Hoppecke FNC User manual

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Technical Documentation
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Creation of the :
Low-pressure
water refilling system FNC
Description / Maintenance
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Th. Schreckenberg
approved
checked :
Automatic low-pressure
water refilling system FNC
F. Mengeringhausen
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TD-LowPressureRefilling-FNC-en-
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005
en
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This document and its contents are the property of Hoppecke or its subsidiaries. This document contains confidential proprietary information. The
reproduction, distribution, utilisation or the communication of this document or any part thereof, without express authorization is strictly prohibited.
© 2012, Hoppecke Batterie System GmbH, all rights reserved.
Document Management
Document History
Version
Date
Responsible party
Reason for change
000
08.10.2012
Th. Schreckenberg
First Issue
001
06.02.2013
Th. Schreckenberg
Material Numbers added, expressions modified
002
19.02.2013
Th. Schreckenberg
Mat. No. for 110VAC waterfilling cart added
003
12.12.2017
I. Fuhrmann
Additions regarding the quality of the water
004
14.06.2018
I. Fuhrmann
Fine-tuning in chapter 4 and 6
005
30.01.2019
I. Fuhrmann
Note on checking the electrolyte level chapter 4

Language : en
Revision : 005
Page :
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Contents
Safety notes...............................................................................................................................3
First-Aid Measures....................................................................................................................4
System Description...................................................................................................................5
3.1 Waterfilling plugs..............................................................................................................5
3.2 Flame arrestor....................................................................................................................5
3.3 Waterfilling system............................................................................................................6
3.4 Waterfilling cart.................................................................................................................7
Filling up the battery with distilled water.................................................................................8
4.1 Prior to Filling ...................................................................................................................8
4.2 Filling Operation................................................................................................................9
4.3 After the Filling Operation ..............................................................................................10
Service and Maintenance........................................................................................................11
5.1 General notes:..................................................................................................................11
5.2 Replacing a waterfilling cart............................................................................................11
Components ............................................................................................................................13
Appendix: Important aspects for proper filling ......................................................................14

Language : en
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Safety notes
It is assumed that qualified personnel only shall be deployed for the operation and
maintenance of the components available. Qualified personnel are individuals who, on the
basis of their education, experience and training, and their knowledge of the relevant
standards, regulations, accident prevention guidelines and operating conditions, are
authorised by those responsible for the safety of the components/system to perform the
respective necessary activities, and thereby identify and prevent any potential hazards.
Among other things, knowledge of first aid measures and the local emergency services is
required.
Failing to observe the operating instructions, not using original replacement
parts when carrying out repairs, performing unauthorised actions, or introducing
additives to the electrolyte, shall invalidate the warranty.
The following precautionary measures relate to the handling of Ni-Cd batteries and must
always be observed with respect to all the work instructions given in these operating
instructions.
Observe and follow the assembly and installation instructions and make them
visibly available at the installation site.
Only trained personnel may perform work on batteries. The instructions for use
must always be accessible to the persons in charge of handling the
rechargeable batteries.
When working on batteries, wear safety goggles and protective clothing. The
accident prevention regulations must be observed and followed.
Smoking is prohibited! No open flames, embers or sparks are allowed in the
vicinity of the battery as they pose an explosion and fire hazard.
Explosion and fire hazard; avoid short circuits.
Caution! As all metal parts contained within the battery cell are constantly
energised, do not place any foreign objects or tools on the battery. Adequate
ventilation must be provided in the battery room so that the explosive gases
generated during charging are removed (DIN EN 50272-2).
Keep an eye rinsing bottle ready at hand. Rinse eyes or skin sprayed with alkali
with plenty of clean water. Consult a doctor immediately. Wash clothing
contaminated with alkali with water.
Electrolyte is highly corrosive. During normal operation it is not possible to come
into contact with the electrolyte. Electrolyte can get released only if the cell
housing gets damaged.

Language : en
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Do not tilt the battery. The cells are very heavy. Use only approved lifting and
transportation equipment, e.g. lifting gear. Lifting hooks must not cause damage
to cells, connectors or cables.
Dangerous electrical voltage. Use only tools and measuring instruments that are
suitable and appropriate.
Ni-Cd batteries or cells fall under the fire class E (see DIN EN 2). In the event of electrical
fires, it may happen that the devices and equipment are live! Water and foam used for
extinguishing fires are ideal electrical conductors. You may suffer electric shocks.
Electrical fires must be extinguished using fire extinguishing powder or carbon dioxide,
CO2.
First-Aid Measures
Eye contact with the electrolyte
Rinse immediately with plenty of water for at least 10 minutes.
Rinse the eyes with boric acid solution if it is available.
Get comprehensive instructions at an eye clinic.
Skin contact with the electrolyte
Remove clothing soaked with the electrolyte immediately and wash off the main
body parts affected with plenty of water. In case of complaints, consult a doctor.
Skin that has come into contact with the electrolyte shows a soapy consistency,
which means that it must continue to be rinsed with water until this condition is
eliminated.
Swallowing electrolyte
Gargle with plenty of water and drink large quantities of water repeatedly.
Do not cause vomiting. Call for an emergency doctor promptly.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
System Description
3.1 Waterfilling plugs
The plugs used to top up distilled water work
without any moving parts. The water is
pumped with a steady flow rate into the top-up
system and flows into the cells one after the
other. In the process, the air inside the cells
escapes through the vertical tube. As soon as
this tube gets submerged when the electrolyte
reaches the maximum level, air can no longer
escape and water intake is prevented.
The waterfilling plug is sealed off from the cell
with two O-rings so that air may escape
through the plug but not directly from the cell.
This is absolutely necessary for the cell to
work.
Figure 1: Waterfilling plugs
3.2 Flame arrestor
Hydrogen and oxygen formed while charging
are fed through the hose pipes to a central de-
gasification facility with flame arrestor and,
thus, released into the environment in a
controlled manner.
Figure 2: Flame arrestor

Language : en
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
3.3 Waterfilling system
The waterfilling plugs are provided with two hosepipe connections each. The individual
plugs are connected to one another with hose pipes and, in this manner, connected
virtually in series to a water top-up chain. A hosepipe with a quick coupler is fixed at the
first and last plug in the series. The flame arrestor is installed during normal operation. To
fill up the battery, it is removed and the waterfilling cart is connected to the battery with
the help of the quick couplers. The topping up procedure may be started using the
appropriate button and then runs completely automatically. Water is pumped with a steady
flow rate into the system starting from the first plug and flows back into the waterfilling cart
when all cells have been topped up one after another. The water flows into an internal
intermediate tank from there. If this tank is full, the excess water is extracted from the top-
up system and the internal tank and pumped into the external residual water tank. The
top-up procedure is completed with this step. The waterfilling cart may now be
disconnected from the battery at the quick couplers and the flame arrestor system may
be reinstalled.
Figure 3: Battery completely assembled and connected with hose pipes / Water connection with the flame
arrestor installed

Language : en
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
3.4 Waterfilling cart
The waterfilling cart with a 60 litre tank
enables simple topping up of the batteries at
site. The cart may be pulled easily with the
handle. The cart is provided with an internal
rechargeable battery in order to ensure the
maximum degree of portability.
Caution:
The waterfilling cart must be stored and
operated at temperatures > 0°C in order to
prevent the distilled water from freezing in
the tank and inside the carriage. It may get
damaged otherwise.
Caution:
Required quality of the water:
IEC EN 60 993
1: Start button
2: On/Off switch
3: Power supply 230V
4: Filter
5: Return flow quick coupler
6: Extension hosepipe (2 pieces, 6 m
each)
7: Return flow hosepipe, 4 m
8: Ventilation valve
9: Inlet hosepipe, 4 m
10: Inlet quick coupler
11: Display
12: Residual water tank
Figure 4: Waterfilling carte, front view
Figure 5: Waterfilling cart, side view
12

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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Filling up the battery with distilled water
4.1 Prior to Filling
Figure 6: Connecting the waterfilling cart
1: Battery
2: Ventilation valve
3: Filter
4: Water tank
5: Pilot lamp
Before refilling distilled water, check the electrolyte levels. Refer to the battery
system's project-specific documentation for instructions
Ensure that the battery of the waterfilling cart is charged (LED 5 lights up in green
colour).
The storage tank must be filled up sufficiently.
The residual water tank must be empty.
1. Detach the flame arrestor from the battery.
2. Connect both the hose pipes of the waterfilling cart to the battery using the quick
couplers.
Caution:
Disconnect the waterfilling cart from the mains supply; it should not be
connected to the mains during the filling operation.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
4.2 Filling Operation
1. Switch on the waterfilling cart; the
software version is displayed for 10
seconds.
2. Start the filling operation with the help
of the Start button.The pilot lamp lights
up in yellow.
Figure 6: Switching on
Figure 7: Display of the software version
Note:
The filling operation runs automatically. As soon as all cells have been filled, the
waterfilling cart extracts excess water from the connected hose pipes. The filling
operation takes a few minutes depending on the number of cells and the water level in
the cells.
Note:
Avoid overfilling.
Carry out the refilling activity once only per maintenance interval.
Repeated triggering of the refilling activity at the same maintenance interval can overfill
the battery system. This can lead to leakage of electrolyte and a higher pollution of the
battery system during operation.
In addition, overfilling will change the electrolyte density and the performance of the
battery can be negatively affected.
If cells are filled above maximum level, contact HOPPECKE service.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
4.3 After the Filling Operation
After the water refill car has stopped pumping, the battery is fully charged. The display
shows the amount of water replenished in litres.
1. Disconnect the hose pipes from the waterfilling cart at the appropriate quick
couplers.
2. Reinstall the flame arrestor with the help of the quick couplers.
3. Drain the water extracted from the small tank.
4. Shut down the waterfilling cart and, if required, connect it to the 230V mains
supply to charge up the internal rechargeable battery.
Caution:
The water extracted may contain alkaline residues! Please observe and follow
the local / relevant provisions for disposal.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Service and Maintenance
5.1 General notes:
The water refilling system is almost maintenance-free and does not require any intensive
service. Hence, the system is subjected only to visual inspection. If required, individual
plugs, hose pipes or fastening material that has become defective may be replaced.
During maintenance, the following points must be attended to:
Please take special care to ensure that the hosepipe connecting pieces are not
contaminated or do not get damaged. Nonetheless, if contamination is found,
clean the relevant components with clean water.
The hosepipe of the waterfilling cart should not get twisted.
The tank of the waterfilling cart must always be filled up with a sufficient quantity
of distilled water (The water quality should conform to IEC EN 60 993).
The waterfilling plugs on the battery should not be damaged. Any damaged plug
must be replaced with a new one. Damaged plugs may lead to overfilling of cells
and discharge of water and electrolyte.
5.2 Replacing a waterfilling cart
Figure 8: Cell with waterfilling plug installed
1. Pull out the hose pipes
from the associated
connecting pieces.

Language : en
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Figure 9: Removing the plug
2. Pull the plug out, vertically
up from the cell. It should
not be tilted while doing so.
Figure 10: Proper fit of the plug
Figure 11: Proper fit of the hose pipes
3. Inserting the new
waterfilling plug: The
waterfilling plug must be
inserted straight into the
cell. It must be possible to
slide it in by pressing lightly
on it with the ball of the
hand. The plug should not
be hammered in with tools
(hammer or something
similar) under any
circumstances.
4. It must be ensured that the
waterfilling plug fits
completely in the cell.
5. The hose pipes are
inserted. Whilst doing so, it
must be ensured that they
fit completely into the
connecting piece for the
hosepipe.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Components
The water refilling system consists of the following components:
Illustration of the components
Name / Description of the components
Waterfilling cart, complete
230VAC: 414 700 0230
Optional 110VAC: 414 700 0235
All other components are project-specific and are listed in the illustrated parts list (BOM)
of the respective project.

Language : en
Revision : 005
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Low-pressure water
refilling system
FNC
© 2012, Hoppecke Batterie Systeme GmbH, all rights reserved.
Appendix: Important aspects for proper filling
Procedure:
Repeated start-up of the filling operation may lead to the cells getting overfilled.
As soon as the waterfilling cart has shut down, all cells are completely filled.
Ensure that the waterfilling cart is connected to the proper power supply when
charging it.
While filling, the waterfilling cart should not be connected to the mains supply.
The waterfilling cart should be stored and operated only at temperatures > 0°C.
Installation:
Avoid the hose pipes from getting entangled since the flow rate would
otherwise get reduced. The hose pipes should not get twisted. If angles of 90°
are required, appropriate angular connectors must be used. Hose pipes of
different diameters should not be used on one battery.
Take care to see that all hose pipes fit securely on the connecting pieces of
the plugs and that the plugs are installed properly in the cells. Leakages
resulting from improper installation affect the proper working of the system and
lead to the cells getting overfilled and discharge of the electrolyte.