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Installation

Manual_Grid_Power_FNC_en_V3_0

8.2.

Installing the Battery System

DANGER!

Risk of serious injury or death caused by high voltages and electric shocks.

Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit.



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.



Remove watches and jewellery before 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 delivered according to your order:



Filled and charged (FC)



Unfilled and uncharged (UU)



Filled and uncharged (FU)

The cells are supplied sealed with yellow transport plugs or the standard vent plugs are
already mounted.

grid|power FNC

VR cells are supplied sealed with yellow transport plugs. The VR plugs are

separately enclosed in the delivery.

Note

It is recommended to leave the yellow transport plugs on the cells until you have completed the

connection and installation of the battery system.

Содержание grid power FNC Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 _________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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