Table of contents

1 Preface ............................................................................................................. 4
2 Safety notices ................................................................................................... 5
2.1 Explanation of the symbols used in the manual ............................................ 5
2.2 Explanation of the symbols used on the battery ............................................ 5
2.3 General information ................................................................................... 6
2.4 Personal Protective Equipment, Safety Clothing, Equipment ......................... 7
2.5 Safety precautions ..................................................................................... 7
2.5.1 Sulfuric acid........................................................................................ 7
2.5.2 Explosive Gase .................................................................................... 8
2.5.3 Electrostatic discharges ...................................................................... 8
2.5.4 Electric shock and burns ..................................................................... 9
3 General information ........................................................................................ 10
3.1 Specifications .......................................................................................... 10
3.2 Disposal and Recycling ............................................................................. 11
3.3 Service .................................................................................................... 12
3.4 Warranty .................................................................................................. 12
3.5 References to the standards and regulations .............................................. 13
3.6 CE and UKCA marking .............................................................................. 14
4 Transport ........................................................................................................ 14
4.1 General information ................................................................................. 14
4.2 Delivery completeness and externally visible damage ................................. 15
4.3 Defects ................................................................................................... 15
5 Storage ........................................................................................................... 15
5.1 General information ................................................................................. 15
5.2 Storage time ............................................................................................ 16
5.3 Recharge ................................................................................................. 17
6 Installation ..................................................................................................... 18
6.1 Requirements for the installation site ........................................................ 18
6.1.1 Ventilation of the battery room ........................................................... 19
6.1.1.1 Avoidance of explosion hazards ...................................................... 20
6.1.1.2 Calculating Ventilation Requirements for Battery Rooms .................. 20

1
 6.1.2 Calculating the safety distance .......................................................... 22
6.2 Tools and equipment to carry out the installation........................................ 23
6.3 Commissioning and maintenance protocol ................................................ 24
6.4 Installing racks and cabinets ..................................................................... 24
6.5 General information on connecting the batteries ........................................ 25
6.6 Installing the batteries .............................................................................. 26
6.6.1 Inserting batteries into the racks ......................................................... 27
6.6.2 Horizontal Installation ....................................................................... 28
6.6.3 Open-circuit voltage measurement .................................................... 30
6.6.4 Connecting batteries ......................................................................... 31
6.6.4.1 Connection Terminals .................................................................... 31
6.6.4.2 Type of connecting cables .............................................................. 31
6.6.5 Connect batteries to battery connectors ............................................. 32
6.6.6 Installing the screw connectors .......................................................... 32
6.6.7 Clamp the connection plates to the batteries ...................................... 34
6.6.8 Connect the battery system to the DC power supply ............................ 36
6.7 Commissioning charge (initial charge) ....................................................... 37
6.7.1 Commissioning charge with constant voltage (IU characteristic curve).. 37
6.7.2 Extended commissioning charge ........................................................ 38
7 Battery operation ............................................................................................ 38
7.1 Modes ..................................................................................................... 38
7.1.1 Standby parallel operation ................................................................. 38
7.1.2 Floating operation ............................................................................. 39
7.1.3 Switch mode operation (charge/discharge operation) ........................... 39
7.2 General information on the operation ........................................................ 40
7.2.1 Discharging....................................................................................... 41
7.2.2 Charging – General ............................................................................ 41
7.2.3 Float charging ................................................................................... 42
7.2.4 Equalizing charge (correction charge) ................................................. 43
8 Battery maintenance ....................................................................................... 45
8.1 Cleaning the battery ................................................................................. 45
8.2 Check the battery system ......................................................................... 46

2
 8.2.1 Preparing the battery system for capacity testing ................................. 46
8.2.2 General information on how to carry out the capacity check ................. 48
8.2.3 Implementation of the capacity test and evaluation ............................. 49
8.3 Notes on impedance measurement........................................................... 51
9 Troubleshooting .............................................................................................. 51
9.1 Scattering of the individual cell voltages .................................................... 51
9.2 Available capacity too low......................................................................... 52
9.3 Insulation resistance too low .................................................................... 52
9.4 Battery voltage not measurable ................................................................. 52
9.5 Replacement of a cell/battery in the string ................................................. 52
10 Disassembly ............................................................................................... 53
11 Parameter data sheet for sun | power VR batteries ......................................... 55

3
1 Preface
Dear customer,

Thank you very much for choosing a product from our company.

Before carrying out any activities related to lead-acid batteries, we ask you to read this
documentation carefully and calmly. It contains important information on the safe and
professional unpacking, storage, installation, commissioning, operation and maintenance of
lead-acid batteries. Failure to follow the safety instructions can lead to serious personal injury
and property damage. We assume no liability for direct and indirect damage resulting from
improper handling and any warranty claim expires.

We reserve the right to make changes to the content of this documentation. HOPPECKE Batterien
GmbH & Co. KG is not liable for any errors in this documentation. Liability for indirect damages
arising in connection with the use of this documentation is also excluded. Our products are
constantly evolving. Therefore, there may be discrepancies between the representations in this
documentation and the product you purchased.

Please keep this documentation in such a way that it is immediately available to all persons who
need to carry out activities related to the batteries.

If you have any questions, we will be happy to help you. You can reach us at the following e-mail
address:
info@hoppecke.com
or by telephone on working days between 8.00 a.m. and 4.00 p.m. (CET) at
Phone +49(0)2963 61-0
Fax +49(0)2963 61-481.

Your team of
HOPPECKE Batterien GmbH & Co. KG

Mailing address:
HOPPECKE Batterien GmbH & Co. KG
Postfach 11 40
D-59914 Brilon

Address headquarters:
HOPPECKE Batterien GmbH & Co. KG
Bontkirchener Straße 1
D-59929 Brillon-Hopecke
Telephone +49(0)2963 61-0
Fax +49(0)2963 61-449
Internet www.hoppecke.com
E-Mail info@hoppecke.com

4
2 Safety notices
When handling the batteries and their components, observe the following safety
instructions. Please also note the information in the ZVEI leaflet "Information on the safe
handling of lead-acid batteries (lead-acid batteries)".

2.1 Explanation of the symbols used in the manual

Danger from explosion, pressure
There is a risk to the health of persons,
waves, hot or molten substances flying
to the battery(s) or to the environment.
around. Explosion and fire hazard,
Failure to comply with these hazard
avoid short circuits. Failure to comply
warnings can result in serious injury or
Danger! with these hazard warnings can result
even death.
in serious injury or even death.
There is a risk to the battery(s), to
objects or to the environment. Dangers
to people are not to be expected.
Risk of chemical burns due to leaking
Failure to do so may result in
electrolyte. Electrolyte is highly
malfunctions and damage to the
corrosive.
Attention! battery(s). Furthermore, property
damage and environmental damage
can occur.
Danger to life and health due to
electrical voltages. Failure to comply
Warning of battery hazards.
with these hazard warnings can result
in serious injury or even death.

No smoking. No open flame, embers

Recycling/Reuse or sparks near the battery, as there is a
risk of explosion and fire.

Use protective clothing Wear conductive footwear.

Use eye protection Use face shields

Use handguards Hint

Lead-acid batteries that are not used

in the recycling process must be
Take first aid measures
disposed of as hazardous waste in
compliance with all regulations.

2.2 Explanation of the symbols used on the battery

Danger of explosion. Avoid short

Warning of a danger spot.
circuits

5
 Danger from electrical voltage. Risk of chemical burns due to leaking
electrolyte.

Wear safety goggles when handling

Avoid open flames and sparks.
battery cells/blocks.

Observe the operating instructions for

assembly, commissioning and Battery with low antimony content.
operation.

Used batteries that cannot be recycled

must be disposed of as hazardous
Recycling/Reuse
waste in compliance with all
regulations.

2.3 General information

As a result of damage to the battery housing, very small amounts of electrolyte or
hydrogen gases can escape from sealed lead-acid batteries. Therefore, always follow the
usual safety precautions for handling lead-acid batteries.

Lead-acid batteries contain lead metal (CAS No. 7439-92-1), a substance

on the REACH Candidate List.
Attention!
Improper use of the products described here may result in personal injury
and property damage.
In the event of improper use, HOPPECKE assumes neither responsibility
Danger!
nor liability for direct or indirect personal injury or property damage
resulting from the handling of the products described here.

Without proper and regular maintenance of the batteries by HOPPECKE

specialists (or personnel trained by HOPPECKE), the safety and reliability
of the power supply in an emergency may not be guaranteed.
Attention!
Work on batteries, in particular their installation and maintenance, may
only be carried out by trained HOPPECKE specialist personnel (or
personnel trained by HOPPECKE) who are familiar with the handling of
Danger!
batteries and know the necessary precautions.

Please also observe all regulations, writings and standards, as described in chap. 3.5 .

Risk of fire, explosion or burns. Do not disassemble, heat above 45°C or

burn.
Danger!

6
2.4 Personal Protective Equipment, Safety Clothing, Equipment
When working on batteries, wear face protection
(impact-resistant visor according to EN 166 Class
F or comparable), safety goggles, protective
gloves and protective clothing!
Observe the accident prevention regulations as
well as DIN EN 50110-1 and IEC 62485-2
(stationary batteries) or IEC 62485-3 (traction
batteries).
When handling lead-acid batteries, at least the following equipment must be available:

• Voltage-insulated tool
• Rubber gloves
• Safety shoes
• Fire extinguisher
• Rubber apron
• Goggles
• Face protection (impact-resistant visor according to EN 166 class F or
comparable)
• Face mask
• Emergency eyewash (recommended)

To avoid electrostatic charging when handling batteries, textiles, safety

shoes and gloves must have a surface resistance < 108 ohms and an
insulation resistance ≥ 105 ohms (see IEC 62485-2 and DIN EN ISO
20345:2011
Personal protective equipment – safety shoes). If possible, wear so-called
ESD shoes.

Put down watches, rings, necklaces, jewelry and other metal objects when
working with batteries.
Never smoke in the immediate vicinity of batteries, handle open flames or
Danger!
generate sparks.
Never place tools or metal parts on batteries.

The use of proper tools and protective equipment can prevent injuries or mitigate the
consequences of injury in the event of an accident.

2.5 Safety precautions

2.5.1 Sulfuric acid
Sealed lead-acid batteries are safe when handled properly. However, they contain dilute
sulfuric acid (H2SO4), which is bound in gel or fleece. The bound sulfuric acid can cause
severe chemical burns and serious injuries.

7
2.5.2 Explosive Gase
Inside lead-acid batteries is an explosive hydrogen/oxygen-gas mixture that
can leak out of the battery. In the event of an explosion of the mixture,
serious personal injury can occur due to flying particles.
Danger!
• Always wear prescribed protective clothing (face protection (impact-
resistant visor according to EN 166 Class F or comparable), safety
goggles, voltage-insulating gloves and safety shoes, etc.)
• Use only proper tools ("non-sparking", with voltage-insulated
handles, etc.)
• Prevent any ignition sources such as sparks, flames, arcs
• Prevent electrostatic discharge. Wear cotton clothing and ground
yourself, if necessary, when working directly on the batteries

In the event of a fire, extinguish exclusively with water or CO2! Do not point
the fire extinguisher directly at the battery(s) to be extinguished. There is a
risk that the battery housing will crack as a result of thermal stress.
Danger!
Furthermore, there is a risk of explosion due to possible static charges on
the battery surface. Turn off the battery charging voltage.
Use breathing apparatus with a self-sufficient breathing air supply during
extinguishing work. When using extinguishing water/foam, there is a risk of
reactions with the electrolyte and, as a result, violent splashing. Therefore,
wear acid-resistant protective clothing.
When plastic material is burned, toxic fumes can be produced.
In this case, leave the scene of the fire as quickly as possible, unless you are
wearing the above-mentioned breathing apparatus.

When using CO2 fire extinguishers, there is a risk that the battery will
explode as a result of static charge!
Please also note the information in the ZVEI leaflet "Information on the safe
Danger!
handling of lead-acid batteries (lead-acid batteries)".

2.5.3 Electrostatic discharges

All lead-acid batteries develop hydrogen and oxygen gas, also known as oxyhydrogen gas,
during operation, but especially during charging. These gases escape from the batteries
into the environment. In the case of natural or forced ventilation, which must always be
provided, it must be assumed that an ignitable hydrogen-oxygen-gas mixture is only
present in the vicinity of the battery cell openings. Inside the battery housing itself there
is always an ignitable hydrogen-oxygen-gas mixture.

This is true regardless of battery technology, design or manufacturer and is typical of all
lead-acid batteries. The energy required to ignite oxyhydrogen is very low and can be
released or supplied in the following ways:

8
Open flames or fire, smoldering sparks or flying sparks during grinding work, electrical
sparks from switches or fuses, hot surfaces > 200 °C and – an often-underestimated
cause – electrostatic discharges.

Measures to avoid oxyhydrogen ignition due to electrostatic discharges:

Please note the following points to avoid electrostatic discharge on the battery, your body
or your clothing:

• Do not rub the battery with dry cloth, especially not with a cloth made of synthetic
material! Rubbing on plastic surfaces (battery housings are usually made of
plastic) generates electrostatic charges.
• Clean battery surfaces only with cotton cloths moistened with water. When wiping
with moistened cotton cloths, no charges are built up.
• When working on batteries, avoid letting your clothing (e.g. wool) rub against the
battery, as this can build up electrostatic charges on the battery housing or on your
body or clothing.
• Wear shoes and clothing with special surface resistance to avoid electrostatic
charges on your body or clothing.
• Do not remove labels stuck to the battery without special safety precautions.
Removing or peeling plastic labels from plastic surfaces can lead to the
accumulation of electrostatic charges, which can ignite oxyhydrogen when
discharged.

Wipe the battery with a damp cloth before removing the label.

2.5.4 Electric shock and burns

Before making the connections, check the correct polarity of the batteries!

Batteries can cause severe electric shocks. In the event of a short circuit,
Danger!
very high currents can flow. Do not touch bare battery parts, connectors,
terminals and poles. In the case of battery installations with a nominal
voltage of more than 1500 V DC, devices for separation into groups of cells
of less than 1500 V DC must be available. Be very careful when working on
the battery system to prevent serious injury from electric shock and burns.

Always wear prescribed protective clothing (voltage-insulating rubber

gloves, rubber shoes, etc.) and only use tools that are made of non-
conductive material or are stress-insulated.

Put down watches, rings, necklaces, jewelry and other metal objects when
working with batteries.

9
Before performing any work on the battery system:

Check if the battery system is grounded, which we generally do not recommend. If this is
the case, disconnect the connection. Unintentional contact with a grounded battery can
result in severe electric shock. This risk can be significantly reduced without an earth
connection. The racks or cabinets used to hold batteries must be properly grounded or
fully insulated in accordance with IEC 62485-2.

In the case of a grounded battery system ...

There is tension between the earth and the ungrounded pole. If this pole is
touched by a grounded person, there may be a danger to life! There is also a
risk of a short circuit if dirt and acid deposits on the ungrounded terminal
come into contact with the battery rack.

If there is an (unintentional) additional ground fault via some cells within the
(grounded) battery system, there is a risk of short circuits or fire and
explosion.

In the case of an ungrounded battery system ...

If there is an unintentional ground fault within the battery system, there is

an electrical voltage between the earth and the ungrounded pole. The
voltage can sometimes be dangerously high – danger to life due to electric
shock.

If there is also a second unintentional earth fault, there is a risk of short

circuit or fire and explosion.

If you have any questions about the above or any other questions related to safety when
working on a battery system, please contact your local HOPPECKE dealer. Alternatively,
you can reach us directly at the head office.

3 General information
HOPPECKE offers numerous lead-acid batteries as a single cell (nominal voltage 2 V) or
block (nominal voltage: 4 V, 6 V or 12 V) for a wide variety of applications.

3.1 Specifications
Each cell/battery block has its own nameplate on the top of the cell/block cover. Below
is an example.

10
Figure 3-1 - Nameplate

The details on the nameplate are: grid power V L 2-215

DIN designation 4 OPzS 200
4 OPzS 200 = Number of positive plates
4 OPzS 200 = Design
4 OPzS 200 = Capacity according to DIN C10
d = Electrolyte density
Ufloat = Float charge voltage
T = Reference temperature
213 Ah = Actual capacity C10 (capacity when discharged with
ten-hour current (I10))

3.2 Disposal and Recycling

Used batteries with this symbol are recyclable assets and must be fed into
the recycling process.

Used batteries that are not used in the recycling process must be disposed
of as hazardous waste in compliance with all regulations.

HOPPECKE offers its customers its own battery take-back system. Taking into account:

• Of the Circular Economy and Waste Act

• The Battery Regulation
• The Transport Permit Ordinance
• In accordance with the principles of general environmental protection and our
corporate guidelines, we supply all lead-acid batteries to the secondary lead
smelter at the Hoppecke site.

The HOPPECKE metal smelter is the only lead smelter in Europe to be successfully
certified according to:

• DIN EN ISO 9001 (Procedures and Procedures)

• DIN EN ISO 14001 (Environmental Audit)

11
 • Waste Management Company Ordinance for Waste Management Specialist with
all associated waste codes for storage, treatment and recycling.

For more information, please call: +49(0)2963 61-280.

3.3 Service
HOPPECKE has a worldwide service network that you should take advantage of. The
HOPPECKE service is available to you if you would like to have professional supervision
during the installation of the battery system, if you need parts or accessories or if
maintenance work must be carried out on the system. Please contact us or your local
HOPPECKE contractual partner about this.

The HOPPECKE service number is:

Phone +49(0)800 246 77 32
Fax +49(0)2963 61-481
E-Mail service@hoppecke.com

3.4 Warranty
Commissioning and maintenance must be documented. For this, you can use our
template, which you can find here:

service_maintenance_comissioning_protocoll_en_de.pdf (hoppecke.com)

or via the QR code:

Alternatively, you can use your own templates, as long as they contain the necessary data
fields. This documentation should be kept together with the other battery
documentation.

Note: Acid density fields are not required for VRLA (sealed lead-acid batteries) products
and can be left empty.

For warranty claims, the documentation must be submitted to the manufacturer. Battery
performance and service life, especially in terms of charging, temperature and cycles,
affect the warranty. The customer/battery operator must prove that the parameters were
within the recommended ranges. The protocols must be made available to the
manufacturer. The service life only applies under optimal conditions.

HOPPECKE recommends the use of a stationary battery monitoring system. For more
information, please contact your local HOPPECKE representative.

12
Information about sun | power batteries

For special applications, such as solar and off-grid applications, the service life is
strongly influenced by the operating factors. In order to determine whether a battery fault
has been caused by manufacturing defects or operation, the parameters must be
recorded and secured regularly. This data must be forwarded to the manufacturer for
analysis.

3.5 References to the standards and regulations

The references to the applicable standards, regulations, etc. should help you to install
and use the HOPPECKE products correctly. However, it is not possible to always cite all
regulations and applicable standards according to the current edition. Therefore, these
instructions are to be understood as support and not as direct instructions. In order to
implement the requirements of the standards/regulations, the current and applicable
standard or regulation must be available, regardless of the edition of the
standard/regulation manually quoted here in HOPPECKE.

Please note the following regulations (IEEE standards only apply to the USA):

• 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 secondary 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”

When working on batteries, always observe the safety regulations documented in DIN EN
50110-1 “Operation of electrical installations”:

o Always proceed in the correct order when installing and removing the
battery and when connecting it to the charger
o Pay attention to polarity.

13
 o Make sure that the connections are tight.
o Only use technically flawless charging cables in sufficient cross-sections.
o Batteries must not be connected or disconnected while power is flowing,
or the charger is on.
o Before opening the charging circuit, check the switched off state of the
charger by voltage measurement.
o Secure the charger against reconnection.
o Observe the operating instructions of the charger manufacturer.

3.6 CE and UKCA marking

For batteries that cover a voltage range of 4 V to 1500 V DC, a CE declaration of conformity
is required in accordance with the Battery Regulation EU 2023/1542. In addition, the
requirements of the Low Voltage Directive 2014/35/EU must be observed for battery
systems with a nominal voltage of 75 V to 1500 V DC. The labelling requirement also
applies to the UK, but the associated declarations of conformity must bear the UKCA
mark by 31.12.2024 in accordance with The Electrical Equipment (Safety) Regulations
2016. The installer of the battery system is responsible for issuing the CE or UKCA
declaration and affixing the CE or UKCA marking on or next to the battery's nameplate.

Use the QR code or this link to access the performance and lifetime data provided in
accordance with Battery Regulation EU2023/1542 (Attachment IV, Part A):

4 Transport
4.1 General information
We pack the batteries that are shipped with the greatest possible care so that they arrive
undamaged. Nevertheless, we strongly recommend that you inspect the delivery
immediately upon arrival for any transport damage.

Filled lead-acid batteries are not treated as dangerous goods during road transport if:

• They are undamaged and leak-proof

• They are protected against falling over, slipping and short circuits
• They are firmly bound to a pallet
• There are no dangerous traces of acid or alkali etc. on the outside of the package

14
 When transporting trucks, careful load securing is essential!

Danger!
Block batteries/cells have a high weight (depending on the type between
approx. 3 kg and max. 1100 kg per cell/block), please use safety shoes. Use
only suitable transport equipment for transport and assembly!
Attention!

4.2 Delivery completeness and externally visible damage

Check the delivery for completeness immediately after arrival, while the carrier is still
present, using the delivery note. Pay special attention to the number of battery pallets
and the boxes with accessories. Then check the goods for possible transport damage.

Make a note if necessary

• Damage to the outer packaging

• Visible stains or moisture that could indicate leaked electrolytes

In the event of incomplete delivery or transport damage

• Write a short defect report on the delivery note before signing it

• Ask the carrier for an audit and make a note of the name of the examiner
• Write a defect report, which you will forward to us and the forwarding company
within 14 days

4.3 Defects
Take all necessary safety measures to avoid electric shock. Remember that
you are handling energized batteries!

Unpack the goods as soon as possible after delivery and check them for defects,
especially if commissioning is planned soon.

Check the entire scope of delivery using the detailed delivery note (or packing list). If
defects or incompleteness are reported to the carrier too late, this may result in the loss
of your claims. If you have any questions in connection with incompleteness of the
delivery or damage to the delivered products, please contact your local HOPPECKE
contractual partner. Alternatively, you can reach us directly at the head office.

5 Storage
5.1 General information
After receiving them, you should unpack, install and charge the batteries as soon as
possible. If this is not possible, store the batteries in a fully charged state in a clean, dry,

15
cool and frost-free room and do not expose the batteries to direct sunlight. During
storage, batteries lose capacity due to self-discharge. High storage temperatures
increase self-discharge and reduce the permissible storage time.

Do not stack the pallets with the batteries, as this may cause damage
that is not covered by the warranty.
Attention!

5.2 Storage time

The Figure 5.2-1 shows the relationship of the available capacity over the
storage time, as well as the maximum storage time for different storage
temperatures. When calculating the exact time, use the commissioning
Attention!
date in production (according to the imprint on the cell/block). In order to
prevent damage, the batteries must be recharged in accordance with
chap. 5.3.
Failure to observe this can lead to sulphation of the electrodes and
consequently to a loss of performance and a shorter service life of the
battery. Recharging during the storage period should be done a maximum
of two times. The battery must then be operated in constant charge
maintenance. The useful life of the battery(s) begins with delivery from the
HOPPECKE factory. Storage times on site are to be fully credited towards
the useful life.

If a longer storage period (e.g. several months) is planned, it is

recommended that you obtain a suitable charger in good time so that the
above-mentioned recharging can be carried out. The batteries should be
arranged in such a way that they can be provisionally connected in series
for charging. Leave them on their pallets until they are finally installed.
If batteries need to be cleaned during storage, never use detergents, but
cotton cloths soaked in water without additives.
Failure to comply with the recharging intervals voids the warranty claim.

16
 Figure 5.2-1 - Capacity over storage time

5.3 Recharge
Perform the recharge as follows:

1. The permissible temperature range for recharging is 15°C to 35°C.

2. Charging with IU characteristic curve, up to max. 2.40 V/cell up to 24 hours. The
charging current must not be higher than 20 A per 100 Ah nominal capacity.
3. When charging temporarily connected batteries, make sure that there is
sufficient ventilation (see chap. 6.1.1).

If the maximum storage time is exceeded and/or at higher average storage

temperatures, charge acceptance may be more difficult during recharging.
In such cases, HOPPECKE recommends the use of an advanced charging
Attention!
method that ensures gentle and complete recharging of the blocks/cells.

Advanced charging method:

Charge with const. current of 1 A or 2 A per 100 Ah C10 battery capacity.
Termination of charge when all cell voltages have risen to at least 2.65
V/cell.

17
6 Installation
6.1 Requirements for the installation site
If you have any questions about the installation of the battery system, please contact
your local HOPPECKE dealer. Alternatively, you can reach us directly at the head office.

When determining the installation location and space requirements and when carrying
out the installation work, please refer to the valid installation drawing, if available. The
floor must be suitable for the installation of the batteries, i.e:

• Suitable load capacity

• Electrolyte-resistant installation surface (otherwise use of acid drip trays) with
vented batteries
• Sufficient conductivity of the floor against the grounded point, measured
according to IEC 61340-4-1:
o for a nominal voltage of the battery ≤ 500 V: 50 kΩ ≤ R ≤ 10 MΩ
o for a nominal voltage of the battery > 500 V: 100 kΩ ≤ R ≤ 10 MΩ
• At ground level
• As vibration-free as possible (otherwise the use of special racks is necessary)

Within the EU, follow VDE 0510-485-2: April 2019, corresponding. IEC 62485-2 "Safety
requirements for batteries and battery installations – Part 2: Stationary batteries".
Table 6.1-1 - Installation site requirements

Request Our recommendation

Ventilation Sufficient room ventilation is absolutely
necessary to keep the hydrogen
concentration (H2 concentration) in the
Danger!
room air of the battery room at a value < 4%
by volume.
Hydrogen is lighter than air! It is imperative
to ensure that hydrogen accumulation (e.g.
in the ceiling area) cannot occur. Ventilation
openings should therefore be installed in
the immediate ceiling area.
Environment The environment must be clean and dry. Water, oil and
dirt residues on the cell surface must be avoided and, if
necessary, removed immediately.
Aisle width/ minimum See IEC 62485-2
distances
Access door Lockable and fire retardant (T90).
Lighting Recommendation: at least 100 lx.
Marking Warning signs corresponding. IEC 62485-2.

18
 Warning of electrical
voltage is only necessary if
battery voltage is > 60 V
DC.
Danger of explosion No ignition sources (e.g. open flames, bulbs, electrical
switches, sparks) in the vicinity of the cell openings.
Ambient temperature The specified operating temperature is 20 °C (based on
IEC 60896). Higher temperatures shorten the service life.
All technical
Dates apply to the nominal temperature of 20 °C. Lower
temperatures reduce the available capacity. Exceeding
the limit temperature of 55 °C is not permitted.
Continuous operating temperatures of 45 °C or more
must be avoided. Batteries must not be exposed to direct
sunlight or other heat sources.
Ambient air The air in the battery compartment must be free of
contaminants, such as suspended solids, metal particles
or flammable gases.
The humidity should be a maximum of 85%.
Insulation resistance The minimum insulation resistance between the battery
circuit and other local conductive parts must be greater
than 100 Ω per volt (the nominal voltage of the battery).
Earthing If the racks or battery cabinets are to be grounded, there
must be a connection to a reliable earthing point.
Accommodation of the We recommend the proper installation of the batteries in
batteries HOPPECKE battery racks or cabinets. The use of
operator-owned solutions may void the warranty for
batteries.
Country-specific. In some countries, it is mandatory that racks with the
regulations batteries be installed in drip trays. Please observe the
local regulations and, if necessary, contact your local
HOPPECKE contractual partner.

6.1.1 Ventilation of the battery room

It must be ensured that the requirements of IEC 62485-2 regarding installation and
ventilation are complied with. If, during commissioning charging, the charging current is
higher than the current used as a basis for the design of the ventilation equipment, the
ventilation of the battery room must be increased for the duration of commissioning and
for one hour thereafter in accordance with the charging current used, e.g. by means of
portable auxiliary fans. The same applies to occasional special charging treatments of
batteries.

19
6.1.1.1 Avoidance of explosion hazards
As the gases produced when charging batteries cannot be avoided, the hydrogen
concentration must be diluted by sufficient ventilation. Spark-generating equipment is
not permitted in the vicinity of batteries.

Ignition sources for oxyhydrogen explosions can be:

• Open flame
• Flying sparks
• Electrical, spark-forming equipment
• Mechanical, spark-forming equipment
• Electrostatic charge

Measures to prevent oxyhydrogen explosions:

• Adequate natural or forced ventilation

• No heating with an open flame or incandescent body (T > 300 °C)
• Separate battery compartments with separate ventilation
• Antistatic clothing, shoes and gloves (in accordance with the currently valid DIN
EN 1149-1)
o Surface leakage resistance < 108 Ω and insulation resistance ≥ 105 Ω
• Hand lamps with mains cable without switch (protection class II)
• Or hand lamps with battery (IP54 protection)
• Warning and prohibition signs

The ventilation requirements for battery compartments, cabinets or compartments

result from the required dilution of the hydrogen produced during charging and the safety
factors, which include the aging of the battery and the possibility of failure ("worst case").

6.1.1.2 Calculating Ventilation Requirements for Battery Rooms

Air Volume Flow Q:
𝑪
𝑸 = 𝒗 × 𝒒 × 𝒔 × 𝒏 × 𝑰𝑮𝒂𝒔 ×
𝟏𝟎𝟎𝟎𝑨𝒉
𝒗= Dilution factor = 96 % air / 4 % H2 = 24

𝒒= Amount of hydrogen produced = 0.42 10–3 m3/Ah hydrogen produced at 0°C

(Note: For calculations at 25 °C, the value q for 0 °C must be multiplied by a factor
of 1.095.)

𝒔= Safety factor = 5

𝒏= Number of cells

𝑰𝑮𝒂𝒔 = Gassing current per 100 Ah

20
𝑪= Nominal capacity of the battery

Summary of factors:

𝒗 × 𝒒 × 𝒔 = 𝟎, 𝟎𝟓

𝑪 𝒎𝟑
𝑸 = 𝟎, 𝟎𝟓 × 𝒏 × 𝑰𝑮𝒂𝒔 × 𝒎𝒊𝒕 𝑸 𝒊𝒏 ,𝑰 𝒊𝒏 𝑨
𝟏𝟎𝟎𝟎𝑨𝒉 𝒉 𝑮𝒂𝒔
𝑰𝑮𝒂𝒔 = 𝑰𝒇𝒍𝒐𝒂𝒕 𝒃𝒛𝒘. 𝑰𝒃𝒐𝒐𝒔𝒕 × 𝒇𝒈 × 𝒇𝒔

Table 6.1-2 - Indicative values for current (extract from IEC 62485-2)

Parameter Lead-acid batteries Lead-acid

vented cells Sb < 3 % batteries VRLA
(antimony content in cells
the positive grid < 3 %)
𝒇𝒈 : Gas emission factor 1 0,2
𝒇𝒔 : Safety factor for gas emission
5
(includes 10% defective cells and 5
aging)
𝑼𝒇𝒍𝒐𝒂𝒕 1: Float charge voltage, V/cell 2,23 2,27
𝑰𝒇𝒍𝒐𝒂𝒕 : Typical float charge current,
1 1
mA per Ah
𝑰𝑮𝒂𝒔 2: Current (float charging), mA
per Ah (refers only to the calculation
5 1
of the air volume flow in float
charging)
𝑼𝒃𝒐𝒐𝒔𝒕 : Boost charge voltage, V/Cell 2,4 2,4
𝑰𝒃𝒐𝒐𝒔𝒕 Typical boost-charge current,
4 8
mA per Ah
𝑰𝑮𝒂𝒔 2: Current (boost charging), mA
per Ah (refers to the calculation of
20 8
the air volume flow during boost
charging)
1
Float and boost-charge voltages may vary depending on the specific electrolyte density
in lead-acid batteries.
2
When using grid | AquaGen recombination systems (only with vented lead-acid
batteries), the current Igas can be reduced to 50%.

For the ventilation design of battery compartments, "natural ventilation" or "forced

ventilation" can be used as a basis depending on the structural conditions.

The following points should be noted:

21
Natural ventilation:

• Supply and exhaust air openings required

o Openings on opposite walls
o Minimum separation distance of 2 m when openings on the same wall
𝑚3
• Minimum cross-section each (Air inlet / outlet): 𝐴 ≥ 28 × 𝑄 (𝐴 𝑖𝑛 𝑐𝑚2 , Q in )
h
m
Assumption: 𝑣𝐿𝑢𝑓𝑡 = 0,1 s
• Ventilation to the outside (not in air conditioning or adjacent rooms)

Forced (artificial) ventilation:

• Increased ventilation with fan (usually suction fan)

• Air flow rate according to the air volume flow 𝑄
• The air sucked in must be clean, Requirements for the installation site
• When charging with heavy gassing, fan run-on of 1 hour is required
• If there are several batteries in a room, the following applies: Air requirement = ∑ 𝑄
• Prevention of a ventilation short circuit due to sufficient distance between the
supply and exhaust air opening
• The ventilation system must be coupled with charger to ensure necessary airflow
at all times

6.1.2 Calculating the safety distance

In the vicinity of batteries, the dilution of explosive gases is not always guaranteed.
Therefore, a safety distance must be maintained through an air section in which no
sparking or glowing equipment must be present (max. surface temperature 300 °C). The
spread of the explosive gases depends on the amount of gas released and the ventilation
in the vicinity of the gas source. The following equation can be used to calculate the safety
distance "d" from the gassing source, assuming a hemispherical spread. The safety
distance d can also be read from Figure 6.1-1. The more detailed calculations are shown
below.

Safety:

The required safety distance must be calculated in accordance with IEC 62485-2.

Volume of a hemisphere:

Air volume flow required to dilute the produced hydrogen H2 to max. 4% in the air:

Required radius of hemisphere:

2
𝑉ℎ = × 𝜋 × 𝑑3
3
Air volume flow required to dilute the produced hydrogen H2 to max. 4% in the air:

22
 −3
𝑚3
𝑄𝐺𝑎𝑠 = 0,05 × 〈𝑛〉 × 𝐼𝐺𝑎𝑠 × 𝐶 × 10 ( )
ℎ
𝑉ℎ
𝑄𝐺𝑎𝑠 =
𝑡
Required radius of hemisphere:
3 3
𝑑 = 28,8 × ( √𝑛 × 3√𝐼𝐺𝑎𝑠 × √𝐶 (𝑚𝑚)

Figure 6.1-1 - Safety distance depending on battery capacity

6.2 Tools and equipment to carry out the installation

The batteries are delivered on pallets, and the necessary accessories are included in
separate packaging units. Please note all the information from the previous chapters.

For the installation, you will need your personal protective equipment, safety clothing,
safety tools and other equipment, as described in chap. 2.4 .

• Lifting trucks (forklifts, pallet trucks or small mobile cranes or similar to facilitate
battery assembly)
• Chalk line and chalk (optional)
• Plastic spirit level (optional)
• Torque wrench
• Supporting elements for aligning the racks (cabinets) (optional)
• Ratchet box (optional)

23
 • Set of open-end wrenches and ring wrenches with insulated handles
• Screwdriver with voltage-insulated handle
• Wiping paper or cloth (made of cotton; do not use synthetic fiber cloths as there
is a risk of static electricity), moistened with water
• Tape measure made of plastic
• Safety equipment and clothing
• Aeronix® battery terminal grease (only for cells/blocks with exposed lead poles)
• Insulating mats for covering conductive parts

6.3 Commissioning and maintenance protocol

This must be documented as proof that commissioning and maintenance have been
carried out correctly. Alternatively, you can use your own templates for documentation.
In any case, these should contain the necessary data/data fields. The documentation of
commissioning and maintenance should be kept together with the other documentation
of the battery/battery system.

Note: The following template contains fields for documenting acid density – these fields
are not used for VRLA (sealed lead-acid batteries) products and can therefore be left
blank.

The log can be downloaded as an extra file at:

service_maintenance_comissioning_protocoll_en_de.pdf (hoppecke.com)

or use the QR code:

This documentation must be submitted to the manufacturer as proof in the event of

warranty claims.

6.4 Installing racks and cabinets

We recommend the proper installation of the batteries in HOPPECKE battery racks or
HOPPECKE battery cabinets. If operator-owned solutions are used, the warranty of the
battery(s) may expire. HOPPECKE supplies various types of racks. For information on the
assembly, please also refer to the separate documentation that comes with each rack.

24
Figure 6.4-1 – Tier rack (left) and step rack (right)

1. Using the installation drawing (if available), mark the outlines of the racks on the
installation surface with chalk.
2. The installation surface must be level and load-bearing.
3. Set up the racks on a trial basis and align them horizontally.
4. Adjust the spacing of the support rails to match the cell or block battery
dimensions.
5. Check the stability of the frames and all screw or clamp connections for tight fit.
6. Ground the racks or frame parts (if provided).

When using wooden frames: Install a flexible connection on each frame joint!

As an alternative to installation in racks, the batteries can also be installed in HOPPECKE

battery cabinets. Either the cabinets are delivered with batteries already installed or the
batteries are installed in the cabinets on site. HOPPECKE supplies various types of
cabinets.

When installing block batteries with L-connectors, it should be noted that

the L-connectors must be installed before being placed in the battery
cabinet.
Note: The L-connectors are not intended for high-current (UPS)
applications. Ask your local HOPPECKE representative about this.

6.5 General information on connecting the batteries

When connecting the batteries, always form the series connections first
and then the parallel connection. A reverse approach is not permitted.
Check the batteries for correct polarity before wiring.
Attention!
To form the series connections, the batteries are arranged in such a way that the positive
pole of one battery is as close as possible to the negative pole of the next battery.

When connecting stationary batteries in parallel, the following points must be observed:

25
 1. Only battery strings of the same length and voltage should be connected to each
other. Cross-connections of the individual strands between cells or blocks should
be avoided, as they mask bad or faulty cells/blocks and can thus be the cause of
overcharging of individual battery strands.
2. Only batteries of the same type and the same state of charge should be connected
(same battery type, plate size and plate construction).
3. The environmental conditions for all strings connected in parallel should be
identical. In particular, temperature differences between the individual
strings/batteries must be avoided.
4. In order to ensure uniform current distribution, the connectors and end
connections should be designed in such a way that there are equal resistance
ratios in the individual feeds to the consumer.
5. The commissioning date of the batteries should be identical (batteries of the same
age, the same service life and the same state of charge).
6. Depending on the application and system voltage, the number of parallel
switched battery strings as follows:

a.) Cyclic operation:

Batteries ≤ 48 𝑉 max. 4-6 strings (max. 10 strings – grid | Xtreme VR)

Batteries > 48 𝑉 max. 2 strings (max. 4 strings – grid | Xtreme VR)

Note: Since the charge factor is usually low in cyclic applications, the risk of
insufficient charging increases if the previously mentioned maximum number of
parallel battery strings is exceeded.

b.) Standby parallel operation:

Batteries ≤ 60 𝑉 grid | Xtreme VR ≤ 230 𝑉 max. 8-10 strings

Batteries > 60 𝑉 grid | Xtreme VR > 230 𝑉 max. 6 strings

In special cases, consultation with Hoppecke is necessary.

If the above points are not met, the strings must be charged separately before the parallel
connection is carried out.

6.6 Installing the batteries

The greatest care must be taken when lifting and moving the batteries, as a falling battery
can cause personal injury and material damage. Be sure to wear safety shoes and safety
goggles. Always lift batteries only from below and never at the poles, as this will result in
the destruction of the battery. Check the batteries for perfect condition before
installation (visual inspection). When installing the batteries, VDE 0510-485-2: April 2019

26
(in accordance with IEC 62485-2) must be observed. For example, electrically conductive
parts must be covered with insulating mats.

6.6.1 Inserting batteries into the racks

1. Apply some soft soap to the support rails of the frame to make it easier to move
the batteries sideways after they have been put down.

Figure 6.6-1 - Treatment of the support rails

2. Position the batteries in the racks one after the other at the correct angle and with
the correct polarity and remove all transportation and lifting aids.

For large batteries, it is convenient to start by mounting them in the middle of the rack. If
you are using racks with tiers, first mount the lower level.

Carefully place the batteries on the support rails of the frame, otherwise
the battery housing may be damaged. When setting down the batteries,
avoid at all costs that they collide with each other. Risk of battery
Attention!
destruction!

The positive and negative terminals of a cell or block must not be short-
circuited under any circumstances. This also applies to the positive and
negative terminals of the entire battery or battery string. Be careful,
Danger!
especially when using step racks!

3. Move the blocks (or cells) sideways until the distance is about 10 mm. If
connectors are used, they specify the distance. When moving the batteries
sideways in the rack, do not press in the middle, but in the area of the (stiffer)
corners. Only press by hand, never use tools!
4. Finally, count all cells/block batteries and check that the installation is complete.

27
6.6.2 Horizontal Installation
Horizontal installation of the grid | power VRL

Batteries of the grid | power VR L and sun | power VR L series can also be placed
horizontally in racks or cabinets. These are optional variants for horizontal operation.
These variants need to be ordered separately. Below you will find an example of the
connection of grid | power VR L battery cells in horizontal orientation.

6-1 Examples of horizontal battery arrangement with grid | power VR L in a cabinet

Care must be taken to ensure that the lids of the battery cells do not rest on the rack or
cabinet bottom (6-1). The cells must be inserted very carefully into the battery cabinet to
avoid damage to the connection between the jar and the lid.

28
6-2 Correct positioning of the vessel - lid - connection on a rack

From the grid | power VR L 2-1570, the cell should only be placed in the toast position
(plates are upright) when applying horizontally, see 6-3.

6-3 Installation of grid | power VR L with horizontal application

Horizontal assembly of AGM cells / blocks (e.g. grid | power VR M)

When installing AGM cells or blocks horizontally, the orientation of the electrodes
("Toasted" – plates are upright / "Pancake" – plates lie flat on top of each other) can be
freely selected. However, HOPPECKE recommends using the "pancake" variant, as this
can actively counteract possible electrolyte stratification during operation.

When installing AGM cells or blocks on a rack or in a cabinet, the same regulations apply
to the positioning of the jar-lid connection as was previously the case with grid | power VR
L (6-2).

29
Note on connecting the cells/batteries:

After positioning the cells/blocks in the cabinet/rack, they should be connected using the
connectors supplied. If a drawing is available, it should be used as a guide:

6-4 Example of horizontal battery assembly with grid | power VR M on a rack

In the case of a seismic battery cabinet, the stiffening struts should be attached after
wiring.

6.6.3 Open-circuit voltage measurement

Before finally connecting the batteries, you should measure the open-circuit voltage of
each individual cell or block battery to check their state of charge and function. At an
electrolyte temperature of 20 °C, fully charged cells have the listed open-circuit voltages.
The open-circuit voltages of the individual cells of a battery must not differ by more than
0.02 V.

6-1 Open-circuit voltage for different cells/block batteries

Type of cell/block battery Open circuit voltage

grid | power VR L 2,080 V ... 2.120 V/Z
sun | power VR L 2,080 V ... 2.120 V/Z
grid | power VR M 2,100 V ... 2.140 V/Z
sun | power VR M 2,100 V ... 2.140 V/Z
power.com SA 2,100 V ... 2.140 V/Z
power.com H.C 2.120 V ... 2.160 V/Z
net.power 12 V 100 Ah und 12 V 150 Ah 2,100 V ... 2.140 V/Z
net.power 12 V 92 Ah und 12 V 170 Ah 2.120 V ... 2.160 V/Z
power.com HC 2,100 V ... 2.140 V/Z
power.com XC 2.120 V ... 2.160 V/Z
grid | power VR X / grid | power VR X FT 2,130 V ... 2,170 V/Z

The following maximum deviations in open-circuit voltage apply to block batteries:

• 4 V Block battery: 0.03 V/Block

30
 • 6 V Block battery: 0.04 V/Block
• 12 V Block battery: 0.05 V/Block

Higher temperatures decrease, lower temperatures increase the open-circuit voltage. If

there is a deviation of 15 K from the nominal temperature, the open-circuit voltage
changes by 0.01 V/cell.

If the open-circuit voltage is low during storage, the battery should either be recharged as
described in chap. 5.3 or put into operation as described in the chap. 6.7. In the event of
major deviations, it is necessary to consult your local HOPPECKE contractual partner.

6.6.4 Connecting batteries

The batteries are now in their final position and can be connected.

6.6.4.1 Connection Terminals

Sealed batteries are equipped with connection terminals that have either a brass or
copper terminal insert and a plastic coating. This eliminates the need for terminal grease.
However, if oxidation is visible on the surface of the terminal inserts, it is important to
clean them before putting on the connectors. This is especially true in the case of visible
oxidation of the pole insert.

6.6.4.2 Type of connecting cables

The supplied battery system is designed to deliver a specified power (kW) or current (A)
at a specified voltage (U) for a certain period of time (standby time). You should be familiar
with these parameters (U, kW, A). If this is not the case, please contact your local
HOPPECKE contractual partner. The battery system has been designed in such a way that
the above performance characteristics are available on the battery terminals. The voltage
drop between the battery terminals and the consumers should therefore be kept to a
minimum. Too high a voltage drop can lead to a reduced standby time of the battery
system.

Therefore, please note the following information:

1. The cable length between batteries and charging rectifier/UPS should be as short
as possible.
2. The cable cross-section should be dimensioned in such a way that there is no
significant voltage drop even with a large current flow. For this purpose, the voltage
drop at nominal current should be calculated based on the intended cable cross-
section. If in doubt, choose the next larger cable cross-section.

The connecting cables between the end connection poles of the battery
system and the battery fuses must be suitable for short-circuit-proof
installation and must be laid in a short-circuit-proof manner. This means:
Danger!
• Routing of cables with simple insulation in separate cable ducts

31
 • Routing of cables with double insulation (e.g. H07RN-F, NSGAFöu) in
a common cable duct
• Insulation strength of the cable is above the maximum possible
system voltage
• Additional insulation of the connectors is required
• Avoidance of any mechanical stress on the cells or battery
terminals. Cables with large cross-sections should be intercepted
by cable clamps

The connecting cables between the main connection poles and the charging rectifier or
UPS should be designed as flexible conductors.

6.6.5 Connect batteries to battery connectors

There are screwable row connectors, step connectors and tier connectors (cf. Figure
6.6.5-1). The row connectors are used to connect the individual cells/block batteries, the
step connectors to connect the individual steps to each other (use of step racks) and the
tier connectors to connect the tiers (use of floor racks).

Figure 6.6.5-1 - Use of series and step connectors

6.6.6 Installing the screw connectors

1. The cells or block batteries are connected by isolated row connectors (see Figure
6.6.6-1). The negative pole of a cell or block is connected to the positive pole of
the next cell or block until the desired total system voltage is reached.

Be careful not to mechanically damage the terminals.

Attention!
2. Attach the connectors as described in Figure 6.6.5-1 shown. Tighten the screws
by hand first to be able to align the cells and connectors again.
3. Tighten the screws with a torque wrench. The prescribed torque is 20 Nm ± 1 Nm.

32
 Exceptions:
Series power.com H.C:
• M5: 2 - 3 Nm
Attention!
• M6: 4 - 5.4 Nm
• M8: 11 - 14 Nm

Series grid | Xtreme VR: 15 Nm

grid | power VM 2-105: 15 Nm

grid | power VM 6-50 and 6-100: 12 Nm
Careful tightening of the connections is essential, as a loose
connection can lead to excessive heating, which could result in
ignition or explosion.
For tightening the pole bolts on block batteries of the grid- and
sun | power VR L as well as grid and sun | power V L is to use a wrench
size of 20 mm.

33
 4. If necessary, install insulating covers for the connectors and the end terminals
(connection plates).

Figure 6.6.6-1 - Pole connection options for voltage taps, monitoring and cable lugs for end connection

6.6.7 Clamp the connection plates to the batteries

There are a total of 11 different types of connection plates (cf. Figure 6.6.7-1). Connection
plates are always used when cables must be connected to cells with several battery
terminals.

To connect the cables to cells with several pairs of battery terminals, the
use of original HOPPECKE connection plates is strongly recommended.
If other solutions are used, there may be a risk of overheating and fire due
Attention!
to increased contact resistance!

34
 Figure 6.6.7-1 - Mounting the terminal plate to the end terminals of the battery

Installation of standard connection plates

1. Screw the connection bracket onto the end terminals of the battery (cf. Figure
6.6.7-1).

Be careful not to mechanically damage the terminals.

Attention!
2. Tighten the screws by hand first to be able to align the cells, connection brackets
and connection plates again.
3. Screw the connection plate to the connection brackets with a torque of 20 Nm.
4. Then tighten the terminal screws with a torque wrench. The prescribed torque is
20 Nm ± 1 Nm.
Exceptions:
Series power.com H.C:
35
 • M5: 2 - 3 Nm
• M6: 4 - 5.4 Nm
• M8: 11 - 14 Nm

Series grid | Xtreme VR: 15 Nm

grid | power VM 2-105: 15 Nm

grid | power VM 6-50 and 6-100: 12 Nm

Careful tightening of the connections is essential, as a loose connection

can lead to excessive heating, which could result in ignition or explosion.
Attention!

6.6.8 Connect the battery system to the DC power supply

Before connecting to the charging rectifier or to the UPS, it must be
ensured that all assembly work has been completed properly!
Attention!
1. Measure the total voltage (setpoint = sum of the open circuit voltages of the
individual cells or block batteries).
2. If necessary: Provide the cells or block batteries with a continuous numbering in
a visible place (from the positive terminal of the battery to the negative terminal).
Number stickers are supplied by HOPPECKE.
3. Attach polarity plates to the battery connectors.
4. Fill in the nameplate in the maintenance and commissioning protocol (see
chap.6.3) and keep this document with the battery system.
5. Attach the safety signs (these are: "Danger from batteries", "No smoking" and
"Danger from voltage if battery voltage > 60 V"). If necessary, additional labels
must be affixed in accordance with local regulations.
6. If necessary: Clean the batteries, the racks and the installation room.

Never clean batteries with feather dusters or dry cloths made of synthetic
fibres! Danger of electrostatic charge and oxyhydrogen explosion! We
recommend using slightly damp cotton or paper towels for cleaning.
Danger!
7. Connect the battery system to the charging rectifier or UPS via the end
connections ("plus to plus" and "minus to minus").

The connecting cables between the end connections of the battery and the charging
rectifier/UPS should be designed as flexible conductors. Rigid conductors can transmit
vibrations, which may lead to the connection being loosened. The cables must be
supported in such a way that no mechanical forces can be transmitted to the connection
terminals (cable trays, cable ducts, cable clamps).

36
6.7 Commissioning charge (initial charge)
As a rule, the batteries are no longer fully charged at the time of installation. This applies
in particular to batteries that have previously been stored for a long time (see chap. 5). To
bring the cells to an optimal state of charge as quickly as possible, you must first carry
out an initial charge. The first charge (time-limited) is a so-called "boost charge".

Baureihe power.com H.C

This battery should be cycled 2 to 3 times before it reaches its nominal

Attention! capacity. Hoppecke recommends C5 - C10 discharge and a charge
according to 6.7.1. After that, the battery can be used normally.

1. Find out what is the maximum voltage allowed that the charging rectifier can
deliver without damaging the peripherals.

2. Divide this maximum value by the number of battery cells connected in series (i.e.
not batteries). The value determined in this way is the maximum possible cell
voltage for the initial charge.

3. Adjust the voltage so that average cell voltages of max. 2.4 V per cell result. The
initial charge can take up to 48 hours.

4. It is important that the first charge is complete. Interruptions are to be avoided as

far as possible. The commissioning must be recorded in the commissioning report
(see test report).

5. During commissioning, the cell voltage on the pilot cells and, after completion of
commissioning, the cell voltage and surface temperature on all cells must be
measured and recorded in the commissioning report with time.

The surface temperature of the battery cells/units must not exceed 55 °C, if
necessary, charging must be interrupted until the temperature has dropped
below 45 °C.
Danger!

6.7.1 Commissioning charge with constant voltage (IU characteristic

curve)
• A charging voltage of max. 2.4 V/cell is required

• The maximum charging current should not be more than 20 A per 100 Ah C10

• If the maximum temperature of 55 °C is exceeded, charging must be interrupted

• Temporarily switch to float charge so that the temperature drops

• The entire commissioning time (IU-together) should take 24 hours

37
6.7.2 Extended commissioning charge
Long storage or climatic influences (humidity, temperature fluctuations) reduce the state
of charge of the cells. This will require extended commissioning charge. Extended
commissioning is only carried out if the storage period (see chap. 5) is not exceeded.

Conduct the extended commissioning charge according to the following procedure:

1. Charging with 10 to 15 A per 100 Ah C10, until 2.4 V/cell is reached (approx. 3 to 5
hours).
2. Charge at 2.4 V/cell until charging current reaches 1 A/100 Ah.
3. Charging with 1 A/100 Ah for 4 hours (cell voltage will exceed 2.4 V).

7 Battery operation
7.1 Modes
Batteries can operate in different modes, each with specific characteristics and
requirements. Each mode of operation has its own characteristics and operating
conditions, which are explained in more detail below.

7.1.1 Standby parallel operation

DC power source Consumer

Battery

Figure 7.1.1-1 - Standby parallel operation

Characteristic of this mode of operation are:

• Consumer, DC power source and battery are constantly connected in parallel

• The charging voltage is the operating voltage of the battery and at the same time
the system voltage
• The DC power source (charging rectifier) can deliver the maximum consumer
current and battery charging current at any time
• The battery will only provide power if the DC power source fails
• The charging voltage to be set is the float charge voltage per cell x the number of
cells connected in series (measured at the end poles of the battery)
38
 • To shorten the recharging time, a charging stage can be used at which the charging
voltage is max. 2.4 V x number of cells (standby parallel operation with recharging
stage)

7.1.2 Floating operation

Characteristic of this mode of operation are:

• Consumer, DC power source and battery are constantly connected in parallel

• The charging voltage is the operating voltage of the battery and at the same time
the system voltage
• The DC power source is not capable of always delivering the maximum consumer
current. The consumer current temporarily exceeds the rated current of the DC
power source. During this time, the battery provides power
• It is therefore not always fully charged
• Therefore, the charging voltage should be set to approx. (2.25 to 2.30 V) for vented
lead batteries and approx. (2.27 to 2.32 V) for valve regulated lead batteries x the
number of cells connected in series in consultation with the battery manufacturer,
depending on the number of discharges

7.1.3 Switch mode operation (charge/discharge operation)

DC power source Consumer

Charger Battery

Figure 7.1.3-1 - Switchover operation

Characteristic of this mode of operation are:

• When charging, the battery is disconnected from the consumer

• Vented lead-acid battery:
The charging voltage is 2.6 to 2.75 V/cell towards the end of the charge
(depending on depth of discharge and number of cyclic loads)
Valve regulated lead-acid battery:
The charging voltage for sealed batteries is max. 2.4 V/cell
• The charging process must be monitored
• Vented lead-acid battery:

39
 After reaching the full charge state, the charge must be terminated or
transferred to float charge in accordance with chap.7.2.3 .
Valve regulated lead-acid battery:
If the charging current at 2.4 V/cell has fallen to 1.5 A per 100 Ah nominal
capacity switch to trickle charging in accordance with chap. 7.2.3
• The battery can be switched to the consumer as needed

7.2 General information on the operation

IEC 62485-1 and IEC 62485-2 apply to the operation of stationary battery systems. Every
battery is subject to a natural electrochemical ageing process, which leads to a reduction
in the internal discharge cross-sections of the battery in particular (corrosion). How
quickly the ageing process progresses, and therefore the service life of the battery,
depends largely on the operating temperature.

The recommended operating temperature range for lead-acid batteries is

10°C to 30°C. The technical data apply to the nominal temperature of
20 °C. The ideal operating temperature range is 20 °C ± 5 K. Higher
Attention!
temperatures shorten the service life. Lower temperatures reduce the
available capacity. Exceeding the limit temperature of 55 °C is not
permitted. Continuous operating temperatures greater than 45 °C are to be
avoided. (Exception: grid | Xtreme VR)
The natural aging process and thus the service life expectation play an
important role, especially in the context of high-current applications. A
high-current application is defined as currents and discharge rates of
≤ C0.5. When discharging with high currents, disproportionately more heat
is generated, which can lead to thermal overloading of the reduced
discharge cross-sections. After a certain ageing progress, the reduced
cross-sections are no longer able to conduct the current designed for the
load case over the defined period. In extreme cases, this can lead to an
unexpected failure of the battery.

Permissible operating temperature ranges:

Vented / VRLA batteries: -20°C to +40°C
grid | Xtreme VR batteries: - 40 °C to + 55 °C (with short peaks up to 60°)

When using the HOPPECKE grid | AquaGen recombination system in the

context of vented batteries, the operating temperature of the
recombination system must always be ≥ 5°C. This prevents icing on the
internal ceramic components and ensures optimum recombination.

Additional intervention in the charging regime, such as through a BMS,

must be discussed with HOPPECKE.
Attention!

40
7.2.1 Discharging
The final discharge voltage of the battery assigned to the discharge current
must not be undercut.
Unless specific information is provided by the manufacturer, no more than
Attention!
the nominal capacity may be withdrawn. After discharges (even partial
discharges), fully charge the battery immediately.

7.2.2 Charging – General

Depending on the application, charging takes place in the operating modes listed in chap.
7.1.1 to chap. 7.1.3 . The charging method is applicable with the limit values according to
DIN 41773 (IU characteristic curve). The sun products are daily discharged and for this
reason the charging profile of these products is different compared to the standby
application. The charging parameters for the cyclic applications (sun products) are listed
in chap. 11.

Superimposed AC currents
Depending on the charger type and charging characteristic curve,
alternating currents flow through the battery during charging and are
Attention!
superimposed onto the charging direct current. These superimposed
alternating currents and the reaction of the loads lead to additional heating
of the battery or batteries and create a cyclical strain on the electrodes.
This might result in premature aging of the battery.

In order to achieve the optimum service life for sealed lead-acid batteries
on float charge, a maximum effective value of the alternating current of 1 A
per 100 Ah nominal capacity is recommended.
During the Boost charging the alternating current should not be higher than
5 A/100 Ah.

Temperature-dependent adjustment of the charging voltage

Temperature compensation of the voltage is necessary if the battery
operating temperature deviates from 20 °C. HOPPECKE recommends
Attention!
-3 mV/K. If the inverter cannot realize the compensation (technically), the
border area would be 15 °C to 25 °C (see Figure 7.2.2-1). Nevertheless, the
compensation should be realized.

Table 7.2.2-1 - Corrected charging voltage as a function of charging temperature for battery types with a float charge
voltage of 2.25 V/cell at Tnenn

Temperatur -10 0 10 20 30 40
[°C]
Charging 2,34 2,31 2,28 2,25 2,22 2,19
voltage [V/cell]

41
Figure 7.2.2-1 - Temperature-dependent adjustment of the float charge voltage for battery types with a float charge
voltage of 2.25 V/cell at Tnenn

Maximum charging currents

Up to 2.4 V/cell the battery is able to absorb the maximum current the battery charger
provides. Using the IU characteristic according to the DIN 41773 a charging current of
5 A to 20 A per 100 Ah rated capacity (C10) is recommended.

7.2.3 Float charging

Float charging serves to maintain the full charge state of the battery(s) and largely
corresponds to the type of charging described in chap. 7.

Use a charger with the specifications according to DIN 41773 (IU characteristic curve).
Adjust the charging voltage so that the average cell voltage is the same as specified in
Table 7.2.3-1.

Example: Nominal voltage of the battery: 60 V, i.e. the charging voltage of the charger for
float charge mode is 30 x float charge voltage per cell. E.g. 30 x battery cells grid | power
VR L result in a charging voltage of 30 x 2.25 V/cell = 67.5 V ± 1 % (= max. 68.18 V / min.
66.83 V).
Table 7.2.3-1 – Float charge voltage in standby parallel operation

Battery Float Voltage

grid | power VR L (OPzV) 2.25 ± 1 % V/Zelle
grid | power VR L (OPzV bloc) 2.25 ± 1 % V/cell
net.power 12 V 100 and 150 Ah 2.25 ± 1 % V/cell

42
 net.power 12 V 92 and 170 Ah 2.27 ± 1 % V/cell
power.com XC 2.27 ± 1 % V/cell
grid | power VR M 2.25 ± 1 % V/cell
power.com HC 2.25 ± 1 % V/cell
sun | power VR L 2.25 ± 1 % V/cell
sun | power VR M 2.25 ± 1 % V/cell
grid | power VR X / grid | power VR X FT 2.28 ± 1 % V/cell
power.com SA 2.25 ± 1 % V/cell
power.com H.C 2.27 ± 1 % V/cell

7.2.4 Equalizing charge (correction charge)

Under normal circumstances, equalizing charges are not necessary. If there are
unacceptably large discrepancies between the cell voltages of the individual cells at float
charge (see Table 7.2.4-1), an equalizing charge must be performed.

Equalizing charges are also required after deep discharges, after insufficient charging
processes, and if the cells have been unevenly warm for a long time (≥ 5K).
Table 7.2.4-1 - Permissible differences in cell voltage under float charge

Voltage per unit Max. permissible deviation of the float charge voltage
from the mean value for single cells/blocks
2V - 0.10 V / + 0.20 V
4V - 0.14 V / + 0.28 V
6V - 0.17 V / + 0.35 V
12 V - 0.25 V / + 0.50 V

Example of grid | power VR L cells: Charge float voltage max. = 2.45 V/cell and min. 2.15
V/cell (at average float charge voltage of 2.25 V/cell).

As the max. permitted load voltage might be exceeded it must be clarified

in advance whether the loads can be disconnected for the duration of the
equalizing charge.
Attention!

Perform the equalizing charge as follows:

1. Charging with IU characteristic curve, up to max. voltage U = 2.4 V/cell up to 48

hours. Thereby the charging current must not be higher than 20 A per 100 Ah
nominal capacity.
2. If the maximum temperature exceeds 45 °C, terminate the charging process or
switch to float charge to allow the temperature to drop.

43
 3. The end of the equalization charge is reached when the cell voltages no longer
increase within 2 hours.

Note that float charge voltages of lead-acid batteries with electrolytes fixed in gel can
fluctuate significantly within the first four years after initial commissioning. The voltages
range in an area between ca. 2.12 V/cells and 2.5 V/cell ± 1 %. The black lines in Figure
7.2.4-1 depict this area of float charge voltage for the first five years of battery service life.
The exact development of the voltage values can not be determined in advance. Figure
7.2.4-1 depicts rather the trend of this typical behaviour and related reasonable alarm
thresholds.

Background:
The scattering of float charge voltages of gel batteries is a normal phenomenon and has
no negative impact on the efficiency or capacity of the battery cells. This voltage
scattering leads to a balanced internal gas recombination within the battrey string with
the result of lower voltage differences and improved cell-internal oxygen and hydrogen
recombination rates. This process can neither be accelerated through cyclitzation of the
battery, nor by raised charge voltages. The normal equalizing charge voltage leads
optimally to a homogeneous gel structure and a high efficency of the battery over the
entire service life.

Figure 7.2.4-1 - Tendency of the float charge voltage over the service life of gel batteries

44
8 Battery maintenance
Regular care and maintenance of your battery system is essential for the required
reliability and longevity. You should document the type and extent of the maintenance
work as well as all measurement results as well as possible. The records can be very
helpful for troubleshooting and are a prerequisite for any warranty claims.

Take the following measurements regularly and record the measured values:

Interval Activity Reference

Measuring the charging voltage of the entire Chap. 7.2.4
battery system
Measuring the individual voltage of some Chap. 7.2.4
cells or block batteries
6 months
Measuring the surface temperature of some Max. deviation 5K,
cells or block batteries Chap. 7.2.4
Measuring the temperature in the battery Chap. 6.1
compartment
Measurement of the individual voltage of all Chap. 7.2.4
cells or block batteries
Measurement of the surface temperature of Max. deviation 5K,
all cells or block batteries Chap. 7.2.4
Measuring the insulation resistance of the Chap. 6.1
battery system
12 months Visual inspection of all bolted connections Chap. 6.1
Testing of all unsecured screw connections Chap. 6.6.6
for tight fit
Visual inspection of the battery racks or Chap. 6.1
battery cabinets
Checking the proper ventilation of the Chap. 6.1.1
battery compartment
Capacity testing (recommended), shorten Chap. 8.2
3 years
the testing interval with age
When evaluating cell or block voltages, also note the special features of lead-acid
batteries with electrolytes fixed in gel according to chap.7.2.4.

HOPPECKE recommends using a stationary battery monitoring system to monitor

relevant data. Please contact your local HOPPECKE representative for more information.

8.1 Cleaning the battery

Regular cleaning of the battery is necessary to ensure availability and
compliance with accident prevention regulations. The battery should be
cleaned at least once a year. The following should be observed:
Danger!
When cleaning the battery, face protection (impact-resistant visor
according to EN 166 Class F or comparable), safety goggles and protective
clothing must be worn. To avoid electrostatic charging when handling

45
 batteries, textiles, safety shoes and gloves must have a surface resistance
≤ 108 ohms.

Do not use dry cleaning clothes when cleaning!

Clean the cell/block containers of the batteries with a slightly damp cotton
or paper towel.
Danger!

8.2 Check the battery system

8.2.1 Preparing the battery system for capacity testing
We recommend carrying out an equalizing charge on the battery system before the test.
This equalization charge should be carried out no more than 7 days ago and at least 3
days!

The most efficient and fastest method for preparing batteries for tests is the IU charging
method, which is also used for equalizing charges. Appropriate measures must be taken
if the permissible load voltages are exceeded, e.g. switching off the loads. The IU
characteristic curve with an increased voltage of (2.33 to 2.40 V) x number of cells is the
most common charging characteristic curve for recharging or commissioning batteries.

Charging is carried out with a constant voltage of max. 2.33 V to 2.40 V/cell for up to 48
hours. The charging current should not exceed 20 A per 100 Ah C10. If the battery
temperature (cell/block temperature) exceeds the maximum value of 45 °C, charging
must be interrupted or temporarily switched to float charging so that the temperature
drops.

46
Figure 8-1 - Characteristic curve IU

An even more effective method of preparing the batteries is the IUIa charging method,
which involves an additional constant current charging step. In contrast to charging with
constant voltage, a constant charging current of 0.8 A/100 Ah is switched on for 3 hours
in the last step after the IU charging has been completed. The charging voltage can rise
to up to 2.65 V per cell.

Figure 8-2 - Characteristic curve IUIa

47
Due to the increased gas development in the IUIa charging method, increased ventilation
of the battery compartment is necessary. A full charge of the battery is generally achieved
if the voltage and charging current no longer change within 2 hours.

8.2.2 General information on how to carry out the capacity check

Tests shall be carried out in accordance with EN 60896-21: "Stationary lead-acid
batteries", Part 21: "Sealed designs – Test methods" (IEC 60896-21:2004). Special test
instructions, e.g. according to DIN VDE 0100-710 and DIN VDE 0100-718, must also be
observed.

Necessary accessories:

- Suitable electronic load or electrical resistance (with adjustable resistance value

to adjust the discharge current/discharge load)
- Suitable current clamp with sufficient accuracy to measure the DC current or
shunt to measure the discharge current
- Voltage meter for measuring electrical voltage
- Thermometer to check the battery temperature
- Clock for measuring discharge time
- Project planning data table for selecting the correct discharge current or
discharge power

Requirements for the accuracy class of the above-mentioned measuring equipment can
be found in Table 8-1.
Table 8-1 - Requirements for the accuracy of the measuring instruments (accuracy class)

For voltage measurement: 0,5

For current measurement: 0,5
For temperature measurement: 1 °C
For timekeeping: 1%

Below you will find general information on how to determine the actual capacity of your
battery system.

1. Make sure all connections are clean, tight, and not corroded.
2. During normal battery operation, measure and record the following parameters:
– Individual voltage of all cells or block batteries
– surface temperature of at least one in ten cells or battery block
– Voltage of the overall battery system
3. Interrupt the connection of the battery system to be measured to the charger and
to all consumers!

48
 4. Prepare an adjustable load that you can connect to the battery system. The load
current must be equal to the maximum allowable current for which the battery is
designed.
5. Provide a shunt that you can connect in series with the load.
6. Provide a voltmeter so that you can measure the total voltage of the battery.
7. Connect the load, the shunt and the voltmeter and start a time measurement at
the same time.
8. Keep the current constant and measure the voltage of the battery system at
regular intervals.
9. Check the row connectors (block connectors), step connectors and tier
connectors for impermissibly high heating.
10. Calculate the capacity of the battery system using the following equation:
Capacitance [% at 20 °C] = (Ta ⁄ Ts) × 100
Ta = actual discharge time until the allowable minimum voltage is reached
Ts = theoretical discharge time until the permissible minimum voltage is reached
11. Reconnect the battery system as originally and perform a heavy charge.

8.2.3 Implementation of the capacity test and evaluation

The discharge of the battery is carried out in accordance with the regulations for carrying
capacity tests DIN EN 60896-21. The discharge current and discharge power are selected
according to the design data tables up to a certain final discharge voltage and the given
loads.

In the capacity test, after 10% of the discharge time has elapsed, the discharge current
or discharge power, temperature, battery voltage as well as the cell or block voltage and
the discharge time should be recorded.

In any case, however, the values at 10%, 50%, 80% and 95% of the discharge time must
be recorded. The discharge is to be terminated when the battery voltage has reached the
value n x Uf, where n is the number of cells and Uf is the selected final discharge voltage
per cell.

The discharge must also be terminated as soon as a cell has reached a voltage of U = Uf
– 200 mV or, in the case of block batteries with n cells each, as soon as the voltage of a
block U = Uf – √ n x 200 mV has reached.

Example:

13 Cells grid | power VRL 2-325

5 h Capacity Test
Battery Final Voltage = 23.40 V (for 13 Cells)
Average Voltage Per Cell = 1.80 V
Minimum Single Cell Final Voltage = 1.60 V

49
Table 8-2 - Measured cell voltages and total voltage after 95% of the required discharge time

Cell number Case A Case B Case C

1 1,84 1,84 1,79
2 1,83 1,86 1,80
3 1,83 1,87 1,81
4 1,84 1,87 1,80
5 1,84 1,86 1,81
6 1,85 1,86 1,79
7 1,69 1,87 1,78
8 1,84 1,86 1,80
9 1,83 1,59 1,81
10 1,85 1,84 1,81
11 1,84 1,85 1,80
12 1,84 1,85 1,79
13 1,85 1,85 1,79
Battery 23,77 V 23,87 V 23,38 V

Case A: A "weak cell", capacity test passed, battery OK.

Case B: One cell faulty, capacity test failed, battery not OK
Case C: All cells OK, capacity test failed, battery not OK

Immediately after the capacity test, the battery must be charged.

The measured capacity C (Ah) at the average initial temperature is calculated as the
product of the discharge current (in amperes) and the discharge time (in hours). Since the
battery capacity depends on the temperature, a temperature correction of the measured
battery capacity must be performed.

At temperatures above the nominal temperature of 20 °C, the battery capacity increases,
while at lower temperatures it decreases. If the average initial temperature deviates from
the reference temperature of 20 °C, the capacity must be adjusted. The temperature
correction is carried out in accordance with the DIN EN 60896-21 standard according to
equation [1].
𝐶
𝐶𝑎 = 1 + 𝜆 (𝜗−20°𝐶) [1]

C = measured capacity
λ = Correctionfactor (λ= 0 006 c >3 λ = 0.01 for discharges ≤ 3 h)
ϑ = Initial temperature
Ca = corrected capacity

50
According to the DIN EN 60896-21 standard, a capacity test is considered to have been
passed if the battery reaches 95% of the required capacity at the first discharge. The
battery must deliver 100% of the required capacity after the fifth discharge at the latest.

A report must be drawn up after discharging (see test report).

When handling batteries (e.g. capacity test), the safety requirements

according to IEC 62485-2 (insulated tools, eye protection, protective
clothing, gloves, ventilation, etc.) must be observed!
Attention!

8.3 Notes on impedance measurement

Impedance measurement can also be used to check batteries. Please note that there is
no standardized measurement rule for this method and there are a few things to consider
when using it.

To use the results of an impedance measurement sensibly and correctly, follow the
instructions in the ZVEI Leaflet No. 34.

9 Troubleshooting
If faults are detected on the battery or the charging system, customer service must be
called immediately. Measurement data in accordance with chap. 8 simplifies
troubleshooting and fault rectification. A service contract with us makes it easier to
detect faults in good time.

9.1 Scattering of the individual cell voltages

If you notice that the individual cell voltages differ (see chap. 7), proceed as follows:

Possible cause Remedy

Different cell temperatures Check the charger

Different electrolyte densities of the cells Carry out an equalizing charge, see chap.
(VLA batteries) 7
Measuring cell voltages, replacing
Plate shorts in one or more cells
defective cells
Different charge levels of the cells/block Carry out an equalizing charge, see chap.
batteries 7
Insulation resistance too low see chap. 9.3
Lead-acid battery with fixed electrolyte Normal behaviour within the first years of
(gel) operation, see chap. 7

51
9.2 Available capacity too low
Insufficient capacity can be due to the following causes:

Possible cause Remedy

Carry out an equalizing charge, see chap.
Electrolyte Stratification (VLA)
7
Electrolyte levels below the minimum
Refill distilled water, see chap. 8
(VLA batteries)
Check all connections, replace
Loose or oxidized terminal terminals
connectors if necessary.
Insulation resistance too low see chap. 9.3

9.3 Insulation resistance too low

According to DIN EN IEC 62485-2, the minimum insulation resistance between the
battery circuit and other local conductive parts must be greater than 100 Ω per volt (the
nominal voltage of the battery). In the event of an insulation fault, leakage currents can
reduce the available capacity of the battery. This entails the risk of different cell voltages
occurring. Regular cleaning can prevent these leakage currents and different cell
voltages.

Possible cause Remedy

Battery contamination Cleaning the battery, see chap. 8.1

Fix the cause of the leak; if necessary,
Leaks in a cell/block
replace the cell, see chap. 9.5

9.4 Battery voltage not measurable

If no battery voltage is measurable, do the following:

Possible cause Remedy

Search for the fault, switch or replace the
A fuse has tripped
fuse
Cable break Replace cables

Defective connectors Replace connectors

9.5 Replacement of a cell/battery in the string

It is essential to make sure that the exchange is de-energized. Before disconnecting the
connectors, the circuit must be switched off.

52
 After loosening the connectors, cells/block batteries must be moved,
please refer to the instructions in the chap. 6.6. Lifting the cells/block
batteries at the terminals is prohibited, as this will destroy the cells/block
Attention!
batteries.

Removal of the defective cell / block battery:

1. disconnect the supply lines (circuit breakers, fuses, switches) before starting
disassembly. Only to be carried out by authorized personnel! Check that the
battery is disconnected from all charging equipment and consumers.
2. Loosen the terminal screws and connectors of the affected battery and remove
them directly from the battery.
3. Lighter cells/block batteries can be lifted directly out of the rack manually if space
permits.
4. In the case of heavy cells/block batteries, it is necessary to dismantle other
elements of the affected rack row to facilitate access. The position of the defective
cell/block battery and local conditions will determine which additional elements
need to be removed.
5. Use soft soap to make it easier to move the batteries sideways over the support
rails of the rack. When moving the batteries sideways in the rack, do not press in
the middle, but around the (stiffer) corners. Only press by hand, never use tools!
6. Slide the batteries onto the mobile assembly platform positioned to the side of the
rack and store temporarily for reassembly.
7. Remove the defective cell/block battery from the rack in the same way.

The integration of the cell into the cell network may only take place after successful
commissioning.

Installation of filled and charged batteries

If a cell or a block in a battery string needs to be replaced and the replacement cell/block
is filled and charged, the procedure is described in chap. 6.6.

10 Disassembly
When dismantling a battery system, all safety instructions listed in this document must
be considered, see chap. 2. This includes, in particular, personal protective equipment,
safety clothing and the use of insulated tools.

Follow these steps:

53
• Disconnect the supply lines (circuit breakers, fuses, switches) before starting
disassembly. Only to be carried out by authorized personnel! Check that the
battery is disconnected from all charging equipment and consumers.
• For battery systems with a nominal voltage > 60 V, first remove the group and level
connectors in order to divide the battery system into smaller partial voltages.
• Then remove the connectors between the cells/blocks.
• Loosened connectors and terminal screws must be removed from the battery
immediately.
• Ensure that the battery cells/blocks are aligned vertically at all times during
removal, packaging and transportation. Avoid tilting the battery cells/blocks in any
way.
• The cells/blocks must be packed for transportation in accordance with ADR 598B.
Externally damaged cells must be packed and transported separately (e.g. in a
palox). See also chap. 5.

54
11 Parameter data sheet for sun | power VR batteries
This chapter contains instructions for charging the HOPPECKE sun | power VR L and
sun | power VR M battery cells and blocks in solar applications.
Table 11-1 - Charging and discharging parameters

Parameter sun | power VR L sun | power VR M

Standard charging (regular cycle operation)
IU (followed by switching IU (followed by switching
Characteristic curve
to float) to float)
Max. Current (observe fuses
and cable lengths)
6 x I10 6 x I10
Note: Cable resistance must be
configurable!
Max. voltage in absorption
2.4 - 2.5 Vpc 2.4 Vpc
phase
Recommended absorption time 180 min 180 min
6 h/Charge factor 1.03 6 h/Charge factor 1.02
The absorption phase (or The absorption phase (or
the recharging phase) can the recharging phase) can
last longer or shorter than last longer or shorter than
Absorption Time
the 6h, depending on the the 6h, depending on the
Full Charge /Charge Factor
charging factor. charging factor.
Compliance with the Compliance with the
charge factor is primary charge factor is primary
(recommended). (recommended).
Frequency/cycle based on time
14 days 14 days
period/full charge
No switching due to No switching due to
Float charge threshold value for threshold value for
charging current! charging current!
Voltage 2.25 Vpc ± 1 % 2.25 Vpc ± 1 %
T > 20 °C - 3 mV/K T > 20 °C - 3 mV/K
Temperatur compensation
T < 20 °C + 3 mV/K T < 20 °C + 3 mV/K
Equalizing charge (frequency depending on which of the following criteria occurs
first)
Frequency/cycle based on
10 x Cn 10 x Cn
capacity throughput
Frequency/cycle based on time
40 days 40 days
period

IU/IUIa (followed by IU/IUIa (followed by

Characteristic curve
switching to Float) switching to Float)

For IUIa characteristic For IUIa characteristic

Note on the characteristic curve
curve: Current in Ia phase curve: Current in Ia phase

55
 max. 0.8 A/100 Ah C10 for max. 0.8 A/100 Ah C10 for
2 to 4 h 2 to 4 h
Max. Current (observe fuses
6 x I10 6 x I10
and cable lengths)
2.55 Vpc at IU-
characteristic curve
Max. voltage absorption phase 2.4 Vpc
2.4 Vpc at IUIa-
characteristic curve
6 h/charge factor 1.07 4 h/charge factor 1.04
The absorption phase (or The absorption phase (or
the recharging phase) can the recharging phase) can
last longer or shorter than last longer or shorter than
Absorption Time/Charge Factor the 6 h, depending on the the 6 h, depending on the
charging factor. charging factor.
Compliance with the Compliance with the
charge factor is primary charge factor is primary
(recommended). (recommended).
Battery Discharge
See data sheet and See data sheet and
Discharge characteristics
project planning data project planning data
Recommended (DOD) Cycle
50 % 50 %
Operation
Max. depth of discharge (DOD),
80 % 80 %
immediate recharging required
Max. Discharge current
Limited by BattFuse and Limited by BattFuse and
Note: Line resistance must be
cabling cabling
configurable!
Proposal for characteristic
curve for deep discharge
2.01 Vpc at I ≤ 0.16 x I10 2.01 Vpc at I ≤ 0.16 x I10
protection [U=f(I)]
1.81 Vpc at I ≥ 4 x I10 linear 1.90 Vpc at I ≥ 4 x I10 linear
Note: Deep discharge
interpolation with interpolation with
protection by switching off at
0.16 x I10 < I < 4 x I10 0.16 x I10 < I < 4 x I10
only constant voltage value is
not permitted!

56
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May-25