing, preferably made of cotton to prevent the development of electrostatic charge on clothes and the body ... -
Page 10: Safety Instructions On Charging The Battery System
Safety 2.3.2. Safety Instructions on Charging the Battery System DANGER! Danger of explosion due to formation of oxyhydrogen gas! When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen gas) is formed, which already explodes with low energy input. Keep any source ignition away from the battery system: ... -
Page 11: Protection Against Dangerous Body Contact Currents
Safety 2.3.3. Protection against dangerous body contact currents In stationary battery installations, measures must be taken to guard against direct and indirect contact. For battery installations this protection can take the form of obstacles or distance. According to DIN EN IEC 62485-2: ... -
Page 12: Intended / Unintended Use
Unintended use of the batteries can lead to personal injuries or damage to property. In case of unintended use, HOPPECKE Batterie Systeme GmbH shall not assume any liability for personal injuries or damage to property that result directly or indirectly from handling the batteries. -
Page 13: Directives, Legislation And Standards
Directives, Legislation and Standards Directives, Legislation and Standards Please observe the latest edition of the following rules and regulations: Accident prevention regulations, especially DGUV Regulation 1: Accident prevention regulation; Principles of prevention DIN EN ISO 20345 ("Personal safety gear – Safety boots") ... -
Page 14: Product Description
Product Description Product Description ® grid|power FNC cells are connected to form battery systems and are deployed in standby applications. Here, they fulfil one or more of the following functions: Buffering and supply of the low-voltage networks Providing power in case of an emergency ... - Page 15 20 °C (electrolyte density can be higher on delivery). Note The electrolyte density is no indicator for the state of charge of nickel cadmium batteries. ® For most FNC products, HOPPECKE supplies on request a special electrolyte that allows operation in low temperatures down to –45° Celsius. Manual_Grid_Power_FNC_en_V3_0...
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Page 16: Cell Plugs For Different Use Cases
No water addition or filling is required over a 20 year service life when operated on float charge at 20 °C. Furthermore, the VR plug provides a backfire protection. ® Furthermore, HOPPECKE provides AquaGen vent plugs that are described in a separate documentation. Contact HOPPECKE for further information. Manual_Grid_Power_FNC_en_V3_0... -
Page 17: Operation Modes (See Also Din En Iec 62485-2)
Product Description 5.3. Operation Modes (see also DIN EN IEC 62485-2) 5.3.1. Standby parallel operation Direct Load current source Battery Characteristics of this operating mode are: Load, direct current source and battery are permanently connected in parallel. The charging voltage is the operating voltage of the battery and at the same time the system voltage. -
Page 18: Buffer Operation
Product Description 5.3.2. Buffer operation Direct Load current source Battery Characteristics of this operating mode are: Load, direct current source and battery are permanently connected in parallel. The charging voltage is the operating voltage of the battery and at the same time the system voltage. -
Page 19: Switching Mode (Charge/Discharge Mode)
Product Description 5.3.3. Switching mode (charge/discharge mode) Direct Load current source Charger Battery Characteristics of this operating mode are: When charging, the battery is disconnected from the consumer. The battery can be switched to the consumer as required. ... -
Page 20: Battery Characteristic
Product Description 5.4. Battery Charging Characteristic In the temperature range from 10 °C up to 30 °C the battery system can be operated with the charging voltages as given in the table below: Charging voltage at 20 °C in V per cell connected in series Cell performance Single-stage 2-stage charging... -
Page 21: Battery Capacity
Product Description It is necessary to switch from boost charge to float charge when battery temperature is ≥ +45 °C, to avoid damage to the battery. The hysteresis must be selected so that the switch to boost charge is only possible when the temperature is ≤ +40 °C. ... -
Page 22: Transport
Transport Transport Batteries must be packed, marked and conveyed in accordance with the applicable transport regulations (ADR, IMDG Code, IATA). The cells of the battery should be protected against short-circuiting, sliding, falling over or damage and are to be secured to pallets by suitable means. -
Page 23: Surface Transport (Road/Rail) According To Adr/Rid
Transport 6.1. Surface Transport (Road/Rail) according to ADR/RID Filled batteries having the UN numbers 2795 (batteries/rechargeable batteries, wet, filled with alkalis) are not classified as hazardous goods requiring declaration during transport, if the following requirements are met (according to the ADR special regulation 598, section 3.3): New batteries, if: They are secured against sliding, turning over or damage. -
Page 24: Checking The Delivery
Write a short defect report on the delivery note before you sign it. Ask the carrier for an inspection and make a note of the name of the inspector. Write a defect report and send it within 14 days to HOPPECKE Batterie Systeme GmbH and the forwarding agent. -
Page 25: Storage Of Filled And Charged (Fc) Cells
Note - valid for grid|power FNC VR cells Remove a VR plug carefully. It is recommended to use the HOPPECKE plug opener (Mat. No. 4142500125) Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically pull out the plug from the cell opening. -
Page 26: Storage Of Unfilled And Uncharged (Uu) And Filled And Uncharged (Fu) Grid|Power Fnc ® Cells
® Reconditioning on page 48. If you store the grid|power FNC cells longer than three years, contact HOPPECKE before you put the cells into operation. Note ® If you want to put the stored grid|power FNC cells into operation, you have to charge the cells for recommissioning. -
Page 27: Installation
Ensure adequate ventilation according to DIN EN IEC 62485-2 Agreement with other persons working in the same room (ensures trouble-free installation). HOPPECKE will be pleased to help you in procuring suitable racking. 8.1.2. Checking the Scope of Delivery Check all goods delivered for completeness and for any signs of damage. -
Page 28: Mounting A Rack
Installation 8.1.3. Mounting a Rack Assemble the rack according the instructions delivered from the manufacturer. Observe the following minimum distances: Clearance between rack and wall: min. 50 mm Clearance between cell and wall: min. 100 mm Aisles between racks: min. 500 mm DANGER! Risk of serious injury or death caused by high voltages and electric shocks. -
Page 29: Installing The Battery System
Installation 8.2. Installing the Battery System DANGER! Risk of serious injury or death caused by high voltages and electric shocks. Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit. Be very careful when doing any work on the batteries in order to prevent severe injuries caused by electrical shocks or burns. -
Page 30: Preliminary Work On Unfilled And Uncharged Grid|Power Fnc
(LiOH). It is recommended to use electrolyte delivered by HOPPECKE. If this is not possible for some reasons contact HOPPECKE for instructions on mixing. ATTENTION! Fill immediately (within 1 hour) electrolyte to an unfilled and uncharged cell after you have removed the yellow transport plug. -
Page 31: Connecting The Battery System
Connecting the Battery System ® Connect the grid|power FNC cells electrically after you have placed them to a rack or cabinet. Use only original HOPPECKE accessories. ® Several grid|power FNC cells can form a row. One or more rows form the battery system. - Page 32 Any mechanical loading of the end terminals is to be avoided by the fixing of the row and end connectors. Avoid any mechanical load on the terminals with connecting the row and end connectors. Use only original HOPPECKE accessories. Manual_Grid_Power_FNC_en_V3_0...
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Page 33: Labelling The Battery System
(from the positive to the negative terminal of the battery). Battery systems with a nominal voltage ≥ 75 V installed in the EU must carry a CE conformity marking. Contact HOPPECKE for further information. Commissioning DANGER! -
Page 34: Charging Procedures For The Initial Commissioning
9.1.1. Charging with Constant Current ® It is highly recommended to charge the HOPPECKE grid|power FNC cells during initial commissioning with a constant current for a defined period of time. The diagram below exemplarily shows the charge voltage of one cell depending on time during charge with constant current I for 7.5 hours:... -
Page 35: Charging With Constant Current And Constant Voltage (Cccv)
Commissioning 9.1.2. Charging with Constant Current and Constant Voltage (CCCV) ATTENTION! ® The CCCV charging must not be used for unfilled and uncharged (UU) FNC cells. As an option, you can use the constant current, constant voltage charging method for initial commissioning of the battery system. -
Page 36: Commissioning Of Unfilled And Uncharged (Uu) And Filled And Uncharged (Fu) Grid|Power Fnc Cells
® cell. ® 2. Recommended: Insert a gas venting tube on each grid|power FNC cell, (HOPPECKE material number: 4143180100). 3. Measure the temperature of the battery system by inserting a suitable glass thermometer through the opening of a cell. The cell to be measured should be installed in the center of the system, in order to capture the warmest possible location of the system. -
Page 37: Commissioning Filled And Charged (Fc) Fnc Cells
Commissioning 7. Thoroughly remove any contamination on the battery system with a soft, damp cloth with water. 8. Refill the electrolyte level of each grid|power FNC ® cell with electrolyte to maximum. 9. Place the (vent/VR) plug vertically and insert it carefully to each FNC ®... - Page 38 The individual cell voltages should not vary by more than ± 50 mV from the mean of all cell voltages. If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service. 2. Remove the transport plug of each grid|power FNC ®...
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Page 39: Capacity Testing Of Batteries According To Din Iec 60623
The capacity test is part of the recondition charge, see 10.7 Reconditioning on page Maintenance Have the batteries serviced regularly and properly by HOPPECKE qualified personnel or personnel authorised by HOPPECKE Batterie Systeme GmbH. Observe the notes in chapter 2 Safety on page ... -
Page 40: Checking For Cleanliness And Condition Of The Battery System
Maintenance 10.1. Checking for Cleanliness and Condition of the Battery System A clean battery is absolutely necessary, in order to avoid reduced service life and availability of the battery. Cleaning of cell carriers, trays, racks and insulators is necessary in order to maintain the required insulation of the cells from each other, from the earth, and from other extraneous conductive parts. -
Page 41: Checking The Electrolyte Levels
® The difference between the FNC cells must be not greater than 5 mm. If the level of the electrolyte is not visible, use the glass tube for measuring (HOPPECKE material number: 4144140010) as described below. ® 1. Open or remove the plug of each grid|power FNC cell. - Page 42 Maintenance 4. Close the top opening of the glass tube with the index finger and remove it from the cell. 1 = Glass tube for measuring 2 = MAX electrolyte level 3 = Top of separator 4 = MIN electrolyte level H1 = Height from open cell plug to MAX electrolyte level H2 = Reserve of electrolyte between...
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Page 43: Measuring The Charging Voltage
Maintenance 8. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 10.3. Measuring the Charging Voltage The measurement of the voltage values is used to detect and identify faults. Recording the voltage values measured helps in doing so. Precondition The battery system is connected to a charging device and is being charged. -
Page 44: Testing The Insulation Resistance
Maintenance 10.4. Testing the Insulation Resistance The insulation resistance of a battery is a measure of the conductivity. It results of moisture and contamination of the battery between the battery poles and the chassis (rack/cabinet). Ideally, no conduction should take place here if the insulation resistance of the battery is infinitely large. -
Page 45: Cleaning
Maintenance 10.5. Cleaning A clean battery is absolutely necessary, in order to avoid reduced service life and availability of the battery. ATTENTION! Solvent and wire brushes can attack the walls of the battery cells. Do not use solvents or wire brushes to clean the batteries. ATTENTION! Cleaning water that penetrates into the battery or dirt particles can damage it. -
Page 46: Fill Up The Electrolyte Level With Distilled Water
If, however, you have to fill up the electrolyte level with distilled water, remove the VR plug carefully. It is recommended to use the HOPPECKE plug opener (Mat. No. 4142500125) Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically pull out the plug from the cell opening. - Page 47 Maintenance 2. Refill the electrolyte levels with distilled water to the maximum level. 1 = Glass tube for measuring 2 = MAX electrolyte level 3 = Top of separator 4 = MIN electrolyte level H1 = Height from open cell plug to MAX electrolyte level H2 = Reserve of electrolyte between MIN and MAX label...
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Page 48: Reconditioning
Maintenance 10.7. Reconditioning Reconditioning can eliminate or reduce capacity losses of a battery system. It is carried out by repeatedly discharging/charging of the battery system with constant current. DANGER! Danger of explosion due to formation of oxyhydrogen gas! When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen gas) is formed, which readily explodes with low energy input. - Page 49 Note - valid for grid|power FNC VR cells Remove a VR plug carefully. It is recommended to use the HOPPECKE plug opener (Mat. No. 4142500125) Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically pull out the plug from the cell opening.
- Page 50 If the discharge time is ≤ 4.5 hours, repeat the process from point 8. Note If the discharge time is still ≤ 4.5 hours after 5 repetitions of this procedure, contact HOPPECKE service. 12. Charge the battery system using a constant current of I for 7.5 hours.
- Page 51 18. Measure the voltages of the individual cells using a digital multimeter. Note If the individual cell voltages vary by more than ± 50 mV from the mean of all cell voltages, contact HOPPECKE service. 19. Clean the battery system if necessary. 20. Mount the insulation profiles.
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Page 52: Troubleshooting
Check the ventilation. Differences in the electrolyte density of the The equalization must be performed by cells. HOPPECKE service. Plate short-circuits in one or more cells. Measure the individual cell voltages. Change the defect cell(s). Various charge states of the cells. -
Page 53: Battery Voltage Not Measureable
Old batteries bearing this sign are recyclable economic goods and must be returned via the recycling process. You can use the HOPPECKE recycling system. The old batteries are picked up and returned to the recycling system. Contact HOPPECKE Service for further information. -
Page 54: Appendix
Appendix Appendix 13.1. Commissioning Record A record should be made during commissioning of the battery. Customer: Order No.: Where installed: Supplier: Battery No.: Cell type: No. of cells: Capacity [Ah]: Charging voltage (tick and fill out): Charging with constant current I Charging with constant current and constant voltage Constant current [A]:... - Page 55 Appendix Charging current: Start of charging End of charging Charger current [A] Temperatures: Start of charging End of charging Ambient [°C] Electrolyte [°C] of pilot cell number: Loading time: from Date Time [h] Commissioning confirmation: Date Signature Commissioning carried out by Acceptance (supplier) carried out Acceptance (customer) carried out by...
- Page 56 Appendix Measurement of individual cell voltages: Cell No. Open terminal voltage End-of-charge voltage Cut-off voltage after 5 15 min before end of hours discharge [V] charging [V] Hint: Reproduce this page according to the number of cells of your battery system. Manual_Grid_Power_FNC_en_V3_0...
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Page 57: Maintenance Log
Appendix 13.2. Maintenance Log Note Keep this maintenance log to provide a proof in case of warranty. Number of the battery system: _________________________________________ Commissioning date: _________________________________________ Manual_Grid_Power_FNC_en_V3_0... -
Page 58: Six-Monthly Maintenance Interval
Appendix 13.2.1. Six-monthly Maintenance Interval 13.2.1.1. Visual Inspection and Checking Electrolyte Level Interval Done (mark Date Inspector (name) (years) with a cross) 10.5 11.5 12.5 13.5 14.5 Manual_Grid_Power_FNC_en_V3_0... -
Page 59: Measuring Battery System Voltage
Appendix 13.2.1.2. Measuring battery system voltage Interval Measured Date Inspector (name) (years) value in Volt 10.5 11.5 12.5 13.5 14.5 Manual_Grid_Power_FNC_en_V3_0... -
Page 60: Annual Maintenance Interval
Appendix 13.2.2. Annual Maintenance Interval 13.2.2.1. Cleaning the battery system Interval Done (mark Date Inspector (name) (years) with a cross) Manual_Grid_Power_FNC_en_V3_0... -
Page 61: Insulation Testing
Appendix 13.2.2.2. Insulation testing Interval Measured Date Inspector (name) (years) value in Ohm Manual_Grid_Power_FNC_en_V3_0... -
Page 62: Filling Up Distilled Water
Appendix 13.2.2.3. Filling up distilled water Interval Done (mark Date Inspector (name) (years) with a cross) Manual_Grid_Power_FNC_en_V3_0... -
Page 63: Maintenance Interval Every 5 Years
Appendix 13.2.3. Maintenance Interval Every 5 Years 13.2.3.1. Reconditioning Interval Done (mark Date Inspector (name) (years) with a cross) Manual_Grid_Power_FNC_en_V3_0... -
Page 64: Measuring Of Single Cell Voltages
Appendix 13.2.3.2. Measuring of Single Cell Voltages Interval Cell number Measured Cell number Measured Cell number Measured (years) value in Volt value in Volt value in Volt Date: ______________________ Inspector: ______________________ Hint: Reproduce this page according to the number of cells of your battery system. Manual_Grid_Power_FNC_en_V3_0... - Page 65 Appendix Interval Cell number Measured Cell number Measured Cell number Measured (years) value in Volt value in Volt value in Volt Date: ______________________ Inspector: ______________________ Hint: Reproduce this page according to the number of cells of your battery system. Manual_Grid_Power_FNC_en_V3_0...
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Page 66: Useful Tools
(illustration shows an example) Insulation tester (illustration shows an example) External charge/discharge unit (illustration shows an example) Waterfilling cart: 230 V - HOPPECKE Mat. No.:4147000210 115 V - HOPPECKE Mat. No.:4147000215 Glass tube for measuring (HOPPECKE Mat. No.: 4144140010) Manual_Grid_Power_FNC_en_V3_0... - Page 67 Gas venting tube (HOPPECKE Mat. No.: 4143180100) Cell lifter Format 3, 4, 5: M10: HOPPECKE Mat. No.: 4141900003 Format 1, 2: M8, HOPPECKE Mat. No.: 4141900002 Plug opener for cells with valve plug (VR plug) (HOPPECKE Mat. No.: 4142500125)
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