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Summary of Contents for Hoppecke grid power VR L
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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 ......7 Safety precautions .................. - Page 3 6.1.2 Calculating the safety distance ............22 Tools and equipment to carry out the installation ........23 Commissioning and maintenance protocol ..........24 Installing racks and cabinets ..............24 General information on connecting the batteries ........25 Installing the batteries ................26 6.6.1 Inserting batteries into the racks ............
- Page 4 8.2.1 Preparing the battery system for capacity testing ......... 46 8.2.2 General information on how to carry out the capacity check ....48 8.2.3 Implementation of the capacity test and evaluation ......49 Notes on impedance measurement ............51 Troubleshooting ....................51 Scattering of the individual cell voltages ............
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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. Please also observe all regulations, writings and standards, as described in chap. 3.5 . -
Page 8: Personal Protective Equipment, Safety Clothing, Equipment
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! Observe the accident prevention regulations as well as DIN EN 50110-1 and IEC 62485-2... -
Page 9: Safety Precautions
2.5 Safety precautions 2.5.1 Sulfuric acid Sealed lead-acid batteries are safe when handled properly. However, they contain dilute sulfuric acid (H ), which is bound in gel or fleece. The bound sulfuric acid can cause severe chemical burns and serious injuries. 2.5.2 Explosive Gase Inside lead-acid batteries is an explosive hydrogen/oxygen-gas mixture that can leak out of the battery. -
Page 10: Electric Shock And Burns
This is true regardless of battery technology, design or manufacturer and is typical of all lead-acid batteries. The energy required to ignite oxyhydrogen is very low and can be released or supplied in the following ways: Open flames or fire, smoldering sparks or flying sparks during grinding work, electrical sparks from switches or fuses, hot surfaces >... -
Page 11: 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 12: 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 13: 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 14: 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 15: 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 16: 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 17: 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. If a longer storage period (e.g. several months) is planned, it is recommended that you obtain a suitable charger in good time so that the above-mentioned recharging can be carried out. -
Page 18: 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 19: 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 20: 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 21: 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 22 �� = Nominal capacity of the battery Summary of factors: �� × �� × �� = ��, ���� �� �� �� �� = ��, ���� × �� × �� × ������ �� ���� , �� ���� �� ������ ������ ������������ ��...
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Page 23: Calculating The Safety Distance
The following points should be noted: Natural ventilation: • 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 24: Tools And Equipment To Carry Out The Installation
Air volume flow required to dilute the produced hydrogen H to max. 4% in the air: �� −3 �� = 0,05 × 〈 �� 〉 × �� × �� × 10 ������ ������ ℎ �� ℎ �� ������ �� Required radius of hemisphere: ��... -
Page 25: 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 26: 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 27: 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 28: 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 29: Horizontal Installation
6.6.2 Horizontal Installation Horizontal installation of the grid | power VRL Batteries of the grid | power VR L and sun | power VR L series can also be placed horizontally in racks or cabinets. These are optional variants for horizontal operation. These variants need to be ordered separately. - Page 30 When installing AGM cells or blocks horizontally, the orientation of the electrodes ("Toasted" – plates are upright / "Pancake" – plates lie flat on top of each other) can be freely selected. However, HOPPECKE recommends using the "pancake" variant, as this can actively counteract possible electrolyte stratification during operation.
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Page 31: Open-Circuit Voltage Measurement
Note on connecting the cells/batteries: After positioning the cells/blocks in the cabinet/rack, they should be connected using the connectors supplied. If a drawing is available, it should be used as a guide: 6-4 Example of horizontal battery assembly with grid | power VR M on a rack In the case of a seismic battery cabinet, the stiffening struts should be attached after wiring. -
Page 32: Connecting Batteries
(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 33: Connect Batteries To Battery Connectors
• Routing of cables with double insulation (e.g. H07RN-F, NSGAFöu) in a common cable duct • Insulation strength of the cable is above the maximum possible system voltage • Additional insulation of the connectors is required • Avoidance of any mechanical stress on the cells or battery terminals. - Page 34 Exceptions: Series power.com H.C: • M5: 2 - 3 Nm Attention! • M6: 4 - 5.4 Nm • M8: 11 - 14 Nm Series grid | Xtreme VR: 15 Nm 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.
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Page 35: Clamp The Connection Plates To The Batteries
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! - Page 36 Figure 6.6.7-1 - Mounting the terminal plate to the end terminals of the battery Installation of standard connection plates 1. Screw the connection bracket onto the end terminals of the battery (cf. Figure 6.6.7-1). Be careful not to mechanically damage the terminals. Attention! 2.
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Page 37: 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 38: Commissioning Charge (Initial Charge)
The first charge (time-limited) is a so-called "boost charge". Baureihe power.com H.C This battery should be cycled 2 to 3 times before it reaches its nominal capacity. Hoppecke recommends C discharge and a charge Attention! according to 6.7.1. After that, the battery can be used normally. -
Page 39: Extended Commissioning Charge
6.7.2 Extended commissioning charge Long storage or climatic influences (humidity, temperature fluctuations) reduce the state of charge of the cells. This will require extended commissioning charge. Extended commissioning is only carried out if the storage period (see chap. 5) is not exceeded. Conduct the extended commissioning charge according to the following procedure: 1. -
Page 40: Floating Operation
• To shorten the recharging time, a charging stage can be used at which the charging voltage is max. 2.4 V x number of cells (standby parallel operation with recharging stage) 7.1.2 Floating operation Characteristic of this mode of operation are: •... -
Page 41: General Information On The Operation
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 42: Discharging
5 A/100 Ah. 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! -3 mV/K. If the inverter cannot realize the compensation (technically), the border area would be 10 °C to 30 °C (see Figure 7.2.2-1). Nevertheless, the compensation should be realized. -
Page 43: Float Charging
Figure 7.2.2-1 - Temperature-dependent adjustment of the float charge voltage for battery types with a float charge voltage of 2.25 V/cell at Tnenn Maximum charging currents Up to 2.4 V/cell the battery is able to absorb the maximum current the battery charger provides. -
Page 44: Float Voltage
Table 7.2.3-1 – Float charge voltage in standby parallel operation Battery Float Voltage grid | power VR L (OPzV) 2.25 ± 1 % V/Zelle grid | power VR L (OPzV bloc) 2.25 ± 1 % V/cell net.power 12 V 100 and 150 Ah 2.25 ±... - Page 45 Example of grid | power VR L cells: Charge float voltage max. = 2.45 V/cell and min. 2.15 V/cell (at average float charge voltage of 2.25 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.
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Page 46: Battery Maintenance
Figure 7.2.4-1 - Tendency of the float charge voltage over the service life of gel batteries 8 Battery maintenance Regular care and maintenance of your battery system is essential for the required reliability and longevity. You should document the type and extent of the maintenance work as well as all measurement results as well as possible. -
Page 47: Cleaning The Battery
HOPPECKE recommends using a stationary battery monitoring system to monitor relevant data. Please contact your local HOPPECKE representative for more information. 8.1 Cleaning the battery Regular cleaning of the battery is necessary to ensure availability and compliance with accident prevention regulations. - Page 48 temperature (cell/block temperature) exceeds the maximum value of 45 °C, charging must be interrupted or temporarily switched to float charging so that the temperature drops. Figure 8-1 - Characteristic curve IU An even more effective method of preparing the batteries is the IUIa charging method, which involves an additional constant current charging step.
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Page 49: General Information On How To Carry Out The Capacity Check
Figure 8-2 - Characteristic curve IUIa Due to the increased gas development in the IUI charging method, increased ventilation of the battery compartment is necessary. A full charge of the battery is generally achieved if the voltage and charging current no longer change within 2 hours. 8.2.2 General information on how to carry out the capacity check Tests shall be carried out in accordance with EN 60896-21: "Stationary lead-acid batteries", Part 21: "Sealed designs –... -
Page 50: Implementation Of The Capacity Test And Evaluation
Table 8-1 - Requirements for the accuracy of the measuring instruments (accuracy class) For voltage measurement: For current measurement: For temperature measurement: 1 °C For timekeeping: Below you will find general information on how to determine the actual capacity of your battery system. - Page 51 In any case, however, the values at 10%, 50%, 80% and 95% of the discharge time must be recorded. The discharge is to be terminated when the battery voltage has reached the value n x U , where n is the number of cells and U is the selected final discharge voltage per cell.
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Page 52: Notes On Impedance Measurement
At temperatures above the nominal temperature of 20 °C, the battery capacity increases, while at lower temperatures it decreases. If the average initial temperature deviates from the reference temperature of 20 °C, the capacity must be adjusted. The temperature correction is carried out in accordance with the DIN EN 60896-21 standard according to equation [1]. -
Page 53: Available Capacity Too Low
Possible cause Remedy Different cell temperatures Check the charger Different electrolyte densities of the cells Carry out an equalizing charge, see chap. (VLA batteries) Measuring cell voltages, replacing Plate shorts in one or more cells defective cells Different charge levels of the cells/block Carry out an equalizing charge, see chap. -
Page 54: Replacement Of A Cell/Battery In The String
Possible cause Remedy Search for the fault, switch or replace the A fuse has tripped fuse Cable break Replace cables Defective connectors Replace connectors 9.5 Replacement of a cell/battery in the string It is essential to make sure that the exchange is de-energized. Before disconnecting the connectors, the circuit must be switched off. -
Page 55: Disassembly
Installation of filled and charged batteries If a cell or a block in a battery string needs to be replaced and the replacement cell/block is filled and charged, the procedure is described in chap. 6.6. 10 Disassembly When dismantling a battery system, all safety instructions listed in this document must be considered, see chap. -
Page 56: Parameter Data Sheet For Sun | Power Vr Batteries
11 Parameter data sheet for sun | power VR batteries This chapter contains instructions for charging the HOPPECKE sun | power VR L and sun | power VR M battery cells and blocks in solar applications. Table 11-1 - Charging and discharging parameters... - Page 57 max. 0.8 A/100 Ah C max. 0.8 A/100 Ah C 2 to 4 h 2 to 4 h Max. Current (observe fuses 6 x I 6 x I and cable lengths) 2.55 Vpc at IU- characteristic curve Max. voltage absorption phase 2.4 Vpc 2.4 Vpc at IUIa- characteristic curve...
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