Operating instructions

Operating instructions
Operating instructions
Valve regulated stationary lead-acid batteries
Installation by:
Nominal voltage UN: 2.0 V x number of cells
connected in series
Nominal Capacity CN = C10: 10 hour
discharge (see type label)
Nominal discharge current: IN = I10:
10 h
Final discharge voltage Us: 1.80 V/Cell
Commissioning by:
Safety markings affixed by:
Nominal temperature TN: 20°C
Valve regulated stationary lead-acid batteries consist of cells which for their entire service life must not be topped up with water.
Excess pressure valves are used as vent
plugs and will be destroyed if opened.
Observe operating instructions
and display visibly near to the
Work on batteries only after
instruction by qualified staff.
No smoking. No open flame,
embers or sparks in the vicinity
of the battery, to avoid risk of
explosion and fire.
Wear eye protection and protective clothing when working with
Observe accident prevention regulations, also DIN EN 50272 T2,
DIN EN 50110 Part 1!
Acid splashes in the eyes or on
the skin must be washed out or
off with plenty of water. Then
see a doctor immediately. Acid
splashes on clothing should be
washed out with water!
Explosion and fire risk, avoid
Warning! Metal parts of the battery cells are always live. Never
place foreign objects or tools on
the battery.
Electrolyte is highly corrosive. In
normal operation there is no
possibility of contact with the
electrolyte. Should the casing be
destroyed, the combined electrolyte released is as corrosive as
liquid electrolyte.
Monobloc batteries/cells are very
Ensure secure installation! Use
only suitable conveying equipment!
Dangerous electrical voltage.
Further information can be found
in the detailed installation, commissioning and operating instructions under www.hoppecke.com.
1. Commissioning
Before commissioning all cells/blocks must
be inspected for mechanical damage, cells
must be connected with the correct polarity
and connectors firmly seated.
The following torque applies for screw
M8 with 20 Nm ± 1 Nm,
M5/M6 with 8 Nm ± 1 Nm.
If necessary the terminal covers must be
put on.
With charger off and loads isolated, connect
battery to the direct current power supply,
maintaining correct polarity (positive terminal to positive post).
Switch on the charger and charge as described in section 2.2.
2. Operation
For the assembly and operation of stationary
battery installations DIN EN 50272 Part 1
and DIN EN 50272 Part 2 resp. IEC 624852 apply.
The battery must be installed in such a way
that an ambient temperature difference of
> 3°C cannot occur between individual
2.1 Discharging
Never allow the final discharge voltage of the
battery to drop below that assigned for the
discharge current. Unless the manufacturer
has specified otherwise, no more than the
nominal capacity is to be consumed. Charge
immediately after discharge, including partial discharge.
2.2 Charging
The charging procedure with limit values as
defined under DIN 41 773 (IU characteristic) may be used.
Depending on the system at hand, charging may be carried out under the following
operating modes (in accordance with DIN EN
50272 Part 1 draft).
a) Stand-by parallel operation and floating
Here the load, direct current source and battery are continuously connected in parallel.
This means that the charging voltage is the
operating voltage of the battery and at the
same time the battery system voltage.
Under stand-by parallel operation, the direct
current source is at any time capable of supplying the maximum load current and the
battery charging current. The battery only
supplies current when the direct current
source fails. The charge voltage should be
set at 2.25 V ± 1% x number of cells in
series, measured at the battery’s terminals.
To reduce the recharging time a charging
stage can be applied in which the charging
voltage is max. 2.35 V x number of cells
(stand-by parallel operation with recharging
stage). Automatic changeover to the charging voltage of 2.25 V ± 1% (2,27 V ± 1%
for power.com H.C, power.com XC, dry.power
and net.power 12 V 92 as well as 12 V 170)
x number of cells in series follows.
With floating operation the direct current
source is not able to supply the maximum
load current at all times. The load current
intermittently exceeds the nominal current of
the direct current source.
During this period the battery supplies power.
It is not fully charged at all times. Therefore,
depending on the load, the charge voltage
must be set at approx. 2.27 to 2.30 V x
number of cells following consultation with
the battery manufacturer.
b) Switch mode operation
When charging, the battery is separated from
the load. The charge voltage of the battery is
max. 2.35 V/cell. The charging process must
be monitored. When the charge current has
decreased to 1.5 A/100 Ah nominal capacity
at 2.35 V/cell, the battery is switched to
float charging as under section 2.3 or switching takes place on reaching 2.35 V/cell.
c) Battery operation (charge/discharge)
The load is supplied only by the battery. The
charging method depends on the user and
must be clarified with the battery manufacturer.
2.3 Maintaining the full charge (float
Devices complying with the provisions of
DIN 41773 must be used. They are to be
set so that the average cell voltage is 2.25 V
± 1% (2,27 V ± 1% for power.com H.C,
power.com XC, dry.power and net.power 12 V
92 as well as 12 V 170).
2.4 Equalising charge
Because it is possible to exceed the permitted
load voltages, appropriate measures must be
taken, e.g. disconnection of the load.
An equalising charge is necessary after an
exhaustive discharge and/or after an inadequate charge; it can be carried out at a constant voltage of max. 2.35 V/cell for up to
48 hours. The end of equalising charge is rea-
ched when the electrolyte densities and cell
voltages no longer rise within a period of 2
hours. The charging current should not exceed
20 A per 100 Ah nominal capacity. Should the
maximum temperature of 45°C be exceeded,
the charging process must be interrupted or
temporarily switched to float charge to allow
the temperature to drop.
3. Battery maintenance and inspection
To avoid leakage currents keep the battery
clean and dry. Cleaning the battery should be
carried out as specified in the ZVEI pamphlet
on battery cleaning.
6. Storage and taking out of operation
Should cells/batteries be stored or be taken
out of operation for extended periods, they
must be stored fully charged in a dry, frostfree room. Direct sunlight must be avoided.
Plastic battery components, in particular the
cell containers, must only be cleaned with
pure water.
To prevent damage, the following charging
conditions should be chosen:
2.5 Superimposed alternating currents
While recharging up to 2.35 V/cell in accordance with the operating modes of section
2.2, the actual value of the alternating current
is occasionally permitted to reach a max. 20 A
per 100 Ah nominal capacity. After recharging
and continuous charging (float charging) in
standby parallel operation or floating operation, the effective value of the alternating
current must not exceed 5 A per 100 Ah nominal capacity.
At least every 6 months the following must be
measured and recorded:
- battery voltage;
- voltage of a few selected cells/monobloc
- surface temperature of a few selected
cells/monobloc batteries;
- temperature in the battery room.
2.7 Temperature
The recommended operating temperature
range for lead-acid batteries is 10°C to 30°C.
The ideal operating temperature range is 20°C
± 5K.
Higher temperatures will reduce battery service
life. The technical data apply to the nominal
temperature of 20°C. Lower temperatures
reduce the available capacity. The maximum
temperature of 55ºC must nor be exceeded.
Continuous operating temperatures in excess
of 45ºC are to be avoided.
2.8 Temperature-related charge voltage
Within the operating temperature range of
15°C to 25°C, temperature-related adjustment
of the charge voltage is not necessary.
Should the operating temperature constantly
lie outside this temperature range, the voltage
should be adjusted. The temperature correction factor is 0.005 V/Cell per K.
Temperature -10 0
Charge voltage 2.40 2.35 2.30 2.25 2.20 2.15
2.9 Electrolyte
The electrolyte is dilute sulphuric acid.
Note: Voltages of batteries with electrolyte
fixed in gel can vary within approximately the
first 2 to 4 years after commissioning. Hence
the cell voltage in float charge can differ from
2.12V/cell ± 1% to 2.5 V/cell ± 1%. These
variations are normal phenomenon for gel
type batteries without negative influence on
capacity resp. efficiency of single battery cells
or blocs.
The following must be measured and recorded
- battery voltage;
- battery voltage of all cells/monobloc batteries;
- surface temperature of all cells/monobloc
- temperature in the battery room.
Annual visual checks:
- on all bolted connectors,
- check all bolt connectors are firmly seated
- on battery installation or arrangement,
- on ventilation.
4. Tests
Tests must be conducted in accordance with
DIN 60896 Part 21 / Part 22. In addition,
special test in-structions, e.g. as set out in
DIN VDE 0100-710 and DIN 0100-718
should be observed.
5. Faults
Should faults be detected in the battery or
the charging device, customer services should
be called in immediately. Measured data
as under section 3 simplify fault detection and
elimination. A service contract with us facilitates the timely detection of faults.
HOPPECKE service number: + 49 (0) 800 246 77 32
Note: Battery charge acceptance might be
restricted by the end of max. storage period.
We recommend application of a different charging method to ensure gentle and full recharge. Refer to corresponding section in the
detailed installation, commissioning and operating instructions.
2. Float charging as under 2.3 above.
The period of use commences with delivery
of the filled and charged battery from the
HOPPECKE plant. Storage times are to be
added to the period of use in full. In addition,
batteries require recharging.
Note: Max. two recharges during storage
period. Battery has to be operated under permanent float voltage thereafter.
7. Transport
Filled lead-acid batteries which are undamaged, show no leaks and are firmly secured on
pallets with protection against sliding, over turning and short-circuits are not treated as
dangerous goods for conveyance by road so
long as there are no dangerous traces (acid,
lye) visible on the outside of the package.
It is essential that loads on road vehicles
are properly secured!
8. Technical data
The nominal voltage, the number of
cells/blocks, the nominal capacity (C10 = CN)
and the battery type can be obtained from
the identification plate.
8.1 Example
Identification plate: 4 OPzV 200
4 = number of positive plates
OPzV = battery type
200 = nominal capacity C10
(capacity for discharge with ten hours’
current (I10) over a discharge time of 10 h
Float charge voltage
HOPPECKE OPzV, power.bloc OPzV, net.power 12 V 100 and 12 V 150 Ah,
power.com SB, power.com HC, OPzV solar.power, OPzV bloc solar.power, solar.bloc
net.power 12 V 92 and 170 Ah, power.com XC
Voltage per unit
Tolerance for float charge voltage for single cells/blocks
-0,10 V/+0,20 V
2,25 ± 1%
-0,14 V/+0,28 V
2,27 ± 1%
12 V
-0,17 V/+0,35 V
-0,25 V/+0,50 V
Old batteries with this marking 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 under the relevant regulations.
HOPPECKE Batterien GmbH & Co. KG
P.O. Box 1140 · D-59914 Brilon
Bontkirchener Straße 1 · D-59929 Brilon-Hoppecke
Phone +49(0)2963 61-0
+49(0)2963 61-449
Email [email protected]
Teil-Nr. 7340204011/03.13/3 K Printed in Germany
2.6 Charging currents
During continuous battery power supply or
floating operation without a recharging stage,
the charging currents are not limited. The
charging current should lie between 10 A and
20 A per 100 Ah nominal capacity (standard
Should the cell voltage deviate from the
average float charge voltage by +0.2 V/cell
or -0.1 V/cell and/or should the surface
temperature of different cells deviate more
than 5K, customer services must be called in.
1. Equalizing charges as defined under 2.4
above, to be given twice a year. At average
ambient temperatures in excess of 20°C,
shorter intervals may be necessary.
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