Installation, Commissioning and Operating Instructions: For Valve-Regulated Stationary Lead-Acid Batteries

Installation, commissioning and operating instructions
for valve-regulated stationary lead-acid batteries
Similar to the illustration

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 this product; all warranty claims become
null and void.
HOPPECKE reserves the right to make changes to the contents of this documentation. HOPPECKE Batterien
GmbH & 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 Email:
[email protected]
or by phone on working days between the hours of 8 am and 4 pm (CET) at the following number:
Telephone +49(0)2963 61-0
Fax +49(0)2963 61-481.
Your Team from

HOPPECKE Batterien GmbH & Co. KG
Postal address:
P.O. Box 11 40
D-59914 Brilon
Germany
Head office address:

Bontkirchener Straße 1
D-59929 Brilon-Hoppecke
Telephone +49(0)2963 61-0
Fax +49(0)2963 61-449
Internet www.hoppecke.com
Email [email protected]

Type und Design: PRIOTEX Medien GmbH, 59609 Anröchte
© 2013 HOPPECKE Batterien GmbH & Co. KG

P.O. Box 11 40
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 & Co. KG. Noncompliance will result in a
claim for damages.
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (03.2021) 7140203153 V1.4 (03.2021)
2 3
Used Symbols Any acid splashes on the skin or in the eyes must be rinsed with plenty of clean water immediately.
Then seek medical assistance.
The following safety notes need to be observed. Listed symbols are used multiple times for safety relevant Spillages on clothing should be rinsed out with water.
information:
Personal health, batteries or the environment are at risk. Recycling.

Failure to observe this hazard notice can lead to severe or fatal injury.
Danger! Spent batteries have to be collected and recycled separately from normal household
Batteries, materials or the environment are at risk. Personal safety is not at risk. wastes.
Failure to observe this notice can lead to malfunction or damage to the batteries. In addition, Pb
material and environmental damage may occur.
Attention! General notice or tip for better understanding and optimum use of the battery or batteries.
Risk of explosion or blast, splashing of hot or molten substances.

Risk of explosion and fire, avoid short circuits.
Avoid electrostatic charges and discharges/sparks.
Failure to observe this hazard notice can lead to severe or fatal injury. 0 Safety notices
0.1 General Information

Risk of corrosion caused by leaking electrolyte.
Electrolyte is strongly corrosive. 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.
Electrical voltages hazardous to health may cause fatal injury.
Danger!
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. Risk of explosion and fire, avoid short circuits.
Avoid electrostatic charges and discharges/spaks.
Attention! Metal parts of the battery or batteries are always live, so never place foreign objects
Warning! Risks caused by batteries. 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.
Do not smoke.
Do not use any naked flame or other sources of ignition.
Risk of explosion and fire. Electrolyte is highly corrosive. Contact with electrolyte is impossible in normal working conditions.
Electrolyte coming out of damaged cells or blocks is highly corrosive too. Acid splashes in the
eyes or on the skin must be washed with plenty of clean water. Then consult a doctor immediately!
General prohibition. Clothing contaminated by acid should be washed in water.
Leaking electrolyte is harmful to the eyes and skin. Refer also to chap. 2.3, Safety precautions!
Observe these instructions and keep them located near the battery for future reference.
Work on batteries only by trained qualified personnel. Incomplete or insufficient maintenance can lead to unexpected battery failure or reduction of
battery power. Maintenance work must be completed once every six months by HOPPECKE
specialists or by qualified personnel trained by HOPPECKKE in accordance with the instructions
While working on batteries wear face protection (impact resistant visor Attention! in this documentation.
according to EN 166 class F or similar), protective eye-glasses, protec-
tive gloves and clothing.
Observe accident prevention regulations as well as EN 50110-1 and Work on batteries, especially installation and maintenance should be performed by trained
IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries). HOPPECKE specialists (or by qualified personnel trained by HOPPECKE) only; personnel must be
familiar with battery handling and the required precautionary measures. Unauthorized persons
must keep away from the batteries.
Wear conductive shoes. Danger!
Without proper and regular maintenance of the batteries by HOPPECKE specialists (or personnel autho-
General order. rized by HOPPECKE), the safety and reliability of the power supply during operation cannot be ensured.
Sealed lead-acid batteries are always filled before delivery. Sealed stationary lead-acid battery
cells must not be refilled with water during the entire battery service life. Overpressure valves are
used as sealing plugs. These plugs cannot be opened without damaging.
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HOPPECKE offers the following type ranges as valve regulated lead-acid (VRLA) batteries: Following symbols and pictograms are pictured on each battery cell or on each battery block:
net.power
power.com HC
Read the instruction for installation, commissioning and operation carefully.
power.com SA
power.com XC
power.com H.C
grid | power VR L (OPzV/OPzV bloc) Always wear protective goggles and cloths.
grid | power VR M (power.com SB)
grid | power VR X
grid | Xtreme
Avoid naked flames and sparks.
sun | power VR L (OPzV solar.power/OPzV bloc solar.power)
sun | power VR M (solar.bloc)
The product names used for HOPPECKE battery series have been changed. General danger warning.
In the overview below you will find the respective counterparts of old and new names.
In the rest of this document old names will be listed in brackets.
Risk of electrical voltage.
Risk of chemical burns through electrolyte.

OLD NEW
OPzV bloc solar.power sun | power VR L
OPzV solar.power sun | power VR L Risk of explosion, avoid short circuits, electrostatic charge and discharge/sparks.
power.com SB grid | power VR M
solar.bloc sun | power VR M Battery with low concentration of antimony.

OPzV/OPzV bloc grid | power VR L
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.
Pb
0.2 Safety instructions for working with lead-acid batteries
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 connecting
it to the charger
– Pay attention to the polarity
– Make sure the connections are tight
– 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 the charger is in a switched-off state by measuring
the voltage
– 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
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6 7
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.
Observe the following regulations (IEEE standards valid for USA only):
Danger! – ZVEI publication “Instructions for the safe handling of electrolyte for lead-acid accumulators”
– VDE 0510 Part 2: 2001-12, in accordance with IEC 62485-2: “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 Maintenance/Comissioning Protocoll
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 Lead-Acid (VRLA) Batteries
for Stationary Applications”
– IEEE Standard 1375-1998: “Guide for Protection of Stationary Battery Systems”
– DIN EN 50110-1 (VDE 0105-1): “Company of electrical instructions”; German copy EN 50110-
1:2004
Batteries contain corrosive acids which can lead to chemical burn on skin and eyes if the
battery is damaged.
There is a risk of explosion and fire due to explosive gas and injuries from deflagration and
flying particles.
You must wear safety goggles while handling the battery!

When working on batteries, wear a face protection (impact-resistant
visor according to EN 166 class F or similar), protective goggles,
protective gloves and the personal protective clothing provided!
0.3 Warranty, Protocol, Commissioning, Protocols Maintenance
In order to proof the correct commissioning and maintenance these have to be documented1. Below you can
find a table as template for this purpose. Alternatively own templates can be used. Nevertheless these should
contain the relevant data/data fields. The documentation of commissioning and maintenance shall be kept
together with further documentation of the battery/battery installation. In case, that the documentation of com-
missioning and maintenance should be kept separately nearby the battery/battery installation, the template
can be detached from the manual.
Remark: Below template includes fields for documentation of the acid density – these fields are not intended
to be used for VRLA type products and can thus be left empty.
The protocol can be downloaded separately at: https://www.hoppecke.com/en/

or use the QR code.
Please be aware that the manual which has been delivered is updated at the time of delivery, nevertheleless the
updated version should be always downloaded at the hopp.net: https://www.hoppecke.com/de/
This way it is ensured that the actual technical information is applied during some changes or additions in the
battery installation.
The documentation must be submitted to the producer in the unlikely event of a warranty claim.
1
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
✃
7140203153 V1.4 (03.2021)
8
Maintenance/ Comissioning Protocoll Maintenance/ Comissioning Protocoll
Maintenance/ Comissioning Protocoll
Technician name
Technician name Technician name
Battery Inside
Customer Address Location Address BatteryFlaking
Surface Inside Charging Means
Surface Flaking
Risk of Short Circuit Charging
SedimentMeans
Risk of Short Circuit
Expansion Sediment
Separator
Expansion Separator
Electrolyte
Electrolyte Nominal Electolyte density
Electrolyte Level before refill Nominal Electolyte density
Battery Electrolyte Level before refill (kg/l)
(kg/l)
ID Cell Conector
Cells with too high/too low Cells with too high/low
Serial Number Cell plug Cells with too high/too low Cells with too high/low
electrolyte temperature electrolyte density
Brand Charger electrolyte temperature electrolyte density
Type Brand
Voltage
Manufacturing Date Type Voltage
Operation type Characteristic Line Nominal float voltage (V) Measured float voltage
n cells/ batteries Device No. Nominal float voltage (V) Measured float voltage
n strings Manufacturing Date Cells with low or high voltage voltage adjusted
Voltage (V) Cells with low or high voltage voltage adjusted
Current
Currentretention (mA)
Charge Nominal capacity (Ah) -
Inspection/ Comissioning activities
Charge retention
Superimposing (mA)
~ (A) Nominal
C10 (Pb),capacity
C5 (FNC)(Ah) -
### Check all screwed connectors ## Inspection day Superimposing ~ (A) C10 (Pb), C5 (FNC)
### voltage adjusted ## Offer will be sent Battery Outside
Battery Outside
### Battery cleaned ## Final consultation conducted Room Temperatur (°C) Highest Surface Temp. (°C)
### Topped up Room Temperatur (°C) Highest Surface Temp. (°C)
Amount of refilled distilled
Leaking cells Amount
Results Leaking cells water (l) of refilled distilled
water (l)
Battery Inside OK? Overall condition Rack/Cabinet
Battery Outside OK? OK? Rack/Cabinet
Type Battery Rack Number of shelfs
Type
Coating Battery
OK? Rack Number
Isolation of shelfs
(measured) OK?
Rack/Cabinet OK?
Coating OK? Isolation (measured) OK?
Date of last service:
Recommendations
Date/Signature Technician Date/Signature Customer

✃
1/1
1/1 1/1
Maintenance/ Comissioning
Maintenance/ ComissioningProtocoll
Protocoll 1. When renewing old batteries, ensure that all electrical loads are switched off before removing
Maintenance/ Comissioning Protocoll
Technician name
the old battery (separators, fuses, switches). This must be carried out by qualified personnel.
Technician name
SingleTechnician
Single
name
Cells/Blocks Voltage,
Cells/Blocks Temperature,
Voltage, Density
Temperature, Density
Single Cells/Blocks Voltage, Temperature, Density 2. R
emove all wrist watches, rings, chains, jewelry and other metal objects before working with
Block/Block/ Block/ Temp.
Block/ Temp.Density
DensityBlock/
Block/ Block/
Block/ Temp.
Temp. Density
Density batteries.
U [V]U [V] Block/ UU
[V][V] Block/
Cell Block/
Cell U [V]
Temp.
Cell Cell [°C] Density
[°C] [kg/l] Block/
Cell U [V] Cell
[kg/l] Cell Cell Temp.
[°C]
[°C] Density
[kg/l]
[kg/l] Danger!
1 Cell1 1 Cell
1 [°C] [kg/l] 47Cell
47 Cell
4747 [°C] [kg/l]
2 1
2 2 12 48 47
48 4847
48
3. Use insulated tools only.
3 2
3 3 23 49 48
49 4948
49
3 3 49 49
4 4 4 4 50 50 5050
4 4 50
51 50
5 5 5 5 51 5151 4. Wear insulating gloves and protective shoes (refer also to Chap. 2.2).
5 5 51 51
6 6 6 6 52 52 5252
6
7 6
7 52
53 52
53
7 7 53 53
7
8 7
8 53
54 53
54 5. Never place tools or metal components on top of the batteries.
8 8 8
54 54
5454
8
9 9 55 55
9 9 9 9 55 55 5555
10 10 56 56 Danger!
10 10 10 10 56 56 5656
11 11 57 57
11 11 11 11 57 57 5757 6. M
ake sure that the battery or batteries are not mistakenly grounded. If the system is grounded,
12 12 58 58
12 12 12 12 58 58 5858 terminate the connection.
13 13 59 59 Touching a grounded battery by mistake can result in severe electric shock. The risk caused
13 13 14 13 1314 59 59
60 5959
60
Danger! by an incorrect connection can be significantly reduced by terminating the ground connection.
14 14 15 14 1415 60 60
61 6060
61
15 15 16 15 1516 61 61
62 6161
62
16 16 17 16 1617 62 62
63 6262
63
17 17 18 17 1718 63 63
64 6363
64 7. B
efore establishing connections, make sure to check the correct polarity – better one too many
times than one too few.
18 18 19 18 1819 64 64
65 6464
65
Attention!
19 19 20 19 1920 65 65
66 6565
66
20 20 66 66
20 21 20 21 66 67 6667
21 21 67
68 67
21 22 21 22 67 6768 8. F illed lead-acid batteries contain highly explosive gas (hydrogen/air mixture). Never smoke,
22 22 68 68
22 23 22 23 68 69 6869 handle open flames or create sparks near the batteries. Always avoid electrostatic discharge;
23
24 23
24 69
70 69
70 wear cotton clothing and ground yourself if necessary.
23 23 69 69
24
25 24
25 70
71 70
71
24 25 24 25 70 71 7071 Danger!
26 26 72 72
25 26 25 26 71 72 7172
27 27 73 73
26 27 26 27 72 73 7273 9. B
locks/cells are very heavy. Make sure they are installed securely. Only use suitable means of
28 28 74 74
27 28 27 28 73 74 7374 transport. Do not lift or pull up blocks/cells on the poles.
29 29 75 75
28 29 30 28 2930 74 75
76 7475
76 Danger!
29 30 31 29 3031 75 76
77 7576
77
30 31 32 30 3132 76 77
78 7677
78 10. Never carry batteries by the battery terminals.
31 32 33 31 3233 77 78
79 7778
79
32 33 34 32 3334 78 79
80 7879
80 Danger!
33 34 35 33 3435 79 80
81 7980
81
34 35 36 34 3536 80 81
82 8081
82
11. These batteries contain lead and cannot under any circumstances be disposed of with
35 36 37 35 3637 81 82
83 8182
83
household waste or at a waste dump at the end of their service life (for more information,
37 37 83 83
36 38 36 38 82 84 8284 Attention! refer to Chap. 1.4).
38 38 84 84
37 39 37 39 83 85 8385
39 39
40 85
86 85
38 40 38 84 8486
40
41 40
41 86
87 86
87 12. Contains lead-metall (CAS-Nr. 7439-92-1). This metall is one of the reach list chemicals.
39 39 85 85
41
42 41
42 87
88 87
88
40 42 40 42 86 88 8688
43 43 89 89 Attention!
41 43 41 43 87 89 8789
44 44 90 90
42 44 42 44 88 90 8890
45 45 91 91
43 45 46 43 4546 89 91
92 8991
92
44 46 44 46 90 92 9092
45 45 91 91
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Table of contents
Preface................................................................................................................................................... 3 5.10.1 Connection terminals ............................................................................................................. 33
Symbols ............................................................................................................................................... 4 5.10.2 Type of connection cable ........................................................................................................ 33
5.10.3 Clamping batteries using battery connectors ............................................................................ 33
0 Safety notices...................................................................................................................................... 5 5.10.4 Installing the screwed connectors ........................................................................................... 34
0.1 General Information ................................................................................................................. 5 5.10.5 Clamping connection plates onto the batteries ........................................................................ 35
0.2 Safety instructions for working with lead-acid batteries ............................................................... 7 5.11 Connect the battery system to the DC power supply ................................................................. 35
0.3 Warranty, Protocol Commissioning, Protocol Maintenance�� 8 5.12 Commissioning charge (initial charge) ..................................................................................... 36
5.12.1 Commissioning charge with constant voltage (IU characteristic curve) ....................................... 37
1 General Information............................................................................................................................. 12 5.12.2 Extended commissioning charge ............................................................................................. 37
1.1 Safety precautions................................................................................................................... 12
1.2 Technical Data ....................................................................................................................... 12 6 Battery operation................................................................................................................................ 37
1.2.1 Excample for single cell .......................................................................................................... 12 6.1 Discharching ........................................................................................................................... 38
1.2.2 Identification plate battery....................................................................................................... 13 6.2 Charging – general................................................................................................................... 38
1.3 CE-Mark ................................................................................................................................. 13 6.2.1 Standby parallel operation........................................................................................................ 39
1.4 Disposal and recycling ........................................................................................................... 13 6.2.2 Floating operation.................................................................................................................... 40
1.5 Service .................................................................................................................................. 13 6.2.3 Switch mode operation (charge/discharge operation)................................................................. 40
6.2.4 Float charging.......................................................................................................................... 41
2 Safety ............................................................................................................................................. 14 6.2.5 Equalizing charge (correction charge)......................................................................................... 41
2.1 General ................................................................................................................................. 14
2.2 Personal safety equipment, protective clothing, equipment ....................................................... 14 7 ettings for charging HOPPECKE sun | power VR L (OPzV solar.power/OPzV bloc solar.power) and
S
2.3 Safety precautions ................................................................................................................. 15 sun | power VR M (solar.bloc) batteries............................................................................................... 43
2.3.1 Sulfuric acid .......................................................................................................................... 15 7.1 Charge and discharge parameters............................................................................................. 43
2.3.2 Explosive gases ..................................................................................................................... 15 7.2 Alternating currents.................................................................................................................. 44
2.3.3 Electrostatic discharge ........................................................................................................... 16 7.3 Temperature influence on battery performance and service life................................................... 45
2.3.4 Electric shock and burns ........................................................................................................ 17 7.3.1 Temperature influence on battery capacity................................................................................. 45
7.3.2 Temperature influence on battery design life.............................................................................. 45
3 Transport............................................................................................................................................ 18 7.4 Influence of cycling on battery behaviour................................................................................... 46
3.1 General .................................................................................................................................. 18 7.4.1 Endurance in cycles depending on depth of discharge................................................................ 46
3.2 Delivery completeness and externally visible damage ............................................................... 18 7.4.2 Endurance in cycles depending on ambient temperature............................................................. 46
3.3 Defects................................................................................................................................... 19 7.4.3 Electrolyte freezing point depending on depth of discharge (DoD)................................................ 47
7.5 Remarks to warranty management............................................................................................ 48
4 Storage .............................................................................................................................................. 20
4.1 General ................................................................................................................................. 20 8 Battery maintenance........................................................................................................................... 48
4.2 Storage time .......................................................................................................................... 20 8.1 Work to be performed every six months..................................................................................... 48
4.3 Preparing for a several-month storage period ........................................................................... 20 8.2 Work to be performed annullay................................................................................................. 49
8.3 Cleaning of the battery............................................................................................................. 49
5 Installation ....................................................................................................................................... 21
5.1 Demands on the erection site ................................................................................................. 21 9 Testing the battery system.................................................................................................................. 50
5.1.1 Calculation of safety distance ................................................................................................. 23 9.1 Performing the capacity test (short form)................................................................................... 50
5.2 Filling the cells ...................................................................................................................... 24 9.2 Performing the capacity test (extended version)......................................................................... 50
5.2.1 Check ................................................................................................................................... 24 9.3 Capacity test of the battery....................................................................................................... 52
5.2.1.1 Ventilation – preventing explosion ........................................................................................... 24
5.2.1.2 Ventilation – calculation for ventilation requirements of battery rooms ....................................... 24 10 Troubleshooting................................................................................................................................. 54
5.3 Conducting an open-circuit voltage measurement ..................................................................... 26
5.4 Installation tools and equipment ............................................................................................. 26 11 Required ventilation for hydrogen generated by batteries................................................................... 54
5.5 Rack Installation .................................................................................................................... 27
5.6 Cabinet Installation ................................................................................................................ 28 12 Disassembly...................................................................................................................................... 55
5.7 Handling the batteries ............................................................................................................ 29
5.8 General information on connecting the batteries ...................................................................... 29 13 References to the standards and regulations..................................................................................... 55
5.9 Putting the cells/blocks into the racks .................................................................................... 31
5.10 Connecting the batteries ........................................................................................................ 33 Safety data sheet................................................................................................................................... 56
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1 General information 1.2.2 Identification plate battery
The electrolyte of sealed lead-acid batteries is fixed in a glass fiber fleece (AGM) or gel. Therefore an upright The identification plate of the entire battery system can be found on the
or horizontal installation of battery cells or blocks is basically possible. The generation of oxyhydrogen gas is battery rack or inside the battery cabinet.
extremely reduced by an internal recombination circle. Sealed lead-acid battery cells or battery blocks are not The nominal voltage, the number of cells/blocks, the nominal capacity
sealed gas tightly. The integrated valve has to open by pressure overload. Sealed lead-acid batteries must (C10 = CN) and the battery type are listed on the identification plate of
not be opened. HOPPECKE offers numerous sealed lead-acid batteries as single cells (nominal voltage 2 V) or the system.
blocks (nominal tension: 6 V or 12 V) for different applications.
1.1 Safety precautions

Fig. 1-1: Example for type plate on battery rack
Read this documentation carefully and completely before performing any tasks using the batte-
ries. This documentation contains important information regarding the safe and correct unpacking,
storage, installation commissioning, operation and maintenance of filled lead-acid batteries. 1.3 CE-Mark
Danger! Effective as of 1 January 1997, the EC declaration of conformity 2014/95/EC (Low Voltage
To ensure your own safety as well as the safety of your colleagues and the system, it is essential Directive) and the corresponding CE marking for the battery system are required for batteries with
that you have read and understood all instructions in this documentation and adhere to them a nominal voltage between 75 V and 1500 V DC.
strictly. If you have not understood the information contained in this documentation or if local The installer of the battery system is responsible for displaying the declaration and affixing the
regulations and conditions apply which are not covered by the documentation (or run contrary to CE label on or next to the battery’s identification plate.
Danger!
the information in this documentation), please contact your local HOPPECKE representative. You
can also contact us at our head office directly.
1.4 Disposal and recycling
If you are conducting any work on or with the battery system, it is essential that you familiarize Used batteries with this marking are recyclable goods and must be sent for recycling.
yourself with the installation, operation and maintenance of lead-acid batteries.
Attention!
Attention!
Used batteries which are not sent for recycling are to be disposed of as special waste
1.2 Technical data under all relevant regulations.
1.2.1 Example for single cell Pb

Each single cell/each battery block has an own identification plate on the top side of the cell/block cap. We offer our customers our own battery return system. All lead-acid batteries are taken to the
Refer to the example below. 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
5 OPzV 250
non spillable
2 V 250 Ah CN/267 Ah C10 The HOPPECKE smelting plant is the only lead smelter in Europe certified under
Ufloat = 2,25 V/cell – DIN EN ISO 9001 (processes and procedures)
! upright position only ! – DIN EN ISO 14001 (environmental audit)
Made in Germany
– Specialist disposal regulations covering specialist disposal with all associated waste codes for
storage, treatment and recycling
Example: The information on the identification plate is as follows: For further information: +49(0)2963 61-280.
5 OPzV 250
5 = number of positive plates
OPzV = battery type 1.5 Service
250 = Nominal capacity C10
HOPPECKE has a worldwide service network that you should take advantage of. HOPPECKE service is there for
(capacity during discharge with ten hours’ current (I10)
you whenever you need specialist consultation for installation of the battery system, parts and accessories or
over a discharge time of 10 h (t10)) system maintenance. Contact us or your local HOPPECKE representative.
267 = actual capacity C10
(capacity of discharge with 10 h current) HOPPECKE service:
Email: [email protected]
Refer to the HOPPECKE website for contact data of all international HOPPECKE branches:
Internet: www.hoppecke.com
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12 13
2 Safety 2.3 Safety precautions
2.1 General 2.3.1 Sulfuric acid
If the casing of a sealed lead-acid battery is damaged, small quantities of electrolyte, acid mist or hydrogen gas Sealed lead-acid batteries are safe when used properly. However, they contain diluted sulfuric acid (H2SO4) that
may leak out. Always take the normal safety precautions when working with lead-acid batteries. is bonded in gel or glass mat. The bonded sulfuric acid is extremely corrosive and can cause serious injury.
Further information to sulfuric acid can be found in the attached material safety data sheet.
Note also the information in the attached ZVEI leaflet “Instructions for the safe handling of lead-acid accumu-
Consider all instructions and engineer standards, as mentioned in chapter 0.2. lators (lead-acid batteries)“.
2.3.2 Explosive gases

Risk of fire, explosion, or burns. Do not disassemble, heat above 45 °C, or incinerate.
Inside lead-acid batteries there is an explosive hydrogen/oxygen gas mixture that can escape from
Danger! the battery. In the event of an explosion of the mixture, serious personal injury may result from
the explosion or from flying particles.
Danger! – Always wear the recommended protective clothing (face protection (impact-resistant visor
2.2 Personal safety equipment, protective clothing, equipment according to EN 166 class F or similar), protective goggles, insulated gloves and protective
shoes, etc.)
While working on batteries wear face protection (impact-resistant visor – Use the correct tools only (“non-sparking“ with insulated grips, etc.)
according to EN 166 class F or similar), protective eye-glasses, protec- – Eliminate all potential sources of ignition such as sparks, flames, arcs
tive gloves and clothing!
– Prevent electrostatic discharge. Wear cotton clothing and ground yourself when you are working
Observe accident prevention regulations as well as EN 50110-1 and
with the batteries directly
IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries).
In case of fire, extinguish using water or CO2 extinguisher only.
If working with lead-acid batteries, the following equipment must be provided at the very least:
Do not point the fire extinguisher directly at the battery or batteries to be extinguished. There
– Insulated tools is a risk that the battery casing may break as a result of thermal tension. In addition, there is
– Protective shoes a risk of static charging on the surface of the battery. This could result in an explosion. Switch
Danger!
– Rubber gloves off the charging voltage of the battery. If extinguishing a fire, use a breathing apparatus with
– Fire extinguisher a self contained air supply. If using water to extinguish a fire, there is a risk that the water/
– Rubber apron foam could react with the electrolyte and result in violent spatter. For this reason, wear
acid-resistant protective clothing. Burning plastic material may produce toxic fumes. If this
– Protective goggles
should occur, leave the location as quickly as possible if you are not wearing the breathing
– Face protection (impact-resistant visor according to EN 166 class F or similar) apparatus described above.
– Face mask
– Emergency eye wash (recommended) If using CO2 fire extinguishers, there is a risk that the battery could explode as a result of
static charging.
To avoid electrostatic charging, all textiles, protective shoes and gloves worn while working with Note also the information in the attached ZVEI leaflet “Instructions for the safe handling of
batteries must have a surface resistance of < 108 ohm and an insulation resistance of ≥ 105 ohm Danger! lead-acid accumulators (lead-acid batteries)”.
(refer IEC 62485-2 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.
Danger! Never place tools or metal components on top of the batteries.
The use of proper tools and safety equipment can help to prevent injury or reduce the severity of injury in case
of an accident.
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2.3.3 Electrostatic discharge 2.3.4 Electric shock and burns
All lead-acid batteries produce hydrogen and oxygen while operating, particularly during charging. These gases Batteries can cause severe electric shock. If there is a short circuit, very strong currents may
leak from the battery in the ambience. Based on the mandatory natural or technical ventilation it can be assumed be present. Do not touch any bare battery components, connectors, clamps or terminals.
that a flame able oxyhydrogen concentration exists only in the close proximity of the battery. A flame able In battery systems with a nominal voltage of over 1500 V DC, you must provide equipment
mixture of oxyhydrogen always exists inside the battery cells. This effect does not depend on the battery techno- Danger! for splitting the batteries into cell groups with voltages lower than 1500 V DC. In order to
logy, design or manufacturer, rather than a specific characteristic of all lead-acid batteries. The energy needed prevent serious injury as a result of electric shock or burns, be very cautious when performing
for an ignition of oxyhydrogen is quite low and can be caused differently. Examples: Open flame, fire, glowing any work on the battery system.
sparks or flying firebrands from grinding, electric spark from switches or fuses, hot surface areas > 200 °C Always wear the recommended protective clothing (insulated rubber gloves and rubber shoes,
and – an underestimated cause – electrostatic discharge. 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
Measures to avoid the ignitions of detonating gas through electrostatic discharges: batteries.
The development of electrostatic discharges on the battery or on your body or on clothes can be avoided if
you consider the information below: Before conducting work on the battery system …
Determine whether the battery system is grounded. We do not recommend this. If the system is grounded,
o not wipe the battery with an arid fabric especially made of synthetic material.
D terminate the connection.
Rubbing on surfaces of plastic material (battery jars are typically made of plastic material) causes Touching a grounded battery by mistake can result in severe electric shock. This risk can be significantly
electrostatic charges. reduced by removing the ground connection. However, the racks (or cabinets) used to hold the batteries do need
to be well grounded or completely insulated.
Clean the surface of batteries with water-moistened cotton fabric only. By using a water-
moistened cotton fabric you avoid the buildup of electrostatic charges. If a battery system is grounded …
hile working on batteries do not rub your clothes (e. g. made of wool) on the battery. Thereby
W There is a voltage between the ground and the ungrounded terminal. If a grounded person touches
electrostatic charges could build up on the battery jar, your body or on your clothes. 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.
ear suitable shoes and clothing with special surface resistance that avoid the buildup of
W
electrostatic charge. Thereby the buildup of electrostatic charge on the body and clothing can If an additional ground connection is made by some cells within the (grounded) battery system,
be avoided. there is a risk of short circuit, fire and explosion.
o not remove self-adhesive labels, from the battery without special safety measures.
D
Removing plastic labels can build up electrostatic charges, which can ignite oxyhydrogen gas.
If a battery system is not grounded …
If an accidental ground connection is made by some cells within the battery system, voltage is
Before pulling off the label, wipe the battery moist. 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
explosion.
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.
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3 Transportation damages 3.3 Defects
3.1 General 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”.
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. Unpack the goods as soon as possible upon delivery (the sooner, the better) and inspect them for any defects
in case commissioning should be carried out promptly.
For road transportation, filled lead-acid rechargeable batteries are not treated as dangerous
goods if
– They are undamaged and sealed The sealed batteries are always filled before delivery.
– They are protected from falling, shifting and short circuit
– They are firmly secured to a pallet Check the entire scope of delivery to make sure that it matches the detailed delivery note (or
– There are no dangerous traces of acids, lye, etc. on the outside of the packaging the packing list).
Failure to promptly inform the carrier of defects or incompleteness could result in the loss of
your claims.
It is essential that loads on road vehicles are properly secured. If you have questions regarding incomplete shipments or damage to the delivered products, please
contact your local HOPPECKE representative. You can also contact us at our head office directly.
Danger!
Monobloc batteries/battery cells are very heavy (depending on type between ca. 10 kg and
max. 240 kg per cell/bloc). Wear protective shoes. Use only the appropriate transportation equip-
ment 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
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4 Storage Observe ventilation requirements (refer to Chap. 5.2.1.1) even for charging of temporarily
connected cells.
4.1 General
Attention!
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 under
the warranty.
Attention!
4.2 Storage time
Capacity [% C10]
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 six months (see Chap. 6.2.5). Calculate
Attention! this exact time starting on the day of delivery. By the end of the max. storage time charge accep-
tance 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 necessary (at
temperatures around 40 °C monthly charges). Refer also to figure 4-1 to retrieve max. storage
times for different storages temperatures. Failure to observe these conditions may result in
sulfating of the electrode plates and significantly reduced capacity and service life of the battery.
Battery recharge during storage time should be carried out max. twice. The battery should be
operated in continuous float charge mode thereafter. Storage time [month]
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. Fig. 4-1: Available Capacity vs. storage time
Required process for charging the batteries by achievement of max. storage duration:
Charge with constant power of 1 A or 2 A per 100 Ah C10 battery capacity. Interrupt charging when 5 Installation
all cell voltages have rised to min 2.65 V/cell (refer also to Chap. 6.2).
Attention! 5.1 Demands on the erection site
The max. storage period for grid | Xtreme VR is 24 months at 20 °C. 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.
Attention! D anger!
4.3 Preparing for a several-month storage period 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 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 If choosing an installation location, determining space requirements and performing the
blocks/cells so that they can be temporarily connected in series for charging. The batteries should remain on installation, observe the relevant installation drawing if it is available.
their pallets until final installation. The floor must be suitable for battery installation; it must:
– Have a suitable load-carrying capacity
To avoid having to perform the previously described work, we strongly recommend that you
connect the battery or batteries to the regular charging voltage supply within six months. Failure – Be sufficiently conductive
to observe the recharging intervals will render the warranty null and void. – 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 IEC 62485-2: “Safety
requirements for secondary batteries and battery installations – Part 2: Stationary batteries”.
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Requirement Our recommendation 5.1.1 Calculation of safety distance
Ventilation source Sufficient room ventilation is absolutely required to limit the In close proximity of the batteries the dilution of explosive gases is not always given. Therefore a safety distance
hydrogen concentration (H2 concentration) in the ambient air of has to be realized by a clearance, in which there must not be any sparking or glowing equipments (max. surface
the battery room to a value of < 2 % by volume. temperature 300 °C). The diffusion of the oxyhydrogen depends on the gas release and the ventilation close
Hydrogen is lighter than air. Make sure that hydrogen does not to the battery. For the following calculation of the safety distance ‘d’ it can be assumed that the oxyhydrogen
Danger! accumulate (e. g., in the ceiling area). Ventilation and deaeration
expands spherical. Figure 5.1 depicts a graphic approximation of the safety distance ‘d’ depending on the
openings should be placed near the ceiling.
battery capacity. Subsequently a detailed calculation is shown.
Environment The ambience has to clean and dry. Water, oil and dirt must be kept away from
the cell surface. Safety clearance:
Passageway width See the IEC 62485-2 Required safety clearance needs to be calculated according to formula stated in IEC 62485-2.
in front of and between
the battery racks Volumes of a hemisphere:
(and cabinets)
Minimum distances See the IEC 62485-2
Air volume flow required to reduce the concentration of generated hydrogen H2 in the air to 4 % max.:
Access door Lockable and fire retardant (T90).
Lighting Recommend: at least 100 lx.
Labeling Warning signs in accordance with IEC 62485-2.
Warning sign depicting risk of electrical volta-

ge only necessary if battery voltage exceeds Required radius of the hemisphere:
60 V DC.
Risk of explosion No sources with ignition (e. g. open flame, glowing objects, electrical switches,
sparks) near to the cell openings.
Ambient temperature The application temperature is 20 °C, which is based on IEC60896. 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 temperatures of 55 °C is not permissible. Avoid
operating at temperatures en excess of 45 °C for long periods of time.
It is not permitted to expose the batteries to the direct sun light or beeing near
to heat sources.
Safety clearance d [mm]

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 %.
Earthing 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 you local HOPPECKE represen-
tative if necessary.
Tab. 5-1: Demands on the erection site

Battery capacity C [Ah]
VLA battery boost charge mode VLA battery float charge mode
VRLA battery boost charge mode VRLA battery float charge mode
Fig. 5-1: Safety distance based on battery capacity (Source HOPPECKE)
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5.2 Filling the cells Sum of factors:
v x q x s = 0.05
Sealed lead-acid batteries are always filled before delivery. Sealed stationary lead-acid battery
cells must not be refilled with water during the entire battery service life. Overpressure valves are C
Q = 0.05 x n x Igas x with Q in m3/h, Igas in A
used as sealing plugs. These plugs cannot be opened without damaging. 1000 Ah

Igas = Ifloat resp. Iboost x fg x fs
5.2.1 Check
Make sure that the installation and ventilation requirements according to IEC 62485-2 are met.
Should commission charging be carried out using higher amperage than you established for the type of Parameter Lead-acid batteries
ventilation equipment, then you must increase the ventilation in the battery room (e. g. using additional portable sealed cells
fans) according to the amperage applied. fg: Gas emissions factor 0.2
Increased ventilation has to be applied during commissioning and for one hour afterwards. The same applies for
occasional special battery charging processes. fs: Safety factor for gas emissions
5
(includes 10 % faulty cells and aging)
Ufloat: Float charge voltage, V/cell 2.27
5.2.1.1 Ventilation – preventing explosion
Ifloat: Typical float charge current, mA per Ah 1
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. Igas: Current (float charge), mA per AH
1
(used only for calculating the air volume flow for float charge)
The following could act as sources of ignition for gas explosions: Uboost: Boos charge voltage, V/cell 2.40
– Open flames
Iboost: Typical boost charge current, mA per Ah 8
– Flying sparks
– Electrical, sparking equipment Igas: Current (boost charge), mA per Ah (used only for calculating the
8
– Mechanical, sparking equipment air volume flow for boost charge)
– Electrostatic charge
Tab. 5-2: Recommended current values (Extract from the IEC 62485-2)
Observe the following measures to prevent gas explosions:
– Sufficient natural or technical ventilation If designing the ventilation in battery rooms, depending on the structural conditions, either “natural ventilation”
– No heating using open flames or glowing objects (T > 300 °C) or “technical ventilation” can be used.
– Separate battery compartments with individual ventilation
– Anti-static clothing, shoes and gloves (according to applicable DIN and EN regulations) Observe the following points:
– Surface conductivity resistance: < 108 Ω and insulating resistance ≥ 105 Ω
Natural ventilation:
– Hand-held lights with power cable without switch (protection class II)
– Intake and exhaust openings required
– Hand-held lights with battery (protection category IP54)
– Minimum cross-section (free opening in wall) (A in cm2, Q in m3/h) (given that: vair = 0.1 m/s)
– Warning and regulatory signs
– Increased ventilation through chimney effect (air routing)
The ventilation requirements for battery rooms, cabinets or compartments are based on the required reduction – Exhaust released outside (not into air-conditioning systems or surrounding rooms)
of the concentration of hydrogen generated during charging and safety factors which include battery aging and
the potential for fault (“worst case”). Technical ventilation:
– Increased ventilation using fan (generally extractor fans)
– Air flow rate according to air volume flow Q
5.2.1.2 Ventilation – calculation for ventilation requirements of battery rooms – Air drawn in must be clean
– If large amounts of gas are released during charging, continued ventilation is required for 1 h after charging
Air volume flow Q:
is complete
Q = v x q x s x n x Igas x C – For multiple batteries in one room: required air flow = ∑Q
1000 Ah
– Avoid a ventilation short circuit by ensuring that there is sufficient distance between the intake and exhaust
v = dillution factor = 96 % air/4 % H2 = 24 opening
q = quantity of hydrogen generated = 0.42 10–3 m3/Ah
s = safety facotr = 5 In case of a technical (forced) ventilation the charger shall be interlocked with the ventilation system or an alarm
n = number of cells shall be actuated to secure the required air flow for the selected charging mode.
IGas = current per 100 Ah
C = nominal capacity of the battery
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Another sample calculation for battery room ventilation is available in Required ventilation for
Equipment Available?
hydrogen generated by batteries, Chap. 10, “Required ventilation for hydrogen generated by
batteries”. Lifting conveyor (forklift truck, lift truck or small mobile crane or similar device to aid
in battery installation)
Chalk line and chalk (optional)
5.3 Conducting an open-circuit voltage measurement
Plastic spirit level (optional)
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 Torque wrench
functioning properly. Fully-charged cells with an electrolyte temperature of 20 °C should have an Backing elements (max. 6 mm) for installing the racks (cabinets) (optional)
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 Ratchet set (optional)
from one another. Wrench and ring wrench set with insulated grips
Screwdriver with insulated grip
Type of cell/monobloc battery Open-circuit voltage
Paper towels or cloths (made of cotton; do not use cloths made out of synthetic
grid | power VR L (OPzV 2 V cell) 2.080 V ... 2.140 V/c fibers as there is a risk of static charging), moisturised with water
grid | power VR L (OPzV bloc) 2.080 V ... 2.140 V/c Brushes with hard plastic bristles (optional)
net.power 12 V 100 und 12 V 150 2.080 V ... 2.140 V/c Plastic measuring tape
net.power 12 V 92 und 170 Ah 2.100 V ... 2.160 V/c Safety equipment and protective clothing
grid | power VR M (power.com SB) 2.080 V ... 2.140 V/c Aeronix®battery terminal grease (only for cells/blocs with exposed lead on post terminals)
power.com HC 2.080 V ... 2.140 V/c Insulating mats for covering conductive parts
sun | power VR L (OPzV solar.power/OPzV bloc solar.power) 2.080 V ... 2.140 V/c Tab. 5-4: Equipment for installation
sun | power VR M (solar.bloc) 2.080 V ... 2.140 V/c
power.com XC 2.100 V ... 2.160 V/c 5.5 Rack installation
grid | power VR X/grid | power VR X FT 2.120 V ... 2.180 V/c
We recommend that batteries are properly installed in HOPPECKE battery racks or HOPPECKE
grid | Xtreme VR 2.120 V ... 2.180 V/c battery cabinets. The use of other operator-specific solutions may render the warranty for the
batteries null and void.
power.com SA 2.080 V ... 2.140 V/c
HOPPECKE produces different types of racks. For installation information, see the separate
power.com H.C 2.180 V ... 2,210 V/c documentation included with each rack.
Tab. 5-3: Open-circuit voltages for different cells/block batteries

Observe the special requirements and regulations when installing battery racks in seismic areas!
The following open-circuit voltage deviations are acceptable for monobloc batteries: Danger!
– 4 V monobloc 0.03 V/block
– 6 V monobloc 0.04 V/block
– 12 V monobloc batteries 0.05 V/block The installation location must fulfill the conditions described in Chap. 5.1.
Comply with the minimum distances listed in Tab. 5-1.
High temperatures decrease the open-circuit voltage while lower temperatures increase it. A Danger!
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.
Fig. 5-2:
For the installation, you will require your personal safety equipment, protective clothing, safety Step rack (left) and
tools and other equipment as described in Chap. 2.2. tier rack (right)
Danger!
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1. If the installation drawing is available, mark the outlines of the racks on the installation surface using chalk. If installing block batteries with L-connectors you should consider, that L-connectors have to be
2. The installation surface must be level and rigid. If backing elements are used, make sure that the thickness mounted before positioning the battery block in the battery cabinet.
does not exceed 6 mm. Note: The L-connectors are not intended for high current applications (e. g. UPS). Please contact
3. Carefully set up the racks and arrange them horizontally. your local HOPPECKE representative in case of questions.
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.
5.7 Handling the batteries
6. If necessary, ground the racks or rack parts.
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.
If using wooden racks: you must fit a flexible connector between each rack joint. Install the battery in accordance with VDE 0510 Part 2: 2001-12 (in accordance with IEC 62485-2).
For example, you must cover conductive parts using insulating mats.
Attention! Make sure that all terminals are covered with insulating caps.
5.6 Cabinet installation 5.8 General information on connecting the batteries

Alternatively, you may choose to install the batteries in HOPPECKE cabinets. If connecting the batteries, always establish the serial connections first followed by the parallel
The cabinets can be delivered with batteries already installed or battery installation can take connection. Do not reverse this procedure.
place onsite. Before connecting, check to make sure that the batteries have the correct polarity.
HOPPECKE provides different types of cabinets.
Attention!
The installation location must fulfill the conditions described in Chap. 5.1. To establish the serial connection, arrange the batteries so that the positive terminal of one
Comply with the minimum distances listed in Tab. 5-1. battery is positioned as near as possible to the negative terminal of the next battery.
Danger!
If sealed stationary batteries are connected in parallel, observe the following:
1. O nly battery strings with the same length and voltage may be connected with one another. Cross connecting
the 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).
6. In the cyclic application max. 2 parallel battery string are allowed. The reason is the low charging factor
which is usual during the cyclic application. The parallel connection of the batteries (more than two string) is
increasing the risk of the too low charging factor.
7. When charging the battery in UPS operation, it is essential to ensure that the number of strings connected
in parallel is max. 4. In special cases an arrangement with Hoppecke is necessary.
If the installation does not comply with all of the above mentioned guidelines, you have to charge each string
Fig. 5-3: Battery cabinet separately and connect them in parallel afterwards.
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In general, connect the batteries using the shortest possible cables. 5.9 Putting the cells/blocks into the racks
Normally, cells are connected in series with alternating polarity,
resulting in the shortest possible connector length. 1. Apply
some soft soap to the profiles of the rack so that the batteries can be adjusted sideways more easily
Batteries of type range OPzV and sun | power VR L can also be mounted once they have been placed onto the rack.
horizontally in racks or cabinets. These are optional variants for hori-
zontal operation. These variants need to be ordered extra. Fig. 5-12
depicts an example for connection of horizontal oriented battery cells.
The lid of the battery cells must not rest on parts of the
battery rack or cabinet.
The cells must be inserted very carefully into the battery
cabinet to avoid damaging the connection between the
lid and the container.
Starting with the 1500 grid | power VR L (OPzV), the cell
should only be placed in the toast position for horizontal
application (plates are upright), see figure below. In
other cases please contact Hoppecke.
The weak point is being shown by the picture below. Fig. 5-13: Greased support profiles
2. P
osition 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.
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.
Fig. 5-12: Example of a horizontal
arrangement of the batteries with
When handling the batteries, observe the instructions in Chap. 5.7.
OPzV-cells in a battery cabinet
Place the batteries carefully onto the profiles of the rack, otherwise the battery casing could be
damaged.
Attention! When placing the batteries on the rack, do not allow the batteries to knock up against one
another. This could destroy the batteries!
The battery connection terminals + and – must under no circumstance be short-circuited. This also
applies also to the + and – pole of the entire battery string. Be very careful when using step racks.
Cells ≤ 12 OPzV 1200 Ah Cells 12 OPzV 1500 Ah
to 24 OPzV 3000 Ah
Danger!
3. Slide
the blocks (or cells) to either side until the distance between the batteries is approx.
10 mm (Fig. 5-14). If connectors are used, these determine the distance between the batteries.
When sliding the batteries sideways in the racks, do not push them at the middle; instead,
Attention! push them at the corners as these are stronger. Push batteries using your hands only; never
use a tool.
✓
grid | power VR L cell
in horizontal application
✗ Fig. 5-14: 10 mm clearance between the batteries
4. Final step: Count all cells/blocks and check for completeness.
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5.10 Connecting the batteries
Information: AGM 2 V cell installation in horizontal position:
The batteries are in their final position and can now be connected.
5.10.1 Connection terminals
The battery terminals of the types sun | power VR M 12 V 58 to 12 V 90 have been greased at
➞ the factory using Aeronix®battery terminal grease. Inspect each terminal for visible damage or
oxidation. If necessary you should clean the terminal by using a brush (with hard plastic bristles).
Regrease by using the above mentioned terminal grease.
Other sealed lead acid battery types don’t need to be greased because the terminals are rubber
molded.
5.10.2 Type of connection cable

HOPPECKE recommends strongly the “pancake” (electrode plates lie flat) position for the horizon-
tal installation of 2 V cells. The battery system that you received is designed to produce a specified amount of power (kW) or current (A) at
a particular voltage for a certain period of time (standby time).
Do not put the cell/battery edge on any surface directly in order to avoid the damage of the You should be familiar with these parameters (U, kW, A). If this is not the case, please contact your local
welding edge. ➞ 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 backup 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:
During the moving of the cells into stack, avoid damages by positioning the cells/batteries exactly – T he insulation strength of the cable is higher than the max. system voltage
according to the height of stack bottom, using a lifting device and eventually greasing the surface – There is a distance of at least 100 mm between wiring and electrically conductive parts
in order to have easier handling. Danger! – Connectors must be furnished with additional insulation
Danger! – Avoid mechanical stress on the cell/battery terminals. Protect cables with large cross-sections
using cable ties and cable clamps
Remark to the connection of cells/batteries:

The connection cables between the main connection terminals and the charging rectifier or UPS
After installation of all single cells/into the racks please connect all cells with the delivered connec-
should be flexible conductors.
tors/screws in accordance to the installation drawing (if available). See example below:
5.10.3 Clamping batteries using battery connectors
There are screwed row, step and tier connectors (see Fig. 5-15).
Row connectors are used to connect 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 case of a seismic rack please install the protection steel bar in front of the cells after complete
wiring. General information on connecting the batteries, see chapter 5.8.
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5.10.5 Clamping connection plates onto the batteries
There are a total of 11 different types of connection plates (see Fig. 5-15). Connection plates are
always used when wires must be connected to cells with multiple battery terminals.
We strongly recommend that you use original HOPPECKE connection plates when connecting
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!
Fig. 5-15: Using row connectors and step connectors
Row, step, tier and end connectors are designed as screwed connectors. After loosening a Installation of standard connection plates
connection, the assembly screws must always be replaced. Screw the connection brackets onto the end terminals of the battery (see Fig. 5-17).
Attention!
Make sure that you do not cause mechanical damage to the
5.10.4 Installing the screwed connectors terminals.
Attention!
In very rare cases, the post sealing may not have the correct
color (blue/minus and red/plus). In this case the post sealing 2. First
attach the screws by hand only so that you can make final adjustments
has to be exchanged by a new one. The best approach is to to the cells, connection brackets and connection plates. Fix the connection
screw the screws symmetrically into the upper surface of the plate to the connection bracket of the battery with a torque of 20 Nm.
post sealing and pull them out by applying a lot of force on both 3. Afterwards tighten the pole screws using a torque wrench. The recommended
sides. The new post sealing should be smeared with a little bit torque is 20 Nm ± 1 Nm.
of silicone oil and pushed into the pole tub within the cover
until the clips of the pole bushing snap into place. It is very important to tighten screws thoroughly as a loose con-
nection can become very hot and result in ignition or explosion.
1. The
batteries are connected using the insulated row connectors Torque for the product range power.com H.C:
(Fig. 5-16). When establishing the serial connection, the batteries are Fig. 5-17: Installing the end
terminals (connection plates) Attention! – M5: 2 - 3 Nm
arranged so that the negative terminal of one battery is connected to the – M6: 4 - 5.4 Nm
positive terminal of the next battery until the entire system has reached – M8: 11 - 14 Nm
the necessary voltage.
Torque for the product range grid | Xtreme VR: 15 Nm
Make sure that you do not cause mechanical damage to
the terminals. Attention!
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 5.11 Connect the battery system to the DC power supply
connectors.
3. Tighten the screws using a torque wrench. The recommended torque is Make sure that all installation work has been performed properly before connecting the battery
20 Nm ± 1 Nm. system to the charging rectifier or UPS.
Torque for the product range power.com H.C:
– M5: 2 - 3 Nm Attention!
– M6: 4 - 5.4 Nm
Attention! – M8: 11 - 14 Nm
Torque for the product range grid | Xtreme VR: 15 Nm
It is very important to tighten screws thoroughly as a loose

connection can become very hot and result in ignition or
explosion. Screws are approved for single use only!
Fig. 5-16: Screwed connector Attention!
installation
For tightening the screws of the product grid | power VR L
(OPzV bloc), please use wrench size 20 mm.
Attention!
4. If
necessary, fit the connectors and end terminals (connection plates)
with insulating covers.
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1. Measure
the total voltage (target value = sum of open-circuit voltages of the individual cells or monobloc 5.12.1 Commissioning charge with constant voltage (IU characteristic curve)
batteries).
2. If necessary: label the cells or monobloc batteries visibly with continuous numbers (from the positive terminal – A charge voltage of max. 2.35 V per cell is required
to the negative terminal of the battery). HOPPECKE includes number stickers in your shipment. – The max. charge current should not be higher than 20 A per 100 Ah C10
3. A ttach polarity labels for the battery connections. – If the max. temperature of 45 °C is exceeded, the charge operation must be interrupted
4. C omplete the identification plate in this documentation (see Chap. 1.2). – You must temporarily switch to float charging to allow the temperature to drop
5. Attach safety marking signs (these include: “Danger: batteries”, “Smoking prohibited” and, for battery – The entire time of the commisioning (IU all over) should be 24 h
voltages > 60 V, “Dangerous voltage”). Attach further marking signs according to local requirements.
6. Attach the safety notices (see Chap. 0). 5.12.2 Extended commissioning charge
7. If necessary: Clean the batteries, the racks and the installation room.
Extended storage or climatic influences (humidity, temperature fluctuations) reduce the charging
Never clean batteries using feather dusters or dry towels. state of the cells. This makes an extended commissioning charge necessary. The extended
Danger of electrostatic charging and gas explosion. We recommend cleaning the batteries comissioning should not be done if the storage time (chapter 4) of the batteries is overstepped.
using damp cotton cloths or paper towels. The excess of the storage time means that the desulphatation charging has to be done, which is
Danger! described in the chapter 4.2.
8. C
onnect the battery system to the charging rectifier/UPS using the end connections (“plus to plus” and Conduct the extended commissioning charge according to the following procedure:
“minus to minus”) and proceed as described in Chap. 5.13. 1. Charge at 10 to 15 A per 100 Ah C10 until 2,35 V/cell is achieved (approx. 3 to 5 hours).
The connection cables between the end connections of the battery and the charging rectifier or 2. Charge at 2,35 V/cell until charging current has reached 1 A per 100 Ah.
UPS should be flexible conductors. 3. Charge with 1 A per 100 Ah for 4 hours (cell voltage will exceed 2,35 V/cell).
Inflexible wires could transfer vibrations, which could loosen the connection under certain
circumstances.
The cables must be supported so that no mechanical load can be transferred to the connection
6 Battery operation
terminals (cable trays, cable ducts, cable clamps).
DIN VDE 0510 Part 1 and IEC 62485-2 apply for the operation of stationary battery systems.
5.12 Commissioning charge (initial charge)
Each battery is subject to a natural electro-chemical aging process, which causes the reduction
Normally, by the time of installation, batteries are no longer fully charged. This applies especially
of the metallic lead within the battery (corrosion). The progress of the aging process and also the
to batteries that have been in storage for a long period of time (see Chap. 4). In order to charge
service life of the battery depend significantly on the operating temperature.
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”.
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
product range power.com H.C
range is 20 °C ± 5 K. Higher temperatures shorten the service life of the battery. Lower tempe-
This battery should be cycled min. 2 to 3 times in order to reach the nominal capacity. Hoppecke
Attention! ratures decrease battery capacity. Exceeding the limit temperature of 55 °C is not permissible.
Attention! recommends C5 - C10 discharge load and recharge profile according to 5.12.1. After commissio-
Avoid operating at temperatures in excess of 45 °C for long periods of time.
ning the battery accoding this recommended profile, it can be used normally.
The natural aging process and thus the service life expectation play an important role especially in
1. Familiarize
yourself with the maximum voltage that the charge rectifier can deliver without damaging the
high current applications. A high current application is an application with currents and discharge
peripherals.
rates ≤ C0,5. Discharging with high currents results in disproportionately more heat, which may
2. Divide this maximum value by the number of battery cells (not batteries) connected in series. This is the lead to a thermal overload of the corroded metallic conductor. From a certain level of the aging
maximum cell voltage for the initial charge. progress the reduced cross sections are not able to conduct the designed maximum permitted
3. Set the voltage so that average cell voltages are at a max. of 2.35 V per cell. The initial charge can take current for the defined period. In an extreme case this can result in an unexpected battery failure.
up to 48 hours.
Permitted operating temperature range VRLA batteries: - 20 °C to + 40 °C
It is important for this initial charge to be carried out completely.
Attention!
Avoid interruptions if at all possible.
Log the commissioning in the commissioning report (see Inspection record).
4. During
commissioning, measure the cell voltage of the pilot cells and after commissioning, measure the Permissible operating temperature range grid | Xtreme VR batteries: - 40 °C to + 55 °C
cell voltage and surface temperature of each cell and log this data in the commissioning report along with
the time.
The surface temperature must not exceed 55 °C. If necessary, the charge operation must be
interrupted, till the temperature drops below 45 °C.
Danger!
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2,35
The capacity test helps to check the efficiency and safety of the batteries and can thus avoid an 2,34
unexpected battery failure. Please note, that during the capacity test the load current must corre- 2,33
spond to the maximum permitted current for which the battery is designed. Regular review of the 2,32
Attention! batteries in compliance with specifications defined in Chap. 9 (Testing the battery system) gene- 2,31
rally eliminates the risk of an unexpected battery failure. We recommend performing the capacity 2,30
Charge Voltage [V/Cell]

2,29
test in accordance with Chap. 9 periodically, but at least once a year. In light of past experience 2,28
during the first 3 years of the operating life of the batteries the capacity test can be omitted. 2,27
2,26
2,25
2,24
Additional tools (like BMS) which are influencing the charging regime, can be only used after the 2,23
consultation with HOPPECKE. 2,22
2,21
Attention! 2,20
2,19
2,18
2,17
6.1 Discharging 2,16
2,15
-10 -5 0 5 10 15 20 25 30 35 40
Never allow the final discharge voltage of the battery to drop below the voltage corresponding to Temperature [°C]
the discharge current.
Fig. 6-1: Temperature related float charge voltage adjustment
Unless the manufacturer has specified otherwise, no more than the nominal capacity is to
Attention! be discharged. Immediately after discharge (including partial discharge), charge the battery
completely.
Temperature charging voltage compensation for products with an extended operating
temperature range (grid | Xtreme VR)
The temperature compensation of -3mV/(cell*K) is limited to +40 °C/+ 104 °F, since the com-
6.2 Charging – general
Attention! pensated charging voltage increasingly approaches the natural open circuit voltage of the battery
from this temperature and therefore there is no sufficient overvoltage available to keep the battery
Depending on how the batteries are used, charging is to be carried out in the operating modes described in
in a fully charged condition.
Chap. 6.2.1 to Chap. 6.2.4.
In the extended temperature range of 40 to 55 °C, the batteries of the grid | Xtreme VR shall
therefore be operated with a constant float charge voltage of 2.225 V/cell.
Apply the charging procedure with limit values in accordance with DIN 41773 (lU characteristic
curve). The sun products are daily discharged and for this reason the charging profile of these
Maximum charge currents
products is different compared to the stand by application. The charging parameter for the cyclic
Up to 2.4 V/cell the battery is able to absorb the maximum current the battery charger provides.
applications (sun products) are listed in the chapter 7.
Using the IU-characteristic according to the DIN 41773 a charging current of 5 A to 20 A per
Attention! 100 Ah rated capacity (C10) is recommended.
Superimposed alternating currents
Depending on the charger type and charging characteristic curve, alternating currents flow through
Permissible charging current with grid | Xtreme VR batteries: 5 to 40 A per 100 Ah)
the battery during charging and are superimposed onto the charging direct current. These superim-
Attention! 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. During the Boost charging the alternating current should not be higher than 5 A/100 Ah.
6.2.1 Standby parallel operation
In order to achieve the optimum service life for sealed lead-acid batteries on float charge,
a maximum effective value of the alternating current of 1 A per 100 Ah nominal capacity is
DC power supply Electrical Load
recommended.
Attention!
Temperature-related adjustment of the charge voltage
The temperature voltage compensation is mandatory if the application temperature deviates
from 20 °C. HOPPECKE recommends 3 mV/K. If the inverter can not realize the compensation
Attention! (technically), the border area would be 15 °C to 25 °C (shown by the figure 6-1). Nevertheless the Battery
compensation should be realized.
Fig. 6-2: Standby parallel operation
Temperature [°C] - 10 0 10 20 30 40
Charge voltage [V/cell] 2.34 2.31 2.28 2.25 2.22 2.19
Tab. 6-1: Corrected charge voltage in relation to charge temperature for battery types with 2.25 V/cell float charge
at Tnom
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38 39
The following is characteristic for this operating mode: The following is characteristic for this operating mode:
– Consumers, direct current source and battery are connected in parallel – When charging, the battery is separated from the consumer
– The charge voltage is the operating voltage of the battery and the system voltage at the same time – The max. charge voltage of the battery is 2.4 V/cell
– The direct current source (charging rectifier) is capable of supplying the maximum load current and the battery
– The charging process must be monitored
charge current at any time
– The battery only supplies current when the direct current source fails – At 2.4 V/cell, if the charge current has dropped to 1.5 A per 100 Ah nominal capacity, you must switch to
– The charge voltage should be set at (see Tab. 6-2) x number of cells in series (measured at the battery’s float charging as described in Chap. 6.2.4
terminals) – The battery may be connected to the consumer if required
– To reduce the recharging time, a charging stage can be applied in which the charge voltage is max 2,40 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 6.2.4 Float charging
Float charging is used to keep the battery or batteries in a fully charged state and corresponds to a large extent
Battery type Float charge voltage to the charge type, mentioned in chapter 6.2.1.
OPzV 2.25 ± 1 % V/cell
Use a charger that complies with the specifications described in DIN 41773 (IU characteristic curve).
power.bloc OPzV 2.25 ± 1 % V/cell
Set the voltage so that average voltage is 2.25 V ± 1 % (2.27 V ± 1 % for net.power 12 V 92/170 Ah,
net.power 12 V 100 und 150 Ah 2.25 ± 1 % V/cell 2,285 V ± 1 % for grid | Xtreme VR and power.com XC and 2.28 V ± 1 % for grid | power VR X).
net.power 12 V 92 und 170 Ah 2.27 ± 1 % V/cell
Example: Nominal battery voltage: 60 V, float charge voltage of charging device is 30 x float charge voltage per
power.com XC 2.27 ± 1 % V/cell cell. E. g. 30 x cells OPzV result in 30 x 2.25 V = 67.5 V ± 1 % (=max. 68.18 V/min. 66.83 V).
grid | power VR M (power.com SB) 2.25 ± 1 % V/cell
power.com HC 2.25 ± 1 % V/cell 6.2.5 Equalizing charge (correction charge)
sun | power VR L (OPzV solar.power/OPzV bloc solar.power) 2.25 ± 1 % V/cell
Under normal circumstances equalizing charges are not required.
sun | power VR M (solar.bloc) 2.25 ± 1 % V/cell If there are unacceptably large discrepancies between the cell voltages of the individual cells at float charge
grid | power VR X/grid | power VR X FT 2.28 ± 1 % V/cell (see Tab. 6-3), an equalizing charge must be performed.
Equalizing charges are necessary after exhaustive discharges, after inadequate charging, if the cells have
grid | Xtreme VR 2.285 ± 0.5 % V/cell
been held at non-uniform temperatures for long periods of time or if the voltage value of one or more cells has
power.com SA 2.25 ± 1 % V/cell dropped below the critical threshold as specified in Tab. 6-3 during operation.
power.com H.C 2.27 ± 1 % V/cell
Type Float charge voltage
Tab. 6-2: Float charge voltage adjustment in standby parallel operaion
OPzV, power.bloc OPzV, net.power 12 V 100 and 12 V 150 Ah, 2.25 V/cell ± 1 %
grid | power VR M (power.com SB), power.com HC, power.com SA,
6.2.2 Floating operation sun | power VR L (OPzV solar.power/OPzV bloc solar.power),
sun | power VR M (solar.bloc)
The following is characteristic for this operating mode: net.power 12 V 92 and 170 Ah, power.com XC 2.27 V/cell ± 1 %
– Consumers, direct current source and battery are connected in parallel
grid | power VR X/grid | power VR X FT 2.28 V/cell ± 1 %
– 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- grid | Xtreme VR 2.285 V/cell ± 0.5 %
mittently exceeds the nominal current of the direct current source. During this period the battery supplies Voltage per unit 2V 4V 6V 12 V
power
– The battery is not fully charged at all times Tolerance float charge
– Therefore, depending on the number of discharges, the charge voltage must be set to approx. voltage for single cells
- 0.10 V/+ 0.20 V - 0.14 V/+ 0.28 V - 0.17 V/+ 0.35 V - 0.25 V/+ 0.50 V
(2.27 to 2.30 V) x the number of cells connected in series (deviation from average
float charge voltage)
6.2.3 Switch mode operation (charge/discharge operation) Tab. 6-3: Float charge voltage
Example for OPzV cells: Float charge voltage max. = 2.45 V/cell and min. 2.15 V/cell (at average float charge
DC power supply Elctrical Load 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.
Charger Battery Attention!
Fig. 6-3: Switch mode operation
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Perform the equalizing charge as follows: 7S
ettings for charging HOPPECKE sun | power VR L (OPzV solar.power/
1. Charging with IU characteristic up to max. voltage U = 2.4 V/cell up to 48 hours. The charge current must OPzV bloc solar.power) and sun | power VR M (solar.bloc) batteries
not be higher than 20 A per 100 Ah nominal capacity.
2. If the maximum temperature exceeds 45 °C, terminate the charging process or switch to float charge to This chapter contains instructions for charging of HOPPECKE sun | power VR L (OPzV solar.power/
allow the temperature to drop. OPzV bloc solar.power) battery cells and battery blocks in solar applications.
3. T he 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: 7.1 Charge and discharge parameters
Refer to Chap. 4.
sun | power VR L sun | power VR M

Parameter
Note that float charge voltages of lead-acid batteries with electrolytes fixed in gel can fluctuate OPzV solar.power solar.bloc
significantly within the first four years after initial commissioning. The voltages range in an area
between ca. 2.12 V/cells and 2.5 V/cell ± 1 %. The black lines in fig. 6-4 depict this area of float battery charge
charge voltage for the first five years of battery service life. The exact development of the voltage recommended charging current 6 x l10 6 x l10
values can not be determined in advance. Fig. 6-4 depicts rather the trend of this typical behaviour
and related reasonable alarm thresholds. standard charge (regular operating cycles)
IU IU
characteristic (with subsequent (with subsequent
Background: The scattering of float charge voltages of gel batteries is a normal phenomenon and switchover to float) switchover to float)
has no negative impact on the efficiency or capacity of the battery cells. This voltage scattering
leads to a balanced internal gas recombination within the battrey string with the result of lower max. current (consider the fuses and cable lengths) 6 x l10 6 x l10
voltage differences and improved cell-internal oxygen and hydrogen recombination rates. This
max. voltage absorption phase 2.4 - 2.5 V/cell 2.4 V/cell
process can neither be accelerated through cyclitzation of the battery, nor by raised charge
voltages. The normal equalizing charge voltage leads optimally to a homogeneous gel structure recommended absorption time 180 min 180 min
and a high efficency of the battery over the entire service life.
6 h/charging factor 1.03 6 h/charging factor 1.02
The absorbtion time (or The absorbtion time (or
the last charging phase) the last charging phase)
can be shorter or longer can be shorter or longer
absorption time full charge/charging factor
than the 6 h depending on than the 6 h depending on
charging factor. The kee- charging factor. The kee-
ping of the charging factor ping of the charging factor
is rather recommended. is rather recommended.
frequency/cycle, based on time period (full charge) 14 days 14 days
No change-over due to a No change-over due to a
float charge
current threshold! current threshold!
Cell Voltage U [V/Cell]
voltage 2.25 V/cell ± 1 % 2.25 V/cell ± 1 %

T > 20 °C - 3 mV/K T > 20 °C - 3 mV/K
temperature correction
T < 20 °C + 3 mV/K T < 20 °C + 3 mV/K
equalization charge (frequency depending on which of the following two criteria occurs first)
frequency/cycle, based on capacity throughput 10 x Cn 10 x Cn
frequency/cycle, based on time period 40 days 40 days
IU/IUIa IU/IUIa
characteristic (with subsequent (with subsequent
Time [Years]
switchover to float) switchover to float)
Fig. 6-4: Trend of float charge voltage over service life of gel batteries. At IUIa characteristic: At IUIa characteristic:
current in Ia phase max. current in Ia phase max.
comment to the characteristic
0.8 A/100 Ah 5 A/100 Ah
C10 for 2 to 4 h C10 für 2 bis 4 h
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42 43
7.3 Temperature influence on battery performance and service life
max. current (note the fuses and cable lengths) 6 x l10 6 x l10
2.55 V/c 7.3.1 Temperature influence on battery capacity
at IU-characteristic
max. voltage absorption phase 2.5 V/c Battery capacity depends significantly on ambient temperature. Lead acid batteries loose capacity with
2.4 V/c
at IUIa-characteristic decreasing temperature and vice versa, as shown in fig. 7-6. This should be considered when sizing the battery.
6 h/charging factor 1.07 4 h/charging factor 1.04 Temperature range for sun | power VR L (OPzV solar.power/OPzV bloc solar.power) batteries:
The absorbtion time (or The absorbtion time (or
the last charging phase) the last charging phase) Possible temperature range: - 20 °C to 45 °C
can be shorter or longer can be shorter or longer Recommend temperature range: 15 °C to 35 °C
absorption time/charging factor
than the 6 h depending on than the 4 h depending on
charging factor. The kee- charging factor. The kee-
ping of the charging factor ping of the charging factor
is rather recommended. is rather recommended.
battery discharge
Battery Capacity in %
refer to the data sheet refer to the data sheet
discharge characteristic
and project data and project data
recommended (DOD) cycle operation 50 % 50 %
max. depth of discharge (DOD),
80 % 80 %
immediate recharge is necessary
limited by battery fuse limited by battery fuse
max. discharge
and cable and cable
proposal for characteristic for deep discharge 2.01 V/c at I ≤ 0.16 x I10 2.01 V/c at I ≤ 0.16 x I10 Temperature in °C
protection [U=f(I)] 1.81 V/c at I ≥ 4 x I10 1.90 V/c at I ≥ 4 x I10
comment: deep discharge protection by switching off linear interpolation at linear interpolation at Fig. 7-6: sun | power VR L (OPzV solar.power/OPzV bloc solar.power): Dependency of battery capacity on temperature
relating to a constant voltage value is forbidden! 0.16 x I10 < I < 4 x I10 0.16 x I10 < I < 4 x I10
Tab. 7-1: Charge and discharge parameters 7.3.2 Temperature influence on battery design life
As corrosion processes in lead acid batteries are significantly depending on battery temperature, the battery
7.2 Alternating currents design life is directly 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).
Depending on the charging equipment, its specification and its characteristics, superimposed alternating Thus battery design life will be halved in case the temperature rises by 10 K.
currents may contribute to battery charging current. Alternating currents and the corresponding reaction by the The following graph (refer to fig. 7-7) shows this relationship. The diagram depicts operation in float charge
connected electrical loads may lead to an additional battery temperature increase, and – consequently – to a mode. Additionally, the endurance in cycles has to be taken into account.
shortened battery service life as a result of stressed electrodes (micro cycling).
The alternating current must not exceed 1 A (RMS)/100 Ah nominal capacity.
During the Boost charging the alternating current should not be higher than 5 A/100 Ah.
Design life in %
Ambient Temperature in °C
Fig. 7-7: Service life of sun | power VR L (OPzV solar.power) cell as a function of ambient temperature (standby
application in float charge operation with 2.25 V/cell)
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7.4 Influence of cycling on battery behavior The following figure depicts dependency of the endurance in cycles on depth of discharge and temperature.
7.4.1 Endurance in cycles depending on depth of discharge
The endurance in cycles is defined as number of discharging and charging cycles until the actual remaining
battery capacity drops below 80 % of the nominal capacity (C10). The endurance in cycles 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 endurance in cycles may vary significantly.
The following chart (refer to fig. 7-8) shows the cycling behavior of a HOPPECKE sun | power VR L
Cycle numbe [n]

(OPzV solar.power/OPzV bloc solar.power) under ideal operating conditions. The cycle life refers to one discharge
per day. Endurance in cycles cannot exceed stated service life under float charge conditions. The cycles shown
by the following diagramms are measured and calculated according to IEC 61427 and IEC 60896.
Cycle Number [n]
Depth of Discharge (DoD) in %

sun | power VR L at 20 °C sun | power VR L at 25 °C sun | power VR L at 30 °C
sun | power VR L at 40 °C sun | power VR L at 45 °C sun | power VR L at 35 °C
Fig. 7-10: Endurance in cycles of sun | power VR L (OPzV solar.power) depending on DoD and temperature
Depth of Discharge DoD [%]
Fig. 7-8: Endurance in cycles of sun | power VR L (OPzV solar.power) as a function of DoD (at 20 °C) 7.4.3 Electrolyte freezing point depending on depth of discharge (DoD)
The freezing point of the electrolyte (sulfuric acid) rises with increasing depth of discharge.
7.4.2 Endurance in cycles depending on ambient temperature In case the battery is exposed to cold ambient temperatures (< 0 °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
Since design life mainly depends on temperature, the cycle lifetime is affected by temperature as well. example for this relation. Example: If depth of discharge is below 60 % the operating temperature must not be
Fig. 7-9 depicts this relation for a regular battery depth of discharge of 80 %. below - 23.4 °C.
Freezing Point in °C
Cycles [n]
Depth of Discharge (DoD)
Fig. 7-11: Electrolyte freezing point as a function of depth of discharge (DoD)
Ambient Temperature in °C
Fig. 7-9: Endurance in cycles of sun | power VR L (OPzV solar.power) as a function of ambient temperature
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7.5 Remarks to warranty management 8.2 Work to be performed annually
Above mentioned information about battery performance and service life, particularly concerning the charging Take the following measurements and record the measurement values:
procedure and the influence of temperature and cycling, affect terms of warranty as well. 1. Voltage of the complete battery system
In case of a warranty claim the customer/battery operator needs to prove the compliance of above mentioned 2. Individual voltage of all cells or monobloc batteries
parameters with the allowed/recommended limits. Corresponding measurement logs have to be sent to the 3. Surface temperature of all cells or monobloc batteries
battery manufacturer.
4. Temperature in battery room
The service life of the battery is valid for operation under optimal conditions only. 5. Perform a visual check of all screwed connectors
6. Check all screwed connectors to make sure that they are firmly secured
For a better understanding of the life time terms, please pay attention to the information leaflet No. 23e 7. Visual check of battery racks or battery cabinets
(Edition August 2013) of the Fachverband Batterien of the ZVEI – Zentralverband Elektrotechnik und Elektro- 8. Check to make sure that the battery room is properly ventilated and deaerated
industrie (https://www.zvei.org/fileadmin/user_upload/Verband/Fachverbaende/Batterien/Merkblaetter/
Industriebatterien/23e_Definition_of_different_life_time_terms_for_batteries_2013-08.pdf). With regard to the HOPPECKE recommends the use of a stationary battery monitoring system for the inspection of relevant data.
assertion of warranty claims only the respective contractual provisions are decisive. Please contact your local HOPPECKE representative for further information.
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 8.3 Cleaning of the battery
battery failure was caused by manufacturing defects or operational conditions, above mentioned parameters
need to be monitored and registered on a regular basis. These data have to be forwarded to the manufacturer Cleaning the batteries on a regular basis is necessary to maintain battery availability and to meet
for further analysis. accident prevention regulations.
Batteries should be cleaned at least once per year. Note the following points:
HOPPECKE recommends the usage of a battery monitoring system for monitoring and logging of critical data. While cleaning the batteries you must wear face protection (impact-resistant visor
Danger!
Please contact your local HOPPECKE representative for information on HOPPECKE battery monitoring equipment according to EN 166 class F or similar), safety goggles and safety clothes. To avoid
and accessories. electrostatic charges while handling the batteries your clothes, safety shoes and saftey gloves
must have a surface resistance of ≤ 10^8O hm.
Do not use dry cleaning cloth!

8 Battery maintenance
Danger!
Work on batteries, especially installation and maintenance should be performed by
Plastic parts of the batteries, especially the cell container, have to be cleaned with water or water
HOPPECKE specialists (or by qualified personnel trained by HOPPECKE) only; personnel must be
moistened cleaning cloth without additives.
familiar with battery handling and the required precautionary measures. Unauthorized persons
After cleaning the battery surface has to be dried with apporiate measures, like moist antistatic
Danger! must keep away from the batteries
cleaning cloth (e. g. cotton).
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
2. Individual voltage of selected cells or monobloc batteries
3. Surface temperature of selected cells or monobloc batteries
4. Temperature in battery room
If the cell voltage deviates from the average float charge voltage by more than + 0.2 V/cell or
- 0.1 V/cell and/or if the surface temperature of various cells or monobloc batteries differs by
more than 5 K, contact customer service.
Also note specifics of lead-acid batteries with electrolytes, fixed in gel. (see chapter 6.2.5)
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9 Testing the battery system
9.1 Performing the capacity test (short form)
For tests, proceed as directed in EN 60896-21: “Stationary lead acid batteries – Part 21: Valve
regulated types – Methods of test” (IEC 60896-21:2004).
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:
– Individual voltage of all cells or monobloc batteries
– Surface temperature of at least one out of every ten cells or 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.
4. Prepare an adjustable load that you can connect to the battery system. The load current must correspond Fig. 9-1: IU characteristic
to the maximum permitted current for which the battery is designed.
5. Prepare a shunt that you can connect in series with the load. The IUIa charging method is an even better method for preparing the batteries; it is a charge with an additional
6. P repare the voltmeter so that you can test the total voltage of the battery. 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 0.8 A per 100 Ah is applied for 3 hours. The charge voltage
7. Connect the load, the shunt and the voltmeter. Simultaneously start a time measurement.
can then increase up to 2.65 V per cell.
8. K eep the load current constant and measure the voltage of the battery system in regular time intervals.
9. C heck the row connectors (block connectors), step connectors and tier connectors for excessive heating.
10. C alculate the capacity of the battery system using the following formula:
Capacity (% at 20 °C) = (Ta/Ts) x 100
Ta = actual discharge time until the permitted minimum voltage is reached.
Ts = theoretical discharge time until the permitted minimum voltage is reached.
11. R econnect the battery system as originally connected and perform a boost charge (see Chap. 5.13).
9.2 Performing the capacity test (extended version)
Preparation
The best and quickest method for preparing batteries for testing is the IU charge method, also used for
equalizing 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 to 2.40 V) x number of cells is the most common
charging characteristic used for commissioning the batteries.
The charge is performed with a constant voltage of max. 2.40 V/cell for up to 48 hours. The charge current
should not be higher than 20 A per 100 Ah nominal capacity. If the elcetrolyte temperature of the cells/blocs 0.8
exceeds the maximum of 45 °C, terminate the charge or switch to float charge to allow the temperature to drop.
Fig. 9-2: IUIa characteristic
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Note that an increased proportion of hydrogen is produced and that the battery room must be provided with Cell numer Case A Case B Case C
sufficient ventilation.
Depending on storage time and storage conditions, the battery may require an additional charge for commis- 1 1.84 1.84 1.79
sioning. 2 1.83 1.86 1.80
The battery is completely charged when the voltage and the charge current no longer change within a period 3 1.83 1.87 1.81
of 2 hours. 4 1.84 1.87 1.80
5 1.84 1.86 1.81
9.3 Capacity test of the battery 6 1.85 1.86 1.79
7 1.69 1.87 1.78
Necessary accessories:
8 1.84 1.86 1.80
– Suitable electronic load or electrical resistance (with adjustable resistance value to adjust the discharge
9 1.83 1.59 1.81
current or discharge load)
– Suitable current probe with sufficient precision for measuring the DC current or shunt for measuring the 10 1.85 1.84 1.81
discharge current 11 1.84 1.85 1.80
– Voltage measuring device for measuring the electrical voltage 12 1.84 1.85 1.79
– Thermometer for measuring the battery temperature (surface temperature) 13 1.85 1.85 1.79
– Clock for measuring the discharge time Battery voltage 23.77 V 23.87 V 23.38 V
– Project planning data table for selecting the correct discharge current or the correct discharge power
Tab 9-2: Measured cell voltages and total voltage after 95 % of the discharge time has elapsed
Carry out the battery discharge in accordance with the regulations on performing capacity tests EN 60896-21.
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. Case A: a “weak cell,“ passed capacity test, battery okay
Case B: a faulty cell, failed capacity test, battery not okay
Minimum precision requirements for the measuring devices (precision class): Case C: all cells okay, failed capacity test, battery not okay
The battery must be charged immediately following the capacity test.

For voltage measurement: 0.5 The measured capacity C (Ah) at the average start temperature  is calculated as a product of the discharge
For current measurement: 0.5 current (in A) and the discharge time (in hours).
For temperature measurement: 1 °C As the battery capacity is dependent on the temperature, the measured battery capacity needs to adjusted for
temperature.
For time measurement: 1%
At temperatures higher than 20 °C nominal temperature, the battery capacity increases whereas the capacity
Tab 9-1: Precision requirements for the measuring devices 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
During the capacity test, record the discharge current or discharge power, temperature, battery and cell-/ DIN EN 60896-21 using the equation [1]:
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. C
Ca = [1]
Terminate the discharge when the battery voltage has reached the value n x Uf where n is the number of cells 1 +  (  - 20 °C)
and Uf is the selected final discharge voltage per cell.
Also terminate the discharge when a cell has reached a voltage of U = Uf – 200 mV or a monobloc battery C = measured capacity
with n cells has reached a voltage of U = Uf - √ n x 200 mV.  = correction factor (with  = 0.006 for discharges > 3 h and  = 0,01 for discharges ≤ 3 h)
 = start temperature
Example: Ca = corrected capacity
13 cells 6 OPzV 300
5 h-capacity test According to the DIN EN 60896-21 standard, the battery has passed the capacity test when 95 % of the
End voltage of the battery = 23.40 V (for 13 cells) required power is attained in the first capacity test. After the 5th discharge, 100 % of the required power must
Average voltage per cell = 1.80 V be attained.
minimum end voltage of individual cells = 1.60 V
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 IEC 62485-2 (insulated tools, protective eyewear, protective
clothing, gloves, ventilation, etc.)!
Attention!
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10 Troubleshooting Qair = 0.05 m3 x 2 x 30 Cells x 1 mA x 200 Ah x 1 x 5 x 0.2 x 10-3
Ah Ah
If malfunctions occur in the battery or charger, contact customer service immediately. Qair = 0.6 m3
Measured data as described in Chap. 8.1 simplifies fault detection and elimination. h
A service contract with us facilitates the timely detection of faults.
Result: For a 60 V battery composed of 2 x 30 cells 4 OPzV 200 operating on float charge, an airflow of
0.6 m3/h is required for proper ventilation.
11 Required ventilation for hydrogen generated by batteries
What is the appropriate diameter for intake and exhaust openings with natural ventilation?
Compliance with VDE 0510 Part 2 or IEC 62485-2 is required to ensure safe ventilation and prevent dangerous The necessary cross-section for ventilation openings can be calculated using the following formula:
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 % A = Qair x 28
and the safety factor is 5. The equation can be derived accordingly: Qair = Necessary ventilation [in m3/h]
A = Necessary cross-section for ventilation openings [in cm2]
(Attenuation factor at maximum permissible hydrogen concentration) A = 0.6 m3 x 28 = 16.8 cm2
h
Result: Ventilation openings (intake and exhaust) with a cross-section of 16.8 cm2 ensure ventilation with an
(Quantiy of accumulated hydrogen per actual Ah capacity) airflow of 0.6 m3/h.
What factors must be considered when installing a natural ventilation system?

(safety factor) If possible, the ventilation openings should be positioned on opposite walls. If they must both be on the same
wall, make sure to maintain a distance of at least 2 m between the openings.
12 Disassembly
This results in the total equation for the necessary ventilation in [in m3/h]: Observe all safety precautions for disassembly of the battery system (refer to chapter 0,1 and 2). This includes
among others personal safety equipment, protective clothing and usage of insulated tools.
Qair = 0.05 x n x Igas x CN x 10–3
Igas = Ifloat × fg × fs resp. Igas = Iboost × fg × fs Proceed in the following way:
– Before starting ensure that all electrical loads are switched off (separators, fuses, switches). This must be
Qair = Necessary ventilation/air flow rate [in m3/h]
carried out by qualified personnel. Ensure that the battery is disconnected from all charging devices and
n = Number of cells electrical loads.
Ifloat = Proportion
of charge current in mA/Ah used for water dissociation on float charge per 1 Ah nominal – For battery systems with nominal voltage > 60 V: Remove group-/step connectors first in order to divide
capacity of the battery. = 1 mA/Ah the battery system voltage in smaller partial voltages. Removed connector and post terminal bolts need to
be removed from the battery immediately. You must not use automatic screwdrivers for loosening the post
Iboost = P
roportion of charge current in mA/Ah used for water dissociation on boost charge per 1 Ah nominal
terminal bolts.
capacity of the battery. = 8 mA/Ah
– Remove the connectors between cell/blocks. Removed connector and post terminal bolts need to be removed
CN = Nominal capacity of the battery (C10 capacity). from the battery immediately. You must not use automatic screwdrivers for loosening the post terminal bolts.
fg = Gas emissions factor. Proportion of the charge current responsible for hydrogen accumulation. = 0.2 – Battery cells/blocks need to be packed according to ADR 598B. Visible damaged cells/blocks must be packed
(e. g. Paloxe) and transported separately. Refer also to chapter 1.4.
fs = Safety
factor which includes the potential for faults resulting from a damaged cell (possible short circuit)
and battery aging. = 5
13 References to the standards and regulations

Example 1:
A battery with 2 x 60 V (60 V nominal voltage), 4 OPzV 200 (200 Ah) is equivalent to 2 x 30 cells. The references to the applicable standards, regulations etc. should help you to install and use the HOPPECKE
The battery is on float charge at 2.25 V per cell. products correctly. However, it is not possible to quote all regulations and applicable standards according to the
latest edition always. Therefore, these quotes are to be understood as support and not as direct instructions.
CN = Nominal capacity of the battery = 200 Ah In order to implement the specifications of the standards/regulations, the current and applicable standard or
regulation must be available, regardless of the edition of the standard/regulation, which is cited here in the
n = Number of cells = 2 x 30 cells
HOPPECKE manual.
fg = Gas emissions factor = 0.2
fs = Safety factor = 5
Ifloat = 1 mA/Ah
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Batteries are marked with the following hazard symbols:
6. Measures to be taken in
case of unintentional
The meaning of the hazard symbols is:
release
Cleaning / take-up procedures

No smoking, no open flames, no sparks.
Use a bonding agent, such as
sand, to absorb split acid;
Wear safety goggles.
Use lime / sodium carbonate for
ZVEI information leaflet No. 1e neutralisation; dispose with due
Edition September 2012 regard to the official local
Sulphuric acid. regulations, do not permit
penetration into the sewage
system, the earth or water
bodies.
Observe operating instructions.
Instructions for the safe handling of
lead-acid accumulators (lead-acid batteries) Explosive gas mixture.
The REACH-regulation (1907

/2006/EC) has replaced the 2. Hazardous substances
directive on safety data sheets 4. First-aid measures
(91/155/EC). REACH CAS-No. Description Content R-phrases
describes the setting up and General Information:
updating of safety data sheets Sulphuric acid acts corrosive and damages
for substances and
7439-92-1 blue lead – tissue
preparations. For articles –
like lead-acid batteries – after contact with skin rinse with water, remove and wash 7. Handling and storage
safety data sheets are not wetted clothing
required. 7439-92-1 lead alloys with 34 Weight % – Store frost-free under roof;
traces of As,Sb after inhalation of acid inhale fresh air
mist*) prevent short circuits.
This leaflet addresses
manufacturers of batteries after contact with the rinse under running water for Protect plastic housings against
lead-containing 31 Weight % R 61-20/22-33-
and is meant to apply eyes*) serveral minutes exposition to direct sun
Battery paste 62-52/53
voluntarily. radiation.
after swallowing*) drink a lot of water immediately,
The notes are meant to help 7664-93-9 sulphuric acid 34 Weight % R 35 and swallow activated carbon Seek agreement with local water
to comply with legal require- Lead-containing classified as toxic for reproduction authorities in case of larger
ments but do not replace battery paste quantities.
them.
after contact with skin clean with water and soap If batteries have to be stored in
3. Potential hazards storage rooms, it is imperative
that the instructions for use are
1. Substances / formulation No hazards in case of an intact - They have an internal *) seek the advice of a doctor. observed.
and company name battery and observation of the voltage, which – depending
instructions for use. on their level – can be
Data on the product dangerous to the human
Trade name Lead-acid batteries have body when touched.
significant characteristics:
Lead-acid battery - Standard EN 50272-2 1) 5. Fire-fighting measures
filled with - They contain diluted includes safety requirements
Suitable extinguishing agents
diluted sulphuric acid sulphuric acid, which may for batteries and battery
When electrical devices are set in fire in general water is the suitable extinguishing
cause servere acid burns. installations and describes
agent. For incipient fires CO2 is the most effective agent. Fire brigades are trained
Data on the manufacturer: the basic precautions to
to keep a distance of 1 m when extinguishing an electrical fire (up to 1 kV) with
- During the Charging process protect against dangers
spray jet and a distance of 5 m with full jet. For electrical fires in electrical
they develop hydrogen gas deriving from electric
installations with voltages > 1 kV other distances are applicable depending on the
Telephone: and oxygen, which unter currents, leaking gases or
respective voltage. For fires in photovoltaic installations other rules apply.
Facsimile: certain circumstances may electrolytes.
turn into an explosive Unsuitable extinguishing agents
mixture. Powder fire extinguishers are not suitable, amongst others because of only minor
efficiency, possible risks or collateral damages.
Special protective equipment
This leaflet was prepared by the Working Group on Environment and Occupational Health of the For larger stationary battery installations or larger stored quantities: protective
ZVEI – German Electrical and Electronic Manufacturer’s Association
goggles, respiratory and acid protective equipment, acid-proof clothing. 2/5
1)
replaced by: IEC 62485-2
• UN-no.: 2794 • Hazard label: 8
8. Exposure limits and 11. Data on toxicology of the 13. Recycling information • Proper shipping name: • EmS: F-A, S-B
personal protective constituents BATTERIES, WET, FILLED
equipments The points of sale, the • Special Provision 238
WITH ACID no. 1 + 2: no transport as
Sulphuric acid manufacturers and importers of
8.1 No exposure caused by lead and lead-containing battery • Packaging group: none dangerous goods (non-
acts intensely corrosive on skin batteries, respectively the metal
paste. spillable batteries are not
and mucous membranes. The dealers take back dead • EmS: F-A, S-B
8.2 Possible exposure caused by sulphuric acid and acid mist inhalations of mists may cause batteries, and render them to the subject to other requirements
• Packaging Instruction: P 801 of IMDG Code if they meet the
during filling and charging. damage to the respiratory tract. secondary lead smelters for
processing. • Hazard label: 8 requirements according to
CAS-Nr. 7664-93-9 Lead and lead-containing Special Provision 238. An
battery paste Spent lead-acid batteries are not Air transportation according appropriate manufacturer`s
R-phrases R – 35 Causes severe burns. confirmation is necessary.
may cause damage to the blood, subject to accountability of the to IATA-DGR
S-phrases S – 1/2 Keep looked up and out of nerves, and kidneys when taken German Waste Prove Batteries which do not meet
• Class: 8 the requirements according to
reach of children. in. Lead-containing battery paste Ordinance. They are marked
is classified as toxic for with the recycling / return symbol • UN-no.: 2794 Special Provision 238 have to
S – 26 In case of contact with eyes reproduction. and with a crossed-out roller be packed as listed in 14.1
rinse immediately with plenty • Proper shipping name:
container (cf. chapter 15 BATTERIES, WET, FILLED Sea transportation IMDG
water and seek medical 12. Data on the ecology of the "Marking"). Code according to Packaging
advice. WITH ACID
constituents Instruction P 801 and carried
• Hazard class: 8 as dangerous goods
S – 30 Never add water to this Spent lead-acid batteries are not
product (applies for Preliminary remark: allowed to be mixed with other • Packaging Instruction: 870 according to UN 2794.)
concentrated acid only Relevant only if release is batteries in order not to
caused by destruction of the compliance the processing. Air transportation according
battery 14.2 Batteries, wet, to IATA DGR
S – 45 In case of accident or if you By no means may the non-spillable
feel unwell seek medical • Hazard class: 8
Sulphuric acid electrolyte, the diluted sulphuric Land transportation according
advice immediately (show the Water-polluting liquid within the acid, be emptied in an inexpert • UN-no.: 2800
label where possible) to ADR/RID
meaning of the German Water- manner. This process is to be • Proper shipping name:
3 Resources Act (WHG) Water carried out by the processing • Un-no.: 2800 BATTERIES, WET, NON-
Threshold value on workplace 0,1 mg/m *)
pollution class: 1 (mildly water companies. • Hazard class: 8 SPILLABLE
Hazard symbol C, corrosive polluting).
• Proper shipping name: • Packing group: none
14. Transport instructions
As described in section 6 use a BATTERIES, WET, NON- • Packaging Instruction: 872
Personal protective equipment: Rubber, PVC gloves, acid- bonding agent, such as sand, to SPILLABLE
14.1 Batteries, wet, • Hazard label: 8
proof goggles, acid-proof clothing, safety boots. absorb spilled acid or neutralise • Packing group: none
filled with acid
3) using lime / sodium carbonate. • Special Provision A 67: no
0,5 mg/m3 at the lead battery production. • Packaging Instruction: P 003 transport as dangerous
Dispose of under the locally
applicable provisions. Land transportation according • Hazard label: 8 goods (non-spillable batteries
to ADR/RID • Special Provision 238 para. are not subject to other
Dispose with due regard to requirements of IATA DGR if
official local regulations, • Special Provision 598: no a) + b): no transport as
transport as dangerous dangerous goods (non- they meet the requirements of
9. Physical and chemical 10. Stability and reactivity of Special Provision A 67.
Do not allow progression into the goods (new + spent batteries spillable batteries are not
properties sulphuric acid Provided that poles are
sewage system, soil or bodies of are not subject to other subject to other requirements
(30 to 38,5%) secured against short-circuit.
water. requirements of ADR/RID if of ADR/RID if they meet the
Lead An appropriate
Appearance: they meet the requirements requirements according to
– Corrosive, inflammable manufacturer`s confirmation
according to Special Provision special provision 238. An
form: solid liquid. is necessary. Batteries which
Lead and lead-containing 598) appropriate manufacturer`s
colour: grey do not meet the requirements
– Thermal decomposition at battery paste confirmation is necessary.
odour: odourless • If the requirements of Special according to Special Provision
338 ˚C. are hardly soluble in water. Provision 598 are not fulfilled Batteries which do not meet
the requirements according to A 67 have to be packed as
Safety-related data – Destroys organic materials Lead can be dissolved in an the transport of new and spent listed in 14.1 Air transportation
batteries has to be declared Special Provision 238 have to
Solidification point: 327 ˚C such as cardboard, wood, acidic or alkaline environment. IATA-DGR according to
as dangerous goods as be packed and carried as
Boiling point: 1740 ˚C textiles. Chemical and physical treatment Packing Instruction 870 and
follows: listed in 14.1 Land
Solubility in water (25 ˚C): is required for elimination from carried as dangerous goods
– Reacts with metals transportation ADR/RID
low (0,15 mg/l) water. Waste water containing • Hazard class: 8 according to UN 2794.)
producing hydrogen. according to Special Provision
density (20˚C): 11,35 g/cm³ lead must not be disposed of in
• UN-no.: 2794 598.)
vapour pressure (20 ˚C) – Vigorous reactions with lyes untreated condition.
and alkalis. • Naming and description:
Sea transportation according 14.3 Batteries, damaged:
Sulphuric acid (30 – 38,5 %) BATTERIES, WET, FILLED
form: liquid WITH ACID to IMDG Code Land transportation according
colour: colourless • Hazard class: 8 to ADR/RID
• Packing group: none
odour: odourless • Hazard class: 8
• Hazard label: 8 • UN-no.: 2800
• Proper shipping name: • UN-no.: 2794
Solidification point: • ADR Tunnel restriction code:
– 35 bis – 60˚C E BATTERIES, WET, NON- • Proper shipping name:
Boiling point: ca. 108 – 114 ˚C SPILLABLE BATTERIES, WET, FILLED
Solubility in water (25 ˚C): • Packing group: none WITH ACID
Sea transportation according
complete to IMDG Code • Packing group: none
density (20 ˚C): 1,2 – 1,3 g/cm³ • Packaging Instructions: P 003
vapour pressure (20 ˚C) • Hazard class: 8 and PP 16
3/5 4/5
• Packing Instruction P 801 a: The manufactures and sellers of
transport as dangerous 15. Marking the batteries subject to
goods (packing in accu identification requirements
boxes) In accordance with the German (packaging, technical
tech
or Special Provision VV 14: law governing the sale, return instructions, leaflets) shall
s be
transport as dangerous and environmentally sound responsible for this information.
goods (in bulk) disposal of batteries and
• Hazard label: 8 secondary cells (Batteries Act –
Batteriegesetz, BattG) from 25 16. Other information
• ADR Tunnel restriction code: June 2009 (national Fachverband Batterien
E transposition of directive The data rendered above are Postfach 70 12 61
• Note: these references can be 2006/66/EC (battery directive) based on today's knowledge, 60591 Frankfurt am Main
applied by transportation of lead-acid batteries have to be and do not constitute an
Lyoner Straße 9
Lead-acid
acid batteries of UN-no.
UN marked with a crossed-out assurance op properties.
60528 Frankfurt am Main
2800 as well. wheelie bin with the chemical Existing laws and regulations
symbol for lead Pb shown have to be observed by the Tel.: (0 69) 63 02-209
below. recipient pf the product in own Fax: (0 69) 63 02-279
responsibility. e-mail: [email protected]
Information Leaflet
In addition, the ISO-return /
recycling symbol is rendered.
Safety data sheet on accumulator acid
(diluted sulphuric acid) (in compliance with EC Directive 91/155/EU)
1 Substance / formulation and company name

The manufacturer, respectively
the importer of the batteries shall
be responsible for the Data on the product: diluted sulphuric acid (1,22 . . . 1,29 kg/l)
attachment of the symbols. In Trade name: accumulator acid
addition, a consumer / user
information on the significance Data on the manufacturer:
of the symbols has to be
attached, which is required by
the German Battery Ordinance
quoted above as well as by the Telephone: Facsimile:
voluntary agreement of the
battery manufactures concluded 2 Composition / data on the constituents
with the German Federal
Minister of the Environment in Chemical characteristics:
September 1988. 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
3 Potential hazards 4 First- aid measures
Diluted sulphuric acid may cause General instructions: Remove soiled, wetted clothing
Editor: immediately.
severe acid burns
ZVEI – Zentralverband Elektrotechnik-
Elektrotechnik und Elektronikindustrie e. V. after contact to skin Rinse with a lot of water immediately
Fachverband Batterien
after contact to skin.
Lyoner Straße 9
after inhalation of acid mist *) Inhale fresh air.
60528 Frankfurt
after contact with the eyes *) Rinse under running water for
several minutes.
283
Fon.: +49 69 6302-283 *)
after swallowing Drink a lot of water immediately,
Fax: +49 69 6302-362
362
Mail: [email protected] and swallow activated carbon.
*) Seek the advice of a doctor.
© ZVEI 2012 This leaflet was prepared within the Committee on Environmental Affairs of the Division Batteries of the German
In spite of all due care, however, we cannot accept any liability Electrical and Electronic Manufacturers’ Association, ZVEI.
that the information is complete or correct or up to date. (Revised Edition November 2003).
5/5
5 Fire-fighting measures 8 Exposure limits and personal protective equipment 14 Transport regulations
Suitable extinguishing agents Possible exposure caused by sulphuric acid and acid mist during filling Land transport: ADR chapter 3.2, UN 2796
in case of surrounding fires: and charging: RID chapter 3.2, UN 2796
CO2 and solid existinguishing
agent. Threshold value on workplace: 0,1 mg/m3 * Description of the goods: Battery, fluid, Acid
Personal protective equipment: Rubber, PVC gloves, acid-proof Danger number: 80
goggles, acid proof clothing UN number: 2796
6 Measures to be taken in safety boots
case of unintentional Sea transport: IMDG-Code chapter 3.2, UN 2796
*)
release 0,5 mg/m3 at the lead battery production
Cleaning / take-up procedures: 9 Physical and chemical properties Air transport: IATA-DGR chapter 3.2, sulphuric acid
Use a bonding agent, such as
sand, to absorb spilt acid; use Appearance
lime / sodium carbonate for neu- form: liquid Other data: Dispatch per mail service impermissible
tralisation, dispose with due colour: colourless
regard to the official local regu- odour: odourless
lations. 15 Regulations
Safety-related data
solidification point: – 35 . . . – 60 ˚C Marking according to German Regulations
7 Handling and storage boiling point: approx. 108 . . . 114 ˚C on Hazardous Materials Identification requirement
Solubility in water: complete Danger symbol C, corrosive
Store frost-free under roof. Seek flash point: N.A.
R-phrases 35 Causes severe burns.
agreement with local water ignition temperature: N.A.
authorities in case of larger quan- lower explosive limit: N.A. S-phrases 1/2 Keep locked up and out
tities. Observe VAWS. densitiy (20 ˚C): (1.2 – 1.3) g/cm3 of reach of children
vapour pressure (20 ˚C): 14.6 mbar 26 In case of contact with eyes rinse
bulk density: N.A. immediately with plenty of water
pH value: < 1 (at 20 ˚C) and seek medical advice
dynamic viscosity: approx. 2.8 mPa . s (at 20 ˚C) *)
30 Never add water to this product
45 In case of accident or if you feel
10 Stability and reactivity 12 Data on the ecology unwell seek medical advice
of the sulphuric acid of the constituents immediately (show the label where
(30 . . . 38.5 %) possible.
– Water-polluting liquid within
– Corrosive, inflammable liquid. the meaning of the German *) applies for concentrated acid only, and
Water Resources Act not for refilling the battery with water
– Thermal decomposition at
338 ˚C. – Water pollution class: 1 National regulations:
(mildly water polluting).
– Destroys organic materials, Water pollution class: 1 (list material)
such as cardboard, wood, – In order to avoid damage to
textiles. the sewage system, the acid Other regulations: To be observed in case of storage: German Water Resources Act
has to be neutralised by
– Reacts with metals producing
means of lime or sodium
hydrogen. 16 Miscellaneous data
carbonate before disposal.
– Vigorous reactions with lyes
– Ecological damage is The data rendered above are ba-
and alkalis.
possible by change of pH. sed on today’s knowledge, and
do not constitute an assurance
of properties. Existing laws and
11 Data on the toxicology 13 Instructions for
regulations have to be observed
of the constituents processing / disposal
by the recipient of the product in
– acts intensely caustic on skin – The batteries have to be pro- own responsibility.
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.
2 3
7140203153 V1.4 (03.2021)
63
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
7140203153 EN

P.O. Box 1140 · D-59914 Brilon · Germany Phone +49(0)2963 61-0 Email [email protected]
Bontkirchener Straße 1 · D-59929 Brilon Fax +49(0)2963 61-270 www.hoppecke.com

Installation, Commissioning and Operating Instructions: For Valve-Regulated Stationary Lead-Acid Batteries

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Installation, commissioning and operating instructions

for valve-regulated stationary lead-acid batteries

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Head office address:

Installation, commissioning and operating instructions

Type und Design: PRIOTEX Medien GmbH, 59609 Anröchte

© 2013 HOPPECKE Batterien GmbH & Co. KG

Personal health, batteries or the environment are at risk. Recycling.

Risk of explosion or blast, splashing of hot or molten substances.

0.1 General Information

Risk of chemical burns through electrolyte.

OPzV bloc solar.power sun | power VR L

power.com SB grid | power VR M

solar.bloc sun | power VR M Battery with low concentration of antimony.

Used batteries with this symbol have to be recycled.

You must wear safety goggles while handling the battery!

0.3 Warranty, Protocol, Commissioning, Protocols Maintenance

The protocol can be downloaded separately at: https://www.hoppecke.com/en/

7140203153 V1.4 (03.2021)

Date/Signature Technician Date/Signature Customer

46 46 92 1/1 92 7140203153 V1.4 (03.2021)

1.1 Safety precautions

1.2.1 Example for single cell Pb

2.1 General 2.3.1 Sulfuric acid

2.3.2 Explosive gases

3.2 Delivery completeness and externally visible damage

If the delivery is incomplete or damaged as a result of shipping

4.2 Storage time

Warning sign depicting risk of electrical volta-

Safety clearance d [mm]

Tab. 5-1: Demands on the erection site

Fig. 5-1: Safety distance based on battery capacity (Source HOPPECKE)

Tab. 5-3: Open-circuit voltages for different cells/block batteries

5.4 Installation tools and equipment

5.6 Cabinet installation 5.8 General information on connecting the batteries

If sealed stationary batteries are connected in parallel, observe the following:

✗ Fig. 5-14: 10 mm clearance between the batteries

4. Final step: Count all cells/blocks and check for completeness.

5.10.1 Connection terminals

5.10.2 Type of connection cable

Remark to the connection of cells/batteries:

5.10.3 Clamping batteries using battery connectors

It is very important to tighten screws thoroughly as a loose

Charge Voltage [V/Cell]

Fig. 6-3: Switch mode operation

sun | power VR L sun | power VR M

voltage 2.25 V/cell ± 1 % 2.25 V/cell ± 1 %

7.4.1 Endurance in cycles depending on depth of discharge

Cycle numbe [n]

Depth of Discharge (DoD) in %

sun | power VR L at 40 °C sun | power VR L at 45 °C sun | power VR L at 35 °C

Depth of Discharge (DoD)

Fig. 7-11: Electrolyte freezing point as a function of depth of discharge (DoD)

Do not use dry cleaning cloth!

8.1 Work to be performed every six months

Take the following measurements and record the measurement values:

We recommend performing an equalizing charge on the battery system (as described in

9.2 Performing the capacity test (extended version)

Warning sign depicting risk of electrical volta-

4. Final step: Count all cells/blocks and check for completeness.