Hoppecke 5 OPzV 250 Installation, Commissioning And Operating Instructions
for valve-regulated stationary lead-acid batteries
Installation, commissioning and operating instructions
Similar to the illustration
2 3
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
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:
info@hoppecke.com
or by phone on working days between the hours of 8 am and 4 pm (CET) at the following number:
Telephone +49(0)2963 61-0
Fax +49(0)2963 61-481.
Your Team from
HOPPECKE Batterien GmbH & Co. KG
Postal address:
HOPPECKE Batterien GmbH & Co. KG
P.O. Box 11 40
D-59914 Brilon
Germany
Head office address:
HOPPECKE Batterien GmbH & Co. KG
Bontkirchener Straße 1
D-59929 Brilon-Hoppecke
Telephone +49(0)2963 61-0
Fax +49(0)2963 61-449
Internet www.hoppecke.com
Email info@hoppecke.com
Installation, commissioning and operating instructions
for valve-regulated stationary lead-acid batteries
Type und Design: PRIOTEX Medien GmbH, 59929 Brilon
© 2013 HOPPECKE Batterien GmbH & Co. KG
P.O. Box 1140
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.
4 5
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Used Symbols
The following safety notes need to be observed. Listed symbols are used multiple times for safety relevant
information:
Danger!
Personal health, batteries or the environment are at risk.
Failure to observe this hazard notice can lead to severe or fatal injury.
Attention!
Batteries, materials or the environment are at risk. Personal safety is not at risk.
Failure to observe this notice can lead to malfunction or damage to the batteries. In addition,
material and environmental damage may occur.
Risk of explosion or blast, splashing of hot or molten substances.
Risk of explosion and fire, avoid short circuits.
Avoid electrostatic charges and discharges/sparks.
Failure to observe this hazard notice can lead to severe or fatal injury.
Risk of corrosion caused by leaking electrolyte.
Electrolyte is strongly corrosive.
Electrical voltages hazardous to health may cause fatal injury.
Metal parts of the battery are always alive, therefore do not place items or tools on the battery.
Failure to observe this hazard notice can lead to severe or fatal injury.
Warning! Risks caused by batteries.
Do not smoke!
Do not use any naked flame or other sources of ignition.
Risk of explosion and fire!
General prohibition
Observe these instructions and keep them located near the battery for future reference.
Work on batteries only by trained qualified personnel.
While working on batteries wear protective eye-glasses, protective gloves and
clothing!
Observe accident prevention regulations as well as EN 50110-1 and
IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries).
Wear conductive shoes.
General order
Any acid splashes on the skin or in the eyes must be rinsed with plenty of clean water immediately. Then seek medical assistance.
Spillages on clothing should be rinsed out with water!
Recycling
Spent batteries have to be collected and recycled separately from normal household
wastes.
General notice or tip for better understanding and optimum use of the battery or batteries.
Pb
0 Safety notices
0.1 General Information
Danger!
Incorrect use of the products described here can lead to personal and material damage.
HOPPECKE is not responsible or liable for direct or indirect personal and material damages which
occur as a result of handling the products described here.
Risk of explosion and fire, avoid short circuits. Avoid electrostatic charges and discharges/spaks.
Attention! Metal parts of the battery or batteries are always live, so never place foreign objects
or tools on top of the batteries.
Electrostatic discharges can ignite oxyhydrogen gas and therefore cause an explosion of the
battery! Exploding parts can lead to heavy injuries.
Electrolyte is highly corrosive.
Contact with electrolyte is impossible in normal working conditions. Electrolyte coming out of
damaged cells or blocks is highly corrosive too. Acid splashes in the eyes or on the skin must be
washed with plenty of clean water. Then consult a doctor immediately!
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!
Attention!
Incomplete or insufficient maintenance can lead to unexpected battery failure or reduction of
battery power. Maintenance work must be completed once every six months by HOPPECKE
specialists or by qualified personnel trained by HOPPECKKE in accordance with the instructions
in this documentation.
Danger!
Work on batteries, especially installation and maintenance should be performed by trained
HOPPECKE specialists (or by qualified personnel trained by HOPPECKE) only; personnel must be
familiar with battery handling and the required precautionary measures. Unauthorized persons
must keep away from the batteries!
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.
Sealed lead-acid batteries are always filled before delivery. Sealed stationary lead-acid battery
cells must not be refilled with water during the entire battery service life. Overpressure valves are
used as sealing plugs. These plugs cannot be opened without damaging.
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Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
HOPPECKE offers the following type ranges as valve regulated lead-acid (VRLA) batteries:
net.power
OPzV
power.bloc OPzV
power.com HC
power.com XC
grid | power
VR M (power.com SB)
grid | power
VR X/grid | power VR X FT
sun | power VR L (OPzV solar.power/OPzV bloc solar.power)
sun | power
VR M (solar.bloc)
The product names used for HOPPECKE battery series have been changed. 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.
Pb
Following symbols and pictograms are pictured on each battery cell or on each battery block:
Read the instruction for installation, commissioning and operation carefully.
Always wear protective goggles and cloths.
Avoid naked flames and sparks.
General danger warning.
Risk of electrical voltage.
Risk of chemical burns through electrolyte.
Risk of explosion, avoid short circuits, electrostatic charge and discharge/sparks.
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.
Old new
OPzV bloc solar.power sun | power
VR L
OPzV solar.power sun | power VR L
power.com SB grid | power VR M
solar.bloc sun | power VR M
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Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
0.2 Safety instructions for working with lead-acid batteries
When working on batteries, always observe the safety regulations documented in DIN EN
50110-1 (VDE 0105-1) Operation of electrical installations:
• Always proceed in the correct order when installing and removing the battery and when connecting it to the charger.
• Pay attention to the polarity!
• Make sure the connections are tight.
• Use only battery charger leads that are in perfect technical condition and that have adequate
cross-sections.
• Batteries must not be connected or disconnected while current is flowing or while the charger
is switched on.
• Before opening the load circuit, make sure that the charger is in a switched-off state by measuring the voltage.
• Secure the charger to prevent it from being switched back on again!
• Heed the instructions given in the operating manual provided by the manufacturer of the battery
charger.
Danger!
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.
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 secon-
dary batteries and battery installations - Part 2: Stationary batteries“.
– DIN EN 50110–1 (VDE 0105–1): Operation of electrical installations; German version EN
50110-1:2004.
– IEEE Standard 485–1997: „Recommended Practice for Sizing Large Lead Acid Storage Batteries
for Generating Stations.“
– IEEE Standard 1187–2002: „Recommended Practice for Installation Design and Installation of
Valve Regulated Lead-Acid Storage Batteries for Stationary Applications“.
– IEEE Standard 1188–2005: „Recommended Practice for Maintenance, Testing and Replacement
of Valve Regulated Lead-Acid (VRLA) Batteries for Stationary Applications“.
– IEEE Standard 1189–2007: „Guide for Selection of Valve-Regulated Lead-Acid (VRLA) Batteries
for Stationary Applications“.
– IEEE Standard 1375–1998: „Guide for Protection of Stationary Battery Systems“.
– DIN EN 50110-1 (VDE 0105-1): “Company of electrical instructions” ; German copy EN 50110-
1:2004
Batteries contain corrosive acids which can lead to chemical burn on skin and eyes if the
battery is damaged.
You must wear safety goggles while handling the battery!
Wear all the intended personal safety clothing while handling the batteries.
1. When renewing old batteries, ensure that all electrical loads are switched off before removing
the old battery (separators, fuses, switches). This must be carried out by qualified personnel.
Danger!
2. Remove all wrist watches, rings, chains, jewelry and other metal objects before working with
batteries.
3. Use insulated tools only.
4. Wear insulating gloves and protective shoes (refer to also to Chap. 2.2).
Danger!
5. Never place tools or metal components on top of the batteries.
Danger!
6. Make sure that the battery or batteries are not mistakenly grounded. If the system is grounded,
terminate the connection.
Touching a grounded battery by mistake can result in severe electric shock. The risk caused
by an incorrect connection can be significantly reduced by terminating the ground connection.
Attention!
7. Before establishing connections, make sure to check the correct polarity - better one too many
times than one too few.
Danger!
8. Filled lead-acid batteries contain highly explosive gas (hydrogen/air mixture). Never smoke,
handle open flames or create sparks near the batteries. Always avoid electrostatic discharge;
wear cotton clothing and ground yourself if necessary.
Danger!
9. Blocks/cells are very heavy. Make sure they are installed securely. Only use suitable means of
transport. Do not lift or pull up blocks/cells on the poles.
Danger!
10. Never carry batteries by the battery terminals.
Attention!
11. These batteries contain lead and cannot under any circumstances be disposed of with
household waste or at a waste dump at the end of their service life (for more information,
refer to Chap. 1.4).
Attention!
12. Contains lead-metall (CAS- Nr. 7439-92-1). This metall is one of the reach list chemicals.
10 11
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Table of contents
Preface .................................................................................................................................................. 3
Symbols .............................................................................................................................................. 4
0 Safety notices ..................................................................................................................................... 5
0.1 General Information ................................................................................................................ 5
0.2 Safety instructions for working with lead-acid batteries .............................................................. 8
1 General Information ............................................................................................................................ 12
1.1 Safety precautions .................................................................................................................. 12
1.2 Technical Data ...................................................................................................................... 12
1.2.1 Excample for single cell ......................................................................................................... 12
1.2.2 Identification plate battery ...................................................................................................... 13
1.3 CE-Mark ................................................................................................................................ 13
1.4 Disposal and recycling ........................................................................................................... 13
1.5 Service ................................................................................................................................. 13
2 Safety ............................................................................................................................................ 14
2.1 General ................................................................................................................................ 14
2.2 Personal safety equipment, protective clothing, equipment ...................................................... 14
2.3 Safety precautions ................................................................................................................ 14
2.3.1 Sulfuric acid ......................................................................................................................... 14
2.3.2 Explosive gases .................................................................................................................... 15
2.3.3 Electrostatic discharge .......................................................................................................... 16
2.3.4 Electric shock and burns ....................................................................................................... 17
3 Transport ........................................................................................................................................... 18
3.1 General ................................................................................................................................. 18
3.2 Delivery completeness and externally visible damage .............................................................. 18
3.3 Latent defects ........................................................................................................................ 19
4 Storing batteries before installation .................................................................................................... 20
4.1 General ................................................................................................................................ 20
4.2 Storage time ......................................................................................................................... 20
4.3 Preparing for a several-month storage period .......................................................................... 20
5 Installation ....................................................................................................................................... 21
5.1 Demands on the erection site ................................................................................................ 21
5.1.1 Calculation of safety distance ................................................................................................ 23
5.2 Filling the cells ..................................................................................................................... 24
5.2.1 Check .................................................................................................................................. 24
5.2.1.1 Ventilation - preventing explosion ........................................................................................... 24
5.2.1.2 Ventilation - calculation for ventilation requirements of battery rooms ....................................... 24
5.3 Conducting an open-circuit voltage measurement .................................................................... 26
5.4 Installation tools and equipment ............................................................................................ 26
5.5 Rack Installation ................................................................................................................... 27
5.6 Cabinet Installation ............................................................................................................... 28
5.7 Handling the batteries ........................................................................................................... 29
5.8 General information on connecting the batteries ..................................................................... 29
5.9 Putting the cells/blocks into the racks ................................................................................... 30
5.10 Connecting the batteries ....................................................................................................... 32
5.10.1 Connection terminals ............................................................................................................ 32
5.10.2 Type of connection cable ....................................................................................................... 32
5.10.3 Clamping batteries using battery connectors ........................................................................... 32
5.10.4 Installing the screwed connectors .......................................................................................... 33
5.10.5 Clamping connection plates onto the batteries ....................................................................... 33
5.11 Connect the battery system to the DC power supply ................................................................ 34
5.12 Commissioning charge (initial charge) .................................................................................... 35
5.12.1 Commissioning charge with constant voltage (IU characteristic curve) ...................................... 35
5.12.2 Extended commissioning charge ............................................................................................ 35
6 Battery operation ............................................................................................................................... 36
6.1 Unloading ............................................................................................................................... 36
6.2 Charging - general ................................................................................................................... 36
6.2.1 Standby parallel operation ....................................................................................................... 38
6.2.2 Floating operation ................................................................................................................... 39
6.2.3 Switch mode operation (charge/discharge operation) ................................................................ 39
6.2.4 Float charging ......................................................................................................................... 39
6.2.5 Equalizing charge (correction charge) ........................................................................................ 40
7 Charging of HOPPECKE sun |power
VR L battery in Solar Applications ................................................... 42
7.1 Charge and discharge parameters ............................................................................................ 42
7.2 Alternating currents ................................................................................................................. 43
7.3 Temperature influence on battery performance and lifetime ....................................................... 43
7.3.1 Temperature influence on battery capacity ................................................................................ 44
7.3.2 Temperature influence on battery service life ............................................................................ 44
7.4 Influence of cycling on battery behaviour .................................................................................. 44
7.4.1 Endurance in cycles depending on depth of discharge ............................................................... 45
7.4.2 Endurance in cycles depending on ambient temperature ............................................................ 45
7.4.3 Electrolyte freezing point depending on depth of discharge (DoD) ............................................... 46
7.5 Remarks to warranty management ........................................................................................... 47
8 Battery maintenance .......................................................................................................................... 47
8.1 Work to be performed every six months .................................................................................... 47
8.2 Work to be performed annullay ................................................................................................ 48
8.3 Cleaning of battery .................................................................................................................. 48
9 Testing the battery system ................................................................................................................. 49
9.1 Performing the capacity test (short form) .................................................................................. 49
9.2 Performing the capacity test (extended version) ........................................................................ 49
9.3 Capacity test of the battery ...................................................................................................... 51
10 Fault Retification ............................................................................................................................. 53
11 Required ventilation for hydrogen generated by batteries................................................................... 53
12 Disassembly ..................................................................................................................................... 54
Inspection protocol ................................................................................................................................ 55
Safety data sheet .................................................................................................................................. 56
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Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
1 General information
The electrolyte of sealed lead-acid batteries is fixed in a glass fiber fleece (AGM) or gel. Therefore an upright
or horizontal installation of battery cells or blocks is basically possible. The generation of oxyhydrogen gas is
extremely reduced by an internal recombination circle. Sealed lead-acid battery cells or battery blocks are not
sealed gas tightly. The integrated valve has to open by pressure overload. Sealed lead-acid batteries must
not be opened. HOPPECKE offers numerous sealed lead-acid batteries as single cells (nominal voltage 2 V) or
blocks (nominal tension:6 V or 12 V) for different applications.
1.1 Safety precautions
Danger!
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 batteries.
Danger!
To ensure your own safety as well as the safety of your colleagues and the system, it is essential
that you have read and understood all instructions in this documentation and adhere to them
strictly. If you have not understood the information contained in this documentation or if local
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
can also contact us at our head office directly.
Danger!
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.
1.2 Technical data
1.2.1 Example for single cell
Each single cell/each battery block has an own identification plate on the top side of the cell/block cap. Refer
to the example below.
Example: The information on the identification plate is as follows:
5 OPzV 250
5 = number of positive plates
OPzV = battery type
250 = Nominal capacity C
10
(capacity during discharge with ten
hours´ current (I10) over a discharge time of 10 h (t10))
267 = actual capacity C
10
(capacity of discharge with 10 h
current)
5 OPzV 250
2V 250Ah CN / 267 Ah C
10
U
float
= 2,25 V/cell
! upright position only !
Made in Germany
non spillable
1.2.2 Identification plate battery
The identification plate of the entire battery system can be found on the
battery rack or inside the battery cabinet.
The nominal voltage, the number of cells/blocks, the nominal capacity
(C10 = CN) and the battery type are listed on the identification plate of
the system.
Fig. 1–1: Example for type plate on battery rack
1.3 CE-Mark
Effective as of 1 January 1997, the EC declaration of conformity 2006/95/EC (Low Voltage
Directive) and the corresponding CE marking for the battery system are required for batteries with
a nominal voltage between 75 V and 1500 V DC.
The installer of the battery system is responsible for displaying the declaration and affixing the CE
label on or next to the battery’s identification plate.
1.4 Disposal and recycling
Attention!
Used 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 all relevant regulations.
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
– recycling and waste law
– battery regulations
– transport approval regulations
– t
ogether with the general principles of environmental protection and our own corporate guidelines.
The HOPPECKE smelting plant is the only lead smelter in Europe certified under
– DIN EN ISO 9001 (processes and procedures),
– DIN EN ISO 14001 (environmental audit),
– and specialist disposal regulations covering specialist disposal with all associated waste codes
for storage, treatment and recycling.
For further information: +49(0)2963 61-280.
1.5 Service
HOPPECKE has a worldwide service network that you should take advantage of. HOPPECKE service is there for
you whenever you need specialist consultation for installation of the battery system, parts and accessories or
system maintenance. Contact us or your local HOPPECKE representative.
HOPPECKE service:
Email: service@hoppecke.com
Refer to the HOPPECKE website for contact data of all international HOPPECKE branches:
Internet: www.hoppecke.com
Pb
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Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
2 Safety
2.1 General
If the casing of a sealed lead-acid battery is damaged, small quantities of electrolyte, acid mist or hydrogen gas
may leak out. Always take the normal safety precautions when working with lead-acid batteries.
Consider all instructions and engineer standards, as mentioned in chapter 0.2.
2.2 Personal safety equipment, protective clothing, equipment
While working on batteries wear protective eye-glasses, protective gloves and
clothing!
Observe accident prevention regulations as well as EN 50110-1 and
IEC 62485-2 (Stationary batteries) or IEC 62485-3 (Traction batteries).
If working with lead-acid batteries, the following equipment must be provided at the very least:
– Insulated tools
– Protective shoes
– Rubber gloves
– Fire extinguisher
– Rubber apron
– Protective goggles
– Face shield
– Face mask
– Emergency eye wash (recommended).
To avoid electrostatic charging, all textiles, protective shoes and gloves worn while working with
batteries must have a surface resistance of <10
8
ohm and an insulation resistance of ≥105 ohm
(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
batteries.
Never smoke, handle open flames or create sparks near the batteries.
Never place tools or metal components on top of the batteries.
The use of proper tools and safety equipment can help to prevent injury or reduce the severity of injury in
case of an accident.
2.3 Safety precautions
2.3.1 Sulfuric acid
Sealed lead-acid batteries are safe when used properly. However, they contain diluted sulfuric acid (H2SO4) that
is bonded in gel or glass mat. The bonded sulfuric acid is extremely corrosive and can cause serious injury.
Further information to sulfuric acid can be found in the attached material safety data sheet.
Note also the information in the attached ZVEI leaflet “Instructions for the safe handling of lead-acid accumulators (lead-acid batteries)”.
2.3.2 Explosive gases
Danger!
Lead-acid batteries can release an explosive mixture of hydrogen and oxygen gases. Severe personal injury could occur in the event of an explosion of this mixture.
– Always wear the recommended protective clothing (protective goggles, insulated gloves and
protective shoes, etc.)
– 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.
Danger!
In case of fire, extinguish using water or CO
2
extinguisher only.
Do not point the fire extinguisher directly at the battery or batteries to be extinguished. There
is a risk that the battery casing may break as a result of thermal tension. In addition, there is
a risk of static charging on the surface of the battery. This could result in an explosion. Switch
off the charging voltage of the battery. If extinguishing a fire, use a breathing apparatus with
a self contained air supply. If using water to extinguish a fire, there is a risk that the water/
foam could react with the electrolyte and result in violent spatter. For this reason, wear acidresistant protective clothing. Burning plastic material may produce toxic fumes. If this should
occur, leave the location as quickly as possible if you are not wearing the breathing apparatus
described above.
Danger!
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 leadacid accumulators (lead-acid batteries)”.
16 17
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
2.3.4 Electric shock and burns
Danger!
Batteries can cause severe electric shock. If there is a short circuit, very strong currents may
be present. Do not touch any bare battery components, connectors, clamps or terminals.
In battery systems with a nominal voltage of over 1,500 V DC, you must provide equipment
for splitting the batteries into cell groups with voltages lower than 1,500 V DC. In order to
prevent serious injury as a result of electric shock or burns, be very cautious when performing
any work on the battery system.
Always wear the recommended protective clothing (insulated rubber gloves and rubber shoes,
etc.) and always use insulated tools or tools made of non-conductive material.
Remove all wrist watches, rings, chains, jewelry and other metal objects before working with
batteries.
Before conducting work on the battery system...
Determine whether the battery system is grounded. We do not recommend this. If the system is grounded,
terminate the connection.
Touching a grounded battery by mistake can result in severe electric shock. This risk can be significantly reduced by removing the ground connection. However, the racks (or cabinets) used to hold the batteries do need to
be well grounded or completely insulated.
If a battery system is grounded…
There is a voltage between the ground and the ungrounded terminal. If a grounded person touches
this terminal, there is risk of fatal injury. There is also a risk of short circuit if dirt or acid on the
ungrounded terminal come in contact with the battery rack.
If an additional ground connection is made by some cells within the (grounded) battery system,
there is a risk of short circuit, fire and explosion.
If a battery system is not grounded…
If an accidental ground connection is made by some cells within the battery system, voltage is
created between the ground and the ungrounded terminal. The voltage can be dangerously high risk of fatal injury due to electric shock.
If a second accidental ground connection is made, there is a risk of short circuit, fire and explosion.
If you have questions about these instructions or any other questions regarding safety when
working with a battery system, please contact your local HOPPECKE representative. You can also
contact us at our head office directly.
2.3.3 Electrostatic discharge
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 assumed that a flame able oxyhydrogen concentration exists only in the close proximity of the battery. A flame able
mixture of oxyhydrogen always exists inside the battery cells. This effect does not depend on the battery technology, design or manufacturer, rather than a specific characteristic of all lead-acid batteries. The energy needed
for an ignition of oxyhydrogen is quite low and can be caused differently. Examples: Open 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.
Measures to avoid the ignitions of detonating gas through electrostatic discharges
The development of electrostatic discharges on the battery or on your body or on clothes can be avoided if you
consider the information below:
Do not wipe the battery with an arid fabric especially made of synthetic material.
Rubbing on surfaces of plastic material (battery jars are typically made of plastic material) causes
electrostatic charges.
Clean the surface of batteries with water- moistened cotton fabric only. By using a water-moistened cotton fabric you avoid the buildup of electrostatic charges.
While working on batteries do not rub your clothes (e.g. made of wool) on the battery. Thereby
electrostatic charges could build up on the battery jar, your body or on your clothes.
Wear suitable shoes and clothing with special surface resistance th
at avoid the buildup of electrostatic charge. Thereby the buildup of electrostatic charge on the body and clothing can be
avoide
d.
Do not remove self-adhesive labels, from the battery without special safety measures.
Removing plastic labels can build up electrostatic charges, which can ignite oxyhydrogen gas.
Before pulling off the label, wipe the battery moist.
18 19
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
Installation, commissioning and operating instructions for valve-regulated stationary lead-acid batteries
7140203153 V1.4 (09.2018)
3 Transportation damages
3.1 General
We take great care in packaging the batteries that we send to you so that they arrive without damage. We
strongly recommend that you inspect the delivery for possible shipping damage as soon as it arrives.
For road transportation, filled lead-acid rechargeable batteries are not treated as dangerous
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
Danger!
It is essential that loads on road vehicles are properly secured.
Attention!
Monobloc batteries/battery cells are very heavy (depending on type between ca. 10kg and max.
240kg per cell/bloc). Wear protective shoes. Use only the appropriate transportation equipment
for transport and installation.
3.2 Delivery completeness and externally visible damage
Check immediately upon delivery (while the carrier is still present) to make sure that your shipment is complete
(compare with the delivery note). In particular, check the number of battery pallets and the number of boxes
with accessories. Then inspect the goods for possible shipping damage.
Note all
– damages to the outer packaging
– visible stains or moisture that might indicate electrolyte leakage
If the delivery is incomplete or damaged as a result of shipping
– Write a short defect notice on the delivery note before signing it.
– Ask the carrier for an inspection and note the name of the inspector.
– Compose a defect report and send it to us and to the carrier within 14 days.
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 “Safety”.
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.
The sealed batteries are always filled before delivery.
Check the entire scope of delivery to make sure that it matches the detailed delivery note (or
the packing list).
Failure to promptly inform the carrier of defects or incompleteness could result in the loss of
your claims.
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.
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