Installationsinstruktion - Nicd

HOPPECKE
Assembly and Installation Instructions
Stationary Nickel-Cadmium Batteries
with FNC cells
(Batteries / Racks / Cabinet)
It is assumed that only qualified personnel are engaged in assembly and installation of the components provided.
Qualified personnel are persons who,
on the strength of their training, experience and instruction, together with
their knowledge of the relevant standards, provisions, accident prevention
regulations and operating conditions,
have been authorised by those responsible for the safety of the components / installation, to carry out the relevant necessary work, with the ability to recognise and avoid possible hazards.
Amongst other things, knowledge of
First Aid and of local rescue equipment
are also necessary.
Failure to observe the instructions on use, repair with non-original parts, unauthorised intervention, or use of additives to
the electrolyte shall render the
warranty void.
Safety instructions
The following safety measures relate to
the handling of batteries and are to be
observed in connection with all operating instructions contained in these instructions.
Observe assembly and installation instructions and display visibly at point of installation.
Work on batteries only after instruction by qualified staff. The
operating instructions must always be accessible to personnel
responsible for dealing with batteries.
Wear eye protection and protective clothing when working
with batteries.
Observe accident prevention regulations.
No smoking. No open flame,
embers or sparks in the vicinity
of the battery, to avoid risk of
explosion and fire.
Explosion and fire risk, avoid
short-circuits.
Warning! Metal parts of the
battery cells are always live.
Never place objects or tools on
the battery. Ensure adequate
ventilation of the battery room,
so that explosive gases
produced during charging are
drawn off (see DIN EN
50272-2).
Have eye rinsing bottle ready at
hand. If electrolyte splashes into
the eyes or onto the skin, rinse
with plenty of clear water and
seek immediate medical advice.
Clothing contaminated with
electrolyte is to be washed thoroughly.
Electrolyte is highly corrosive. In
normal operation there is no
possibility of contact with the
electrolyte. Electrolyte is released only if the cell housing is
destroyed.
Do not tilt the battery
Use only approved lifting and
conveying equipment e.g. lifting
gear. Lifting hooks must not cause damage to cells, connectors
or connection cables.
Dangerous electrical voltage.
Use only suitable tools and
measuring instruments.
First Aid measures
Electrolyte in contact with the eyes:
• Rinse immediately with plenty of water
for at least 10 minutes.
• If available, rinse the eyes with boric
acid solution.
• Immediately visit the eye clinic/eye
casualty department.
Electrolyte in contact with the skin:
• Immediately remove clothing contaminated by electrolyte, and wash affected areas of skin with plenty of water.
Visit doctor if any problems occur.
• Skin which has been in contact with
electrolyte has a soapy consistency.
Continue rinsing with water until normal skin condition has been restored.
If electrolyte is swallowed:
• Rinse out mouth immediately with
plenty of water, and repeatedly drink
large amounts of water.
• Do not induce vomiting. Call emergency medical service immediately.
Protection against dangerous
body contact currents
In stationary battery installations, measures must be taken to guard against direct and indirect contact. For battery installations this protection can take the
form of obstacles or distance. Battery installations with a rated voltage of more
than 120 V must be accommodated in
enclosed, electrical operating areas.
Doors of battery rooms and cubicles
count as obstacles when they are identified by the following warning plates (fitted externally):
• Warning plate “Dangerous Voltage”,
if the battery voltage exceeds 60 V
(see ISO 3864)
• Prohibition sign: “No fire, naked flame or smoking”
• Warning plate “Battery Room” to indicate electrolyte, explosive gases, dangerous voltages and currents.
Protection against direct contact may be
provided through the insulation of live
parts, by covering or enclosure, or by
obstacles or distance. Batteries with a
rated voltage of less than 60 V require
no protection against direct contact. If
covering or enclosure is chosen for protection against direct contact for a battery with a rated voltage in excess of
60 V, then at least protection type IP2X
or IPXXB must be used.
Protection against indirect contact may
be provided by means of automatic disconnection, by the use of equipment of
protection class II or by isolation. In particular applications this protection may
also be provided by the use of non-conductive areas or by earth-free, localised
potential equalisation.
Certain protective measures require a
protective conductor. These protective
conductors may contain no switches or
overcurrent devices. Battery racks or
battery cubicles made of metal must be
either connected to the protective conductor or else isolated from the battery
and the point of installation. If overcurrent devices are used, then disconnection of the connected equipment must
take place within five seconds.
• Ensure adequate ventilation
• Agreement with other persons working in the same room (ensures trouble-free installation).
HOPPECKE will be pleased to help you
in procuring suitable racking.
Scope of delivery of racks/
cabinets and documentation
The goods delivered should be checked
for completeness and for any signs of
damage. All oarts should be cleaned if
necessary. The accompanying documentation should be noted and followed.
This documentation should comprise an
assembly drawing for the rack or cubicle, together with battery connection instructions. If the documents required for
correct assembly of the rack are missing, they should be requested before
starting assembly. Only undamaged
cells may be used, since otherwise the
whole battery may be adversely affected by escaping electrolyte.
Rack assembly
The rack is assembled in accordance
with the instructions supplied (example
below).
Before commencing rack or cubicle
assembly:
• Ensure correct floor loading and floor
quality (access routes and battery
room)
• Ensure that the mounting surface (floor
of the battery room or electrolyte tray)
is resistant to electrolyte
• Protection against sources of ignition
(naked flame, glowing matter, electrical switches) in the vicinity of the cell
opening, 500 mm “filament distance”
as specified in DIN EN 50272-2
If component voltages in excess
of 120 V are reached or if the
rated voltage of the battery is
above this value, then a minimum distance of 1.5 m is to be
maintained between non-insulated connections or connectors
and earthed parts (e.g. water
pipes, heating) and between the
end terminals of the battery.
Setting-up the cabinets
Normally battery cubicles are supplied
fully assembled. If however the cubicle
is supplied in separate parts, then it
should be assembled in accordance
with the assembly drawing supplied, as
for the racks. The following minimum
clearances are to be observed:
• Clearance between cubicle and wall:
min. 50 mm
• Aisles between cubicles:
min. 500 mm
HOPPECKE FNC (fibre-structured) nickel-cadmium cells are
designed for use solely in the
upright position. These cells
may never be installed in a
lying position or tilted at an
angle.
Rack or cabinet assembly
Before starting assembly it must be ensured that the battery room is clean and
dry and has a door which can be closed. The battery room must, as described above in the section “Protection
against dangerous body contact currents”, be provided with warning signs
conforming to DIN EN 50272-2.
Particular attention should also be paid
to the following:
wing minimum clearances are to be observed:
• Clearance between rack and wall:
min. 50 mm
• Clearance between cell and wall:
min. 100 mm
• Aisles between racks:
min. 500 mm
Ventilation requirements
We recommend that the individual side
elements are assembled first. The side
elements are then erected and the diagonal connectors are bolted to the reverse. The horizontal support rails on which
the cells will subsequently stand are then
assembled and screwed into place. The
spacing of the support rails should correspond to the cell dimensions. Finally
check the stability of the rack, and that
all screw and clip connections are secure.
The rack is then brought into its final position and aligned using a spirit level
and the spacer material supplied (e.g.
adjustable insulators).
It is essential to ensure that the battery
room or cubicle has adequate ventilation. In subsequent operation, the ventilation of the battery room should keep
the hydrogen concentration during battery charging below the threshold of 4%
by volume, in accordance with DIN EN
50272-2.
The volume of air which must be changed hourly may be calculated by the following formula:
Q = 0.05 * n * I
Q = volume of air in m3/h
n = number of individual cells in the
battery
I = charging current in A
Setting-up the rack
The battery room or battery cabinet
may be ventilated by natural or forcedl
means. If natural ventilation (airflow
The rack is set up in accordance with
the erection drawing supplied. The follo-
0.1 m/s) is used, then the inlet and outlet vents should have a minimum crosssection, which is calculated as follows:
A = 28 * Q
A = cross-section of vent in cm2
Q = volume of air in m3 / h
The inlet and outlet vents are to be provided at suitable locations to obtain the
most advantageous conditions for exchange of air.
may be made with both insulated and
non-insulated connectors. Only original
HOPPECKE accessories may be used for
this inter-connection.
Non-insulated connectors with insulator
cover:
Non-insulated connectors
screw
connector
spring washer
Installation of the battery
terminal
Use insulated tools and wear suitable
clothing! Do not wear rings, watches or
metal objects when working on the battery installation.
Equipping the rack or cabinets
FNC cells are basically supplied sealed
by yellow transport plugs. These cells
may be filled and charged (GUG) or unfilled and uncharged (UUU). The yellow
transport plugs remain on the cells until
completion of connection and installation of the battery (important to avoid
atmospheric oxygen coming into contact
with the electrodes!).
In general, when handling the
cells during installation of the
batteries, the yellow transport
plugs should be used for sealing. Unfilled cells in particular
should always be sealed with a
yellow transport plug. After removal of the yellow transport
plug, the cell should be filled
with electrolyte immediately.
If the cells are unfilled (UUU), then they
should be filled only after the battery
has been installed and connected. Before the cells are placed on the rack or in
the cubicle, they should be individually
checked and cleaned. In particular the
contact surfaces of the terminals and the
connectors should be in a clean and
perfect condition. The polarity of the
cells should also be checked with a suitable voltmeter. Place the individual cells
on the rack or in the cubicle one after
the other, with correct polarity and as
shown on the connection drawing, and
at right-angles to the horizontal support
rails. It is not necessary to maintain a distance between the individual cells.
Connection of the battery
After fitting in place, the individual cells
are connected into groups. Connection
The contacts must be clean and free
from any traces of corrosion. General,
spring washers are used. These spring
washers ensure, when the screws are
tightened with the correct torque, a lasting and secure fit of the connectors on
the terminal posts.
For tightening the terminal screws with
the correct torque, only torque spanners
with sockets may be used. Insulated terminal screws in particular may be damaged through the use of ring or jaw
spanners.
Insulated connectors
screw
(head with
insulator
connector
spring washer
Like the non-insulated connectors, the
contacts must be clean and free from
any traces of corrosion. Principally,
spring washers are used. These spring
washers ensure, when the crews are
tightened with the correct torque, a lasting and secure fit of the connectors on
the terminal posts.
For tightening the terminal screws with
the correct torque, only torque spanners
with sockets may be used. Insulated terminal screws in particular may be damaged through the use of ring or jaw
spanners.
The isolation caps are available as a
yard good, also in UL listed material.
The isolation cover can be used both for
3 mm and for 6 mm of standard connectors. By using these insulator cover
we are reduce both, the assembly and
dismantling time, and the risk of faulty
assembly.
insulator
cover cap
terminal
When using insulated connectors, care
has to be taken during assembly to
avoid the clamping of plastic parts between conductive metal parts lying on
top of one another. An appropriate
check is to see that there is slight play
between the plastic cover caps and the
plastic insulation of the connectors when
they are moved gently to and from in a
horizontal direction. Only then can correct assembly be ensured. Without this
play there could be clamped plastic
parts which may melt or scorch when
current flows. This can lead to reduced
performance and increased risk of fire.
After the individual cells have been
interconnected by means of connectors,
the individual rows, levels and tiers are
connected. The individual cell groups
are interconnected. Here, care should
be taken with regard to the cross-section
of the group connectors. Only approved
cable types should be used.
Group or end connectors
cover cap
screw
spring washer
cable with cable eye
terminal
Group or end connectors with connection bracket:
cable with cable eye
nut
spring ring
screw
spring washer
screw
connection
bracket
washer
terminal
The wiring of the group and end connectors should be proof against short-circuits. This means that the wiring used
should have a dielectric strength of at least 3 kV, or else an air gap of at least
10 mm should be maintained between
the wiring and electrically conductive
parts. Alternatively, additional insulation
may be used. Any mechanical loading
of the end terminals is to be avoided by
the fixing of the group and end connectors.
The connectors ensure the optimal flow
of current and therefore require perfect
contacts. For this reason a torque spanner should be used for tightening. The
starting torque of the screws depends on
the thread size of the screws and the design of the terminal screw:
Thread size
M8
M10
Insulated
terminal screw
16 Nm ± 1 Nm
20 Nm ± 1 Nm
Non-insulated
terminal screw
20 Nm ± 1 Nm
25 Nm ± 1 Nm
Concluding work
After connection of the battery, the yellow transport plugs are removed from
all cells. These transport plugs should be
stored near the battery for possible reuse. If the cells concerned are unfilled
(UUU) then they should be filled with
electrolyte up to the level of the min.
mark + 10 mm. During filling with electrolyte, slight heating may occur. Topping-up with electrolyte to the max.
mark takes place after the battery has
been brought into operation for the first
Cd
time. The cells must be filled with electrolyte as soon as possible (within 1 hour)
after removal of the transport plugs. The
cells should never remain empty when
they are not fully discharged, otherwise
they will be permanently damaged.
The electrolyte is a solution of potassium
hydroxide (KOH) in distilled or demineralised water with an addition of lithium
hydroxide (LiOH) and is designed for a
use in temperatures of between -25°C
and +45°C. The lithium hydroxide in the
electrolyte varies between the different
cell types (H, M, L). Production of the
electrolyte is governed by DIN IEC 993.
When the cells are retracted, the density
of the electrolyte is normally 1.19 kg/l
± 0.01 kg/l at the reference temperature of 20° Celsius (electrolyte density
may be higher on delivery)
With nickel-cadmium cells, electrolyte
density is not an indication of the state
of charge. For most FNC products
HOPPECKE will supply on request a special electrolyte which allows operation
in low temperatures down to -45° Celsius.
sary the cells may be provided with consecutive numbers (from the positive to
the negative terminal of the battery) at a
clearly visible point.
Since 1.1.97, in accordance with the
Low Voltage Directive 73/23/EEC, batteries with a rated voltage in excess of
75 V must be provided with the CE
mark. This marking also includes the
provision of an EU declaration of conformity. By this declaration the installer
confirms that the batteries have been set
up in accordance with the applicable
standard (DIN EN 50272-2). In general, the fitter is also the installer.
Only electrolyte approved and
recommended by HOPPECKE
should be used. Observe the safety instructions for dealing with
electrolyte.
Sulphuric acid should never be
used!
At an electrolyte temperature of 20° Celsius, the cells have a minimum open-circuit voltage of 1.27 V. This measurement may be used to determine whether
the polarity of individual cells has been
reversed during installation. The measurement can of course only be made with
filled cells. If the cells were supplied unfilled and uncharged (UUU), then a 12
hour waiting period should elapse between filling and initial operation.
Immediately after filling the cells should
be closed using the standard vent plugs
supplied (hinged lid plugs) or else
AquaGen vent plugs.
Electrolyte residues should be removed
without using cleaning agents. We recommend using a damp cloth. Plastic
parts of the battery, in particular cell
containers, may be cleaned only with
water with no additives.
Marking of the battery
Testing of the battery installation
As a final test of battery installation, the
open-circuit voltage of the filled battery
must be measured using a suitable voltmeter. The open-circuit voltage of the
battery is the total of the individual
open-circuit voltages of the cells.
Dangerous contact voltages are
possible.
Further action, in particular bringing the battery into operation
for the first time, is described in
the instructions “Commissioning
of stationary nickel-cadmium
batteries with fibre-structured
(FNC) electrodes”. These instructions are supplied with the
battery, and it is essential that
they are observed.
Polarity plates must be affixed visibly to
the end terminals of the battery. If neces-
Used batteries with this mark are recyclable goods and must be sent for recycling. Used batteries
which are not sent for recycling are to be disposed of as special waste, observing all the
applicable regulations. HOPPECKE has a ”closed loop recycling system” for NiCd batteries,
please contact your local HOPPECKE dealer for any questions according recycling of batteries.
HOPPECKE
HOPPECKE Batterie Systeme GmbH
P.O.Box 11 40
D-59914 Brilon (Hoppecke)
Phone (0 29 61) 97 06-2 12 · Fax 97 06-2 51
http://www.hoppecke.de
e-Mail: [email protected]