Hoppecke grid power FNC Series Manual Download Page 1

Page: 1 / 67

Manual_Grid_Power_FNC_en_V3_0

Executive
department:
SVA

Responsible
department:
SVA

Document type:
Technical Documentation

State of
confidentiality:
External

Created/changed (current Index):
2019-05-16, W. Pickart

Operation and Installation Manual

Document state
Approved

Checked (current index)
2019-06-13, I. Fuhrmann

Approved (current index)
2019-11-13, Dr. K. Gutzeit

File name:
Manual_Grid_Power_FNC_en_V3_0.doc
x

Revision:
03

Language:
EN

Page:
1

grid|power FNC

Batteries

Fibre Nickel Cadmium Batteries for Standby
Applications

Manual

Revision

Date

Name

Chapter

Reason for Changes

001

2015-07-22

I. Fuhrmann

Initial version

002

2017-10-24

I. Fuhrmann

7.1

Notes for recommissioning

003

2019-05-16

W.Pickart

All

Changes in structure chapters 2-7

Summary of Contents for grid power FNC Series

Page 1: ...Checked current index 2019 06 13 I Fuhrmann Approved current index 2019 11 13 Dr K Gutzeit File name Manual_Grid_Power_FNC_en_V3_0 doc x Revision 03 Language EN Page 1 grid power FNC Batteries Fibre N...

Page 2: ...nual is not covered by any change service Keep this documentation in such a manner that it is available immediately to all those who need to carry out work in connection with the battery system or its...

Page 3: ...ainst dangerous body contact currents 11 2 3 4 Special hazards in the event of fire 11 3 INTENDED UNINTENDED USE 12 3 1 Intended Use 12 3 2 Unintended Use 12 4 DIRECTIVES LEGISLATION AND STANDARDS 13...

Page 4: ...nitial Commissioning 34 9 1 1 Charging with Constant Current 34 9 1 2 Charging with Constant Current and Constant Voltage CCCV 35 9 2 Commissioning of Unfilled and Uncharged UU and Filled and uncharge...

Page 5: ...l 58 13 2 1 1 Visual Inspection and Checking Electrolyte Level 58 13 2 1 2 Measuring battery system voltage 59 13 2 2 Annual Maintenance Interval 60 13 2 2 1 Cleaning the battery system 60 13 2 2 2 In...

Page 6: ...authorised personnel Personnel authorised by HOPPECKE Batterie Systeme GmbH HOPPECKE experts Experts from the operator of the battery system 1 2 Means of Representation The following icons and signal...

Page 7: ...ion Definition Explanation Reconditioning Describes the defined discharge and subsequent charging of the battery with constant current This allows the capacity losses of the battery system to be elimi...

Page 8: ...ircuit Please be very careful when doing any work on the batteries in order to prevent severe injuries caused by electrical shocks or burns Never place tools or other metallic objects on a battery Rem...

Page 9: ...discharged if the housing of an grid power FNC cell is damaged It can cause severe burn injuries on the skin and to the eyes Wear safety glasses and safety gloves when working on the battery system F...

Page 10: ...the potential explosive gas mixture is discharged Note The following instructions are meant to prevent explosions caused by electrostatic discharges Source ZVEI German Electrical and Electronic Manufa...

Page 11: ...bition sign No fire naked flame or smoking Warning plate Battery Room to indicate electrolyte explosive gases dangerous voltages and currents 2 3 4 Special hazards in the event of fire Danger Wear per...

Page 12: ...ed use HOPPECKE Batterie Systeme GmbH shall not assume any liability for personal injuries or damage to property that result directly or indirectly from handling the batteries The operator shall be so...

Page 13: ...tteries containing alkaline or other non acid electrolytes Vented nickel cadmium prismatic rechargeable single cells applicable primarily to the testing of cells type test series production test and f...

Page 14: ...fiber electrodes with active material High to very high values of current can flow during charging and discharging No carbonates are formed in the electrolyte The batteries have long service life and...

Page 15: ...etween the different cell types X H M L DIN IEC 993 is valid for the production of the electrolyte When the cells are in operation the density of the standard electrolyte is 1 19 kg l 0 01 kg l at the...

Page 16: ...and refill the electrolyte level The lid contains a filter that works as backfire protection Valve regulated plug VR A low pressure valve recombines oxygen and hydrogen gasses inside the cell with up...

Page 17: ...d the battery charging current The battery only supplies power when the direct current source fails The charging voltage to be set is 1 40 1 45 V per cell x number of cells connected in series measure...

Page 18: ...time the system voltage The direct current source charging rectifier is not able to supply the maximum load current at all times The load current temporarily exceeds the rated current of the DC sourc...

Page 19: ...the consumer as required The charging voltage of the battery is max 1 50 1 60 V cell boost charge or 1 40 1 45 V cell float charge see also Section 5 3 1 The battery also can be charged with constant...

Page 20: ...advantages of the VR technology no water addition or filling is required over the service life If the operating temperature differ from the range mentioned above it is recommended to use a temperatur...

Page 21: ...n in a way that charging is only switched on again when the temperature 55 C 5 5 Battery Capacity A battery s capacity is the amount of electric charge it can deliver at the rated voltage The capacity...

Page 22: ...ing receipt and inspection of batteries the battery cells should be replaced in their original packing This provides the battery with good protection against damage while it is in storage prior to ins...

Page 23: ...t short circuit Used batteries are those that are transported for the purpose of recycling after normal use If the conditions of special regulation 598 are not complied with declare and transport new...

Page 24: ...them for defects by visually inspecting them see 10 1 Checking for Cleanliness and Condition of the Battery System on page 40 Note If you notify the freight forwarder too late of defects or incomplet...

Page 25: ...mended to use the HOPPECKE plug opener Mat No 4142500125 Alternatively use a small slot screwdriver Grab the plug with your hand and slowly twist and vertically pull out the plug from the cell opening...

Page 26: ...hree years the UU cells must be filled and a recondition charge is necessary see 10 7 Reconditioning on page 48 If you store the grid power FNC cells longer than three years contact HOPPECKE before yo...

Page 27: ...hould also be paid to the following 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 resi...

Page 28: ...n separate parts Observe the following minimum clearances Clearance between cabinet and wall min 50 mm Aisles between cabinets min 500 mm 8 1 5 Ventilation Requirements Ensure that the battery room or...

Page 29: ...ore doing any work on the batteries Do not touch any exposed battery parts connectors terminals or poles Use insulated tools and wear personal protective equipment The grid power FNC cells are deliver...

Page 30: ...d power FNC cell up to the minimum level 10 mm Note Topping up with electrolyte to the maximum level takes place after the commissioning of the battery system see 9 Commissioning on page 33 3 Let the...

Page 31: ...t be clean and free from any traces of corrosion 2 Connect the grid power FNC cells to each other to form a row 1 screw 2 spring washer 3 connector 4 terminal Note Use spring washers Spring washers en...

Page 32: ...ew 5 washer 6 terminal 7 connection bracket 8 spring washer 9 screw Note Ensure that the wiring of the row and end connectors is proof against short circuits Use wiring material with at least 3 kV die...

Page 33: ...rogen gas When the cells are charged water is decomposed and a hydrogen oxygen gas mixture oxyhydrogen gas is formed which already explodes with low energy input Keep any source ignition away from the...

Page 34: ...ws the charge voltage of one cell depending on time during charge with constant current I5 for 7 5 hours Note Voltages up to 1 9 V per cell can occur during the initial charging with constant current...

Page 35: ...n as the voltage limitation takes place the charging current decreases automatically The following table shows the specified charging time for charging with limited charging voltage Voltage V Time h C...

Page 36: ...e wait at least 12 hours before you begin with the commissioning works 1 Remove the transport plug of each grid power FNC cell 2 Recommended Insert a gas venting tube on each grid power FNC cell HOPPE...

Page 37: ...xxxxx2610 production week 26 Production year 2010 DANGER Danger of explosion due to formation of oxyhydrogen gas When the cells are charged water is decomposed and a hydrogen oxygen gas mixture oxyhyd...

Page 38: ...he warmest possible location of the system 7 Charge the battery system using a constant current of I5 for 7 5 hours ATTENTION The battery system must not exceed a temperature of 45 C during charging O...

Page 39: ...or stored The following table shows the measures for preventive maintenance Activity Interval Reference Visual inspection of the battery system and the FNC cells 6 months 10 1 Checking for Cleanliness...

Page 40: ...ensure high availability required but is also an essential part of accident prevention regulations 1 Keep the cells of the battery system clean and dry since dust and moisture can lead to leakage curr...

Page 41: ...maximum level refer to 10 6 Fill up the Electrolyte Level with Distilled Water on page 46 The difference between the FNC cells must be not greater than 5 mm If the level of the electrolyte is not visi...

Page 42: ...217 5 Middle between Min and Max 19 Maximum level 276 15 Middle between Min and Max 36 Maximum level 373 22 5 Middle between Min and Max 55 Maximum level 5 If the level is higher than the middle betw...

Page 43: ...ice and is being charged DANGER Depending on installation conditions there can be a risk of death or severe injuries when establishing access to or accessing the battery system Carry out the prescribe...

Page 44: ...METRAWATT METRISO 5000 D PI Nominal battery voltage 500 V set the measuring device to 500 V DC 1 minute Nominal battery voltage 500 V set the measuring device to 1000 V DC 1 minute ATTENTION An insula...

Page 45: ...e cell plugs or transport plugs 1 Clean the battery with a clean damp cloth and with water without adding any detergents or cleaning agents 2 Rinse off the cell plugs with water if this is necessary 3...

Page 46: ...use a small slot screwdriver Grab the plug with your hand and slowly twist and vertically pull out the plug from the cell opening Wear personal protective equipment because grid power FNC VR cells ope...

Page 47: ...imum electrolyte levels according to the cell type to distinguish by the enclosure height Enclosure height mm Maximum level measured with the glass tube for measuring mm 217 19 276 36 373 55 ATTENTION...

Page 48: ...tem WARNING Contact with the electrolyte can happen when measuring the electrolyte level It can cause severe chemical burns to the skin and severe damage to the eyes Wear safety glasses and safety glo...

Page 49: ...The individual cell voltages should not vary by more than 50 mV from the mean of all cell voltages If the open circuit voltage of a cell is 1 2 V contact HOPPECKE service 4 It is recommended to inser...

Page 50: ...d This is the capacity test Note If the battery system takes 5 hours to drop 1 0 V per grid power FNC cell its capacity is 100 5 hours 100 4 hours 80 3 hours 60 11 Allow the battery system to rest for...

Page 51: ...page 46 17 Remount the plugs to the FNC cells 18 Measure the voltages of the individual cells using a digital multimeter Note If the individual cell voltages vary by more than 50 mV from the mean of a...

Page 52: ...circuits in one or more cells Measure the individual cell voltages Change the defect cell s Various charge states of the cells Run a reconditioning charge Insulation resistance is too low See 11 4 In...

Page 53: ...sconnect any supply and load cables fuses Based on the content of cadmium and caustic potassium grid power FNC batteries must not be disposed of at the end of their service life with household waste C...

Page 54: ...Customer Order No Where installed Supplier Battery No Cell type No of cells Capacity Ah Charging voltage tick and fill out Charging with constant current I5 Charging with constant current and constan...

Page 55: ...ging Charger current A Temperatures Start of charging End of charging Ambient C Electrolyte C of pilot cell number Loading time from to Date Time h Commissioning confirmation Date Signature Commission...

Page 56: ...surement of individual cell voltages Cell No Open terminal voltage V End of charge voltage 15 min before end of charging V Cut off voltage after 5 hours discharge V Hint Reproduce this page according...

Page 57: ...n_V3_0 57 13 2 Maintenance Log Note Keep this maintenance log to provide a proof in case of warranty Number of the battery system _________________________________________ Commissioning date _________...

Page 58: ...Six monthly Maintenance Interval 13 2 1 1 Visual Inspection and Checking Electrolyte Level Interval years Done mark with a cross Date Inspector name 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 6 5 7 7 5 8 8...

Page 59: ..._Power_FNC_en_V3_0 59 13 2 1 2 Measuring battery system voltage Interval years Measured value in Volt Date Inspector name 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 6 5 7 7 5 8 8 5 9 9 5 10 10 5 11 11 5 12 1...

Page 60: ...pendix Manual_Grid_Power_FNC_en_V3_0 60 13 2 2 Annual Maintenance Interval 13 2 2 1 Cleaning the battery system Interval years Done mark with a cross Date Inspector name 1 2 3 4 5 6 7 8 9 10 11 12 13...

Page 61: ...Appendix Manual_Grid_Power_FNC_en_V3_0 61 13 2 2 2 Insulation testing Interval years Measured value in Ohm Date Inspector name 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 62: ...Appendix Manual_Grid_Power_FNC_en_V3_0 62 13 2 2 3 Filling up distilled water Interval years Done mark with a cross Date Inspector name 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 63: ...Appendix Manual_Grid_Power_FNC_en_V3_0 63 13 2 3 Maintenance Interval Every 5 Years 13 2 3 1 Reconditioning Interval years Done mark with a cross Date Inspector name 5 10...

Page 64: ...l Voltages Interval years Cell number Measured value in Volt Cell number Measured value in Volt Cell number Measured value in Volt 5 Date ______________________ Inspector ______________________ Hint R...

Page 65: ...ars Cell number Measured value in Volt Cell number Measured value in Volt Cell number Measured value in Volt 10 Date ______________________ Inspector ______________________ Hint Reproduce this page ac...

Page 66: ...ntenance and service Tool Description Voltmeter multimeter illustration shows an example Insulation tester illustration shows an example External charge discharge unit illustration shows an example Wa...

Page 67: ...NC_en_V3_0 67 Gas venting tube HOPPECKE Mat No 4143180100 Cell lifter Format 3 4 5 M10 HOPPECKE Mat No 4141900003 Format 1 2 M8 HOPPECKE Mat No 4141900002 Plug opener for cells with valve plug VR plug...

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