DC UPS

Table 2: maximum permitted charging currents in A per 100 Ah C10for I and W charging Charging must continue until — all cells have reached a minimum of 2.6 V — the electrolyte density in

We reserve all rights in this document and in the information contained therein Reproduction, use or disclosure to third parties without express authority is strictly forbidden © STATRON 2003

Statron AG · Industrie Nord · CH-5506 Mägenwil · TEL ++41 62 887 4 887 · FAX ++41 62 887 4 888 · statron@statron.com

page 2 M311540-11-2

and Handling Instructions A311540-010 Single line & Layout of Equipment

7140203191_install Battery Installation-Manual

7140203021_operating Battery Operating-Manual

NHT/11/G/BT -/WD/102 S311540-111 Set of Drawings & Partslist (BTM10 ) NHT/11/G/BT -/WD/103 (Dimensions/Layout/Terminal list/Wiring Diagrams)

NHT/11/G/BR -/WD/102 S311540-121 Set of Drawings & Partslist (BRU20, BRB10/20) NHT/11/G/BR -/WD/103

NHT/11/G/BT -/WD/105 S311540-131 Set of Drawings & Partslist (BUB10) NHT/11/G/BT -/WD/106

S311540-132 Set of Drawings & Partslist (BUC10/20) NHT/11/G/BT -/WD/107 (Dimensions/Layout/Terminal list/Wiring Diagrams)

NHT/11/G/BR_BT -/EM/090

(2)

J.Hunger H.Würsch J.Hunger E 1/13

Valid for: Replaces: Order-nbr.: Data set:

Q:\MANUALS\Allgemein\640004\M640004-E.doc

We reserve all rights in this document and in the information contained therein Reproduction, use or disclosure to third parties without express authority is strictly forbidden  STATRON 2007 Statron AG · Industrie Nord · CH-5506 Mägenwil · TEL ++41 62 887 4 887 · FAX ++41 62 887 4 888

ERECTION, ASSEMBLY, SHIPPING

&

HANDLING INSTRUCTIONS

for

DC and UPS System

(in IS2 cabinets)

(3)

This side intentionally left blank

(4)

Table of Contents

1 HANDLING 4

1.1 E QUIPMENT D ESCRIPTION 4

1.2 I NTERMEDIATE S TORAGE 4

1.3 T RANSPORT 5

2 ERECTION 7

2.1 C HECKS ON DELIVERY 7

2.2 C ONSTRUCTIONAL REQUIREMENTS 7

2.3 E RECTION AND CONNECTION OF THE CUBICLES 8

2.3.1 Additional informations for switchgear positioning 9

2.4 F ASTENING METHODS TO FOUNDATION 9

2.5 D RIP PROTECTION ROOF ( OPTIONAL ) 12

3 CABLE CONNECTIONS, WIRING 13

(5)

1 HANDLING

1.1 Equipment Description

General The critical source panels, i.e chargers, inverters and

distribution boards are built-up of single cabinets in fixed technique The basic elements of the frames are C- sections of 2mm thick sheet steel with holes at 25mm intervals The parts of the frame are secured with thread- forming screws and require no maintenance The single cabinets are separated by separation walls The cabinets are equipped with rear plates, hinged front doors and end plates

1.2 Intermediate Storage

The nature and duration of intermediate storage are dependent on the type of packaging

Cubicles in standard packaging Store indoors after arrival where no condensation can

occur Unpack immediately Open the doors for several hours to acclimatize the equipment Cover the cubicles with plastic sheeting for any subsequent storage periods Check regularly for condensation forming under the sheeting until the start of installation

Cubicles with export/

packaging is undamaged

• Possibility of intermediate storage outdoors

• Storage period of maximum 12 months if wrapped in heat sealed PE sheeting and the packaging is undamaged

• When the storage period is exceeded, the drying agent must be replaced and the plastic sheeting has

to be resealed

it is completely dry Open the doors for several hours to acclimatize the unit or run the cubicle heaters for 2-3 days

(6)

Tilting and canting must be avoided

Cubicles may easily tip over when transported

with a hand-pulled truck Therefore the

distance between the wooden cross beam or

the pallet and the underground should not be

more than 3 mm

(7)

By crane

(8)

forwarding agent within one week

made, the manufacturer can disclaim all liability

2.2 Constructional requirements

To prevent damage being caused by moisture and dirt the following tasks (only examples) must be carried out before erection of the switchgear:

• Openings in the floor, wall and ceiling for cables, conductors pipes, bars and ventilation in accordance with the construction drawings provided

frames assembled and painted

• If necessary, assemble braces appropriate to the basic dimensions of the switchgear installation with cross struts corresponding to the cubicle divisions

Suitable indoor conditions must be maintained Adequate lighting as well as free access to the switchgear rooms must be provided Excessive temperature fluctuations together with high humidity should be prevented by heating the room Condensation should also be prevented

(9)

2.3 Erection and connection of the cubicles

The erection of the cubicles should be carried out, as described the following:

The shipping units which are to be erected in one row have to be aligned accurately and checked that they are vertical Doors and panels must not be twisted or stressed The erection can start at the left or at the right The frames of the shipping units have to be screwed together The vertical sections are already fitted on the front and rear with special nuts

Note: for protection class IP5x and

higher or IPx1 and higher the rubber

seal has to be be attached between

the frames

joints in the vertical sections is obstructed, the bottom sections can be screwed together using the frame connectors which are enclosed

(10)

The protective conductor (PE or PEN) is to be connected

to the PE/PEN bar Additional connections to the central earthing system can be made at any point of the perforated PE/PEN bar Local regulations must be complied with

The lifting angles may be removed and afterwards the fastening holes have to be plugged with attached plug

2.3.1 Additional informations for switchgear

In case of left-mounted doors, the minimal distance between the (left) wall and the (left) end cubicle should

be also 150 mm, such that the door can be opened in an angle of more than 90°

The distance from the upper edge of the (highest) cubicle

to the ceiling should be at least 500 mm for cubicles with ventilation grids on the top

2.4 Fastening methods to foundation

The erection of switchgears having the cable entries at the bottom requires a foundation with an opening, a cable duct or a special base frame

The cubicles should preferably be erected on a base frame which is either

• rests as false floor on supports

When erecting the base frame the following must be observed:

the supervision of a suppliers fitter

• The horizontal tolerance of the frame must not exceed +1 mm over a length of 1 m This is to be ensured by using suitable levelling devices (e.g spirit level, 1 m long surveyors rod)

(11)

• The frame must not ondulate ( 2/1000 according to DIN ISO 1101)

• The levelling of base frames can be performed e.g with PRESTOJACK levelling spindles

During erection the switchgear is welded or screwed to the base frame

• The length of the weld seams at the front and rear of each cubicle should not be less than 20 mm All weldings must be protected against corrosion by a coat of paint (e.g zinc paint)

transverse section The mounting holes required for metal straddling dowels M 10 must be drilled during erection

(12)

When false floors are used, notice that:

• The subsoil must be fimm, so that the tolerances are not exceeded by settling of the soil (especially when using insulation layers and adhesives)

• The false floor has to have a carrying capacity of p=20 kN/m2 (Compression load from top to bottom)

During erection the switchgear is welded or screwed to the false floor

• The length of the weld seams at the front and rear of each cubicle should not be less than 20 mm Then a reliable earth connection is provided All weldings must be protected against corrosion by a coat of paint (e.g zinc paint)

• If welding is not possible, the switchgear can be bolted to the false floor The necessary mounting holes should be drilled on site

Care should be taken to ensure that the base sections of each cubicle rests evenly on the supports Taking into account the bending radius of the cables and adequate accessibility, a minimum floor height of 500 mm is recommended

(13)

2.5 Drip protection roof (optional)

A drip proof top is only recommended if tubes containing water or other solvents are placed above the cubicles The top shall be installed only after the cubicles are placed and screwed together

Mount the lifting bolts (or tubes) and install the tops

FRONT VIEW

Note: for protection degree >IP40 the delivered rubber foam gasket must be applied between the cabinets (see chapter 2.3)

(14)

3 CABLE CONNECTIONS, WIRING

• Power and control cables are to be attached to the cable mounting rails in the cable compartment

• Power and control cables are to be stripped off their jacket below the connections of each module

• Before fastening the cables at the power terminals they must be supported or bended so that no tension or pressure is exerted on the cable connection unit

connected to several different terminal blocks are to be stripped within the cable compartment

protective conductor (PE or PEN) must be connected to the cabinet ground bar

The continuous connection of the protective conductor circuits to inactive metal parts of the building (in accordance with IEC 60439 or DIN VDE 0100 Part 540) is to

be carried out according to the conditions at the erection site

The terminal list is part of the Set of Drawings , for each cabinet, on the pages with group nr -040 099

(15)

DC / UPS SYSTEM

BTL10, BTM10, BTA10GS100, BTB10GS100 BTA10, BTB10

BUA10, BUB10, BUC10, BUC20 BRU10, BRA10, BRA20

BRU20, BRB10, BRB20

SEITE/PAGE VON/OF

E D C B

A A

PANEL DIMENSIONS 1 PANEL DIMENSIONS 2 FOOTPRINT OF CABINETS

Owner's Identification No. EPC Contractor Identification No.

ALSTOM Document code NHT/00/G/BR_BT -/WD/101

(16)

SEITE/PAGE VON/OF

E D C B

A A

<U low voltage

>U high voltage

<U> low & high voltage

non polarized capacitor for AC or DC voltage

miscellaneous

E

cabinet heater

fuse, plug type with socket

overcurrent monitoring device

relay coil time delay function

relay coil bistable (remanence) relay

break contact left: delayed when activated right: delayed when de-activated

disconnector (isolator)

switch-disconnector (on load isolating switch)

circuit breaker MCCB moulded case circuit breaker general / detailed symbol

fused switch-disconnector

mcb, miniature circuit breaker with thermal and magnetic release 1-pole / 2-pole / 3-pole (ppower circuits) key lockable handle

for circuit breakers and switch-disconnectors

resistors

R

resistor, general left: resistor with adjustable tap right: potentiometer shunt resistor with separate current and voltage terminals

switching devices for control circuits

S

switch with automatic return operated by pushing switch with non-automatic return operated by pushing switch with non-automatic return operated by turning key operated switch (can be combined with the above options)

voltage transformer

auto-transformer

auto-transformer with voltage regulation

current transformer

converter

U

converter left: AC to AC right: DC to DC

converter left: AC to DC (rectifier/charger) right: DC to AC (inverter)

7 +

8 1

-11 12 + -

M8742

4-20mA 0 300VDC 230VAC 9 3

10

measuring transmitter with galvanic isolation between input, output and aux voltage supply

thyristor

IGBT insulated-gate bipolar transistor terminals, plugs, sockets

cable adapter (ribbon cable to single wire)

filters, limiters

Z

varistor voltage depend resistor transient suppressor R-C unit radio interference filter EMI filter

+15 -15 O/P M LEM transmitter

Hall effect current transmitter

(17)

CHARGER 220BDT200 220V/166A

A A

Rev D

BTL10 GS100

CHARGER DISTURBED CHARGER FAILURE BATTERY FAILURE

-X10 -X10 -X13

3 15A

-F10

230VAC -X9 0

220V DC

BUC10 GS101

BUA10 GS100

FAILURE DIST

TO INVERTER BRU10 TO DISTRIBUTION

BUC10

CHARGER 220BDT200 220V/166A

BATTERY 220V

108 x GroE 425 425Ah/10h

-X11 -X11 -X14 -X01

-F10

220V DC

CF

-X02 -X02

FAILURE DIST

TO INVERTER BRU20

TO DISTRIBUTION BUC10

315A -X04

-Q9

NOTE:

BUC00GS100 closed only when one of Q2 in BTL or BTM

is open!

BTL00 GS100

BUB10 GS100

BRU20 GS101

BUC10 GS102

BTM10 GS100

230 VAC -X90

3x100A 3P

UNDERVOLTAGE RELAY

OVERVOLTAGE RELAY

27 59

A A

Rev D

A

200A -X01a

FROM DISTRIBUTION BUA10 BUC10GS101

FROM DISTRIBUTION BUB10 BUC10GS102

FAILURE DIST

V

300V -X17

230VAC -X9 0

59 27 64

UNDERVOLTAGE RELAY

OVERVOLTAGE RELAY

27 59

EARTH FAULT RELAY

(19)

MANUAL BYPASS SWITCH

230VAC

BRU10

INVERTER IDS 020 2V2 15kVA

CF

FROM BUA10 BRU10GS101 220V DC

V

SEITE/PAGE VON/OF

E D C B

A A

Rev D

50 A 2P

3 00V

BUSBAR DISTURBED ACT VAL VOLTAGE

-X45

-X45

DISTURBED FAIL URE -X40

230VAC

BRU20

INVERTER IDS 020 2V2 15kVA

CF

FROM BUB10 BRU20GS101 220V DC

V

50A 2P

300V

BUSBAR DISTURBED ACT VAL VOLTAGE

-X46 -X46

DISTURBED FAILURE -X41

2 30VAC -X90

~

ACT VAL.

VOLTAGE BUSBAR DISTURBED

-X48 -X48

(20)

Container not to scale!

For cabinet dimension & arrangement only.

SEITE/PAGE VON/OF

E D C B

A A

BRU20 BRB10 BRB20

(21)

Door opening 180°

SEITE/PAGE VON/OF

E D C B

A A

(22)

Door opening 180°

SEITE/PAGE VON/OF

E D C B

A A

(23)

594 98

A A

Rev D

(24)

(Sicherung) (fuse)

Länge length

BTL10AH001 BJA - - - - +HB-X90 102/103 BUA10

BUA10 - +HB-X90 102/103 2 x 2.5 +JB-X90 102/103 BTL10 BTL10 - +JB-X90 102/103 2 x 2,5 +JA-X90 102/103 BRU10 BTM10AH001 BJA - - - - +HB-X90 102/103 BUB10

BUB10 - +HB-X90 102/103 2 x 2,5 +JB-X90 102/103 BTM10 BTM10 - +JB-X90 102/103 2 x 2,5 +JA-X90 102/103 BRU20 BRU20 - +JA-X90 102/103 2 x 2,5 +HB-X90 102/103 BUC10 BUA10GW701 BRA10 BRA10HA003 +KA003-X02 L/N 2 x 1,5 4A +HB-X01 100/101 BUA10 BUC00GW001 BRA10 BRA10HA004 +KA004-X02 L/N 2 x 1,5 4A +HB003-X1 8/7 BUC10 BUB10GW701 BRB10 BRB10HA004 +KA004-X02 L/N 2 x 1,5 4A +HB-X01 100/101 BUB10 BTL10EA002 BTL10 - +JB-X04 1-4 4 x 1.5 4A +JB-X04 1-4 BTM10 BTL00GS100 BTL10 - +JB-X04 +/- 2 x 185 315A +JB-X04 +/- BTM10 BRU10GS101 BUA10 BUA10FA002 +HB002-X02 +/- 2 x 25 63A +KA001-X01a +/- BRU10 BUC10GS101 BUA10 BUA10DB001 +HB001-X02a +/- 2 x 95 200A +KA001-X01a L+/L- BUC10 BRU20GS101 BUB10 BUB10FA002 +HB002-X02 +/- 2 x 25 63A +KA001-X01a +/- BRU20 BUC10GS102 BUB10 BUB10DB001 +HB001-X02a +/- 2 x 95 200A +KA002-X01b L+/L- BUC10 BTA10 BUA10 BTA10GS100 +GA-X02 +/- 2 x 185 315A cell 1 / cell 106 +/- BTA10 BTB10 BUB10 BTB10GS100 +GA-X02 +/- 2 x 185 315A cell 1 / cell 106 +/- BTB10

** je nach Länge des Kabels muss der Querschnitt ev angepasst werden.

** section of cables depend on length and may have to be increased to reduce voltage drop

(25)

We reserve all rights in this document and in the information contained therein Reproduction, use or disclosure to third parties without express authority is strictly forbidden © STATRON 2003

Statron AG · Industrie Nord · CH-5506 Mägenwil · TEL ++41 62 887 4 887 · FAX ++41 62 887 4 888 · statron@statron.com

(4) Duration

of Period (minutes)

(5) Time to End

of Section (minutes)

(6) Capacity at

T Min Rate Amps/Pos(Rt)

(7) Required Section Size (3) / (6)

= Positive Plates

Section 1 - First 1 Period(s) Only - if A2 is greater than A1, go to Section 2

Maximum Section Size (8) 13.0 + Random Section Size (9) 0.0 = Uncorrected Size (US) (10) 13.0

US (11) 13.0 X Temp Corr (12) 1.00 X Design Margin (13) 1.10 X Aging Factor (14) 1.00 = (15) 14.3 Positive Plates

When the cell size (15) is greater than a standard cell size, The next larger cell is required.

Calculated Capacity: 14.35 Positive Plates Recommended Battery: 1 X 108 X 15 GroE 375 Nominal Capacity: 375.00 Ah

(29)

(2)

Load (Amperes)

(3) Change in Load (Amperes)

(4) Duration

of Period (minutes)

(5) Time to End

of Section (minutes)

(6) Capacity at

T Min Rate Amps/Pos(Rt)

(7) Required Section Size (3) / (6)

= Positive Plates

Section 1 - First 1 Period(s) Only - if A2 is greater than A1, go to Section 2

Maximum Section Size (8) 16.9 + Random Section Size (9) 0.0 = Uncorrected Size (US) (10) 16.9

US (11) 16.9 X Temp Corr (12) 1.00 X Design Margin (13) 1.00 X Aging Factor (14) 1.00 = (15) 16.9 Positive Plates

When the cell size (15) is greater than a standard cell size, The next larger cell is required.

Calculated Capacity: 16.93 Positive Plates Recommended Battery: 1 X 108 X 17 GroE 425 Nominal Capacity: 425.00 Ah

(30)

1 1 1 1 1 1 1

.h., 011 :

rev,oo I 1 , 1 1 I

porl no weighl

Sctraube Di i thoutloLef'0"'IC8 li.i l range

Installation instructions for stationary batteries

(Batteries / stands / cabinets)

Observe the operating instructions!

Work on batteries only under

instruc-tion of skilled personnel only,

obser-ving commissioning instructions and

instructions for use!

When working on batteries wear

protective glasses and clothing!

Observe the accident prevention

rules as well as EN 50272-2,

VDE 0105 part 1!

Smoking prohibited! Do not expose

the battery to open flame, glowing

embers or sparks as explosion and

fire hazard exists!

Acid splashes in the eyes or on the

skin must be washed out or off with

plenty of water Then consult a

doc-tor immediately Clothing

contami-nated with acid should be washed

with water!

Explosion and fire hazard, avoid

short circuits! Caution! Metal parts of

the batteries are always live, do not

place tools or other objects on the

battery!

Electrolyte is strongly corrosive.

Under normal operating conditions

exposure to electrolyte is impossible.

Should the casing be destroyed, the

released fixed electrolyte is as

corro-sive as liquid electrolyte.

Block batteries and cells are

extremely heavy!

Ensure secure installation!

Only use suitable handling

equipment, tools and measuring

bat-be set out and marked with warning marks according to EN 50272-2 Particular atten- tion must be paid to the following:

- floor load-carrying capacity and nature (conveying paths and battery room)

- electrolyte resistance of battery installation surface

- no ignitable sources (e.g open flame, glowing objects, electric switches) near the cell openings (500 mm ”safety distance”)

- ventilation conditions

To ensure smooth operation, coordination between other persons working in the same room is necessary.

1.2.Check deliveries for completeness and damage If necessary, clean all parts before assembling.

1.3.Observe all documentation included with the delivery (e.g battery-, rack-, cabinet-assembly drawings).

1.4.Before renewing old batteries ensure that all electric loads are switched off (sepa- rator, fuses, switches) This must be carried out by qualified personnel.

CAUTION: Do not carry out authorised switching!

un-1.5. Open-circuit voltage measurements

of individual cells or block batteries Ensure correct polarity With unfilled and charged batteries these measurements can only be carried out after start-up Fully charged cells have the following listed open circuit voltages at an electrolyte temperature of 20°C:

(33)

deviations for block batteries apply:

4 V block batteries 0.03 V/block

6 V block batteries 0.04 V/block

12 V block batteries 0.05 V/block

Higher temperatures decrease, lower

tem-peratures increase the open-circuit voltage.

With a deviation of 15 K from the nominal

temperature the open-circuit voltage

changes by 0.01 V/cell Should greater

deviations occur, consult the supplier.

2 Racks

2.1.Align the racks according to the

instal-lation drawing Should an instalinstal-lation

draw-ing be missdraw-ing, the followdraw-ing minimum

di-stances must be observed:

- To the wall: 100 mm on all sides for the

cell or block container, or 50 mm for the rack.

- 1.5 metres by a nominal or component

voltage > 120 V between non-insulated

terminals or connectors and earthed parts

(e.g water pipes) or between the battery’s

end terminals.

During installation it must be ensured that

DIN VDE 0510, Part 2, EN 50272-2 is

adhered to (e.g.

cover electrically conductive parts with

insulating mats).

- To ignitable sources: For distance from the

nearest cell vent see EN 50272-2.

- To passageways: 1.5 x cell width

(in-stallation depth) but not less than 50 cm.

2.2.Align racks horizontally using the

le-velling parts or adjustable insulators

provi-ded The distances of the support profiles

must correspond with the cell or block

bat-tery size Check rack stability and ensure

that all screw and clamp connectors are

firmly seated If stipulated, earth the rack or

parts thereof Protect screw connectors from

corrosion.

Please note that when using wooden racks

a flexible connector must be fitted between

each rack joint.

2.3.Check that cells or block batteries are

sound (visually, polarity).

rack.

- Arrange cells or batteries plumb and level with the correct polarity.

- Distance between the cells should be approx.

10 mm or according to the length of the connectors supplied.

- If necessary clean the contact surface of the terminals and connectors.

- With screwed connectors:

· Remove protective caps from terminals

· that the threaded insert is sufficiently full

of neutraliser and the terminal contact surface is greased.

- Fit cell or block connectors and tighten with an insulated torque wrench (20 Nm  1 Nm) Caution: Screws are approved for single use

- Fit row, step, tier connectors and tighten observing the specified torques.

- After fitting, the welded connectors of the individual cells GroE/OGi/OPzS/

OSP.HC/max.power must be aligned and welded to the terminals as specified

Observe the specifications under VBG 15.

- If necessary, fit insulating caps onto cell/

block connectors and end terminals.

- Ensure short-circuit proof installation work.

Wiring with a dielectric strength and a signed operating voltage above the maxi- mum possible battery system voltage must

de-be used, or a distance of approx 10 mm between wiring and electrically conductive parts must be kept or the connectors must

be furnished with additional insulation.

Avoid mechanical stress on the cell/

fea-3 Cabinets 3.1 Cabinets with built-in battery:

- The battery cabinet is assembled on site (observing the relevant accident preven- tion rules).

- Take into account additional space needed between wall and cabinet for possible or planned cable entries.

- Remove any transport safety devices from the built-in cells or block batteries.

- Check cells or block batteries for correct position and mechanical damage.

3.2 Cabinets with separately vered cells or block batteries:

deli Only filled and charged cells or block batteries (vented or sealed) are built into cabinets.

- Assemble cabinet, place in designated location and align (observing the relevant accident prevention rules).

- Place cells or block batteries into the net according to assembly plan and spa- cing specified, connect them and mark (see item 2.4).

cabi-4 CE marking

Since 01.01.97 an EC declaration of formity under the low voltage regulation is required for batteries from 75 V to 1500 V nominal voltage with the corresponding CE labelling on the battery The battery installer

con-of the battery plant is responsible for issuing the declaration and affixing the CE label on

or next to the battery’s nameplate.

C A U T I O N ! Before connecting to the charger ensure that all assembly work has been duly completed!

(34)

Commissioning Instructions

and report for a vented stationary lead-acid battery

Commissioning instructions

Observe commissioning instructions!

Work on batteries only under

instruc-tions of skilled personnel!

Smoking prohibited! Do not expose

battery to open flame, glowing fire or

sparks as expiosion and fire hazard

exists!

When working on botteries wear

pro-tective glasses and clothing! Observe

the accident prevention rules as well

as DIN VDE 0510, VDE 0105 Part 1!

Acid splashes in the eyes or on the

skin must be washed out or off with

plenty of water Then see a doctor

immediately Acid splashes on

clo-thing should be washed out with

water!

Expiosion and fire hazard, avoid

short circuits! Caution! Metal parts of

the battery cells are always live, do

not place items or tools on the

bat-tery!

Electrolyte is strongly corrosive!

Monobloc batteries are very heavy!

Ensure secure installation! Only use

suitable transport equipment!

Non-compliance with the commissioning

instruc-tions, tampering or use of additives for the

elec-trolyte (alleged ”enhancing agents”) render the

warranty null and void.

1 Inspection/check

The battery installation and charging unit must

be inspected for mechanical soundness All ted connections within the circuit must be pro- perly tightened for optimum contact as set out

bol-in the operatbol-ing bol-instructions.

The charging unit must be checked for nal readiness Ensure that the polarity is cor- rect.

operatio-Before filling the cells ensure that the conditions

as set out in DIN VDE 0510 Part 2 regarding installation and ventilation are observed.

Should a higher charging current be used than permitted for the ventilation layout by start up charging, the ventilation in the battery room must be increased according to the loading cur- rent applied for the start-up period and for one hour afterwards, e.g by additional portable ventilators The same applies to occasional spe- cial battery charging processes.

2 Filling cells

Acid with the density according to Table 1 must comply with the purity specifications according DIN 43 530 Part 2.

If concentrated sulphuric acid is supplied, the mixing instructions must be observed.

The acid temperature should be in the range of 15°C to 30°C Before filling the temperature must be measured and noted in the commissio- ning report.

Aher removing the transport plugs or opening the vent plugs the cells must be filled to the lower electrolyte level mark using acid-resistant filling devices.

It is not permitted to use transport plugs when operating the battery They must be replaced

by vent plugs delivered with the batteries Higher temperatures reduce the electrolyte den- sity and lower temperatures increase the elec- trolyte density The associated correction factor

If the temperature rise is less than 5 K and the electrolyte density has not fallen more than 0.02 kg/l below the acid density, a commissio- ning charge as under 4.1 or 4.2 is adequate Should one of the deviations be higher than an extended commissioning charge as under 4.3

is necessary.

4 Commissioning

With non-transparent cell containers the vent plugs remain open in order to observe whether gassing is taking place evenly in all the cells towards the end of the charge.

It is important that the first charge is carried out

to completion This is only possible with a ging voltage above 2.35 V/cell Interruptions should be avoided if possible Commissioning should be recorded in the commissioning report overleaf.

ended on

Table 1: Electrolyte density in kg/l at 20°C Cell type Filling Nominal

(kg/l) density (kg/l) GroE 1.21 1.22 OPzS/HOPzS 1.23 1.24 OGi 1,23 1.24 OSP* 1.23/1.26 1.24/1.27 USV/SIBE 1.28 1.29

The completed commissioning

report must be sent back to the

battery manufacturer.

* depending on type

(35)

The electrolyte temperature must not exceed

55°C, if necessary the charge operation must

The charge current on commencing the charge

shouid be a minimum of 5 A per 100 Ah C10.

The electrolyte density only rises slowly during

the charge The charge time can therefore take

several days before reaching a minimum

elec-trolyte density of nominal elecelec-trolyte density

-0.01 kg/l.

Subsequently switch to the float charge voltage

as set out in the operoting instructions The

electrolyte density rises to the nominal density

The maximum permitted currents can be

obtai-ned from Table 2.

Table 2: maximum permitted charging currents

in A per 100 Ah C10for I and W charging

Charging must continue until

— all cells have reached a minimum of 2.6 V

— the electrolyte density in all cells has risen to

the nominal value of ± 0.01 kg/l and these

cease to rise over a further period of 2

hours.

Subsequently switch to the floot charging

volta-ge as set out in the operating instructions.

4.3 Extended commissioning

charge

Extended storage or climatic influences

(humidi-ty, temperature fluctuations) reduce the charge

state of the cells This makes an extended

com-missioning charge along the following

procedu-re necessary:

1 Charge at 15 A per 100 Ah C10until

2.4 V/cell is achieved (ca 3 - 5 hours),

2 Charge for 14 hours with 5 A per 100 Ah

C10(voltage exceeds 2.4 V/cell),

— all cells have reached a minimum 2.6 V

— the electrolyte density in all cells has risen to the nominol value of ± 0.01 kg/l and these cease to rise for a further 2 hours.

Subsequently switch to the float charge voltage

as set out in the operating instructions.

4.4 Electrolyte level ment

adjust-On completion of commissioning top up with acid to bring the electrolyte level to the upper electrolyte level mark.

4.5 Electrolyte density adjustment

If the electrolyte density at the end of sioning is too high, reploce part of the electro- lyte with purified water as specified in DIN 43 530 Part 4.

commis-The comparative electrolyte density in dual cells should not deviate more than 0.01 kg/l With greater deviations adjust the electrolyte density and then carry out an equali- zing charge as set out in the operating instruc- tions.

indivi-5 Notes

Carefully remove or neutralise leaked or spilt acid This can be done with soda solution (1 kg soda to 10 l water) or other neutralising agents Neutralising agents must not enter the cells.

Finally clean the battery surface (see ZVEI pamphlet on cleaning batteries).

The ZVEI pamphlet on precautionary measures when handling electrolyte for lead-acid batte- ries must be observed.

The operating instructions apply when ting the battery.

opera-6 Commissioning report

— Was the acid delivered with the battery by the battery manufacturer? yes , no 

— If not, was the acid tested for chlorine, iron and other harmful metals? yes , no 

— What did the test show?

— What was the density of the new acid before filling? kg/l at °C

— Acid filling commenced on: at o’clock on cell no

— Acid filling ended on: at o’clock on cell no

— Mean ambient temperature: °C.

5 A

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Pilot cell/block 1 Time d

(kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V) Pilot cell/block 2 Pilot cell/block 3 Pilot cell/block 4

Pilot cell/block 5 Time d

(kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V)

d (kg/l)

ϑ

(°C)

U (V) Pilot cell/block 6 Pilot cell/block 7 Pilot cell/block 8

— With monobloc batteries the cell voltage (if not possible the block voltage) and the electrolyte density

on the cell adjacent to the positive terminal must be measured.

With monobloc batteries the electrolyte density at the cell adjacent to the positive terminal must be

measured.

— The commissioning charge was carried out according to item 4.1 , 4.2 , 4.3 .

— Commissioning charge commenced on (date) o’clock.

— During the first 6 hours of the commissioning charge the cell voltage, electrolyte density and

temperature must be measured hourly and noted on at least 4 pilot cells On completion of

the commissioning charge a further 3 measurements must be taken at hourly intervals.

Electrolyte temperature °C

Temperature-adjusted

electro-lyte density (s item 2) kg/l

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e-Mail: hoppecke.IO@t-online.de

182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225

137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180

92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135

47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90

scharge (see type plate and technical data in

these instructions)

Nominal discharge current: IN= I10:

Final discharge voltage Us:

see technical data in these instructions

Nominal temperature TN: 20°C

”LA”: antimony content < 3% in the grids

(earth carries) or Planté plates of the positive

Observe operating instructions and

affix close within sight of the

battery !

Work on batteries only under

instruc-tions of skilled personnel !

Smoking prohibited !

Do not expose battery to open

fla-me, glowing fire or sparks as

explo-sion and fire hazard exists !

When working on batteries wear

protective glasses and clothing !

Observe the accident prevention

rules as well as DIN VDE 0510/

EN 50272-2, VDE 0105 T !

Acid splashes in the eyes or on the

skin must be washed out or off with

plenty of water Then see a doctor

immediately Acid splashes on

clothing should be washed out with

water !

Explosion and fire hazard, avoid

short circuits !

Caution ! Metal parts of the battery

cells are always live, therefore do

not place items or tools on the

battery !

Electrolyte is strongly corrosive !

Monobloc batteries/cells are very

heavy ! Ensure secure installation !

Only use suitable transport

equip-ment !

Dangerous voltage ! Non-compliance with operating instructions repairs made with other than original parts, tampering or use of additives for the electro- lyte (alleged ”enhancing agents”) render the warranty null and void.

1 Commissioning of filled and ged batteries

char-Before commissioning all cells/blocks must be inspected for mechanical damage, cells must

be connected with the correct polarity and connectors firmly seated The following tor- ques apply for screwed connectors:

M8 with 20 Nm ± 1 Nm M10 with 20 Nm ± 2 Nm

If necessary the terminal covers must be put

on Check the electrolyte level in all cells If necessary top up to maximum level with puri- fied water as under DIN 43530 Part 4.

With charger off and loads isolated connect battery to the direct current power supply maintaining correct polarity (positive terminal

to positive post) Switch on the charger and charge as described under Section 2.2.

2 Operation

For the operation of stationary battery tions DIN VDE 0510 Part 1 (draft) and DIN VDE 0510 Part 2 apply.

installa-2.1 Discharging

Never allow the final discharge voltage of the battery to drop below that assigned for the discharge current Unless the manufacturer has specified otherwise, no more than the nominal capacity is to be consumed Charge immediately after discharge as well as partial discharge Discharge data are given in Table 8.2 for single cells.

Depending on charger type and charging characteristic alternating currents flow through the battery superimposed onto the direct cur- rent These alternating currents and the reac- tion of the loads lead to an additional war- ming of the battery and strain on the electro- des with possible resulting damage (see 2.5).

Depending on the system at hand charging may be carried out under the following opera- tions:

a) Stand-by parallel operation and floating operation

Here the load, direct current and battery are continuously connected in parallel.

Thereby the charging voltage is the operating voltage of the battery and at the same time the battery installation voltage.

With stand-by parallel operation the direct current is at any time capable of supplying the maximum load current and the battery char- ging current The battery only supplies current when the direct current source fails The char-

ge voltage should be set at 2.23 V ± 1% x number of cells connected in series measured

at the batteries’ terminals To reduce the recharging time a charging stage can be ap- plied in which the charging voltage is 2.33 to 2.4 V x number of cells connected in series (stand-by parallel operation with recharging stage) Automatic changeover to the charging voltage of 2.23 V ± 1% x number of cells connected in series follows.

With the floating operation the direct current source is not able to supply the maximum load current at all times The load current intermit- tently supercedes the nominal current of the di- rect current source During this period the bat- tery supplies power It is not fully charged at all times Therefore, depending on the load the charge voltage must be set at 2.25 to 2.30 V x number of cells connected in series b) Switch mode operation

When charging the battery is separated from the load Towards the end of the charging process the charge voltage of the battery is 2.6 - 2.75 V/cell The charging process must

be monitored (see Section 2.4, 2.5 and 2.6).

On reaching a fully charged state the ging process mus be stopped or switched to float charge as under Section 2.3.

char-c) Battery operation (charge/discharge operation)

The load is supplied only by the battery

Here-by the charge voltage of the battery towards the end of the charging process is 2.6 - 2.75 V/cell The charging process must be monitored (see Section 2.4, 2.5 and 2.6).

On reaching a fully charged state the ging process must be switched off The battery can be switched to the load as necessary.

char-2.3 Maintaining the full charge

(float charge) Devices complying with the stipulations under DIN 41773 must be used They are to be set

so that the average cell voltage is 2.23 V

± 1% and the electrolyte density does not decrease over a protracted period.

2.4 Equalizing charge

Because it is possible to exceed the permitted load voltages, appropriate measures must be taken, e g switch off the load.

Equalizing charges are required after stive discharges and after inadequate char-

exhau-CN

10 h

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55°C charging must either be stopped or

pro-ceed with reduced current or be switched to

float charge to allow the temperature to drop.

The equalizing charge is completed when the

electrolyte densities and cell voltages no

lon-ger increase within 2 hours.

2.5 Alternating currents with periodic

deviations

On recharging up to 2.4 V/cell as under

ope-ration modes a) to c) the actual value of the

alternating current is ocassionally permitted

to reach max 20 A per 100 Ah nominal

capacity.

Above 2.4 V/cells 10 A per 100 Ah nominal

capacity may not be exceeded.

In a fully charged state with a charge voltage

of 2.23 to 2.30 V/cell the actual value of the

alternating current may not exceed 5 A per

100 Ah nominal capacity.

2.6 Charging currents

The charging currents are not limited to

2.4 V/cell When exceeding the charging

voltage of 2.4 V/ cell greater water

decom-position occurs The charging currents per

100 Ah nominal capacity shown in Table 1

may not be exceeded.

2.7 Temperature

The recommended operating temperature for

lead-acid batteries is10°C to 30°C The

tech-nical data apply for the nominal temperature

20°C The ideal operating temperature is

20°C ± 5°C Higher temperatures shorten the

service life Lower temperatures reduce the

available capacity The maximum temperature

of 55°C may not be exceeded.

2.8 Temperature-related charge

voltage

A temperature-related adjustment of the

char-ge voltachar-ge within the operating temperature of

10°C to 30°C is not necessary.

Should the temperature range be lower than

10°C and/or higher than 30°C a

temperatu-re-related adjustment of the charge voltage

should be made The temperature correction

factor is (-0.004 V/cell per K).

Should the temperature constantly rise above

40°C, then the factor is (- 0.003 V/c per K).

2.9 Electrolyte

The electrolyte is diluted sulphuric acid The

nominal electrolyte density is based on 20°C

and the nominal electrolyte level when fully

charged maximum deviation ± 0.01 kg/l.

Higher temperatures reduce the electrolyte

density, lower temperatures increase the

elec-trolyte density.

The correction factor is - 0.0007 kg/l per K.

Pb

3 Battery maintenance and control

The electrolyte level must be checked

regular-ly If it has dropped to the lowest electrolyte level mark, purified water must be added as under DIN 43530 Part 4, maximum conduc- ting capacity 30 µS/cm.

To avoid leakage currents keep the battery clean and dry Cleaning the battery should be carried out as specified in the ZVEI pamphlet

on battery cleaning.

Plastic battery components, in particular the vent caps, must only be cleaned with water containing no additives.

At least every 6 months the following must be measured and recorded:

- battery voltage

- voltage of a few selected cells

- electrolyte density of a few selected cells

- electrolyte temperature of a few selected cells

The following must be measured annually:

- voltage of all cells/monobloc batteries

- electrolyte density of all cells

- electrolyte temperature of a few selected cells

Should the float charge voltage in one cell deviate more than + 0.1 V or -0.05 V from the average value (see 2.3), customer services must be called in.

Annual visual checks:

- on bolted connectors, check that unsecured bolt connectors are firmly seated

- on battery installation or arrangement

- on ventilation of the battery room.

4 Tests

Tests must be conducted according to DIN

43539 Part 1 and 4 In addition, special test instructions such as under DIN VDE 0107 and DIN VDE 0108 must be observed.

5 Faults

Should faults be detected in the battery or the charging device, customer services should be called in immediately.

Measurement data under Section 3 simplify fault detection and removal.

A service contract with us facilitates the timely detectian of faults.

6 Storage and taking out of operation

Should cells/batteries be stored or taken out

of operation for a longer period of time, they must be placed, fully charged, in a dry, frost- free room.

To avoid damage the following-charging methods can be chosen:

1 Equalizing charges on a quarterly basis as under Section 2.4 In average ambient tempe- ratures of more than 30°C monthly equalizing charges may be necessary.

2 Float charging as under Section 2.3.

at 2.4 V

at 2.65 V

ly on palettes (GGV’s margin No 2801 a).

The batteries ready for dispatch must not show any external dangerous traces of acid

For all sealed batteries and cells whose ments are leaking or damaged the exceptio- nal regulation No 69 applies.

ele-8 Technical data

The nominal voltage, the number of cells the nominal capacity (C10= CN) and the battery type are obtained from the type plate of the battery installation Other capacities (Cn) at different discharge voltages (In) with the corresponding discharge times (tn) can be calculated using Tables 8.2.1 to 8.2.3 and the example.

8.1 Example:

Determining the 5-hour battery data Data an type plate: 4 GroE 100 Key: 6 V = Nominal voltage of the monobloc battery (with individual cells the nominal volta-

Calculation of plate type:

- Determining the 5-hour capacity per plate (C5/PI): The 5-hour capacity per plate with

43 Ah/PI is shown in Table 8.2.3 under plate model 50 and discharge time t10= 5 h.

8.2 Capacities (C n ) at different discharge times (t n ) up to the permitted final discharge voltage (U S ).

Stationary lead-acid battery type GroE under DIN 40738

with positive Planté plates and negative grid plates nominal electrolyte density 1.22 kg/l.

Discharge time t n

10 min.

C 1/6 /Pl (Ah) 8.65 27.50 1.60 V 1.70 V 1.74 V 1.78 V 1.79 V 1.80 V

13.3 16.6 21.3 23.0 25

100

C 1/2 /Pl (Ah)

C 1 /Pl (Ah)

C 3 /Pl (Ah)

C 5 /Pl (Ah)

C 10 /Pl (Ah)

30 min. 1 h 3 h 5 h 10 hCapacity/

plate at t n

Plate type GroE 25 GroE 100

U s (cell)

Used batteries with this sign are recycable economic goods and must be collected for recycling.

Used batteries which are not collected for recycling are to be disposed of as separate waste observing all the regulations.

Phone (0 29 63) 61-0 · Fax (0 29 63) 6 14 49 http://www.HOPPECKE.de

e-Mail: hoppecke.IO@t-online.de

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