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Related Manuals for Hoppecke grid power VX
Summary of Contents for Hoppecke grid power VX
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Page 2: Table Of Contents
Table of contents Preface ......................4 Safety notices ....................5 Explanation of the symbols used in the manual ..........5 Explanation of the symbols used on the battery ..........6 General information ................... 6 Personal Protective Equipment, Safety Clothing, Equipment ......8 Safety precautions .................. - Page 3 6.1.2 Calculating the safety distance ............24 Tools and equipment to carry out the installation ........25 Commissioning and maintenance protocol ..........26 Installing racks and cabinets ..............26 General information on connecting the batteries ........27 Installing the batteries ................28 6.6.1 Inserting batteries into the racks ............
- Page 4 Electrolyte density adjustment ..............42 Battery operation .................... 42 Modes ..................... 42 7.1.1 Standby parallel operation ..............43 7.1.2 Floating operation ................43 7.1.3 Switch mode operation (charge/discharge operation) ......44 General information on the operation ............44 7.2.1 Discharging ..................45 7.2.2 Charging –...
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Page 5: Preface
We assume no liability for direct and indirect damage resulting from improper handling and any warranty claim expires. We reserve the right to make changes to the content of this documentation. HOPPECKE Batterien GmbH & Co. KG is not liable for any errors in this documentation. Liability for indirect damages arising in connection with the use of this documentation is also excluded. -
Page 6: Safety Notices
2 Safety notices When handling the batteries and their components, observe the following safety instructions. Please also note the information in the ZVEI leaflet "Information on the safe handling of lead-acid batteries (lead-acid batteries)". 2.1 Explanation of the symbols used in the manual Danger from explosion, pressure There is a risk to the health of persons, waves, hot or molten substances flying... -
Page 7: Explanation Of The Symbols Used On The Battery
Attention! Work on batteries, in particular their installation and maintenance, may only be carried out by trained HOPPECKE specialist personnel (or personnel trained by HOPPECKE) who are familiar with the handling of Danger! batteries and know the necessary precautions. - Page 8 Method for absorbing spilled acid: Electrolyte is highly corrosive! In normal operation, contact with the electrolyte is excluded. When the housing is destroyed, the bound electrolyte released is just as corrosive as it is more liquid. Set spilled acid with binder, e.g. sand, and neutralize with lime, soda or caustic soda. Then dispose of in accordance with the official, local regulations.
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Page 9: Personal Protective Equipment, Safety Clothing, Equipment
Please also observe all regulations, writings and standards, as described in chap. 3.5 . Risk of fire, explosion or burns. Do not disassemble, heat above 45°C or burn. Danger! 2.4 Personal Protective Equipment, Safety Clothing, Equipment When working on batteries, wear face protection (impact-resistant visor according to EN 166 Class F or comparable), safety goggles, protective gloves and protective clothing! -
Page 10: Safety Precautions
2.5 Safety precautions 2.5.1 Sulfuric acid Batteries are safe when handled properly. However, they contain sulfuric acid (H which can cause severe chemical burns and serious injuries. Always wear protective gloves when handling lead-acid batteries and use proper tools. Please note the following information and read the ZVEI leaflet "Information Danger! on the safe handling of lead-acid batteries". -
Page 11: Explosive Gase
2.5.2 Explosive Gase Inside lead-acid batteries is an explosive hydrogen/oxygen-gas mixture that can leak out of the battery. In the event of an explosion of the mixture, serious personal injury can occur due to flying particles. Danger! • Always wear prescribed protective clothing (face protection (impact- resistant visor according to EN 166 Class F or comparable), safety goggles, voltage-insulating gloves and safety shoes, etc.) •... -
Page 12: Electric Shock And Burns
Open flames or fire, smoldering sparks or flying sparks during grinding work, electrical sparks from switches or fuses, hot surfaces > 200 °C and – an often-underestimated cause – electrostatic discharges. Measures to avoid oxyhydrogen ignition due to electrostatic discharges: Please note the following points to avoid electrostatic discharge on the battery, your body or your clothing: •... -
Page 13: General Information
3 General information HOPPECKE offers numerous lead-acid batteries as a single cell (nominal voltage 2 V) or block (nominal voltage: 4 V, 6 V or 12 V) for a wide variety of applications. -
Page 14: Disposal And Recycling
Hoppecke site. The HOPPECKE metal smelter is the only lead smelter in Europe to be successfully certified according to: • DIN EN ISO 9001 (Procedures and Procedures) -
Page 15: Service
HOPPECKE has a worldwide service network that you should take advantage of. The HOPPECKE service is available to you if you would like to have professional supervision during the installation of the battery system, if you need parts or accessories or if maintenance work must be carried out on the system. -
Page 16: References To The Standards And Regulations
3.5 References to the standards and regulations The references to the applicable standards, regulations, etc. should help you to install and use the HOPPECKE products correctly. However, it is not possible to always cite all regulations and applicable standards according to the current edition. Therefore, these instructions are to be understood as support and not as direct instructions. -
Page 17: Ce And Ukca Marking
o Make sure that the connections are tight. o Only use technically flawless charging cables in sufficient cross-sections. o Batteries must not be connected or disconnected while power is flowing, or the charger is on. o Before opening the charging circuit, check the switched off state of the charger by voltage measurement. -
Page 18: Delivery Completeness And Externally Visible Damage
If you have any questions in connection with incompleteness of the delivery or damage to the delivered products, please contact your local HOPPECKE contractual partner. Alternatively, you can reach us directly at the head office. -
Page 19: Storage Time
The battery must then be operated in constant charge maintenance. The useful life of the battery(s) begins with delivery from the HOPPECKE factory. Storage times on site are to be fully credited towards the useful life. grid | power VX (GroE) must be recharged after 6 weeks when stored @20 C. -
Page 20: Recharge
If the maximum storage time is exceeded and/or at higher average storage temperatures, charge acceptance may be more difficult during recharging. In such cases, HOPPECKE recommends the use of an advanced charging Attention! method that ensures gentle and complete recharging of the blocks/cells. -
Page 21: Installation
6.1 Requirements for the installation site If you have any questions about the installation of the battery system, please contact your local HOPPECKE dealer. Alternatively, you can reach us directly at the head office. When determining the installation location and space requirements and when carrying out the installation work, please refer to the valid installation drawing, if available. -
Page 22: Ventilation Of The Battery Room
Accommodation of the We recommend the proper installation of the batteries in batteries HOPPECKE battery racks or cabinets. The use of operator-owned solutions may void the warranty for batteries. Country-specific. In some countries, it is mandatory that racks with the regulations batteries be installed in drip trays. -
Page 23: Avoidance Of Explosion Hazards
6.1.1.1 Avoidance of explosion hazards As the gases produced when charging batteries cannot be avoided, the hydrogen concentration must be diluted by sufficient ventilation. Spark-generating equipment is not permitted in the vicinity of batteries. Ignition sources for oxyhydrogen explosions can be: •... -
Page 24: Lead-Acid Batteries
�� = Nominal capacity of the battery Summary of factors: �� × �� × �� = ��, ���� �� �� �� �� = ��, ���� × �� × �� × ������ �� ���� , �� ���� �� ������ ������ ������������ ��... -
Page 25: Calculating The Safety Distance
• Supply and exhaust air openings required o Openings on opposite walls o Minimum separation distance of 2 m when openings on the same wall �� • Minimum cross-section each (Air inlet / outlet): �� ≥ 28 × �� (�� ���� ���� , Q in Assumption: ��... -
Page 26: Tools And Equipment To Carry Out The Installation
�� −3 = 0,05 × 〈 �� 〉 × �� �� × �� × 10 ������ ������ ℎ �� ℎ �� ������ �� Required radius of hemisphere: �� = 28,8 × ( √ �� × √ �� × √�� (����) ������... -
Page 27: Commissioning And Maintenance Protocol
6.4 Installing racks and cabinets We recommend the proper installation of the batteries in HOPPECKE battery racks or HOPPECKE battery cabinets. If operator-owned solutions are used, the warranty of the battery(s) may expire. HOPPECKE supplies various types of racks. For information on the... -
Page 28: General Information On Connecting The Batteries
When using wooden frames: Install a flexible connection on each frame joint! As an alternative to installation in racks, the batteries can also be installed in HOPPECKE battery cabinets. Either the cabinets are delivered with batteries already installed or the batteries are installed in the cabinets on site. -
Page 29: Installing The Batteries
Batteries > 60 �� grid | Xtreme VR > 230 �� max. 6 strings In special cases, consultation with Hoppecke is necessary. If the above points are not met, the strings must be charged separately before the parallel connection is carried out. -
Page 30: Inserting Batteries Into The Racks
(in accordance with IEC 62485-2) must be observed. For example, electrically conductive parts must be covered with insulating mats. 6.6.1 Inserting batteries into the racks 1. Apply some soft soap to the support rails of the frame to make it easier to move the batteries sideways after they have been put down. -
Page 31: Procedure For Filled Batteries
If the open-circuit voltage is low during storage, the battery should either be recharged as described in chap. 5.3 or put into operation as described in the chap. 6.7. In the event of major deviations, it is necessary to consult your local HOPPECKE contractual partner. -
Page 32: Electrolyte Level
(funnels), but not made of stainless steel, must be used. The plugs already fitted to the batteries are HOPPECKE labyrinth plugs. These plugs, or the alternative variants listed in chap. 6.6.4 must remain on the batteries after the cells have been filled and during regular operation. -
Page 33: Variants Of Plugs
6.6.4 Variants of plugs This section describes the different variants of cell plugs. These plugs are included in the HOPPECKE accessories list and can also be retrofitted later if required. 6.6.4.1 Labyrinth plugs (delivery condition) The labyrinth plug prevents aerosols from escaping with the help of the internal labyrinth. -
Page 34: Ceramic And Ceramic Funnel Plugs
Illustration 6-3 - grid | AquaGen pro (max) 6.6.4.3 Ceramic and ceramic funnel plugs Thanks to their porous ceramic body, ceramic plugs ensure better retention of acid aerosols and water vapor. They have a backfire-inhibiting effect. Illustration 6-4 - Ceramicsstopfen Ceramic funnel plugs have the same effect as the previously mentioned ceramic plugs. -
Page 35: Service Plugs
6.6.4.4 Service plugs HOPPECKE cell containers are equipped with service openings, which are sealed with a green EPDM plug (see illustration 6-1). This opening can be used for water refilling, electrolyte removal, acid density measurement and electrolyte temperature measurement. Especially in combination with the recombination plug grid | AquaGen pro, it is recommended to use this opening, as it is no longer necessary to remove the recombination plug. -
Page 36: Type Of Connecting Cables
(U, kW, A). If this is not the case, please contact your local HOPPECKE contractual partner. The battery system has been designed in such a way that the above performance characteristics are available on the battery terminals. The voltage drop between the battery terminals and the consumers should therefore be kept to a minimum. -
Page 37: Connect Batteries To Battery Connectors
• Avoidance of any mechanical stress on the cells or battery terminals. Cables with large cross-sections should be intercepted by cable clamps The connecting cables between the main connection poles and the charging rectifier or UPS should be designed as flexible conductors. 6.6.6 Connect batteries to battery connectors There are screwable row connectors, step connectors and tier connectors (cf. -
Page 38: Clamp The Connection Plates To The Batteries
grid | power VM 2-105: 15 Nm grid | power VM 6-50 and 6-100: 12 Nm Careful tightening of the connections is essential, as a loose connection can lead to excessive heating, which could result in ignition or explosion. For tightening the pole bolts on block batteries of the grid- and sun | power VR L as well as grid and sun | power V L is to use a wrench size of 20 mm. - Page 39 To connect the cables to cells with several pairs of battery terminals, the use of original HOPPECKE connection plates is strongly recommended. If other solutions are used, there may be a risk of overheating and fire due Attention! to increased contact resistance! Figure 6.6.8-1 - Mounting the terminal plate to the end terminals of the battery...
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Page 40: Connect The Battery System To The Dc Power Supply
2. If necessary: Provide the cells or block batteries with a continuous numbering in a visible place (from the positive terminal of the battery to the negative terminal). Number stickers are supplied by HOPPECKE. 3. Attach polarity plates to the battery connectors. -
Page 41: Commissioning Charge (Initial Charge)
vibrations, which may lead to the connection being loosened. The cables must be supported in such a way that no mechanical forces can be transmitted to the connection terminals (cable trays, cable ducts, cable clamps). 6.7 Commissioning charge (initial charge) As a rule, the batteries are no longer fully charged at the time of installation. -
Page 42: Commissioning Charge With Constant (I-Characteristic Curve) Or Decreasing Current (W-Characteristic Curve)
Therefore, the electrolyte density must not be measured in the boost- charge phase. Measuring the acid density in the boost-charge phase can lead to electrostatic discharge and the high hydrogen gas concentration can lead to deflagration. Therefore, the following steps should be followed: •... -
Page 43: Electrolyte Level Check
4. 4 hours of charging with 5 A per 100 Ah C Repeat items 3 and 4 until all • Cells have reached a voltage of at least 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, please note the second warning from the chapter. -
Page 44: Standby Parallel Operation
7.1.1 Standby parallel operation DC power source Consumer Battery Figure 7.1.1-1 - Standby parallel operation Characteristic of this mode of operation are: • Consumer, DC power source and battery are constantly connected in parallel • The charging voltage is the operating voltage of the battery and at the same time the system voltage •... -
Page 45: Switch Mode Operation (Charge/Discharge Operation)
7.1.3 Switch mode operation (charge/discharge operation) DC power source Consumer Charger Battery Figure 7.1.3-1 - Switchover operation Characteristic of this mode of operation are: • When charging, the battery is disconnected from the consumer • Vented lead-acid battery: The charging voltage is 2.6 to 2.75 V/cell towards the end of the charge (depending on depth of discharge and number of cyclic loads) Valve regulated lead-acid battery: The charging voltage for sealed batteries is max. -
Page 46: Discharging
Vented / VRLA batteries: -20°C to +40°C grid | Xtreme VR batteries: - 40 °C to + 55 °C (with short peaks up to 60°) When using the HOPPECKE grid | AquaGen recombination system in the context of vented batteries, the operating temperature of the recombination system must always be ≥... - Page 47 10 A/100 Ah should not be exceeded. Temperature-dependent adjustment of the charging voltage Temperature compensation of the voltage is necessary if the battery operating temperature deviates from 20 °C. Hoppecke recommends Attention! -4 mV/K. If the inverter cannot realize the compensation (technically), the border area would be 15 °C to 25 °C (see Figure 7.2.2-1).
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Page 48: Float Charging
grid | power VL grid | power VM grid | power V X grid | power VH I-characteristic curve 5.0 A 6.5 A 2.6 to 2.75 V/cell (DIN 41776) W characteristic 7.0 A 9.0 A at 2.4 V/cell curve 3.5 A 4.5 A at 2.65 V/cell (DIN 41774) -
Page 49: Battery Maintenance
Example for grid | power V L cells: Float charge voltage max. = 2.33 V/cell and min. 2.18 V/cell (with average charge float voltage of 2.23 V/cell). 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. -
Page 50: Inspection For Cleanliness And Cleaning Of The Battery System
| AquaGen recombination systems. This also includes checking and, if necessary, balancing the electrolyte levels in the battery cells. HOPPECKE recommends using a stationary battery monitoring system to monitor relevant data. Please contact your local HOPPECKE representative. 8.1 Inspection for cleanliness and cleaning of the battery system Regular cleaning of the battery is necessary to ensure availability and compliance with accident prevention regulations. -
Page 51: Measuring The Charging Voltage
Keep the battery clean and dry, as dust and moisture can lead to leakage currents. During the visual inspection, check the battery, the screw connections and the battery rack or battery cabinet for dirt or mechanical damage. The battery must be cleaned if it becomes dirty. -
Page 52: Refill Distilled Water
Figure 8-1 - Hydrometer Dependence of electrolyte density on temperature The electrolyte is diluted sulfuric acid. The nominal density of the electrolyte refers to 20 °C and the nominal electrolyte level in a fully charged state. The maximum permissible deviation is ± 0.01 kg/l. Higher temperatures reduce the electrolyte density, lower temperatures increase the electrolyte density. -
Page 53: Checking The Screw Connections
Minimum value for the battery system: 100 Ω x 2 V x number of battery cells in series. In the case of block batteries, the nominal voltage of the block battery and the number of blocks is applied accordingly. For grid | power batteries, an insulation measuring device with a test voltage of 500 V/1000 V can be used (according to DIN VDE 0100-600). - Page 54 Figure 8-2 - Characteristic curve IU Further characteristic curves are possible according to W or I characteristics. The charging voltages increase to (2.60 to 2.75 V) x number of cells. As a rule, the loads must therefore be switched off beforehand. With the W or I characteristic, the charging currents are not limited until the charging voltage has reached the gassing voltage of 2.40 V x number of cells.
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Page 55: General Information On How To Carry Out The Capacity Check
Figure 8-3 - Characteristic curve IUIa Due to the increased gas development in the W, I or IUIa charging method, increased ventilation of the battery compartment is necessary. A full charge of the battery is generally achieved if the charging voltage/charging current (depending on the charging method) and the electrolyte density no longer change within 2 hours. -
Page 56: Implementation Of The Capacity Test And Evaluation
Requirements for the accuracy class of the above-mentioned measuring equipment can be found in Table 8-5. Table 8-5 - Requirements for the accuracy of the measuring instruments (accuracy class) For voltage measurement: For current measurement: For temperature measurement: 1 °C For timekeeping: Acid density: 0.005 kg/l... - Page 57 to the project planning data tables up to a certain final discharge voltage and the given loads. In the capacity test, after 10% of the discharge time has elapsed, the discharge current or discharge power, temperature, battery voltage as well as the cell or block voltage and the discharge time should be recorded.
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Page 58: Notes On Impedance Measurement
Immediately after the capacity test, the battery must be charged. The measured capacity C (Ah) at the average initial temperature is calculated as the product of the discharge current (in amperes) and the discharge time (in hours). Since the battery capacity depends on the temperature, a temperature correction of the measured battery capacity must be performed. -
Page 59: Troubleshooting
9 Troubleshooting If faults are detected on the battery or the charging system, customer service must be called immediately. Measurement data in accordance with chap. 8 simplifies troubleshooting and fault rectification. A service contract with us makes it easier to detect faults in good time. -
Page 60: Battery Voltage Not Measurable
Possible cause Remedy Battery contamination Cleaning the battery, see chap. 8.1 Fix the cause of the leak; if necessary, Leaks in a cell/block replace the cell, see chap. 9.5 9.4 Battery voltage not measurable If no battery voltage is measurable, do the following: Possible cause Remedy Search for the fault, switch or replace the... -
Page 61: Distilled Water Consumption
See chap. 7.2.4 Check the electrolyte for contamination, Contaminated electrolyte contact Hoppecke if necessary. 10 Disassembly When dismantling a battery system, all safety instructions listed in this document must be considered, see chap. 2. This includes, in particular, personal protective equipment,... - Page 62 • If the battery system is equipped with HOPPECKE grid | AquaGen recombination systems or ceramic funnel plugs, these must be removed in accordance with the relevant operating instructions and the cells/blocks filled with demineralized water up to the max.
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Page 63: Parameter Data Sheet For Sun | Power V L Batteries
11 Parameter data sheet for sun | power V L batteries This chapter contains instructions for charging the HOPPECKE sun | power V L battery cells and blocks in solar applications. sun | power V L sun | power V L... - Page 64 max. 5 A/100 Ah C for 2 max. 5 A/100 Ah C for 2 to 4 h to 4 h Max. Current (observe fuses 6 x I 6 x I and cable lengths) 2.55 Vpc at IU- 2.55 Vpc at IU- characteristic curve characteristic curve Max.
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