Hoppecke trak bloc User manual

Observe the usage instructions
and install in a visible position
at the charging bay. Only trained
personnel may perform work on
batteries.
Wear protective goggles, protec-
tive gloves and protective clo-
thing when working on batteries!
Observe the accident preventi-
on regulations as well as DIN
EN 50110-1 and IEC 62485-3.
During installation/commissio-
ning, maintenance, cleaning and
disassembly wear additional face
protection (impact-resistant visor
according to EN 166 Class F).
Smoking is prohibited. There
must be no naked flames,
embers or sparks in the vicinity of
the battery, as this poses a risk
of explosion and a fire hazard.
Keep children away from bat-
teries!
Rinse eyes or skin splashed with
acid using plenty of clean water.
Then consult a doctor immedia-
tely. Wash clothing contaminated
with acid with plenty of water.
Electrolyte is highly corrosive.
Contact with electrolyte is not
possible during normal operation.
Risk of explosion and fire, avoid
short circuits!
Only use approved lifting and
transportation equipment, e. g.
lifting gear in accordance with
VDI 3616. Lifting hooks must
not cause any damage to cells,
connectors or connecting cables.
Dangerous electrical voltage.
Attention: Metallic parts of the battery cells
are always live. Therefore, no foreign objects
or tools may be placed on the batteries.
Warranty claims will no longer be valid in
the event of non-observance of the usage
instructions, repairs using non-original
spare parts or unauthorised intervention.
1. Start-up
The battery must be checked to ensure that
it is in mechanically perfect condition. The
installation area must be cleaned prior to
installation.
Only interconnect battery blocks with the
same charge state (same open-circuit vol-
tage, tolerance as per the following table).
Never power electrical consumers via a part
of the battery.
The battery terminal end must be connected
with the correct polarity and with reliable
contact. Otherwise, the batteries, the vehic-
le or the charging device may be destroyed.
Following assembly, the terminals must be
greased to protect against corrosion. The
battery must be recharged as per Item.
Tightening torque for pole screws on the
terminal ends and connectors:
2. Operation
The regulations in accordance with Standard
EN 62485 – Safety requirements for
secondary batteries and battery installations
– Part 3 apply for the operation of vehic-
le batteries. Traction batteries for electric
vehicles.
2.1 Discharging
The battery valves must not be closed or
covered. Electrical connections (e.g. plug
connectors) must only be opened or closed
when in de-energised state.
In order to achieve an optimal service life,
discharge of over 60 % of the rated capacity
should be avoided. Discharge of over 80 %
of the rated capacity is a deep discharge
and is not permissible. These significantly
reduce the service life of the battery. Only
those discharge state indicators that have
been approved by the battery manufacturer
may be used.
Discharged batteries must be charged
immediately and must not remain in dischar-
ged state. This also applies to batteries in a
state of deep discharge. Otherwise, the
service life of the battery will be significantly
reduced. The battery may freeze when in
discharged state.
2.2 Charging
Batteries must only be charged with direct
current. The charging methods in accor-
dance with DIN 41773-1 must only be
applied in the modification approved by the
manufacturer HOPPECKE. Therefore, only
those chargers that have been approved by
the battery manufacturer HOPPECKE may
be used. In order to prevent overloading
of the electrical cables and contacts and
impermissible gas formation, the battery
must only be connected to the allocated
charger that is permissible for the respective
battery size.
Operating instruction
trak®bloc
Lead-acid batteries with closed grid plate cells (trak®bloc)
Rated values
1. Rated capacity: see type plate
2. Rated voltage: see type plate
3. Discharge current: C5/5 h or C20/20 h
4. Rated temperature: 30 °C
trak®bloc batteries are closed batteries with suspended electrolytes that must not be topped
up with water for the entire duration of the service life. Pressure relief valves are used as
sealing plugs. These valves stop oxygen getting into the cells and drain off any excess charging
gases. The valves must not be removed. During operation, the same safety requirements apply
to the closed batteries as to batteries with liquid electrolyte in order to prevent electric shock
and explosion of the electrolytic charging gases and to avoid the risk of corrosive electrolytes
if the cell container is destroyed.
Rated
voltage
module
[V]
6
12
Maximum deviation
from mean value -
Ubloc
[V]
± 0,035
± 0,049
Cone terminal
Screw terminal M6/M8
Flat terminal M6
8 ± 1 Nm
20 ± 1 Nm
6 ± 1 Nm

trak®bloc batteries have low gas
emissions but are not completely free
from gas emissions.
It must be ensured that the charging gases
are drained off effectively during charging.
Covers on battery installation spaces must
be opened or removed.
The battery must be connected to the
charger with the correct polarity (positive to
positive and negative to negative) when the
charger is switched off. The charger must
then be switched on.
During charging, the temperature in the
battery increases by approx. 10 K.
Therefore, charging should only be started
when the temperature is below 35 °C. The
temperature prior to charging must be at
least 15 °C, as otherwise the battery will not
reach a sufficient level of charge during the
prescribed charge time.
If temperatures are consistently higher than
40 °C or lower than 15 °C, the charger will
need to undergo constant voltage regulation
dependent upon the temperature.
A correction factor of -0.003 V/Z per K
should be applied here.
2.3 Equalising charge
Equalisation charging is used to guarantee
the service life and to preserve the capacity.
Equalisation charging must be carried out
following normal charging.
This type of charging must be carried out
following deep discharge and repeated
insufficient charging. Only those chargers
that have been approved by the battery
manufacturer may be used for equalisati-
on charging. It is also recommended that
equalisation charging be carried out with
constant current once every quarter. The
charging current can be a maximum of 0.8 A
per 100 Ah C5rated capacity, and must be
deactivated after a maximum of 5 hours.
The charge voltage must not exceed 2,6 V
per cell. Observe the limit temperature!
Charging must be interrupted if the limit
temperature is exceeded.
2.4 Temperature
30 °C battery temperature is considered
the rated temperature. Higher temperatures
reduce the service life, while lower tempera-
tures reduce the available capacity.
45 °C is the upper limit temperature and
is not permissible as an operating tempe-
rature.
Therefore, trak®bloc batteries must not be
exposed to sunlight without protection.
2.5 Electrolyte
The electrolyte takes the form of suspended
sulphuric acid. The density of the electroly-
tes cannot be measured.
3. Maintenance
Do not top up with water!
Never open or remove the valves.
3.1 Daily
Charge the battery immediately after every
discharge.
3.2 Weekly
Carry out a visual inspection for contamina-
tion and mechanical damage.
3.3 Quarterly
The following must be measured and recor-
ded once the battery has been fully charged,
after a waiting time of at least 12 hours:
- Total voltage
- Individual voltage of the block batteries
If significant changes to previous measure-
ments or differences between the block bat-
teries are identified, then Customer Service
must be contacted for further testing or
repairs.
3.4 Yearly
(only for batteries in a steel trough)
In accordance with EN 62485-3, the insu-
lation resistance of the vehicle and the
battery must be checked by a specialised
electrician.
The battery insulation resistance check must
be performed in accordance with EN 1987-1.
The established battery insulation resistance
must not be below 50 Ohm per Volt of rated
voltage.
For batteries with a rated voltage of 20 V,
the minimum value would be 1000 Ohm.
4. Care
The battery must always be kept clean and
dry in order to prevent leakage currents.
Cleaning must be performed in accordance
with the ZVEI data sheet „Cleaning batteries“.
5. Storage
If batteries are taken out of operation for
extended periods, then they must be stored
fully charged in a dry and frost-free location.
In order to ensure that these batteries stay
ready for operation, the following charging
procedures must be applied:
Quarterly full charging as per Item 2.2.
If consumers such as measuring or control
equipment are connected, it may be neces-
sary to carry out a full charge every 14 days.
In general, self-discharge of 2 % per month
is to be expected.
The storage time should be taken into
account in any service life estimates.
6. Faults
If any faults are detected on the battery or
charger, contact Customer Service imme-
diately.
HOPPECKE Service:
[phone]
Measured data as per Item 3.3 make trou-
bleshooting and fault rectification easier.
A service contract with HOPPECKE makes
it easier to detect faults in good time, to
prevent faults and to remedy any faults that
may occur.
7. REACH Statement Pb-Metal:
According to REACH regulation we inform
that, PzS- and PzB Batteries are containing
the SVHC substances Lead-metal (CAS.
Nr. 7439-92-1) with more than 0.1 weight %.
MSDS is available upon request from your
account manager.
For further information regarding REACH
please refer to https://echa.europa.eu.
Teil-Nr. 7240203030/04.21
HOPPECKE Batterien GmbH & Co. KG
P.O. Box 1140 · D-59914 Brilon
Bontkirchener Straße 1 · D-59929 Brilon-Hoppecke
Phone: + 49 (0) 29 63 61-355 Email: [email protected]
Fax: + 49 (0) 29 63 61-735 Internet: www.hoppecke.de
Pb
Used lead-acid batteries constitute waste for recycling that requires special monitoring. These batteries, which feature the
recycling logo and a crossed-out dustbin, must not be disposed of with household waste. The method of return and recycling must
be agreed upon with the manufacturer in accordance with Section 8 of the German Battery Ordinance (BattV).