VL Manual en

Installation, commissioning and operating instructions
for vented stationary lead-acid batteries
Similar to the illustration, grid | aquagen optional

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
Phone +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
Phone +49 (0)2963 61-0
Fax +49 (0)2963 61-449
Internet www.hoppecke.com
Email [email protected]

Type, Design, Print: 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 vented stationary lead-acid batteries Installation, commissioning and operating instructions for vented stationary lead-acid batteries
7140203152 V1.4 (11.2020) 7140203152 V1.4 (11.2020)
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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. Pb
In addition, 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 shortcircuits.
Avoid electrostatic charges and discharges/sparks.
0 Safety notices
Risk of corrosion caused by leaking electrolyte. 0.1 General Information

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
Electrical voltages hazardous to health may cause fatal injury. occur as a result of handling the products described here.
Metal parts of the battery are always alive, therefore do not place items or tools on the battery. Danger!
Risk of explosion and fire, avoid short circuits.
Avoid electrostatic charges and discharges/spaks.
Warning! Risks caused by batteries. Attention! Metal parts of the battery or batteries are always live, so never place foreign objects
or tools on top of the batteries.
Electrostatic discharges can ignite oxyhydrogen gas and therefore cause an explosion of the
Do not smoke. battery! Exploding parts can lead to heavy injuries.
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
General prohibition. eyes or on the skin must be washed with plenty of clean water. Then consult a doctor immediately!
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 after instruction by 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 trained technical
While working on batteries wear protective eye-glasses, protective gloves and specialists in accordance with the instructions in this documentation.
clothing. Attention!
Observe accident prevention regulations as well as EN 50110-1 and
IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries). Work on batteries, especially installation and maintenance should be performed by trained
HOPPECKE specialists (or by personnel trained by HOPPECKE) only; personnel must be familiar
with battery handling and the required precautionary measures. Unauthorized persons must keep
Wear conductive shoes. away from the batteries.
Danger!
General order. Without proper and regular maintenance of the batteries by HOPPECKE specialists (or personnel
authorized by HOPPECKE), the safety and reliability of the power supply during operation cannot
be ensured.
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HOPPECKE offers the following type ranges as vented lead-acid (VLA) batteries: Following symbols and pictograms are pictured on each battery cell or on each battery block:
OPzS
power.bloc OPzS
Read the instruction for installation, commissioning and operation carefully.
max.power
OGi bloc
grid | power V X (GroE)
grid | power V M (OSP.HB/OSP.HC) Always wear protective goggles and cloths.
grid | power V H (OGi bloc/OSP.XC)
sun | power V L (OPzS solar.power/OPzS bloc solar.power)
Avoid naked flames and sparks.
The product names used for HOPPECKE battery series have been changed.
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.
General danger warning.
Risk of electrical voltage.

OLD NEW
GroE grid | power V X
OPzS bloc solar.power sun | power V L Risk of chemical burns through electrolyte.
OPzS solar.power sun | power V L
OSP.HB grid | power V M

Risk of explosion, avoid short circuits, electrostatic charge and discharge/sparks.
OSP.HC grid | power V M
OSP.XC grid | power V H

Battery with low concentration of antimony.
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
–P ay attention to the polarity
–M ake sure the connections are tight
–U se only battery charger leads that are in perfect technical condition and that have adequate
cross-sections
–B atteries 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
–S ecure the charger to prevent it from being switched back on again
–H eed the instructions given in the operating manual provided by the manufacturer of the battery charger
7140203152 V1.4 (11.2020) 7140203152 V1.4 (11.2020)
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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.
There is a risk of explosion and fire due to explosive gas.
Danger! Observe the following regulations (IEEE standards valid for USA only):
– 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” Maintenance/Comissioning Protocoll
– IEEE Standard 1187-2002: “Recommended Practice for Installation Design and Installation of
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”
Batteries contain corrosive acids which can lead to chemical burn on skin and eyes if the
battery is damaged!
You must wear safety goggles while handling the battery!

Wear all the intended personal safety clothing while handling the batteries!
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
commissioning and maintenance should be kept separately nearby the battery/battery installation, the
template can be detached from the manual.
Remark: During commissioning of vented batteries (VLA type products) acid density and voltage have to be
documented from start until end of the commissioning process. This shall be documented separately, the
template does not include this.
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 vented stationary lead-acid batteries
✃
7140203152 V1.4 (11.2020)
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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. Touching a grounded battery by mistake can result in severe electric
13 13 59 59 shock. The risk caused by an incorrect connection can be significantly reduced by terminating
13 13 14 13 1314 59 59
60 5959
60
Danger! 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. T hese 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 refer to Chap. 1.4).
38 38 84 84
37 39 37 39 83 85 8385 Attention!
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 Attention!
43 43 89 89
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
Installation, commissioning and operating instructions for vented stationary lead-acid batteries
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Table of contents 5.11.2 Type of connection cable.......................................................................................................... 33
5.11.3 Clamping batteries using battery connectors.............................................................................. 33
Preface.................................................................................................................................................... 3 5.11.4 Installing the screwed connectors............................................................................................. 34
Used Symbols.......................................................................................................................................... 4 5.11.5 Clamping connection plates onto the batteries.......................................................................... 35
5.12 Connect the battery system to the DC power supply................................................................... 35
0 Safety notices...................................................................................................................................... 5 5.13 Commissioning charge (initial charge)....................................................................................... 36
0.1 General information................................................................................................................... 5 5.13.1 Commissioning charge with constant voltage (IU characteristic curve)......................................... 36
0.2 Safety instructions for working with lead-acid batteries................................................................ 7 5.13.2 Commissioning charge with constant current (I characteristic curve) or decreasing current
0.3 Warranty, Protocol Commissioning, Protocol Maintenance�� 8 (W characteristic curve)............................................................................................................ 37
5.13.3 Extended commissioning charge............................................................................................... 37
1 General information............................................................................................................................. 12 5.14 Electrolyte level check.............................................................................................................. 37
1.1 Safety precautions................................................................................................................... 12 5.15 Electrolyte density adjustment.................................................................................................. 37
1.2 Technical Data........................................................................................................................ 12 5.16 Replacement of a defect cell/battery (dry/formed)��38
1.2.1 Example for single cell............................................................................................................. 12 5.16.1 Before the replacement of the cells/battery��38
1.2.2 Identification plate battery........................................................................................................ 13 5.16.2 Moving the cells/batteries��38
1.3 CE-Mark.................................................................................................................................. 13 5.16.3 Filling of acid into the cells/batteries��38
1.4 Disposal and recycling.............................................................................................................. 13 5.16.4 The commissioning of the cells/batteries��38
1.5 Service.................................................................................................................................... 13 5.16.5 Checking the electrolyte level��38
5.16.6 Adjustment of the electrolyte density��38
2 Safety................................................................................................................................................. 14 5.16.7 Montage of the screw connectors��38
2.1 General................................................................................................................................... 14
2.2 Personal safety equipment, protective clothing, equipment......................................................... 15 6 Battery operation................................................................................................................................ 39
2.3 Safety precautions................................................................................................................... 15 6.1 Discharging............................................................................................................................. 39
2.3.1 Sulfuric acid............................................................................................................................ 15 6.2 Charging – general................................................................................................................... 39
2.3.2 Explosive gases....................................................................................................................... 16 6.2.1 Standby parallel operation........................................................................................................ 41
2.3.3 Electrostatic discharge............................................................................................................. 17 6.2.2 Floating operation.................................................................................................................... 42
2.3.4 Electric shock and burns.......................................................................................................... 17 6.2.3 Switch mode operation (charge/discharge operation)................................................................. 42
6.2.4 Float charging.......................................................................................................................... 43
3 Transportation..................................................................................................................................... 18 6.2.5 Equalizing charge (correction charge)......................................................................................... 43
3.1 General................................................................................................................................... 18
3.2 Delivery completeness and externally visible damage................................................................ 19 7 Settings for charging HOPPECKE sun | power V L (OPzS solar.power/OPzS bloc solar.power) batteries... 44
3.3 Defects................................................................................................................................... 19 7.1 Charge and discharge parameters ............................................................................................ 44
7.2 Alternating currents.................................................................................................................. 45
4 Storage .............................................................................................................................................. 20 7.3 Water consumption.................................................................................................................. 45
4.1 General.................................................................................................................................. 20 7.4 Temperature influence on battery performance and service life................................................... 46
4.2 Storage time........................................................................................................................... 20 7.4.1 Temperature influence on battery capacity................................................................................. 46
4.3 Preparing for a several-months storage period.......................................................................... 20 7.4.2 Temperature influence on battery design life.............................................................................. 46
7.5 Influence of cycling on battery behavior..................................................................................... 47
5 Installation ....................................................................................................................................... 21 7.5.1 Endurance in cycles depending on depth of discharge (DoD)....................................................... 47
5.1 Demands on the erection site................................................................................................... 21 7.5.2 Endurance in cycles depending on ambient temperature............................................................. 47
5.1.1 Calculation of safety distance................................................................................................... 23 7.5.3 Electrolyte freezing point depending on depth of discharge (DoD)................................................ 49
5.2 Variants of cell plugs................................................................................................................ 24 7.6 Remarks to warranty management............................................................................................ 49
5.2.1 Labyrinth plugs (State of delivery)............................................................................................. 24
5.2.2 Ceramic plug........................................................................................................................... 24 8 Battery maintenance........................................................................................................................... 50
5.2.3 Ceramic funnel plugs................................................................................................................ 24 8.1 Work to be performed every six months..................................................................................... 50
5.2.4 grid | aquagen pro (max) Recombination plug............................................................................. 24 8.2 Work to be performed annually................................................................................................. 50
5.3 Filling the cells......................................................................................................................... 25 8.3 Cleaning of batteries................................................................................................................ 51
5.3.1 Check..................................................................................................................................... 25
5.3.1.1 Ventilation – preventing explosions........................................................................................... 25 9 Testing the battery system.................................................................................................................. 52
5.3.1.2 Ventilation – calculation for ventilation requirements of battery rooms......................................... 26 9.1 Performing the capacity test (short form)................................................................................... 52
5.3.2 Filling the cells......................................................................................................................... 27 9.2 Performing the capacity test (extended version)......................................................................... 53
5.3.3 Idle Time................................................................................................................................. 27 9.3 Capacity test of the battery....................................................................................................... 55
5.4 Conducting an open-circuit voltage measurement....................................................................... 28
5.5 Installation tools and equipment............................................................................................... 28 10 Troubleshooting................................................................................................................................. 57
5.6 Rack Installation...................................................................................................................... 29
5.7 Cabinet installation.................................................................................................................. 30 11 Required ventilation for hydrogen generated by batteries................................................................... 57
5.8 Handling the batteries.............................................................................................................. 30
5.9 General information on connecting the batteries........................................................................ 31 12 Disassembly ..................................................................................................................................... 59
5.10 Putting the cells/blocks into the racks...................................................................................... 31
5.11 Connecting the batteries.......................................................................................................... 32 13 References to the standards and regulations..................................................................................... 59
5.11.1 Connection terminals............................................................................................................... 32
Safety data sheet................................................................................................................................... 60
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1 General information 1.2.2 Identification plate battery
Vented lead-acid batteries contain liquid electrolyte. Due to the electro chemical potential oxyhydrogen gas The identification plate of the entire battery system can be found on the
is continuously generated. Decomposed water needs to be refilled from time to time. Using the HOPPECKE battery rack or inside the battery cabinet.
grid | aquagen recombination system (optional accessory) can drastically extend water refilling intervals. Due The nominal voltage, the number of cells/blocks, the nominal capacity
to the liquid electrolyte, vented lead-acid batteries can only be operated in upright position. The HOPPECKE (C10 = CN) and the battery type are listed on the identification plate of
product range comprises several vented lead-acid batteries like single cells (nominal voltage 2 V) or blocs the system.
(nominal voltage of: 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
batteries. This documentation contains important information regarding the safe and correct
unpacking, storage, installation commissioning, operation and maintenance of filled lead-acid 1.3 CE-Mark
Danger! batteries.
Effective as of 1 January 1997, the EC declaration of conformity 2014/95/EC (Low Voltage
Directive) and the corresponding CE marking for the battery system are required for batteries with
To ensure your own safety as well as the safety of your colleagues and the system, it is essential a nominal voltage between 75 V and 1500 V DC. The installer of the battery system is responsible
that you have read and understood all instructions in this documentation and adhere to them for displaying the declaration and affixing the CE label on or next to the battery’s identification plate.
strictly. If you have not understood the information contained in this documentation or if local
Danger! regulations and conditions apply which are not covered by the documentation (or run contrary to
the information in this documentation), please contact your local HOPPECKE representative. You 1.4 Disposal and recycling
can also contact us at our head office directly.
Used batteries with this marking are recyclable goods and must be sent for recycling.
If you are conducting any work on or with the battery system, it is essential that you familiarize
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
under all relevant regulations.
1.2 Technical Data Pb
1.2.1 Example for single cell We offer our customers our own battery return system. All lead-acid batteries are taken to the
secondary lead smelting plant at our HOPPECKE site, observing the provisions of the German
Each battery cell or bloc contains an identification plate on top of the cell/bloc lid. – Recycling and waste law
Refer to the example below. – Battery regulations
– Transport approval regulations
5 OPzS 250 – Together with the general principles of environmental protection and our own corporate guidelines
2 V 250 Ah CN/266 Ah C10
Ufloat = 2.23 V/cell The HOPPECKE smelting plant is the only lead smelter in Europe certified under:
d20 °C/68 °F = 1.24 kg/l – DIN EN ISO 9001 (processes and procedures)
Made in Germany
– DIN EN ISO 14001 (environmental audit)
– Specialist disposal regulations covering specialist disposal with all associated waste codes for
Example: The information on the identification plate is as follows: storage, treatment and recycling
5 OPzS 250 For further information: +49(0)2963 61-280.
5 = number of positive plates
OPzS = battery type 1.5 Service
250 = nominal capacity C10
(capacity during discharge with ten hours’ current (I10) HOPPECKE has a worldwide service network that you should take advantage of. HOPPECKE service is there for
over a discharge time of 10 h (t10)). you whenever you need specialist consultation for installation of the battery system, parts and accessories or
266 = actual capacity C10 system maintenance. Contact us or your local HOPPECKE representative.
(capacity of discharges 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
7140203152 V1.4 (11.2020) 7140203152 V1.4 (11.2020)
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2 Safety 2.2 Personal safety equipment, protective clothing, equipment
2.1 General While working on batteries wear protective eye-glasses, protective gloves and
clothing!
If the container of a filled lead-acid battery is damaged, electrolyte, acid mist or hydrogen gas may escape. Observe accident prevention regulations as well as EN 50110-1 and
Always take the normal safety precautions when working with lead-acid batteries. IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries).
Procedure for handling acid spills: If working with lead-acid batteries, the following equipment must be provided at the very least:
Fix acid using a binding material such as sand and neutralize it using calcium carbonate, sodium carbonate or – Insulated tools
sodium hydroxide. Dispose of the acid according to the official, local regulations. Do not allow acid to escape – Rubber gloves
into the sewage system, soil or water. The following table contains a list of chemicals recommended for – Protective shoes
neutralizing electrolyte in an approved system.
– Fire extinguisher
– Rubber apron
Observe the safety measures, even when neutralizing small amounts of electrolyte. – Protective goggles
– Face shield
Danger! – Face mask
– Emergency eye wash
Mix the required quantities of the chemicals (see Tab. 2-1) with the electrolyte in small portions.
To avoid electrostatic charging, all textiles, protective shoes and gloves worn while working with
batteries must have a surface resistance of < 108 ohm and an insulation resistance of ≥ 105 ohm
Take special care when adding sodium carbonate, as this results in intense foaming. (refer IEC 62485-2 and DIN EN ISO 20345:2011 Personal protective equipment – Safety footwear).
If possible wear ESD shoes.
Danger!
Remove all wrist watches, rings, chains, jewelry and other metal objects before working with
Neutralization is complete when a pH value between 6 and 8 has been reached. If there is no suitable batteries.
mea-suring device available, the degree of neutralization can be checked using common pH paper. Neutralization Never smoke, handle open flames or create sparks near the batteries.
is complete when the pH paper turns olive green to yellow in color. Never place tools or metal components on top of the batteries.
If the pH paper is blue, this indicates that the neutralization point has been exceeded. Acid must be added to Danger!
neutralize the mixture again. Gel electrolyte from damaged or used batteries can be disposed of in the same The use of proper tools and safety equipment can help to prevent injury or reduce the severity of injury in case
way. of an accident.
The following quantities of any these chemicals can be used to neutralize 1 liter of electrolyte with the listed
nominal density: 2.3 Safety precautions
Calcium Sodium Sodium hydroxide (I) 2.3.1 Sulfuric acid

Nominal
carbonate (kg) carbonate (kg) NaOh NaOH
density Batteries are safe when used properly. However, they contain sulfuric acid (H2SO4), which is extremely corrosive
CaO Na2CO3 20 % concentration 45 % concentration and can cause serious injury. Further information to sulfuric acid can be found in the attached material safety
1.20 kg/l 0.19 0.36 1.36 0.60 data sheet.
1.24 kg/l 0.23 0.44 1.65 0.73
Always wear protective gloves and use the proper tools when working with lead-acid batteries.
1.27 kg/l 0.26 0.50 1.88 0.83 Observe the following instructions and read the attached ZVEI publication “Instructions for the
1.29 kg/l 0.28 0.54 2.03 0.90 safe handling of lead-acid accumulators (lead-acid batteries)”.
Danger!
Tab. 2-1: Chemicals for neutralizing 1 liter of electrolyte
The battery room must be equipped with the following:
– Emergency kit to absorb leaked electrolyte
Observe all regulations, documentation and standards as described in Chap. 0.2. – The following materials listed for use in an emergency situation
Danger!
Risk of fire, explosion, or burns. Do not disassemble, heat above 45 °C, or incinerate.
Danger!
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If sulfuric acid comes in contact with the skin: 2.3.3 Electrostatic discharge
– Remove contaminated clothing immediately
– Dab off acid using a cotton or paper towel; do not rub All lead-acid-batteries produce hydrogen and oxygen while operating, particularly during charging. These gases
leak from the battery in the ambience. Based on the mandatory natural or technical ventilation it can be
– Rinse affected area of skin carefully using plenty of water
assumed that a flammable oxyhydrogen concentration exists only in the close proximity of the battery. A
– After rinsing, wash the area using soap flammable mixture of oxyhydrogen always exists inside the battery cells. This effect does not depend on the
– Avoid making contact with the affected areas of the skin battery technology, design or manufacturer, it is rather a specific characteristic of all lead-acid batteries.
– If necessary, contact a doctor
The energy needed for an ignition of oxyhydrogen is quite low and can be caused differently. Examples: Open
If sulfuric acid comes in contact with your eye: flame, fire, glowing sparks or flying firebrands from grinding, electric spark from switches or fuses, hot surface
areas > 200 °C and – an underestimated cause – electrostatic discharge.
– Carefully wash the affected eye with large quantities of water for 15 minutes (using running water or eye
rinsing bottle)
Measures to avoid an explosion or at least minimize the impact of an explosion:
– Avoid using high water pressure Development of electrostatic discharges on the battery or on your body or on clothes can be avoided if you
– Always contact an eye doctor immediately consider the information below.
If electrolyte is ingested: Do not wipe the battery with an arid fabric especially made of synthetic material. Rubbing on
– Immediately drink plenty of water surfaces of plastic material (battery jars are typically made of plastic materials) causes electro-
– Consult doctor or contact a hospital immediately static charges.
– Before the doctor arrives: if available, swallow activated carbon
lean the surface of batteries with water-moistened cotton fabric only. By using a water-moistened
C
cotton fabric you avoid the buildup of electrostatic charges.
If sulfuric acid comes in contact with clothing or other material, immediately:
– Remove contaminated clothing
– Wash clothing in sodium bicarbonate solution (bicarbonate or baking soda) While working on batteries do not rub your clothes (e. g. made of wool) on the battery. Thereby
– When bubbles stop forming, rinse using clean water electrostatic charges could build up on the battery jar, your body or on your clothes.
ear suitable shoes and clothing with special surface resistance that avoid the buildup of electro-
W
2.3.2 Explosive gases static charge. Thereby the buildup of electrostatic charge on the body and clothing can be avoided.
Lead-acid batteries can release an explosive mixture of hydrogen and oxygen gases. Severe o not remove self-adhesive labels, from the battery without special safety measures. Removing
D
personal injury could occur in the event of an explosion of this mixture. plastic labels can build up electrostatic charges, which can ignite oxyhydrogen gas.
– Always wear the recommended protective clothing (protective goggles, insulated gloves and
Danger! protective shoes, etc.)
Before pulling off the label, wipe the battery moist.
– Use the correct tools only (“non-sparking” with insulated grips, etc.)
– Eliminate all potential sources of ignition such as sparks, flames, arcs
– Prevent electrostatic discharge. Wear cotton clothing and ground yourself when you are working
with the batteries directly 2.3.4 Electric shock and burns
In case of fire, extinguish using water or CO2 extinguisher only. Batteries can cause severe electric shock. If there is a short circuit, very strong currents may
Do not point the fire extinguisher directly at the battery or batteries to be extinguished. There be present. Do not touch any bare battery components, connectors, clamps or terminals.
is a risk that the battery casing may break as a result of thermal tension. In addition, there is Note for batteries with voltages over 1500 V DC In battery systems with a nominal voltage of
a risk of static charging on the surface of the battery. This could result in an explosion. Switch Danger! over 1500 V DC, you must provide equipment for splitting the batteries into cell groups with
Danger!
off the charging voltage of the battery. If extinguishing a fire, use a breathing apparatus with voltages lower than 1500 V DC.
a self-contained air supply. If using water to extinguish a fire, there is a risk that the water/ In order to prevent serious injury as a result of electric shock or burns, be very cautious when
foam could react with the electrolyte and result in violent spatter. For this reason, wear performing any work on the battery system.
acid-resistant protective clothing. Burning plastic material may produce toxic fumes. If this Always wear the recommended protective clothing (insulated rubber gloves and rubber shoes,
should occur, leave the location as quickly as possible if you are not wearing the breathing etc.) and always use insulated tools or tools made of non-conductive material.
apparatus described above. Remove all wrist watches, rings, chains, jewelry and other metal objects before working with
batteries.
If using CO2 fire extinguishers, there is a risk that the battery could explode as a result of
static charging.
Note also the information in the attached ZVEI leaflet “Instructions for the safe handling of
Danger! lead-acid accumulators (lead-acid batteries)”.
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Before conducting work on the battery system …
Determine whether the battery system is grounded. We do not recommend this. If the system is grounded, Monobloc batteries/battery cells are very heavy (depending on type between ca. 10 kg and max.
terminate the connection. Touching a grounded battery by mistake can result in severe electric shock. This risk 1100 kg per cell/bloc). Wear protective shoes. Use only the appropriate transportation equipment
can be significantly reduced by removing the ground connection. However, the racks (or cabinets) used to hold for transport and installation.
the batteries do need to be well grounded or completely insulated. Attention!
If a battery system is grounded … During the transport of the batteries, especially grid | power V H (OGi bloc type), is the avoiding
of strong vibrations absolute mandatory. Otherwise the electrolyte could be spilled. Transport
There is a voltage between the ground and the ungrounded terminal. If a grounded person touches inclination over 40 ° has to be avoided strictly.
this terminal, there is risk of fatal injury! There is also a risk of short circuit if dirt or acid on the Attention!
ungrounded terminal come in contact with the battery rack.
If an additional ground connection is made by some cells within the (grounded) battery system, 3.2 Delivery completeness and externally visible damage
there is a risk of short circuit, fire and explosion.
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
If a battery system is not grounded … with accessories. Then inspect the goods for possible shipping damage.
If an accidental ground connection is made by some cells within the battery system, voltage is Note all
created between the ground and the ungrounded terminal. The voltage can be dangerously high – – Damages to the outer packaging
risk of fatal injury due to electric shock. – Visible stains or moisture that might indicate electrolyte leakage
If the delivery is incomplete or damaged as a result of shipping:

If a second accidental ground connection is made, there is a risk of short circuit, fire and
– Write a short defect notice on the delivery note before signing it
explosion.
– 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
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. 3.3 Defects
Observe all required safety measures to avoid electric shock.

Keep in mind that you are handling live batteries. Observe all instructions in Chap. 2.
3 Transportation 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.
3.1 General
The batteries can be delivered filled or unfilled.
We take great care in packaging the batteries that we send to you so that they arrive without damage. We If you have received filled batteries, check the electrolyte level in the cells. The electrolyte level
strongly recommend that you inspect the delivery for possible shipping damage as soon as it arrives. should be adjusted only after commissioning the cells (float charge).
If you have received unfilled batteries, wait to fill the batteries until they have reached their final
For road transportation, filled lead-acid rechargeable batteries are not treated as dangerous destination.
goods if
– They are undamaged and sealed
– They are protected from falling, shifting and short circuit
– They are firmly secured to a pallet
– There are no dangerous traces of acids, lye, etc. on the outside of the packaging
It is essential that loads on road vehicles are properly secured!
Danger!
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Check the entire scope of delivery to make sure that it matches the detailed delivery note (or
the packing list). Observe ventilation requirements (refer to chap. 5.2.1.1) even for charging of temporarily connected
Failure to promptly inform the carrier of defects or incompleteness could result in the loss of cells.
your claims. Attention!
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.
4 Storage
4.1 General
After receiving the batteries, you should unpack, install and charge them as soon as possible. If this is not
available capacity [% C10]

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
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 three months (see Chap. 6.2.5). storage time [months]
Attention! Calculate this exact time starting on the day of delivery. By the end of the max. storage time
charge acceptance might be declined during battery recharge. Hence, HOPPECKE recommends Fig. 4-1: Available Capacity vs. storage time
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 neces-
sary (at temperatures around 40 °C monthly charges). Refer also to figure 4-1 to retrieve max. 5 Installation
storage times for different storage temperatures. Failure to observe these conditions may result
in sulfating of the electrode plates and significantly reduced capacity and service life of the bat- 5.1 Demands on the erection site
tery. Battery recharge during storage time should be carried out max. twice. The battery should
be operated in continuous float charge mode thereafter. Battery service life commences with When renewing old batteries, ensure that all electrical loads are switched off before removing the
delivery of the battery or batteries from the HOPPECKE plant. Storage times have to be added old battery (separator, fuses, switches).
completely to the service life. This must be carried out by qualified personnel!
Unfilled blocks/cells have to be stored in a dry, frost-free location. Avoid direct sunlight. Storage
Danger!
time should not exceed 24 months.
Required process for charging the batteries by achievement of max. storage duration: If you have questions regarding battery system installation, please contact your local HOPPECKE representative.
Charge with constant power of 1 A or 2 A per 100 Ah C10 battery capacity. Interrupt charging when You can also contact us at our head office directly.
all cell voltages have rised to min. 2.6 V/cell (refer also to Chap. 6.2).
Attention!
If choosing an installation location, determining space requirements and performing the installa-
tion, observe the relevant installation drawing if it is available.
4.3 Preparing for a several-month storage period The floor must be suitable for battery installation; it must
– Have a suitable load-carrying capacity
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 – Have an electrolyte-resistant installation surface (or acid collection tanks must be used)
blocks/cells so that they can be temporarily connected in series for charging. The batteries should remain on – Be sufficiently conductive
their pallets until final installation. – 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)
To avoid having to perform the previously described work, we strongly recommend that you Within the EU, follow VDE 0510 Part 2: 2001-12, in accordance with IEC 62485-2: “Safety requi-
connect the battery or batteries to the regular charging voltage supply within three months. rements for secondary batteries and battery installations – Part 2: Stationary batteries”.
Failure to observe the recharging intervals will render the warranty null and void.
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Requirement Our recommendation 5.1.1 Calculation of safety distance
Ventilation source Sufficient room ventilation is absolutely required in order to In close proximity of the batteries the dilution of explosive gases is not always given. Therefore a safety distance
limit the hydrogen concentration (H2 concentration) in the ambi- has to be realized by a clearance, in which there must not be any sparking or glowing equipments (max. surface
ent air of 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 deaera-
expands spherical. Figure 5-1 depicts a graphic approximation of the safety distance ‘d’ depending on the
tion 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 in See the IEC 62485-2 Required safety clearance needs to be calculated according to formula stated in IEC 62485-2.
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 Ix. .
Labeling Warning signs in accordance with IEC 62485-2.
Warning sign depicting risk of electrical voltage

only necessary if battery voltage exceeds Required radius of the hemisphere:
60 V DC. .
Risk of explosion No sources of 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 temperature of 55 °C is not permissible. Avoid
operating at temperatures in 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 distance 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
warranty for the batteries null and void.
Country-specific Some countries require batteries and racks to be installed in collection
regulations tanks. Please observe all local regulations and contact your local HOPPECKE
representative 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
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5.2 Variants of cell plugs 5.3 Filling the cells
This section describes the different types of cell plugs. These plugs are included in the HOPPECKE accessories If the cells or batteries were delivered unfilled (dry) they have to be filled now.
list.
5.2.1 Labyrinth plugs (State of delivery) Empty, but not fully emptied and cleaned acid tanks have to be handled as filled according to the
regulation of dangerous goods for street transport. If acid tanks should be disposed, assure to
The labyrinth plug prevents the release of aerosols by means of the internal labyrinth. It has meet the local legal requirements. Pay also attention to the disposal- and operating recommen-
an anti-backfiring effect. After removing the labyrinth, the plug also acts as an adapter for the dations in the material safety data sheet for sulfuric acid.
grid | aquagen pro (max) recombination plug.
5.3.1 Check
5.2.2 Ceramic plug
Before filling the cells, make sure that the installation and ventilation requirements according to IEC 62485-2
Ceramic plugs have a porous ceramic body that better retains acid aerosols and water vapour. are met. Should commission charging be carried out using higher amperage than you established for the type of
They have an anti-backfiring effect. ventilation equipment, then you must increase the ventilation in the battery room (e. g. using additional portable
Installation: After removing the labyrinth plugs, insert the ceramic plug into the cell opening and fans) according to the amperage applied. Increased ventilation has to be applied during commissioning and for
fix it in place according to the material. one hour afterwards. The same applies for occasional special battery charging processes.
Ensure that the sealing rings are firmly fixed. During the regular battery check, the
ceramic bodies must be kept clean. In the event of external contamination with 5.3.1.1 Ventilation – preventing explosion
e. g. dust, clean with a dry brush.
Attention! 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.
5.2.3 Ceramic funnel plugs The following could act as sources of ignition for gas explosions:
– Open flames
Ceramic funnel plugs have the same effect as the ceramic plugs mentioned above. Additionally, – Flying sparks
they allow refilling of water and measuring of electrolyte density and temperature when mounted.
– Electrical, sparking equipment
Installation: After removing the labyrinth plugs, insert the ceramic plug into the cell opening and
fix it in place according to the material. – Mechanical, sparking equipment
– Electrostatic charge
Ensure that the sealing gaskets are firmly in place. During the periodic battery
inspection, it is important to ensure that the ceramic elements are clean. Observe the following measures to prevent gas explosions:
In case of any external contamination, e. g. dust, use a dry brush for cleaning. – Sufficient natural or technical ventilation
Attention! – No heating using open flames or glowing objects (T > 300 °C)
– Separate battery compartments with individual ventilation
5.2.4 grid | aquagen pro (max) Recombination plug – Anti-static clothing, shoes and gloves (according to applicable DIN and EN regulations)
– Surface conductivity resistance: < 108 Ω and insulating resistance ≥ 105 Ω
The recombination plug causes recombination of water from the resulting oxyhydrogen gas by – Hand-held lights with power cable without switch (protection class II)
means of the recombination effect of a catalyst. This reduces maintenance costs enormously. – Hand-held lights with battery (protection category IP54)
– Warning and regulatory signs
The ventilation requirements for battery rooms, cabinets or compartments are based on the required reduction
of the concentration of hydrogen generated during charging and safety factors which include battery aging and
the potential for fault (“worst case”).
All relevant information is given in the corresponding grid | aquagen pro (max) documentation.
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5.3.1.2 Ventilation – calculation for ventilation requirements of battery rooms Technical ventilation:
– Increased ventilation using fan (generally extractor fans)
Air volume flow Q: – Air flow rate according to air volume flow Q
C
Q = v x q x s x n x Igas x – Air drawn in must be clean
1000 Ah
– If large amounts of gas are released during charging, continued ventilation is required for 1 h after charging
v = dilution factor = 96 % air/4 % H2 = 24 is complete
q = quantity of hydrogen generated = 0.42 10–3 m3/Ah – For multiple batteries in one room: required air flow = ∑Q
s = safety factor = 5 – Avoid a ventilation short circuit by ensuring that there is sufficient distance between the intake and exhaust
n = number of cells opening
Igas = current per 100 Ah
In case of a technical (forced) ventilation the charger shall be interlocked with the ventilation system or an alarm
C = nominal capacity of the battery
shall be actuated to secure the required air flow for the selected charging mode.
Sum of factors:
Another sample calculation for battery room ventilation is available in Required ventilation for hydrogen
v x q x s = 0.05 generated by batteries, Chap. 10, “Required ventilation for hydrogen generated by batteries”.
C
Q = 0.05 x n x Igas x with Q in m3/h, Igas in A
1000 Ah 5.3.2 Filling the cells
Igas = Ifloat resp. Iboost x fg x fs Filling acid with a density according to Tab. 5-3 must comply with the purity specifications according to
DIN 43530 Part 2, IEC 60993-3 or IEEE 450:2002.
The cells must be filled to the lower electrolyte level mark. Use acid-resistant filling devices (funnels); do not
Parameter Lead-acid batteries vented cells use stainless steel Transport plugs are not to be used when operating the battery.
Sb < 3 % The plugs which came fitted on top of the batteries are HOPPECKE Labyrinth plugs. These plugs have to remain
on the batteries after refilling and during operation of the battery.
fg: Gas emissions factor 1
To increase safety and reduce maintenance costs, we recommend the use of HOPPECKE grid | aquagen
fs: Safety factor for gas emissions recombination systems.
5
(includes 10 % faulty cells and aging) High temperatures decrease the electrolyte density while lower temperatures increase it. The correction factor
is 0.0007 kg/l per K.
Ufloat: Float charge voltage, V/cell 2.23 Example: An electrolyte density of 1.23 kg/l at 35 °C corresponds to a density of 1.24 kg/l at 20 °C.
Ifloat: Typical float charge current, mA per Ah 1
Igas1): Current (float charge), mA per Ah (used only for calculating 5.3.3 Idle Time
5
the air volume flow for float charge)
After filling, allow every cell an idle time of 2 hours. Immediately after the idle time, depending on the total
Uboost: Boost charge voltage, V/cell 2.40 number of cells, measure the electrolyte temperature and density in 4 to 8 of the cells (pilot cells) and note
this in the commissioning report.
Iboost: Typical boost charge current, mA per Ah 4
If the temperature increment is less than 5 K and the electrolyte density has not decreased to more than
Igas: Current (boost charge), mA per Ah (used only for calculating 0.02 kg/l less than the density of the filling acid, then a simplified commissioning charge as described in
20
the air volume flow for boost charge) Chap. 5.12.1 and Chap. 5.12.2 is sufficient.
If the discrepancy is larger, then an extended commissioning charge as described in Chap. 5.12.3 is required.
Tab. 5-2: Recommended current values (Extract from IEC 62485-2)
Commissioning charge has to be performed immediately after idle time of the final filled cell.
If designing the ventilation in battery rooms, depending on the structural conditions, either “natural ventilation” Attention!
or “technical ventilation” can be used.
Series Filling density kg/l Nominal density kg/l
Observe the following points:
GroE 1.21 1.22
Natural ventilation: OPzS/power.bloc OPzS 1.23 1.24
– Intake and exhaust openings required max.power 1.23 1.24
– Minimum cross-section (free opening in wall): A ≥ 28 × Q (A in cm2, Q in m3/h) (given that: vair = 0.1 m/s) OGi/OGi bloc/grid | power V H (OGi bloc) 1.23 1.24
– Increased ventilation through chimney effect (air routing) grid | power V M (OSP.HB/OSP.HC) 1.23 1.24
– Exhaust released outside (not into air-conditioning systems or surrounding rooms) grid | power V H (OSP.XC) 1.26 1.27
sun | power V L (OPzS solar.power/OPzS bloc solar.power) 1.23 1.24
Tab. 5-3: Electrolye density in kg/l at 20 °C

1) If grid | aquagen recombination systems are applied Igas can be reduced by 50 %.
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5.4 Conducting an open-circuit voltage measurement
Equipment Available?
Before installing the batteries, conduct an open-circuit voltage measurement of the individual Lifting conveyor (forklift truck, lift truck or small mobile crane or similar device
cells or monobloc batteries to determine their state of charge and to make sure that they are to aid in battery installation)
functioning properly. Fully-charged cells with an electrolyte temperature of 20 °C should have an
open-circuit voltage as listed in Tab. 5-3. Chalk line and chalk (optional)
The open-circuit voltages of the individual cells of a battery must not differ more than 0.02 V Plastic spirit level (optional)
from one another.
Torque wrench
Type of cell/monobloc battery Open-circuit voltage Backing elements (max. 6 mm) for installing the racks (cabinets) (optional)
grid | power VX (GroE) (2.06 ± 0.01) V/c Ratchet set (optional)
grid | power VL (OPzS/OPzS bloc) (2.08 ± 0.01) V/c Wrench and ring wrench set with insulated grips
max.power (2.08 ± 0.01) V/c Screwdriver with insulated grip
grid | power V M (OSP.HB/OSP.HC) (2.08 ± 0.01) V/c Paper towels or cloths (made of cotton; do not use cloths made out of synthetic
fibers as there is a risk of static charging), moisturised with water
grid | power V H (OGi bloc) (2.08 ± 0.01) V/c
Brushes with hard plastic bristles (optional)
grid | power V H (OSP.XC) (2.11 ± 0.01) V/c
Plastic measuring tape
sun | power V L (OPzS solar.power/OPzS bloc solar.power) (2.08 ± 0.01) V/c
Safety equipment and protective clothing
Tab. 5-4: Open-circuit voltages for different cells/monobloc batteries Battery terminal grease Aeronix®(only for cells/blocs with exposed lead on post terminals)
Insulating mats for covering conductive parts
The following open-circuit voltage deviations are acceptable for monobloc batteries:
– 4 V monobloc 0.03 V/block Tab. 5-5: Equipment for installation
– 6 V monobloc 0.04 V/block
– 12 V monobloc batteries 0.05 V/block
5.6 Rack Installation
High temperatures decrease the open-circuit voltage while lower temperatures increase it. A
We recommend that batteries are properly installed in HOPPECKE battery racks or HOPPECKE
deviation of 15 K from the nominal temperature changes the open-circuit voltage by 0.01 V/cell.
battery cabinets. The use of other operator-specific solutions may render the warranty for the
Please consult your local HOPPECKE representative regarding larger deviations.
batteries null and void.
HOPPECKE produces different types of racks. For installation information, see the separate
documentation included with each rack.
5.5 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.
For the installation, you will require your personal safety equipment, protective clothing, safety
tools and other equipment as described in Chap. 2.2.
Danger!
Fig. 5-2:
Step rack (left) and
tier rack (right)
Observe the special requirements and regulations when installing battery racks in seismic areas.
Danger!
The installation location must fulfill the conditions described in Chap. 5.1.
Comply with the minimum distances listed in Tab. 5-1.
Danger!
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1. If the installation drawing is available, mark the outlines of the racks on the installation surface using chalk. 5.9 General information on connecting the batteries
2. The installation surface must be level and rigid. If backing elements are used, make sure that the thickness
does not exceed 6 mm. If connecting the batteries, always establish the serial connections first followed by the parallel
3. Carefully set up the racks and arrange them horizontally. connection. Do not reverse this procedure.
Before connecting, check to make sure that the batteries have the correct polarity.
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. Attention!
6. If
necessary, ground the racks or rack parts.
To establish the serial connection, arrange the batteries so that the positive terminal of one
battery is positioned as near as possible to the negative terminal of the next battery.
If using wooden racks: you must fit a flexible connector between each rack joint.
Attention! 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
5.7 Cabinet installation 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.
Alternatively, you may choose to install the batteries in HOPPECKE cabinets. 2. Only batteries of the same type and same state of charge should be connected (same battery type, plate
The cabinets can be delivered with batteries already installed or battery installation can take size and plate design).
place on-site. 3. The environmental conditions should be the same for each string connected in parallel. In particular, avoid
HOPPECKE provides different types of cabinets. 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.
The installation location must fulfill the conditions described in Chap. 5.1.
Comply with the minimum distances listed in Tab. 5-1. 5. The commissioning date of the batteries should be the same (batteries of the same age, identical storage
Danger! 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
separately and connect them in parallel afterwards.
In general, connect the batteries using the shortest possible cables. Normally, cells are connected in series
with alternating polarity, resulting in the shortest possible connector length.
5.10 Putting the cells/blocks into the racks
1. Apply
some soft soap to the profiles of the rack so that the batteries can be adjusted sideways more easily
once they have been placed onto the rack.
Fig. 5-3: Battery cabinet
5.8 Handling the batteries
Be very careful when lifting and moving the batteries as a falling battery could cause personal injury or mate-
rial damage. Always wear protective shoes and safety goggles. Always lift batteries from below and never lift
batteries using the terminals as this can destroy the battery. Before installing the battery, visually check to
make sure that it is in perfect condition. Install the battery in accordance with VDE 0510 Part 2: 2001-12 Fig. 5-12: Lubricated support profiles
(in accordance with IEC 62485-2). For example, you must cover conductive parts using insulating mats.
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.
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For batteries without rubber molded terminals use the red and blue, resp. the grey for
For large batteries, it is required that you begin installation in the center of the rack.
grid | power V M (OSB.HB), touch protection rings to avoid contact.
When using tier racks, install the batteries on the bottom rack first.
May pertrain to the following types:
– GroE 500 to 2600
– grid | power V M 6-50 to 200 (OSB.HB)
When handling the batteries, observe the instructions in Chap. 5.7.
– grid | power V M 4-100 to 200 (OSB.HB)
Place the batteries carefully onto the profiles of the rack, otherwise the battery casing could be
For GroE the little clearance has to face downwards. The red one is used for the positive terminal
damaged.
and the blue one for the negative terminal. For the neutral grey touch protection rings for
Attention! When placing the batteries on the rack, do not allow the batteries to knock up against one
grid | power V M this specification is irrelevant.
another. This could destroy the batteries and result in an acid leak.
The battery connection terminals + and - must under no circumstance be short-circuited. This
applies also to the plus and minus pole of the entire battery string. Be very careful when using
step racks.
Danger!
3. S
lide the blocks (or cells) to either side until the distance between the batteries is approx.
10 mm (Fig. 5-20). 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, push
Attention! them at the corners as these are stronger. Push batteries using your hands only; never use a tool.
Fig. 5-15: Exemplary touch protection ring for GroE (similar to grid | power V M)
5.11.2 Type of connection cable
The battery system that you received is designed for a certain period (standby time) to produce a
specified amount of power (kW) or current (A) at a particular voltage (U) for a certain period of time
(standby time). You should be familiar with these parameters (U, kW, A). If this is not the case,
please contact your local 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,
Fig. 5-13: 10 mm clerance Fig. 5-14: Labyrinth plugs (left) and grid | aquagen
the standby time of the battery system may be reduced.
between the batteries recombination system (right)
Observe the following information:
4. After
the batteries have been placed in the racks, you can replace the Labyrinth plugs with other plugs if you 1. Keep the cable length between the batteries and the charging rectifier/USV as short as possible.
have ordered them. These plugs could be: ceramic plugs, ceramic funnel plugs, grid | aquagen recombination 2. The cable cross-section should be calculated so that voltage drop is negligible even at a high current flow.
systems. Please refer to the manual for the grid | aquagen recombination system. 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.
5. Final step: Count all cells/blocks and check for completeness.
The connection cable must be short-circuit proof or double-wall insulated. That means:
– The insulation strength of the cable is higher than the max. system voltage
5.11 Connecting the batteries – There is a distance of at least 100 mm between wiring and electrically conductive parts
Danger! – Connectors must be furnished with additional insulation
The batteries are in their final position and can now be connected.
– Avoid mechanical stress on the cell/battery terminals. Protect cables with large cross-sections
using cable ties and cable clamps
5.11.1 Connection terminals
The connection cables between the main connection terminals and the charging rectifier or UPS
For battery cells with partly exposed lead on post terminals: The battery terminals have been should be flexible conductors.
greased at the factory using battery terminal grease. Inspect each terminal for visible damage or
oxidation. If necessary, clean the terminal using brushes (with hard plastic bristles). Re-grease
by using the above mentioned terminal grease. The same treatment is also valid for the PP
(Polypropylene) covered pillar. 5.11.3 Clamping batteries using battery connectors
There are screwed row, step and tier connectors (see Fig. 5-22). 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 addition, there are welded connectors (special design) for individual cells of types GroE/OPzS/
OSP.HC/OSP.XC/max.power.
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5.11.5 Clamping connection plates onto the batteries
There are a total of 11 different types of connection plates (see Fig. 5-16). 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. 5-16: Using row connectors and step connectors Installation of standard connection plates
1. Screw the connection brackets onto the end terminals of the battery (see
Fig. 5-18).
Row, step, tier and end connectors are designed as screwed connectors. After loosening a
connection, the assembly screws must always be replaced.
Attention! Make sure that you do not cause mechanical damage to the
terminals.
Attention!
5.11.4 Installing the screwed connectors
2. F irst attach the screws by hand only so that you can make final adjustments
In very rare cases, the post sealing may not have the correct to the cells, connection brackets and connection plates.
color (blue/minus and red/plus). In this case the post sealing 3. Fix the connection plate to the connection bracket of the battery with a
has to be exchanged by a new one. The best approach is to torque of 20Nm
screw the screws symmetrically into the upper surface of the 4. Afterwards tighten the pole screws using a torque wrench. The recommen-
post sealing and pull them out by applying a lot of force on both Fig. 5-18: ded torque is 20 Nm ± 1 Nm. Exceptions:
sides. The new post sealing should be smeared with a little bit Installing the end terminals grid | power V M 105 (3 OSP.HC 105):
of silicone oil and pushed into the pole tub within the cover until (connection plates) Max. 15 Nm
the clips of the pole bushing snap into place. grid | power V M 6-50 and 6-100 (OSP.HB 6 V 50 Ah and 6 V 100 Ah):
Max. 12 Nm
1. T he batteries are connected using the insulated row connectors (Fig. 5-17).
When establishing the serial connection, the batteries are arranged so that
It is very important to tighten screws thoroughly as a loose con-
the negative terminal of one battery is connected to the positive terminal of
nection can become very hot and result in ignition or explosion.
the next battery until the entire system has reached the necessary voltage.
Attention!
Make sure that you do not cause mechanical damage to the

5.12 Connect the battery system to the DC power supply
terminals.
Attention!
Make sure that all installation work has been performed properly before connecting the battery
system to the charging rectifier or UPS.
2. A
ttach 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 connectors. Attention!
3.
Tighten the screws using a torque wrench. The recommended torque is
20 Nm ± 1 Nm. Exceptions: 1. Measure
the total voltage (target value = sum of open-circuit voltages of the individual cells or monobloc
grid | power V M 105 (3 OSP.HC 105): batteries).
Max. 15 Nm 2. If necessary: label the cells or monobloc batteries visibly with continuous numbers (from the positive terminal
grid | power V M 6-50 and 6-100 (OSP.HB 6 V 50 Ah and 6 V 100 Ah): to the negative terminal of the battery). HOPPECKE includes number stickers in your shipment.
Max. 12 Nm 3. Attach polarity labels for the battery connections.
4. Complete the identification plate in this documentation (see Chap. 1.2).
It is very important to tighten screws thoroughly as a loose con-
nection can become very hot and result in ignition or explosion. 5. Attach safety marking signs (these include: “Danger: batteries”, “Smoking prohibited” and, for battery
Screws are approved for single use only. voltages > 60 V, “Dangerous voltage”). Attach further marking signs according to local requirements.
Attention! 6. Attach the safety notices (see Chap. 0).
Fig. 5-17: Screwed 7. If necessary: Clean the batteries, the racks and the installation room.
connector installation For tightening the screws of the product grid | power V L
(OPzS bloc), please use wrench size 20 mm. Never clean batteries using feather dusters or dry towels.
Attention! Danger of electrostatic charging and gas explosion. We recommend cleaning the batteries
using damp cotton cloths or paper towels.
4. If necessary, fit the connectors and end terminals (connection plates) with Danger!
insulating covers.
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8. C
onnect the battery system to the charging rectifier/UPS using the end connections (“plus to plus” and 5.13.2 C
ommissioning charge with constant current (I characteristic curve) or decreasing current
“minus to minus”) and proceed as described in Chap. 5.12. (W characteristic curve)
The connection cables between the end connections of the battery and the charging rectifier or The maximum permitted currents can be obtained from Tab. 5-6.
UPS should be flexible conductors.
Inflexible wires could transfer vibrations, which could loosen the connection under certain circum-
stances. The cables must be supported so that no mechanical load can be transferred to the Characteristic curve Charge Current
connection terminals (cable trays, cable ducts, cable clamps). I characteristic 5A
W characteristic curve at
5.13 Commissioning charge (initial charge) 2.0 V/Cell 14 A
Normally, by the time of installation, batteries are no longer fully charged. This applies especially 2.4 V/Cell 7.0 A
to batteries that have been in storage for a long period of time (see Chap. 4). In order to charge 2.65 V/Cell 3.5 A
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”. Tab. 5-6: Max. permitted charge currents in A per 100 Ah C10 battery capacity for I and W charging
1. F amiliarize yourself with the maximum voltage that the charge rectifier can deliver without damaging the Charging must continue until
peripherals.
– All cells have reached a minimum of 2.6 V
2. Divide this maximum value by the number of battery cells (not batteries) connected in series. This is the
maximum cell voltage for the initial charge. – The electrolyte density ceases to rise over a further period of 2 hours
3. Set the voltage so that average cell voltages are at a max. of 2,40 V per cell. The initial charge can take Then switch to the float charge voltage as specified in the operating instructions.
up to 72 hours.
It is important for this initial charge to be carried out completely. This is only possible with a 5.13.3 Extended commissioning charge
charge voltage greater than 2.35 V per cell. Avoid interruptions if at all possible. Log the commis-
sioning in the commissioning report (see Inspection record). Extended storage or climatic influences (humidity, temperature fluctuations) reduce the charge
state of the cells. This makes an extended commissioning charge necessary. The extended
4. D
uring commissioning, measure the cell voltage of the pilot cells and after commissioning, measure the comissioning should not be done if the storage time (chapter 4) of the batteries is overstepped.
cell voltage and surface temperature of each cell and log this data in the commissioning report along with The excess of the storage time means that the desulphatation charging has to be done, which is
the time. described in the chapter 4.2.
Conduct the extended commissioning charge according to the following procedure:

The electrolyte temperature must not exceed 55 °C; if necessary, the charge operation must be 1. Charge at 15 A per 100 Ah C10 until 2.4 V/cell is achieved (approx. 3 to 5 hours)
interrupted, until the electrolyte temperature drops below 45 °C. 2. Charge at 5 A per 100 Ah C10 for 14 hours (cell voltage will exceed 2,4 V/cell)
Danger! 3. Interrupt for an hour
4. Charge with 5 A per 100 Ah C10 for 4 hours
The grid | aquagen recombination systems are resistant to overload and may remain on the
cells during commissioning charge. Refer also to the grid | aquagen installation- and operation
documentation. Repeat items 3 and 4 until all
– Cells have reached a minimum of 2.6 V
– The electrolyte density in all cells has risen to the nominal value of ± 0.01 kg/l and these values cease to
Several types of commissioning are possible. rise for a further 2 hours
Subsequently switch to the float charge voltage as set out in Chap. 6.2.4.
5.13.1 Commissioning charge with constant voltage (IU characteristic curve) 5.14 Electrolyte level check
– A charge voltage of 2.35 - 2.40 V per cell is required If the electrolyte has been set below the upper level before commissioning top up with sulfuric acid to bring
– The charge current should be at least 5 A per 100 Ah C10 at the beginning of charging. The electrolyte density electrolyte level to the upper electrolyte level mark.
increases slowly during charging so a charge time of several days may be required before the minimum
electrolyte density reaches the nominal density - 0.01 kg/l
– Then switch to the float charge voltage as specified in the operating instructions 5.15 Electrolyte density adjustment
– The electrolyte density increases to the nominal value during operation
– T he entire time of the commisioning (IU all over) should be 24 h After commissioning is complete, if the electrolyte density is too high, replace a portion of the electrolytes with
demineralized water according to DIN 43530 Part 4 or IEC 60993-1.
The electrolyte density in the individual cells must not differ more than 0.01 kg/l between cells. In case of
large deviations, conduct an electrolyte density adjustment and subsequent equalizing charge according to the
operating instructions.
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5.16 Replacement of a defect cell/battery (dry/formed) 6 Battery operation
If a dry and formed cell or a battery is defect the instructions for the replacement are described in this chapter. DIN VDE 0510 Part 1 and IEC 62485-2 and IEEE 484 apply for the operation of stationary battery
systems. Each battery is subject to a natural electro-chemical aging process, which causes the
reduction of the metallic lead within the battery (corrosion). The progress of the aging process and
5.16.1 Before the replacement of the cells/battery also the service life of the battery depend significantly on the operating temperature.
Please note that you have to work currentless. Before you remove the connectors you should The recommended operating temperature for lead-acid batteries is between 10 °C and 30 °C.
secure the switch-off of the electrical circuit. Technical data is valid for the nominal temperature of 20 °C. The ideal operating temperature
Attention! range is 20 °C ± 5 K. Higher temperatures shorten the service life of the battery. Lower tempe-
Attention! ratures decrease battery capacity. Exceeding the limit temperature of 55 °C is not permissible.
The operating temperature has to be ≥ 5 °C when using the HOPPECKE grid | aquagen recombi-
5.16.2 Moving the cells/batteries nation system. Thereby you avoid icing of the internal ceramic component and assure an optimal
recombination.
After the disconnecting the connectors the cells/batteries have to be moved. For moving
the cells please follow the intructions according chapter 5.7. Especially the lifting of
the cells/batteries has to be done very carefully. Please aware that lifting of the cells/ Additional tools (like BMS) which are influencing the charging regime, can be only used after the
Attention! batteries is not allowed by fixing the pillar screw, this leads to damaging of the batte- consultation with Hoppecke.
ries/cells.
Attention!
5.16.3 Filling of acid into the cells/batteries
For filling of acid into the cells/batteries please follow the instructions according to chapter 5.2.2. 6.1 Discharging
Never allow the final discharge voltage of the battery to drop below the voltage corresponding to
5.16.4 The commissioning of the cells/batteries the discharge current.
Unless the manufacturer has specified otherwise, no more than the nominal capacity is to
The defect cells/batteries which should be replaced should not be charged (according be discharged. Immediately after discharge (including partial discharge), charge the battery
commissioning regime) within the battery because of the very high charging factor (above Attention!
completely.
1,2) and a very high hydrogen concentration. The comissioning has to be done on a
Attention! separate charging rectifier.
6.2 Charging – general
Regime-Commissioning
For the commissioning please follow the instructions according to the chapters 5.12.11 Depending on how the batteries are used, charging is to be carried out in the operating modes described in
5.12.2 and 5.12.3. Chap. 6.2.1 to Chap. 6.2.4.
All charging procedures may be used with their limit values as specified in DIN 41773 (lU
5.16.5 Checking the electrolyte level characteristic curve). DIN 41774 (W characteristic curve) and DIN 41776 (I characteristic curve).
The sun products are daily discharged and for this reason the charging profile of these products is
Please follow the instructions according to the chapter 5.13. different compared to the stand by application. The charging parameter for the cyclic applications
(sun products) are listed in the chapter 7.
5.16.6 Adjustment of the electrolyte density

Superimposed alternating currents
Please see the chapter 5.14. Depending on the charger type and charging characteristic curve, alternating currents flow through
the battery during charging and are superimposed onto the charging direct current. These super-
Attention! imposed alternating currents and the reaction of the loads lead to additional heating of the battery
5.16.7 Montage of the screw connectors or batteries and create a cyclical strain on the electrodes. This might result in premature aging
of the battery.
Please follow the instructions from the chapter 5.10.4. In order to achieve the optimum service life for vented batteries on float charge, a maximum
effective value of the alternating current of 2 A per 100 Ah nominal capacity is recommended.
During the boost charging the value of 10 A/100 Ah should not be exceeded.
Please note the possible mechanical damaging of the pillars (chapter 5.7)
Attention!
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Dependency of electrolyte density on temperature
Temperature-related adjustment of the charge voltage The electrolyte is diluted sulfuric acid. The nominal density of the electro-
The temperature voltage compensation is mandatory if the application temperature deviates lyte is based on a temperature of 20 °C and nominal electrolyte level in
from 20 °C. Hoppecke recommends 4 mV/K. If the inverter can not realize the compensation fully charged condition.
Attention! (technically), the border area would be 10 °C to 30 °C (shown by the figure 6-1). Nevertheless the The maximum permitted deviation is ± 0.01 kg/l.
compensation should be realized. High temperatures reduce the electrolyte density while lower temperatu-
res increase electrolyte density. The correction factor is 0.0007 kg/l per K.
Example: Electrolyte density 1.23 kg/l at 35 °C corresponds to a density of
1.24 kg/l at 20 °C and electrolyte density 1.25 kg/l at 5 °C corresponds
to a density of 1.24 kg/l at 20 °C.
Measuring electrolyte density – prerequisites

The electrolyte density decreases during discharging and increases during
charging. Because electrolyte density is also dependent on temperature
Charging Voltage in V
(see above) and on the fill level of the battery, when measuring the
density, both values should be determined and documented.
Prerequisites for measuring electrolyte density using a hydrometer:
– No water has been added to the battery over the last few days (electro-
Fig. 6-2: Hydrometer lyte layering). Water has a lower density than sulfuric acid (it is lighter),
so mixing requires time
– The battery has been charged for at least 72 hours
– The electrolyte level in the battery is correct
The temperature is 20 °C. If this is not the case, recalculate accordingly
(see above).
Temperature in °C 6.2.1 Standby parallel operation

Fig. 6-1: Temperature related float charge voltage adjustment
DC power supply Electrical Load
Maximum charge currents
Up to 2.4 V/cell the battery is able to absorb the maximum current the battery charger provides.
Using the IU characteristic according to the DIN 41773 a charging current of 10 A to 20 A per
Attention! 100 Ah rated capacity (C10) is recommended. If charge voltages of 2.4 V/cell are exceeded, this
leads to higher water dissociation and electrode stress. Battery
The charge currents per 100 Ah nominal capacity shown in Tab. 6-1 must not be exceeded when
charging with a charge voltage of over 2.4 V/cell.
Fig. 6-3: Standby parallel operation
Charging Series Cell

procedure Voltage The following is characteristic for this operating mode:
OPzS, OPzS power.bloc, max.power, OGi bloc, GroE
grid | power V M (OSP.HB/OSP.HC), – Consumers, direct current source and battery are connected in parallel
grid | power V H (OGi bloc/OSP.XC), – The charge voltage is the operating voltage of the battery and the system voltage at the same time
sun | power V L (OPzS solar.power/OPzS bloc solar.power) – The direct current source (charging rectifier) is capable of supplying the maximum load current and the battery
charge current at any time
I characteristic curve 5.0 A 6.5 A 2.6 to 2.75 V/Cell
(DIN 41776) – The battery only supplies current when the direct current source fails
– The charge voltage should be set at (see Tab. 6-2) x number of cells in series (measured at the battery’s
W characteristic curve 7.0 A 9.0 A for 2.40 V/Cell terminals)
(DIN 41774) 3.5 A 4.5 A for 2.65 V/Cell – To reduce the recharging time, a charging stage can be applied in which the charge voltage is (2.33 V to 2.4 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
Tab. 6-1: Charge currents
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6.2.4 Float charging
Battery type Float charge voltage
grid | power V X (GroE) 2.23 ± 1 % V/cell Float charging is used to keep the battery or batteries in a fully charged state and corresponds to a large extent
to the charge type as described in Chap. 6.2.1.
grid | power VL (OPzS/OPzS bloc) 2.23 ± 1 % V/cell
max.power 2.23 ± 1 % V/cell Use a charger that complies with the specifications described in DIN 41773 (IU characteristic curve).
Set the charger to yield the following average cell voltages:
grid | power V M (OSP.HB/OSP.HC) 2.23 ± 1 % V/cell – OSP.XC cells and USV bloc monobloc batteries: 2.25 V ± 1 %
grid | power V H (OGi bloc) 2.23 ± 1 % V/cell – other HOPPECKE vented product series: 2.23 V ± 1 %
grid | power V H (OSP.XC) 2.25 ± 1 % V/cell Example: Nominal battery voltage: 60 V, float charge voltage of charging device is 30 x float charge voltage per
sun | power V L (OPzS solar.power/OPzS bloc solar.power) 2.23 ± 1 % V/cell cell. E. g. 30 x cells OPzS result in 30 x 2.23 V = 66.9 V ± 1 % (=max. 67.6 V/min. 66.23 V).
Tab. 6-2: Float charge voltage adjustment in standby parallel operaion

6.2.5 Equalizing charge (correction charge)
6.2.2 Float operation Under normal circumstances equalizing charges are not required.
If there are unacceptably large discrepancies between the cell voltages of the individual cells at float charge
The following is characteristic for this operating mode: (see Tab. 6-3), an equalizing charge must be performed.
– Consumers, direct current source and battery are connected in parallel
– The charge voltage is the operating voltage of the battery and the system voltage at the same time Type Float charge
– The direct current source is not able to supply the maximum load current at all times. The load current GroE, grid | power V M (OSP.HC/OSP.HB), OPzS, power.bloc OPzS, 2.23 V/cell ± 1 %
intermittently exceeds the nominal current of the direct current source. During this period the battery supplies OGi bloc, grid | power V H (OGi bloc), max.power,
power sun | power V L (OPzS solar.power/OPzS bloc solar.power)
– The battery is not fully charged at all times
grid | power V H (OSP.XC) 2.25 V/cell ± 1 %
– Therefore, depending on the number of discharges, the charge voltage must be set to approx. (2.25 to 2.30 V)
x the number of cells connected in series Voltage per unit 2V 4V 6V 12 V
Tolerance float charge
voltage for single cells
6.2.3 Switch mode operation (charge/discharge operation) - 0.05 V/+ 0.10 V - 0.07 V/+ 0.14 V - 0.09 V/+ 0.17 V - 0.12 V/+ 0.25 V
(deviation from average
float charge voltage)
DC Power Supply Electrical Load Tab. 6-3: Float charge voltage
Example for OPzS cells: Float charge voltage max. = 2.33 V/cell and min. 2.18 V/cell (at average float charge
voltage of 2.23 V/cell).
Battery Equalizing charges are necessary after exhaustive discharge, after inadequate charging, if the cells have been
Battery
Charger held at different temperatures for long periods of time or if:
– The electrolyte density (temperature adjusted) differs from the target value by 0.01 kg/l in one or more cells
Fig. 6-4: Switch mode operation
– The voltage in one or more cells has dropped below the critical threshold (as defined in Tab. 6-2) during
operation
The following is characteristic for this operating mode:
– When charging, the battery is separated from the consumer As the max. permitted load voltage might be exceeded it must be clarified in advance whether
– Towards the end of charging, the charge voltage of the battery is 2.6 to 2.75 V/cell (depending on the depth the loads can be disconnected for the duration of the equalizing charge.
of discharge and number of cyclical loads) Attention!
– The charging process must be monitored
– On reaching a state of full charge, terminate charging or switch to float charging as described in Chap. 6.2.4 Perform the equalizing charge as follows:
– The battery may be connected to the consumer if required 1. Charging with IU characteristic up to max. voltage U = 2,4 V/cell up to 72 hours.
2. Should the max. temperature exceed 55 °C, interrupt the charging process or continue with reduced current.
You can also temporarily switch to “float charging” to allow the temperature to drop.
3. The 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:
Refer to Chap. 4.
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At IUIa characteristic: At IUIa characteristic:
7 Settings for charging HOPPECKE current in Ia phase max. current in Ia phase max.
comment to the characteristic
sun | power V L (OPzS solar.power/OPzS bloc solar.power) batteries 5 A/100 Ah 5 A/100 Ah
C10 for 2 to 4 h C10 for 2 to 4 h
This chapter contains instructions for charging of HOPPECKE sun | power V L (OPzS solar.power/
max. current (note the fuses and cable lengths) 6 x l10 6 x l10
OPzS bloc solar.power) battery cells and battery blocks in solar applications.
2.55 V/c 2.55 V/c
at IU-characteristic at IU-characteristic
7.1 Charge and discharge parameters max. voltage absorption phase
2.4 V/c 2.4 V/c
at IUIa-characteristic at IUIa-characteristic
sun | power VL sun | power VL 8 h/charging factor 1.3 8 h/charging factor 1.15
The absorbtion time (or The absorbtion time (or
Parameter OPzS solar.power OPzS solar.power
the last charging phase) the last charging phase)
without electrolyte with electrolyte
can be shorter or longer can be shorter or longer
circulation pump circulation pump absorption time/charging factor
than the 8 h depending on than the 8 h depending on
battery charge charging factor. The kee- charging factor. The kee-
ping of the charging factor ping of the charging factor
recommended charging current 6 x l10 6 x l10 is rather recommended. is rather recommended.
standard charge (regular operating cycles) battery discharge
IU IU refer to the data sheet refer to the data sheet
characteristic (with subsequent (with subsequent discharge characteristic
and project data and project data
switchover to float) switchover to float)
recommended (DOD) cycle operation 50 % 50 %
max. current (consider the fuses and cable lengths) 6 x l10 6 x l10
max. depth of discharge (DOD), immediate recharge
max. voltage absorption phase 2.55 V/c 2.4 V/c 80 % 80 %
is necessary
recommended absorption time 180 min 180 min limited by battery fuse limited by battery fuse
max. discharge
6 h/charging factor 1.2 6 h/charging factor 1.05 and cable and cable
The absorbtion time (or The absorbtion time (or proposal for characteristic for deep discharge 1.98 V/c at I ≤ 0.16 x I10 1.98 V/c at I ≤ 0.16 x I10
the last charging phase) the last charging phase) protection [U=f(I)] 1.81 V/c at I ≥ 4 x I10 1.81 V/c at I ≥ 4 x I10
can be shorter or longer can be shorter or longer comment: deep discharge protection by switching off linear interpolation at linear interpolation at
absorption time full charge/charging factor
than the 6 h depending on than the 6 h depending on relating to a constant voltage value is forbidden! 0.16 x I10 < I < 4 x I10 0.16 x I10 < I < 4 x I10
charging factor. The kee- charging factor. The kee-
ping of the charging factor ping of the charging factor
Tab. 7-1: Charge and discharge parameters
is rather recommended. is rather recommended.
frequency/cycle, based on time period (full charge) 14 days 14 days
7.2 Alternating currents
No change-over due to a No change-over due to a
float charge
current threshold! current threshold! Depending on the charging equipment, its specification and its characteristics, superimposed alternating
voltage 2.23 V/cell ± 1 % 2.23 V/cell ± 1 % currents may contribute to battery charging current. Alternating currents and the corresponding reaction by the
connected electrical loads may lead to an additional battery temperature increase, and – consequently – to a
temperature correction 4 mV/K 4 mV/K shortened battery service life as a result of stressed electrodes (micro cycling).
In order to achieve the optimum service life for vented lead acid batteries on float charge, a maximum effective
equalization charge (frequency depending on which of the following two criteria occurs first)
value of the alternating current of 2 A per 100 Ah battery capacity (C10) is recommended.
frequency/cycle, based on capacity throughput 10 x Cn 10 x Cn
frequency/cycle, based on time period 40 days 40 days 7.3 Water consumption
IU/IUIa IU/IUIa
characteristic (with subsequent (with subsequent Every lead acid battery decomposes certain amounts of water into hydrogen and oxygen gas. This effect rises
switchover to float) switchover to float) with increasing amount of charge-/discharge cycles, charging voltage and battery temperature as well.
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7.4 Temperature influence on battery performance and service life 7.5 Influence of cycling on battery behavior
7.4.1 Temperature influence on battery capacity 7.5.1 Endurance in cycles depending on depth of discharge (DoD)
Battery capacity depends significantly on ambient temperature. Lead acid batteries loose capacity with decre- Endurance in cycles is defined as number of discharging and charging cycles until the actual remaining battery
asing temperature and vice versa, as shown in fig. 7-6. This should be considered when sizing the battery. capacity drops below 80 % of the nominal capacity (C10). The endurance in cycles a lead acid battery is directly
depending on the regular depth of discharge (DoD) during these cycles.
Temperature range for sun | power VL (OPzS solar.power/OPzS bloc solar.power) batterie: Depending on different types of batteries and the design of the plates and electrodes, the endurance in cycles
may vary significantly.
Possible temperature range: - 20 °C to 45 °C The following chart (fig. 7-8) shows the cycling behavior of a HOPPECKE sun | power V L (OPzS solar.power)
Recommend temperature range: 10 °C to 30 °C under ideal operating conditions. The endurance in cycles 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.
Battery Capacity in %
Cycle number n
Temperature in °C
Fig. 7-6: sun | power V L (OPzS solar.power/OPzS bloc solar.power): Dependency of battery capacity on temperature
Depth of discharge (DoD) in %
Fig. 7-8: Endurance in cycles of sun | power VL (OPzS solar.power) as a function of DoD (at 20 °C)
7.4.2 Temperature influence on battery design life
As corrosion processes in lead acid batteries are significantly depending on battery temperature, the battery 7.5.2 Endurance in cycles depending on ambient temperature
service life time 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). Since design life mainly depends on temperature, the cycle lifetime is affected by temperature as well.
Thus battery service life will be halved in case the temperature rises by 10 K. For a better understanding of the life time terms, please pay attention to the information leaflet
The following graph (refer to fig. 7-7) shows this relationship. The diagram depicts operation in float charge No. 23e (Edition August 2013) of the Fachverband Batterien of the ZVEI – Zentralverband Elektrotechnik
mode. Additionally, the endurance in cycles has to be taken into account. und Elektroindustrie (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 assertion of warranty claims only the respective contractual provisions are decisive.
Service life in %
Operating Temperature in °C
Fig. 7-7: Service life of sun | power V L (OPzS solar.power) cell as a function of ambient temperature (standby
application in float charge operation with 2.23 V/cell)
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Fig. 7-9 depicts this relation for a regular battery depth of discharge of 80 %. 7.5.3 Electrolyte freezing point depending on depth of discharge (DoD)
The freezing point of the electrolyte (sulfuric acid) rises with increasing depth of discharge.
In case the battery is exposed to cold ambient temperatures (≤ 5 °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
example for this relation. Example: If depth of discharge is below 60 % the operating temperature must not be
below - 18.4 °C.
Cycles n
Freezing Point in °C
Ambient temperature in °C
Fig. 7-9: Endurance in cycles of sun | power VL (OPzS solar.power) as a function of ambient temperature Depth of discharge (DoD)
Fig. 7-11: Electrolyte freezing point as a function of depth of discharge (DoD)

The following figure (refer to fig. 7-10) depicts dependency of endurance in cycles on depth of discharge and
temperature.
7.6 Remarks to warranty management
Above mentioned information about battery performance and service life, particularly concerning the charging
procedure and the influence of temperature and cycling, affect terms of warranty as well.
In case of a warranty claim the customer/battery operator needs to prove the compliance of above mentioned
parameters with the allowed/recommended limits. Corresponding measurement logs have to be sent to the
battery manufacturer. The expected service life is valid for operation under optimal conditions only.
For special demanding operational conditions as well as for solar and off-grid applications the expected battery
Cycle numbers n
service lifetime is heavily influenced by above mentioned operational conditions. In order to decide whether a
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
for further analysis.
HOPPECKE recommends the usage of a battery monitoring system for monitoring and logging of critical data.
Please contact your local HOPPECKE representative for information on HOPPECKE battery monitoring equipment
and accessories.
Depth of discharge (DoD) in %

sun | power VL at 20 °C sun | power VL at 25 °C sun | power VL at 30 °C
sun | power VL at 40 °C sun | power VL at 45 °C sun | power VL at 35 °C
Fig. 7-10: Endurance in cycles of sun | power VL (OPzS solar.power) depending on DoD and temperature
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8 Battery maintenance 8.3 Cleaning of batteries
To ensure the reliability and longevity of your battery system, regular maintenance is required. Cleaning the batteries on a regular basis is necessary to maintain battery availability and to meet
Document the type and scope of maintenance work performed as thoroughly as possible. These accident prevention regulations.
records can be very helpful if troubleshooting is required and are a prerequisite for making Batteries should be cleaned at least once per year. Note the following points:
warranty claims. Danger! While cleaning the batteries you must wear safety goggles and saftey clothes. To avoid electrosta-
tic charges while handling the batteries your clothes, safety shoes and saftey gloves must have
Regular maintenance work described here needs also to be done in case of using grid | aquagen a surface resistance of ≤ 10^8Ohm.
recombination systems. This includes check and if necessary adjustment of electrolyte levels.
Do not use dry cleaning cloth.

8.1 Work to be performed every six months Danger!
Take the following measurements and record the measurement values:

1. Voltage of the complete battery system (on float charge) Cell plugs or grid | aquagen recombination system must not be taken of or opened for cleaning.
2. Individual voltage of selected cells or monobloc batteries (on float charge) Attention!
3. Electrolyte density of selected cells or monobloc batteries (approx. 20 %) The grid | aquagen recombination system has to be cleaned like the batterie cell/block by using
4. Electrolyte temperature of selected cells or monobloc batteries a moist cotton or paper towel.
5. Electrolyte level of the cells Note: While charging – especially boost charge – the grid | aquagen recombination system will
6. Ambient temperature heat up. Therefore do not clean the grid | aquagen recombination systems during boost charge.
Danger!
Plastic parts of the batteries, especially the cell container, have to be cleaned with water or water
8.2 Work to be performed annually moistened cleaning cloth without additives.
After cleaning the battery surface has to be dried with appropriate measures, like moist antistatic
Take the following measurements and record the measurement values: cleaning cloth (e. g. cotton).
1. Voltage of the complete battery system (on float charge)
Note: In OSP.HC and OSP.XC battery cells deposits (streak formations) might buildup on the
2. Individual voltage of all cells or monobloc batteries (on float charge) inner surface of the cell jar. This occurs mainly in the area of the electrolyte level surface. These
3. Electrolyte density of all cells or monobloc batteries deposits are caused by additves in the separators which are used as antioxidant to protect the
4. Electrolyte temperature of all cells or monobloc batteries plastic material of the separator. Light washouts of this additives over battery service life cannot
5. Electrolyte level of all cells or monobloc batteries be avoided. This fact has neither negative impact on the electric performance of the battery nor
6. Ambient temperature on battery service life.
7. Perform a visual check of all screwed connectors
8. Check all screwed connectors to make sure that they are firmly secured
9. Visual check of battery racks or battery cabinets
10. Check to make sure that the battery room is properly ventilated and deaerated
Should the float charge voltage of any cell vary by more than + 0.1 V or - 0.05 V from the average
value (refer Chap. 6.2.5), perform an equalizing charge as a control measure or contact customer
service.
HOPPECKE recommends the use of a stationary battery monitoring system for the inspection of
relevant data. Please contact your local HOPPECKE representative for further information.
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9 Testing the battery system 9.2 Performing the capacity test (extended version)
9.1 Performing the capacity test (short form) Preperation

The best and quickest method for preparing batteries for testing is the IU charge method, also used for equa-
Perform tests in accordance with EN 60896-11 “Stationary leadacid batteries – Part 11: Vented lizing charges. Because it is possible to exceed the permitted load voltages, appropriate measures must be
types; General requirements and methods of tests.” In addition, note special test instructions, taken, e. g. disconnection of the consumers.
e. g. in accordance with DIN VDE 0100-710 and DIN VDE 0100-718. 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 following is the short form of the procedure for testing the actual capacity of your battery system. Also The charge is performed with a constant voltage of max. 2.33 V to 2.40 V/cell for up to 48 hours. The charge
observe all instructions in Chap. 9.2. current should not be higher than 20 A per 100 Ah nominal capacity If the elcetrolyte temperature of the cells/
blocs exceeds the maximum of 45 °C, terminate the charge or switch to float charge to allow the temperature
We recommend performing an equalizing charge on the battery system (as described in to drop.
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:
– Electrolyte density
– Voltage of each cell (or monobloc battery)
– Temperature of at least one out of every ten cells (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
to the maximum permitted current for which the battery is designed.
5. Prepare a shunt that you can connect in series with the load.
6. P repare the voltmeter so that you can test the total voltage of the battery.
7. Connect the load, the shunt and the voltmeter. Simultaneously start a time measurement.
8. Keep the load current constant and measure the voltage of the battery system in regular time intervals.
9. Check the row connectors (block connectors), step connectors and tier connectors for excessive heating.
10. Calculate 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. Reconnect the battery system as originally connected and perform a boost charge (see Chap. 5.13) Fig. 9-1: IU characteristic
W and I characteristic curves are also possible.

The charge voltages then increase to (2.60 to 2.75 V) x number of cells. Therefore, the consumers are normally
switched off. With the W or I characteristic curves, the charge currents are not limited until the charge voltage
reaches the gassing voltage of 2.40 V x number of cells.
At this point, the following limit values apply:
Charge current limit values above the gassing voltage of 2.40 V/cell per 100 Ah10.
Charging procedure Charge current Cell voltage

I characteristic curve 5.0 A/100 Ah 2.60 - 2.75 V/cell
W characteristic curve 7.0 A/100 Ah at 2.40 V/cell
3.5 A/100 Ah at 2.65 V/cell
Tab. 9-1: Charge current and cell voltage in relation to charging procedure
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The recharging time is 6 to 8 hours. Charging must be monitored and terminated or switched to float charge 9.3 Capacity test of the battery
voltage when charging is complete.
The state of full charge is reached when the charge currents/charge voltages (depending on the charging Necessary accessories:
procedure) and the electrolyte densities no longer increase within a period of 2 hours. – Suitable electronic load or electrical resistance (with adjustable resistance value to adjust the discharge
current or discharge load)
– Suitable current probe with sufficient precision for measuring the DC current or shunt for measuring the
discharge current
– Voltage measuring device for measuring the electrical voltage
– Thermometer for measuring the battery temperature
– Clock for measuring the discharge time
– Project planning data table for selecting the correct discharge current or the correct discharge power
– Acid density measuring device for vented batteries with a measuring range of 1.10 kg/l to 1.29 kg/l
Carry out the battery discharge in accordance with the regulations on performing capacity tests EN 60896-11.
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.
Minimum precision requirements for the measuring devices (precision class):
For voltage measurement: 0.5

For current measurement: 0.5
For temperature measurement: 1 °C
For time measurement: 1%
Acid density (for vented batteries only) 0.005 kg/l
Tab. 9-2: Precision requirements for the measuring devices
Fig. 9-2: IUIa characteristic During the capacity test, record the discharge current or discharge power, temperature, battery and cell-/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.
The IUIa charging method is an even better method for preparing the batteries; it is a charge with an additional
Terminate the discharge when the battery voltage has reached the value n x Uf where n is the number of cells
constant current at the end of the charging. In contrast to the charge with constant voltage, in the last step,
and Uf is the selected final discharge voltage per cell.
after IU charging, a constant charge current with 5 A/100 Ah is applied for 3 hours. The charge voltage can
Also terminate the discharge when a cell has reached a voltage of U = Uf – 200 mV or a monobloc battery with
then increase up to 2.60 V to 2.75 V per cell.
n cells has reached a voltage of U = Uf – √ n x 200 mV.
The W, I and IUIa characteristic curves result in increased gas generation; when using these characteristic
curves, increased ventilation is required. Example:
13 cells 12 GroE 300
5 h – capacity test
End voltage of the battery = 23.40 V (for 13 cells)
Average voltage per cell = 1.80 V
minimum end voltage of individual cells = 1.60 V
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Cell number Case A Case B Case C According to the DIN EN 60896-11 standard, the battery has passed the capacity test when 95 % of the
required power is attained in the first capacity test. After the 5th discharge, 100 % of the required power must
1 1.84 1.84 1.79
be attained.
2 1.83 1.86 1.80 After discharging, a log must be made (see Inspection record).
3 1.83 1.87 1.81
4 1.84 1.87 1.80 When handling batteries (e. g. performing capacity tests) you must observe the safety require-
5 1.84 1.86 1.81 ments in accordance with IEC 62485-2 (insulated tools, protective eyewear, protective clothing,
gloves, ventilation, etc.)!
6 1.85 1.86 1.79 Attention!
7 1.69 1.87 1.78
8 1.84 1.86 1.80
9 1.83 1.59 1.81 10 Troubleshooting
10 1.85 1.84 1.81
If malfunctions occur in the battery or charger, contact customer service immediately.
11 1.84 1.85 1.80 Measured data as described in Chap. 8.1 simplifies fault detection and elimination.
12 1.84 1.85 1.79 A service contract with us facilitates the timely detection of faults.
13 1.85 1.85 1.79
Battery voltage 23.77 V 23.87 V 23.38 V
11 Required ventilation for hydrogen generated by batteries
Tab. 9-3: Measured cell voltages and total voltage after 95 % of the discharge time has elapsed
Compliance with VDE 0510 Part 2 or IEC 62485-2 is required to ensure safe ventilation and prevent dangerous
mixtures of hydrogen and oxygen gases (hydrogen approx. 4 %).
Case A: a “weak cell”, passed capacity test, battery okay Two values form the basis of the equation: the maximum permissible hydrogen concentration in the air is 4 %
Case B: a faulty cell, failed capacity test, battery not okay and the safety factor is 5. The equation can be derived accordingly:
Case C: all cells okay, failed capacity test, battery not okay
The battery must be charged immediately following the capacity test. (Attenuation factor at maximum permissible hydrogen concentration)
The measured capacity C (Ah) at the average start temperature  is calculated as a product of the discharge
current (in A) and the discharge time (in hours).
As the battery capacity is dependent on the temperature, the measured battery capacity needs to be adjusted
for temperature. . (Quantiy of accumulated hydrogen per actual Ah capacity)
At temperatures higher than 20 °C nominal temperature, the battery capacity increases whereas the capacity
decreases at lower temperatures. If the average start temperature ℓ deviates 20 °C from the reference tempe-
rature, the capacity must be corrected. (safety factor)
The start temperature is used to carry out the temperature correction in accordance with the standard DIN EN
60896-11 using the equation [1]: .
C
Ca = [1]
1 +  (  - 20 °C)
This results in the total equation for the necessary ventilation in [m3/h]:
C = measured capacity
Qair = 0.05 x n x Igas x CN x 10–3
 = correction factor (with  = 0.006 for discharges > 3 h and  = 0.01 for discharges ≤ 3 h)
Igas = Ifloat × fg × fs resp. Igas = Iboost × fg × fs
 = start temperature
Ca = corrected capacity Qair = Necessary ventilation/air flow rate [m3/h]
n = Number of cells
Ifloat = Proportion
of charge current in mA/Ah used for water dissociation on boost charge per 1 Ah nominal
capacity of the battery = 1 mA/Ah
Iboost = P
roportion of charge current in mA/Ah used for water dissociation on boost charge per 1 Ah nominal
capacity of the battery = 4 mA/Ah
CN = Nominal capacity of the battery (C10 capacity).
fg = Gas emissions factor. Proportion of the charge current responsible for hydrogen accumulation = 1
fs = Safety
factor which includes the potential for faults resulting from a damaged cell (possible short circuit)
and battery aging = 5
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Example 1: 12 Disassembly
A battery with 2 x 60 V (60 V nominal voltage), 4 OPzS 200 (200 Ah) is equivalent to 2 x 30 cells. The battery
is on float charge at 2.23 V per cell.
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.
CN = Nominal capacity of the battery = 200 Ah
n = Number of cells = 2 x 30 Cells Proceed in the following way:
fg = Gas emissions factor = 1 – Before starting ensure that all electrical loads are switched off (separators, fuses, switches). This must be
carried out by qualified personnel. Ensure that the battery is disconnected from all charging devices and
fs = Safety factor = 5
electrical loads.
Ifloat = 1 mA/Ah – If the electrolyte liquid is not at the max level (due to insufficient maintenance) adjust the electrolyte level to
Qair = 0.05 m3 x 2 x 30 Cells x 1 mA x 200 Ah x 1 x 5 x 10-3 the max marking before continuing any with further steps.
Ah Ah – If the battery system is equipped with HOPPECKE grid | aquagen recombination systems or ceramic funnel
plugs remove these plugs according to the assembly and operating manual. Top up the cells/blocks with
Qair = 3 m3
h demineralized water to max level. Insert the original bayonet plugs with labyrinth inserts thereafter.
– For battery systems with nominal voltage > 60 V: Remove group-/step connectors first in order to divide
Result: For a 60 V battery composed of 2 x 30 cells 4 OPzS 200 operating on float charge, an airflow of 3 m3/h the battery system voltage in smaller partial voltages. Removed connector and post terminal bolts need to
is required for proper ventilation. be removed from the battery immediately. You must not use automatic screwdrivers for loosening the post
terminal bolts.
What is the appropriate diameter for intake and exhaust openings with natural ventilation? – Remove the connectors between cells/blocks. Removed connector and post terminal bolts need to be removed
The necessary cross-section for ventilation openings can be calculated using the following formula: from the battery immediately. You must not use automatic screwdrivers for loosening the post terminal bolts.
– Ensure that the battery cells/blocks are always positioned vertically during disassembly, packaging and
A = Qair x 28 transport. Avoid tilted position of the battery cells/blocks.
– Battery cells/blocks need to be packed according to ADR 598B. Visible damaged cells/blocks must be packed
Qair = Necessary ventilation/air flow rate [m3/h] (e. g. Paloxe) and transported separately. Refer also to chapter 1.4.
A = Necessary cross-section for ventilation openings [cm2]
A = 3 m3 x 28 = 84 cm2
h
13 References to the standards and regulations
Result: Ventilation openings (intake and exhaust) with a cross-section of 84 cm2 ensure ventilation with an
airflow of 3 m3/h. The references to the applicable standards, regulations etc. should help you to install and use the HOPPECKE
products correctly. However, it is not possible to quote all regulations and applicable standards according to the
What factors must be considered when installing a natural ventilation system? latest edition always. Therefore, these quotes are to be understood as support and not as direct instructions.
If possible, the ventilation openings should be positioned on opposite walls. If they must both be on the same In order to implement the specifications of the standards/regulations, the current and applicable standard or
wall, make sure to maintain a distance of at least 2 m between the openings. regulation must be available, regardless of the edition of the standard/regulation, which is cited here in the
HOPPECKE manual.
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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
14 Transport regulations
5 Fire-fighting measures 8 Exposure limits and personal protective equipment
Land transport: ADR chapter 3.2, UN 2796
RID chapter 3.2, UN 2796
Suitable extinguishing agents Possible exposure caused by sulphuric acid and acid mist during filling
in case of surrounding fires: and charging:
Description of the goods: Battery, fluid, Acid
CO2 and solid existinguishing
Danger number: 80
agent. Threshold value on workplace: 0,1 mg/m3 *
UN number: 2796
Personal protective equipment: Rubber, PVC gloves, acid-proof
goggles, acid proof clothing
Sea transport: IMDG-Code chapter 3.2, UN 2796
6 Measures to be taken in safety boots
case of unintentional
*) 3
release 0,5 mg/m at the lead battery production
Air transport: IATA-DGR chapter 3.2, sulphuric acid
Cleaning / take-up procedures: 9 Physical and chemical properties
Use a bonding agent, such as
sand, to absorb spilt acid; use Appearance Other data: Dispatch per mail service impermissible
lime / sodium carbonate for neu- form: liquid
tralisation, dispose with due colour: colourless
regard to the official local regu- odour: odourless 15 Regulations
lations.
Safety-related data Marking according to German Regulations
solidification point: – 35 . . . – 60 ˚C on Hazardous Materials Identification requirement
7 Handling and storage boiling point: approx. 108 . . . 114 ˚C Danger symbol C, corrosive
Solubility in water: complete R-phrases 35 Causes severe burns.
Store frost-free under roof. Seek flash point: N.A.
S-phrases 1/2 Keep locked up and out
agreement with local water ignition temperature: N.A.
of reach of children
authorities in case of larger quan- lower explosive limit: N.A.
tities. Observe VAWS. densitiy (20 ˚C): (1.2 – 1.3) g/cm3 26 In case of contact with eyes rinse
vapour pressure (20 ˚C): 14.6 mbar immediately with plenty of water
bulk density: N.A. and seek medical advice
pH value: < 1 (at 20 ˚C) *)
30 Never add water to this product
dynamic viscosity: approx. 2.8 mPa . s (at 20 ˚C)
45 In case of accident or if you feel
unwell seek medical advice
immediately (show the label where
10 Stability and reactivity 12 Data on the ecology
possible.
of the sulphuric acid of the constituents
(30 . . . 38.5 %) *) applies for concentrated acid only, and
– Water-polluting liquid within
– Corrosive, inflammable liquid. the meaning of the German not for refilling the battery with water
Water Resources Act National regulations:
– Thermal decomposition at
338 ˚C. – Water pollution class: 1
Water pollution class: 1 (list material)
(mildly water polluting).
– Destroys organic materials, Other regulations: To be observed in case of storage: German Water Resources Act
such as cardboard, wood, – In order to avoid damage to
textiles. the sewage system, the acid
has to be neutralised by 16 Miscellaneous data
– Reacts with metals producing
means of lime or sodium
hydrogen.
carbonate before disposal. The data rendered above are ba-
– Vigorous reactions with lyes sed on today’s knowledge, and
– Ecological damage is
and alkalis. do not constitute an assurance
possible by change of pH.
of properties. Existing laws and
regulations have to be observed
11 Data on the toxicology 13 Instructions for by the recipient of the product in
of the constituents processing / disposal own responsibility.
– acts intensely caustic on skin – The batteries have to be pro-
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.
3
2
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
7140203152

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

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Installation, commissioning and operating instructions

for vented stationary lead-acid batteries

Similar to the illustration, grid | aquagen optional

Your team from

Head office address:

Installation, commissioning and operating instructions

Type, Design, Print: 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.

Risk of corrosion caused by leaking electrolyte. 0.1 General Information

Risk of electrical voltage.

GroE grid | power V X

OSP.HB grid | power V M

OSP.XC grid | power V H

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/

7140203152 V1.4 (11.2020)

Date/Signature Technician Date/Signature Customer

46 46 92 1/1 92 7140203152 V1.4 (11.2020)

1.1 Safety precautions

Calcium Sodium Sodium hydroxide (I) 2.3.1 Sulfuric acid

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

Observe all required safety measures to avoid electric shock.

It is essential that loads on road vehicles are properly secured!

available capacity [% C10]

4.2 Storage time

Labeling Warning signs in accordance with IEC 62485-2.

Warning sign depicting risk of electrical voltage

Safety distance d [mm]

Tab. 5-1: Demands on the erection site

Fig. 5-1: Safety distance based on battery capacity

Tab. 5-3: Electrolye density in kg/l at 20 °C

grid | power VX (GroE) (2.06 ± 0.01) V/c Ratchet set (optional)

max.power (2.08 ± 0.01) V/c Screwdriver with insulated grip

5.10 Putting the cells/blocks into the racks

Fig. 5-3: Battery cabinet

5.8 Handling the batteries

5.11.2 Type of connection cable

Make sure that you do not cause mechanical damage to the

Conduct the extended commissioning charge according to the following procedure:

5.16.6 Adjustment of the electrolyte density

Measuring electrolyte density – prerequisites

Temperature in °C 6.2.1 Standby parallel operation

Charging Series Cell

Tab. 6-2: Float charge voltage adjustment in standby parallel operaion

DC Power Supply Electrical Load Tab. 6-3: Float charge voltage

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

Depth of discharge (DoD) in %

sun | power VL at 40 °C sun | power VL at 45 °C sun | power VL at 35 °C

Do not use dry cleaning cloth.

Take the following measurements and record the measurement values:

9.1 Performing the capacity test (short form) Preperation

W and I characteristic curves are also possible.

Charging procedure Charge current Cell voltage

Minimum precision requirements for the measuring devices (precision class):

For voltage measurement: 0.5

Warning sign depicting risk of electrical voltage

Do not use dry cleaning cloth.