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Hoppecke grid Xtreme VR 12-110 Installation, Commissioning And Operating Instructions

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Summary of Contents for Hoppecke grid Xtreme VR 12-110

  • 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 ............21 Tools and equipment to carry out the installation ........23 Commissioning and maintenance protocol ..........23 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 8.2.2 General information on how to carry out the capacity check ....43 8.2.3 Implementation of the capacity test and evaluation ......44 Notes on impedance measurement ............46 Troubleshooting ....................46 Scattering of the individual cell voltages ............ 46 Available capacity too low.................

  • 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

    HOPPECKE dealer. Alternatively, you can reach us directly at the head office. 3 General information The HOPPECKE grid | Xtreme VR series are maintenance-free VRLA batteries with a nominal voltage of 12 V. 3.1 Specifications Each cell/battery block has its own nameplate on the top of the cell/block cover.

  • 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

    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...
  • Page 14 HOPPECKE. Please note the following regulations (IEEE standards only apply to the USA): •...

  • Page 15: Ce And Ukca Marking

    3.6 CE and UKCA marking For batteries that cover a voltage range of 4 V to 1500 V DC, a CE declaration of conformity is required in accordance with the Battery Regulation EU 2023/1542. In addition, the requirements of the Low Voltage Directive 2014/35/EU must be observed for battery systems with a nominal voltage of 75 V to 1500 V DC.

  • 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: 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 19 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 20: Ventilation Of The Battery Room

    6.1.1 Ventilation of the battery room It must be ensured that the requirements of IEC 62485-2 regarding installation and ventilation are complied with. If, during commissioning charging, the charging current is higher than the current used as a basis for the design of the ventilation equipment, the ventilation of the battery room must be increased for the duration of commissioning and for one hour thereafter in accordance with the charging current used, e.g.

  • Page 21: Calculating Ventilation Requirements For Battery Rooms

    6.1.1.2 Calculating Ventilation Requirements for Battery Rooms Air Volume Flow Q: �� �� = �� × �� × �� × �� × �� × ������ ������������ �� = Dilution factor = 96 % air / 4 % H2 = 24 ��...

  • Page 22: Natural Ventilation

    Typical boost-charge current, �� ���������� mA per Ah : Current (boost charging), mA �� ������ per Ah (refers to the calculation of the air volume flow during boost charging) Float and boost-charge voltages may vary depending on the specific electrolyte density in lead-acid batteries.
  • Page 23 distance "d" from the gassing source, assuming a hemispherical spread. The safety distance d can also be read from Figure 6.1-1. The more detailed calculations are shown below. Safety: The required safety distance must be calculated in accordance with IEC 62485-2. Volume of a hemisphere: Air volume flow required to dilute the produced hydrogen H to max.

  • Page 24: Tools And Equipment To Carry Out The Installation

    6.2 Tools and equipment to carry out the installation The batteries are delivered on pallets, and the necessary accessories are included in separate packaging units. Please note all the information from the previous chapters. For the installation, you will need your personal protective equipment, safety clothing, safety tools and other equipment, as described in chap.

  • Page 25: Installing Racks And Cabinets

    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 assembly, please also refer to the separate documentation that comes with each rack.

  • Page 26: General Information On Connecting The Batteries

    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. HOPPECKE supplies various types of cabinets.

  • 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: Horizontal Installation

    When installing the grid | Xtreme VR, 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.

  • Page 29: Open-Circuit Voltage Measurement

    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 30: 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 31: Connect Batteries To Battery Connectors

    6.6.5 Connect batteries to battery connectors There are screwable row connectors, step connectors and tier connectors (cf. Figure 6.6.5-1). The row connectors are used to connect the individual cells/block batteries, the step connectors to connect the individual steps to each other (use of step racks) and the tier connectors to connect the tiers (use of floor racks).

  • Page 32: 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 33: 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 34: Commissioning Charge With Constant Voltage (Iu Characteristic Curve)

    5. During commissioning, the cell voltage on the pilot cells and, after completion of commissioning, the cell voltage and surface temperature on all cells must be measured and recorded in the commissioning report with time. The surface temperature of the battery cells/units must not exceed 55 °C, if necessary, charging must be interrupted until the temperature has dropped below 45 °C.

  • Page 35: 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 36: 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 37: 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 38: Charging - General

    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! -2,5 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 39: Float Charging

    Figure 7.2.2-1 - Temperature-dependent adjustment of the float charge voltage for grid | Xtreme VR with a float charge voltage of 2.30 V/cell at T nominal Maximum charging currents grid | Xtreme VR batteries have a very high charging acceptance and are therefore ideally suited for applications that need to be ready for use again in a short time.

  • Page 40: Equalizing Charge (Correction Charge)

    Example: Nominal voltage of the battery: 60 V, i.e. the charging voltage of the charger for float charge mode is 30 x float charge voltage per cell. E.g. 30 x battery cells grid | Xtreme VR results in a charging voltage of 30 x 2.30 V/cell = 69 V ± 1 % (= max. 68.31 V / min. 69.69 7.2.4 Equalizing charge (correction charge) Under normal circumstances, equalizing charges are not necessary.

  • Page 41: Battery Maintenance

    Please note that the float charge voltages of grid | Xtreme VR batteries may fluctuate significantly in the first 6 months after commissioning. Initially observed voltage fluctuations typically decrease with continuous standby Attention! parallel operation and then stabilize at the usual level. Background: Since pure lead batteries do not have alloy components in the electrodes, discrete voltage levels with steep rising edges are formed.

  • Page 42: 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 43 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. In contrast to charging with constant voltage, a constant charging current of 0.8 A/100 Ah is switched on for 3 hours in the last step after the IU charging has been completed.

  • Page 44: General Information On How To Carry Out The Capacity Check

    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 45: Implementation Of The Capacity Test And Evaluation

    4. Prepare an adjustable load that you can connect to the battery system. The load current must be equal to the maximum allowable current for which the battery is designed. 5. Provide a shunt that you can connect in series with the load. 6.
  • Page 46 Table 8-2 - Measured cell voltages and total voltage after 95% of the required discharge time Cell number Case A Case B Case C 1,84 1,84 1,79 1,83 1,86 1,80 1,83 1,87 1,81 1,84 1,87 1,80 1,84 1,86 1,81 1,85 1,86 1,79 1,69...

  • Page 47: Notes On Impedance Measurement

    According to the DIN EN 60896-21 standard, a capacity test is considered to have been passed if the battery reaches 95% of the required capacity at the first discharge. The battery must deliver 100% of the required capacity after the fifth discharge at the latest. A report must be drawn up after discharging (see test report).

  • Page 48: Available Capacity Too Low

    9.2 Available capacity too low Insufficient capacity can be due to the following causes: Possible cause Remedy Carry out an equalizing charge, see chap. Electrolyte Stratification (VLA) Electrolyte levels below the minimum Refill distilled water, see chap. 8 (VLA batteries) Check all connections, replace Loose or oxidized terminal terminals connectors if necessary.

  • Page 49: Disassembly

    After loosening the connectors, cells/block batteries must be moved, please refer to the instructions in the chap. 6.6. Lifting the cells/block batteries at the terminals is prohibited, as this will destroy the cells/block Attention! batteries. Removal of the defective cell / block battery: 1.
  • Page 50 • Disconnect the supply lines (circuit breakers, fuses, switches) before starting disassembly. Only to be carried out by authorized personnel! Check that the battery is disconnected from all charging equipment and consumers. • For battery systems with a nominal voltage > 60 V, first remove the group and level connectors in order to divide the battery system into smaller partial voltages.

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