Hoppecke grid power FNC Series User manual

Manual_Grid_Power_FNC_en_V3_0
Executive
department:
SVA
Responsible
department:
SVA
Document type:
Technical Documentation
State of
confidentiality:
External
Created/changed (current Index):
2019-05-16, W. Pickart
Operation and Installation Manual
Document state
Approved
Checked (current index)
2019-06-13, I. Fuhrmann
Approved (current index)
2019-11-13, Dr. K. Gutzeit
File name:
Manual_Grid_Power_FNC_en_V3_0.doc
x
Revision:
03
Language:
EN
Page:
1
grid|power FNC®Batteries
Fibre Nickel Cadmium Batteries for Standby
Applications
Manual
Revision
Date
Name
Chapter
Reason for Changes
001
2015-07-22
I. Fuhrmann
Initial version
002
2017-10-24
I. Fuhrmann
7.1
Notes for recommissioning
003
2019-05-16
W.Pickart
All
Changes in structure chapters 2-7

Manual_Grid_Power_FNC_en_V3_0
Foreword
Dear Customer,
Thank you very much for having decided in favour of a product bearing our brand name.
Please read this documentation carefully before working on the batteries or their
components. It contains important information on safe and proper unpacking, storage,
installation, commissioning and on operation and maintenance of grid|power FNC®
batteries.
Amendments to this documentation are subject to change without prior notice. Our products
undergo continuous advanced development. As a result, there may be deviations between
the illustrations given in this documentation and the purchased product. This installation
manual is not covered by any change service.
Keep this documentation in such a manner that it is available immediately to all those who
need to carry out work in connection with the battery system or its components.
HOPPECKE Batterie Systeme GmbH
Postfach 11 80, D-59914 Brilon
Bontkirchener Str.1, D-59929 Brilon
Telefon: [phone]
Fax: [phone]
Internet: www.HOPPECKE.com
E-Mail: [e-mail]
Service hotline Germany:
0800 246 77 32
International service hotline:
[phone]
Copyright HOPPECKE Batterie Systeme GmbH
All rights reserved including those of patent and utility model applications.
Disclosure of as well as copying this documentation and using or revealing its contents are
not permissible unless this has been expressly approved in writing by HOPPECKE Batterie
Systeme GmbH. Infringements will lead to liability for damages.

Manual_Grid_Power_FNC_en_V3_0
Table of Contents
1. USING THIS MANUAL 6
1.1. Target group of this document 6
1.2. Means of Representation 6
1.3. Notation of Nominal Data 7
1.4. Abbreviations and Definitions 7
2. SAFETY 8
2.1. General Safety Instructions 8
2.2. Personal Protective Equipment 9
2.3. Specific Safety Instructions for grid|power FNC®Battery Systems 9
2.3.1. Safety Instructions on Handling with Electrolyte 9
2.3.2. Safety Instructions on Charging the Battery System 10
2.3.3. Protection against dangerous body contact currents 11
2.3.4. Special hazards in the event of fire 11
3. INTENDED / UNINTENDED USE 12
3.1. Intended Use 12
3.2. Unintended Use 12
4. DIRECTIVES, LEGISLATION AND STANDARDS 13
5. PRODUCT DESCRIPTION 14
5.1. grid|power FNC®cell 14
5.2. Cell Plugs for Different Use Cases 16
5.3. Operation Modes (see also DIN EN IEC 62485-2) 17
5.3.1. Standby parallel operation 17
5.3.2. Buffer operation 18
5.3.3. Switching mode (charge/discharge mode) 19
5.4. Battery Characteristic 20
5.5. Battery Capacity 21
6. TRANSPORT 22
6.1. Surface Transport (Road/Rail) according to ADR/RID 23
6.2. Transport by sea according to the IMDG Code 23
6.3. Air Freight 23
6.4. Checking the delivery 24
7. STORAGE 24

Using this manual
Manual_Grid_Power_FNC_en_V3_0 4
7.1. Storage of Filled and Charged (FC) Cells 25
7.2. Storage of Unfilled and Uncharged (UU) and Filled and Uncharged (FU) grid|power
FNC®Cells 26
8. INSTALLATION 27
8.1. Mounting a Rack or Cabinet 27
8.1.1. Before Mounting a Rack or Cabinet 27
8.1.2. Checking the Scope of Delivery 27
8.1.3. Mounting a Rack 28
8.1.4. Mounting a Cabinet 28
8.1.5. Ventilation Requirements 28
8.2. Installing the Battery System 29
8.2.1. Preliminary Work on Unfilled and Uncharged grid|power FNC®Cells 30
8.2.2. Equipping the Rack or Cabinet 30
8.2.3. Connecting the Battery System 31
8.2.4. Labelling the Battery System 33
9. COMMISSIONING 33
9.1. Charging Procedures for the Initial Commissioning 34
9.1.1. Charging with Constant Current 34
9.1.2. Charging with Constant Current and Constant Voltage (CCCV) 35
9.2. Commissioning of Unfilled and Uncharged (UU) and Filled and uncharged (FU)
grid|power FNC®Cells 36
9.3. Commissioning Filled and Charged (FC) FNC®Cells 37
9.4. Capacity Testing of Batteries According to DIN IEC 60623 39
10. MAINTENANCE 39
10.1. Checking for Cleanliness and Condition of the Battery System 40
10.2. Checking the Electrolyte Levels 41
10.3. Measuring the Charging Voltage 43
10.4. Testing the Insulation Resistance 44
10.5. Cleaning 45
10.6. Fill up the Electrolyte Level with Distilled Water 46
10.7. Reconditioning 48
11. TROUBLESHOOTING 52
11.1. Over Consumption of Distilled Water 52
11.2. Dispersion of the Individual Cell Voltages 52
11.3. Available Battery Capacity is Low 52
11.4. Insulation Resistance is Low 52
11.5. Battery Voltage not Measureable 53

Using this manual
Manual_Grid_Power_FNC_en_V3_0 5
12. DISASSEMBLY, DISPOSAL AND RECYCLING 53
13. APPENDIX 54
13.1. Commissioning Record 54
13.2. Maintenance Log 57
13.2.1. Six-monthly Maintenance Interval 58
13.2.1.1. Visual Inspection and Checking Electrolyte Level 58
13.2.1.2. Measuring battery system voltage 59
13.2.2. Annual Maintenance Interval 60
13.2.2.1. Cleaning the battery system 60
13.2.2.2. Insulation testing 61
13.2.2.3. Filling up distilled water 62
13.2.3. Maintenance Interval Every 5 Years 63
13.2.3.1. Reconditioning 63
13.2.3.2. Measuring of Single Cell Voltages 64
13.3. Useful tools 66

Using this manual
Manual_Grid_Power_FNC_en_V3_0 6
1. Using this manual
This operating and installation manual is intended to assist with the optimal operation of the
HOPPECKE nickel-cadmium batteries used, as well as their installation and maintenance.
This is the only way in which a maximum service life can be achieved.
Please contact your local authorised dealer:
If you have any queries on this documentation
If there are local regulations or provisions that are not covered by this documentation or
are contrary to its contents
1.1. Target group of this document
All work on the battery system and the grid|power FNC®cells must only be carried out by
trained, fully qualified and authorised personnel:
Personnel authorised by HOPPECKE Batterie Systeme GmbH
HOPPECKE experts
Experts from the operator of the battery system
1.2. Means of Representation
The following icons and signal words are used in this operating and installation manual:
DANGER!
Denotes an immediate hazard with a high level of risk that could lead to death or severe physical
injury if it is not prevented.
WARNING!
Denotes a potential hazard with a medium level of risk that could lead to death or severe physical
injury if it is not prevented.
CAUTION!
Denotes a hazard with a low level of risk that could lead to minor or medium degree of physical
injury if it is not prevented.
ATTENTION!
Denotes a hazard in which the product, other objects or the environment may get damaged if it is
not prevented.
Denotes first-aid measures.
Note
Denotes important instructions to make best use of the product.

Using this manual
Manual_Grid_Power_FNC_en_V3_0 7
1.3. Notation of Nominal Data
Nominal battery data is used in accordance with the following notation in this operation and
installation manual:
Notation
Meaning
Value
Un
Nominal voltage
1.2 V multiplied by the number of cells connected in
series
Cn
Nominal capacity
C5
available capacity at discharge at I5(see nameplate) up
to 1.0 V for each cell connected in series at nominal
temperature
In
Nominal current
I5(see nameplate) = Cn/5h
Tn
Nominal
temperature
20 °C
1.4. Abbreviations and Definitions
Abbreviation /
Definition
Explanation
Reconditioning
Describes the defined discharge and subsequent charging of the
battery with constant current. This allows the capacity losses of the
battery system to be eliminated or reduced.
Float Charging
The charge of an accumulator to compensate for its self-discharge
with the aim of keeping the accumulator fully charged.
Boost Charging
Indicates the charging of an accumulator with increased voltage and
a defined current in order to fully charge the accumulator as quickly
as possible.
Electrolyte
FNC® grid batteries are NiCd batteries and contain potassium
hydroxide (KOH) as electrolyte with an addition of lithium hydroxide
(LiOH). When handled properly, FNC® grid batteries are safe.
Contact with the electrolyte is excluded.

Safety
Manual_Grid_Power_FNC_en_V3_0 8
2. Safety
Observe the safety instructions while handling the battery system and its components.
2.1. General Safety Instructions
DANGER!
Caused by:
Explosions
Pressure waves
Flying hot or molten substances
Avoid:
Short-circuits
Electrostatic charges and discharges
Sparking or arcs
DANGER!
Caused by:
Voltages
Electric shocks
Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit.
Please be very careful when doing any work on the batteries in order to prevent severe
injuries caused by electrical shocks or burns.
Never place tools or other metallic objects on a battery.
Remove watches and jewellery before doing any work on the batteries.
Do not touch any exposed battery parts, connectors, terminals or poles.
DANGER!
Reverse polarity of batteries or cells can cause overheating and thereby result in the electrolyte
being ejected from the cell vents.
Check for correct polarity before making connections.
ATTENTION!
Toxic substances.
The cells of the batteries contain more than 0.1% cadmium by weight.
Symbol: Cd
CAS number: 7440-43-9

Safety
Manual_Grid_Power_FNC_en_V3_0 9
2.2. Personal Protective Equipment
Always wear the following personal protective equipment when working on the batteries or
their components:
Safety glasses
Safety gloves
Protective clothing, preferably made of cotton to prevent the development of electrostatic
charge on clothes and the body
Safety boots
In this way, you can prevent or at least mitigate injuries in the event of an accident.
The conductivity of textiles and shoes must have the following characteristics to prevent
electrostatic charge:
An insulation resistance ≥ 105Ω
A surface resistance < 108Ω
2.3. Specific Safety Instructions for grid|power FNC®Battery
Systems
2.3.1. Safety Instructions on Handling with Electrolyte
grid|power FNC®cells are NiCd batteries and contain caustic potassium hydroxide solution
as electrolyte.
WARNING!
Contact with the electrolyte can occur if you work on open cells. Electrolyte can be discharged if
the housing of an grid|power FNC®cell is damaged. It can cause severe burn injuries on the skin
and to the eyes.
Wear safety glasses and safety gloves when working on the battery system.
First-aid measures
Take the following actions if you have come into contact with the electrolyte:
Electrolyte solution on the skin or in the hair
Dab it with a cotton or paper-based cloth, but do not wipe it off.
Remove pieces of clothing that have been contaminated, and while doing so, avoid contact
with the affected parts of the body as far as possible.
Rinse off the affected parts for a longer period of time under flowing water.
Electrolyte in the eyes
Gently rinse off the eye for up to 15 minutes with an eyewash or wash the eye in flowing
water. Avoid excessive water pressure when doing so. Remove any contact lens as far as
possible and continue to rinse off the eye.
Consult an eye specialist or physician immediately.
Electrolyte in the mouth
Rinse the mouth with water. DO NOT induce vomiting.
Contact a doctor immediately or look for a hospital.
Note
Use water to wash off clothes contaminated with electrolyte.

Safety
Manual_Grid_Power_FNC_en_V3_0 10
2.3.2. Safety Instructions on Charging the Battery System
DANGER!
Danger of explosion due to formation of oxyhydrogen gas!
When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture
(oxyhydrogen gas) is formed, which already explodes with low energy input.
Keep any source ignition away from the battery system:
Open flames or fire
Smoking
Glowing embers
Flying sparks during grinding work
Electrical sparks caused by switches or fuses
Hot surfaces with temperature above 300 °C
Electrostatic discharges
Work with electrically insulated tools that do not strike sparks. Ground yourself when working
directly on the battery system.
Make sure that there is adequate ventilation in the container room in accordance with DIN EN
IEC 62485-2, so that the potential explosive gas mixture is discharged.
Note
The following instructions are meant to prevent explosions caused by electrostatic discharges
(Source: ZVEI –German Electrical and Electronic Manufacturers' Association - Professional
Association for Batteries):
Do not rub batteries with a plastic housing with a dry cloth or one made of synthetic material!
Rubbing plastic surfaces generates electrostatic charge.
Clean the batteries only with a cotton cloth moistened in water. Wiping with a cotton cloth
moistened in water does not generate electrostatic charge.
Wear shoes and clothes that prevent the formation of electrostatic charge on account of their
special surface resistance (see chapter 2.2 Personal Protective Equipment on page 9).
Use hand-held lamps with a mains cable without a switch (Protection class II) or hand-held
lamps with a battery (Protection class IP54).
Moisten a label of a battery (with water) before you pull off a label. Pulling off plastic labels
can develop electrostatic charge.

Safety
Manual_Grid_Power_FNC_en_V3_0 11
2.3.3. Protection against dangerous body contact currents
In stationary battery installations, measures must be taken to guard against direct and
indirect contact. For battery installations this protection can take the form of obstacles or
distance.
According to DIN EN IEC 62485-2:
Battery installations with a rated voltage of 60 V … 120 V must be accommodated in
electrical operation areas.
Battery installations with a rated voltage of more than 120 V must be accommodated in
enclosed, electrical operating areas.
Doors of battery rooms and cubicles count as obstacles when they are identified by the
following warning plates (fitted externally):
Warning plate “Dangerous Voltage”, if the battery voltage exceeds 60 V (see ISO 3864)
Prohibition sign: “No fire, naked flame or smoking”
Warning plate “Battery Room” to indicate electrolyte, explosive gases, dangerous
voltages and currents.
2.3.4. Special hazards in the event of fire
Danger!
Wear personal protective equipment against alkaline solutions (2.2 Personal Protective
Equipment on page 9), for large battery systems also use breathing protection with self-
sufficient breathing air supply.
Disconnect battery electrically.
Extinguish incipient fires with CO2.
When extinguishing electric fires with water in low-voltage systems (up to 1 kV), maintain a
spray distance of 1 m and a full spray distance of 5 m.
Wear alkali-resistant protective clothing! In case of contact with water, there is a risk of
reactions with the electrolyte (caustic solution) and consequently of violent spraying.
Extinguish in short intervals. Otherwise, there is danger of explosion due to possible static
charging on the battery housing.
Failure to do so may result in death or serious injury.

Intended / Unintended Use
Manual_Grid_Power_FNC_en_V3_0 12
3. Intended / Unintended Use
3.1. Intended Use
The grid|power FNC®cells of the battery system are used to store and release electrical
energy in standby applications, for example, uninterruptible power supply.
Intended use includes the following requirements:
Operating the battery system only if it is in proper condition
No deactivation or disassembly of safety devices
Compliance with all instructions given in this operating and installation manual
3.2. Unintended Use
DANGER!
Unintended use of the batteries can lead to personal injuries or damage to property.
In case of unintended use, HOPPECKE Batterie Systeme GmbH shall not assume any liability for
personal injuries or damage to property that result directly or indirectly from handling the
batteries. The operator shall be solely responsible for the risks arising from unintended use.
Any other use than described under "Intended use" is not intended and therefore not
permitted.
The unintended use of the product includes in particular:
Operation in explosion-endangered areas
Operation in safety-relevant applications, unless these applications are expressly
specified or permitted in the product documentation.
Operation without permanent/insufficient fastening
Operation outside the technical data
Operation or storage outside the specified environmental conditions
The electrical connection does not correspond to the documentation supplied with the
battery.

Directives, Legislation and Standards
Manual_Grid_Power_FNC_en_V3_0 13
4. Directives, Legislation and Standards
Please observe the latest edition of the following rules and regulations:
Accident prevention regulations, especially DGUV Regulation 1: Accident prevention
regulation; Principles of prevention
DIN EN ISO 20345 ("Personal safety gear –Safety boots")
DIN VDE 0105 ("Operation of electrical equipment"), in particular, governs the
requirements for quality and qualification for working on electrical equipment
(DIN VDE 0105-100).
DIN VDE 100/IEC 60364 ("Erection of low-voltage installations")
DIN EN 50110/VDE 0105 ("Operation of electrical installations")
DIN EN IEC 62485/VDE 0510 ("Safety requirements for secondary batteries and battery
installations"), particularly applicable for calculating the air ventilation required in battery
rooms (in DIN EN IEC 62485-2).
DIN EN 60623/IEC 60623 ("Secondary cells and batteries containing alkaline or other
non-acid electrolytes. Vented nickel-cadmium prismatic rechargeable single cells"),
applicable primarily to the testing of cells (type test, series production test and field test).
DIN EN 60993/IEC 60993 ("Electrolyte for vented nickel-cadmium cells")
DIN VDE 0100-600 Low-voltage electrical installations - Part 6: Verification (IEC 60364-
6:2006, modified); German implementation HD 60364-6:2007
ADR/RID: European Treaty on the international transport of hazardous goods by road /
Ordinance on the international transport of hazardous goods by rail
IATA-DGR: Dangerous goods regulations - international air transport association.
German: Gefahrgut-Bestimmungen - Internationale Flug-Transport-Vereinigung
IMDG Code: International Maritime Code for Dangerous Goods, German:
Gefahrgutkennzeichnung für gefährliche Güter im Seeschiffsverkehr
Ordinance on the supervision of waste and residual materials (German Federal Law
Gazette, 1996)
In addition, observe and follow all applicable territorial and national, corporate and project-
specific regulations and accident prevention regulations.

Product Description
Manual_Grid_Power_FNC_en_V3_0 14
5. Product Description
grid|power FNC®cells are connected to form battery systems and are deployed in standby
applications.
Here, they fulfil one or more of the following functions:
Buffering and supply of the low-voltage networks
Providing power in case of an emergency
To start a standby gen set/engine
5.1. grid|power FNC®cell
grid|power FNC®cells are nickel-cadmium cells, which are produced with fiber structure
technology. It uses an extremely porous, three-dimensional synthetic fleece, metallized with
nickel.
The particular characteristics are:
The best volume/weight ratio by 90% volume filling of the fiber electrodes with active
material
High to very high values of current can flow during charging and discharging.
No carbonates are formed in the electrolyte.
The batteries have long service life and several charging cycles even under extreme
temperature conditions
It withstands the most extreme of stress caused by shocks and vibrations
Cell housings made optionally either of polyether sulphone, polyamide or polypropylene
A large variety of constructions ranging from high and extremely flat to low with a large
surface area
The following drawing shows the internal structure of a grid|power FNC®cell:
1 = Positive pole
2 = Negative pole
3 = Cell casing
4 = Cell lid
5 = Vent plug
6 = Pole nut
7 = Cell pole
8 = Negative electrode stack
9 = Positive electrode stack
10 = Positive fiber structure electrode
11 = Current tab
12 = Negative fiber structure electrode
13 = Separator

Product Description
Manual_Grid_Power_FNC_en_V3_0 15
The electrolyte is a solution of potassium hydroxide (KOH) in distilled water with an addition
of lithium hydroxide (LiOH). The standard electrolyte is designed for use in temperatures of
between –25 °C and +45 °C. The lithium hydroxide in the electrolyte varies between the
different cell types (X, H, M, L). DIN IEC 993 is valid for the production of the electrolyte.
When the cells are in operation, the density of the standard electrolyte is 1.19 kg/l ± 0.01
kg/l at the reference temperature of 20 °C (electrolyte density can be higher on delivery).
Note
The electrolyte density is no indicator for the state of charge of nickel cadmium batteries.
For most FNC®products, HOPPECKE supplies on request a special electrolyte that allows
operation in low temperatures down to –45° Celsius.

Product Description
Manual_Grid_Power_FNC_en_V3_0 16
5.2. Cell Plugs for Different Use Cases
Cell Plug
Description
Yellow transport plug:
grid|power FNC®cells are sealed with yellow transport plugs at
delivery.
Vent plug:
The vent plug is the standard plug for FNC®standby applications. It
provides easy access to control and refill the electrolyte level. The
lid contains a filter that works as backfire protection.
Valve regulated plug (VR):
A low-pressure valve recombines oxygen and hydrogen gasses
inside the cell with up to 90% efficiency.
No water addition or filling is required over a 20 year service life
when operated on float charge at 20 °C.
Furthermore, the VR plug provides a backfire protection.
Furthermore, HOPPECKE provides AquaGen®vent plugs that are described in a separate
documentation. Contact HOPPECKE for further information.

Product Description
Manual_Grid_Power_FNC_en_V3_0 17
5.3. Operation Modes (see also DIN EN IEC 62485-2)
5.3.1. Standby parallel operation
Characteristics of this operating mode are:
Load, direct current source and battery are permanently connected in parallel.
The charging voltage is the operating voltage of the battery and at the same time the
system voltage.
The direct current source (charging rectifier) is always able to supply the maximum load
current and the battery charging current.
The battery only supplies power when the direct current source fails.
The charging voltage to be set is 1.40...1.45 V per cell x number of cells connected in
series (measured at the end poles of the battery). This is called float charging. The
battery is permanently in the state of charging with float charge voltage.
To shorten the recharge time, a charging stage can be used where the charging voltage
is set to 1.50...1.60 V per cell x number of cells connected in series. This is referred to as
boost charging.
After charging in boost charge, an automatic switchover to float charge takes place.
Direct
current
source
Load
Battery

Product Description
Manual_Grid_Power_FNC_en_V3_0 18
5.3.2. Buffer operation
Characteristics of this operating mode are:
Load, direct current source and battery are permanently connected in parallel.
The charging voltage is the operating voltage of the battery and at the same time the
system voltage.
The direct current source (charging rectifier) is not able to supply the maximum load
current at all times. The load current temporarily exceeds the rated current of the DC
source. During this time, the battery supplies current.
The battery is therefore not fully charged at all times.
The charging voltage to be set is 1.45...1.55 V per cell x number of cells connected in
series (measured at the end poles of the battery).
Direct
current
source Load
Battery

Product Description
Manual_Grid_Power_FNC_en_V3_0 19
5.3.3. Switching mode (charge/discharge mode)
Characteristics of this operating mode are:
When charging, the battery is disconnected from the consumer.
The battery can be switched to the consumer as required.
The charging voltage of the battery is max. 1.50...1.60 V/cell (boost charge) or
1.40...1.45 V/cell (float charge), see also Section 5.3.1.
The battery also can be charged with constant current I5. A secure shutdown criterion is
required for this. Voltages up to 1.9 V / cell can occur.
The charging process must be monitored.
Secured shutdown criterion required (up to 1.9V/cell)
Direct
current
source Load
Battery
Charger

Product Description
Manual_Grid_Power_FNC_en_V3_0 20
5.4. Battery Charging Characteristic
In the temperature range from 10 °C up to 30 °C the battery system can be operated with
the charging voltages as given in the table below:
Charging voltage at 20 °C in V per cell connected in series
Cell performance
class according
to EN 60623
Single-stage
charging (IU)
2-stage charging
(IU0U),
float charging
2 - stage
charging (IU0U),
Boost charge
Temperature
compensation
in V/degrees/cell;
starting from 20 °C
L
1.55
1.45
1.55 … 1.60
-0.003
M
1.52
H
1.48
X
1.45
VR L
- 1)
1.42
1.57
VR M
1.40
1.55
1) It is not recommended to use the single stage charging as charging characteristic for
grid|power FNC®VR cells, because you cannot achieve the advantages of the VR
technology (no water addition or filling is required over the service life).
If the operating temperature differ from the range mentioned above, it is recommended to
use a temperature compensated charging method.
The following diagram illustrates the charging voltage of each cell connected in series
depending on the temperature of the electrolyte monitored by the charger (constant voltage,
constant current characteristic, with current limitation).
1 = Float charge 2 = Boost charge
The following conditions are applicable to the characteristic shown:
Switch from float charge to boost charge:
The current permanently overshoots a value of I20 = Cn/20h.
Switch from boost charge to float charge:
The current permanently undershoots a value of I20 = Cn/20h.
Current limit I5= Cn/5h (recommended value, there may be deviations to higher or lower
values of current)
Charge voltage [V]
Temperature of the electrolyte [°C]