Hoppecke Electrolyte Circulation System Bedienungsanleitung
Electrolyte Circulation System
Installation and Operating Instructions
2
Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Installation and Operating Instructions
Electrolyte Circulation System
Type, Design, Print: Koerdt Promo4you GmbH, 59929 Brilon
© 2013 HOPPECKE Batterien GmbH & Co. KG
P.O. Box 1140
D-59914 Brilon
All rights reserved, even for patent and utility patent applications.
The distribution and duplication of this document and the use and disclosure of its contents are prohibited
unless written permission is granted by HOPPECKE Batterien GmbH & Co. KG. Noncompliance will result in a
claim for damages.
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Table of contents
Preface ................................................................................................................................................... 4
Safety precautions .................................................................................................................................. 5
Required parts and tools.......................................................................................................................... 6
Parts of delivery ...................................................................................................................................... 7
System overview ..................................................................................................................................... 8
Installation............................................................................................................................................ 10
Step 1: Equip battery cells with air tubes .............................................................................................10
Step 2: Connect all air tubes ............................................................................................................... 12
Step 3: Mount the pump- and control unit ............................................................................................ 13
Step 4: Connect air tube to the pump and control unit .......................................................................... 14
Step 5: Install current sensor .............................................................................................................. 15
Step 6: Connect power supply ............................................................................................................. 17
Operation ............................................................................................................................................. 21
Connection terminals............................................................................................................................. 22
Error states........................................................................................................................................... 22
Maintenance ......................................................................................................................................... 22
Technical Data ...................................................................................................................................... 23
Annex A: References ............................................................................................................................ 24
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Preface
The HOPPECKE Electrolyte Circulation System pumps ambient air to the bottom of each battery
cell. Emerging air bubbles rise through the electrolyte, ensuring a homogeneous electrolyte den-
sity distribution in each battery cell.
The HOPPECKE Electrolyte Circulation System provides several important benefits:
• Economic recharge - increased charging efficiency, reduced recharge time and cost reduction
• Environment-friendly - reduced runtime of additional (Diesel) generators and cost savings
• Extended battery service life - no acid stratification
• Minimum maintenance costs - maintenance free pump system (automatically controlled)
• Reduced battery service costs - reduced water loss for longer refill intervals
The HOPPECKE Electrolyte Circulation System is applicable for HOPPECKE OPzS solar.power
batteries (6 OPzS solar.power 910 Ah to 26 OPzS solar.power 4700 Ah) only. Figure 1 shows the
general architecture of the system.
Note: The Electrolyte Circulation System cannot be used with a recombination system (HOPPECKE
AquaGen® premium.top) simultaneously. Any recombination system plugs need to be replaced by
the HOPPECKE Labyrinth plugs (refer also to /3/).
Figure 1: System overview
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Safety precautions
Incorrect use of the product described here can lead to personal and material damage.
HOPPECKE is not responsible or liable for direct or indirect personal and material damages
which occur as a result of handling the products described here.
Danger!
Risk of explosion or blast, splashing of hot or molten substances.
Explosion and fire hazard, avoid short circuits!
Avoid electrostatic charge and discharge / sparks.
Failure to observe this hazard notice can lead to severe or fatal injury.
Electrical voltages hazardous to health may cause fatal injury.
Metal parts of the battery are always alive, therefore do not place items or tools on the battery.
Failure to observe this hazard notice can lead to severe or fatal injury.
Do not smoke!
Do not use any naked flame or other sources of ignition.
Risk of explosion and fire!
Danger!
Electrolyte is highly corrosive. Leaking electrolyte is harmful to the eyes and skin.
Note: Potential hazards: Diluted acid may cause severe acid burns.
First-aid measures:
General instructions: Remove soiled, wetted clothing immediately
After contact: Rinse with a lot of water immediately after contact to skin.
After inhalation of acid mist: Inhale fresh air1)
After contact with eyes: Rinse under running water for several minutes1)
After swallowing: Drink a lot of water immediately and swallow activated carbon1)
1) Seek the advice of a medical doctor immediately.
Danger!
Work on batteries, especially installation and maintenance should be performed by
trained HOPPECKE specialists (or by personnel authorized by HOPPECKE) only; personnel
must be familiar with battery handling and the required precautionary measures.
Unauthorized persons must keep away from the batteries.
Observe the following regulations (IEEE standards valid for USA only):
· ZVEI publication „Instructions for the safe handling of electrolyte for lead-acid accumulators.“
· ZVEI publication „Safety data sheet on accumulator acid (diluted sulfuric acid).“
· VDE 0510 Part 2: 2001-12, in accordance with EN 50272-2:2001: „Safety requirements for
secondary batteries and battery installations - Part 2: Stationary batteries“.
· IEEE Standard 450-2002: „Recommended Practice for Maintenance, Testing and Replacement
of Vented Lead Acid Batteries for Stationary Application.“
· IEEE Standard 1375-1998: „Guide for Protection of Stationary Battery Systems”
Further on observe the following safety rules:
1. Ensure that all electrical loads are switched off (separators, fuses, switches). The electrolyte
circulation pump system needs to be switched off (via the two corresponding fuses) as well.
This must be carried out by qualified personnel.
2. Remove all wrist watches, rings, chains, jewelry and other metal objects before working with
batteries.
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
3. Use insulated tools only.
4. Wear insulating rubber gloves and rubber shoes.
5. Never place tools or metal components on top of the batteries.
6. Make sure that the battery or batteries are not mistakenly grounded. If the system is grounded,
terminate the connection. Touching a grounded battery by mistake can result in severe electric
shock. The risk caused by an incorrect connection can be significantly reduced by terminating
the ground connection.
7. Before establishing connections, make sure to check the correct polarity – better one too many
times than one too few.
8. Filled lead-acid batteries contain highly explosive gas (hydrogen/ air mixture).
Never smoke, handle open flames or create sparks near the batteries. Always avoid electro-
static discharge; wear cotton clothing and ground yourself if necessary.
9. Wear the appropriate safety clothing and equipment.
To avoid electrostatic charging, all textiles, protective shoes and gloves worn while working with
batteries must have a surface resistance of <108Ohm and an insulation resistance of ≥105Ohm
(refer EN 50272-2 and DIN EN ISO 20345:2011 Personal protective equipment – Safety footwear).
Refer also to the HOPPECKE manual “Installation, commissioning and operating instructions for vented statio-
nary lead-acid batteries” (refer to /1/).
For questions and comments refer to:
www.hoppecke.com
Required parts and tools
The following tools are required for installation of the Electrolyte Circulation System:
1. Power drill
2. Cutter knife or scissors
3. Screwdriver
4. Crimping pliers
Depending on the installation site various anchor bolts are required for wall mounting of the pump- and control
unit as well as for the DIN cap rail (required for the fuse holders).
Depending on the operating conditions of the system an additional installation box is required for the fuse
holders.
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Parts of delivery
1 x Housing with DC-pump- and control
unit
1 x Sensor unit for current detection
2 x Battery terminal connection bolts
1 x DIN cap rail (35 mm) for installation
of fuse holders
2 x Fuse holders for DIN cap rail
mounting
2 x Fuses (2A)
Air Tubes with connectors
1 x Back-pressure valve
Connection Cables for power supply
(1.5 mm2and 6 mm2)
2x Cable lugs for 6 mm2power supply
cable
2 x Wire termination (6 mm2) for power
supply cables
4 x Wire strips
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
System overview
The pump- and control unit comes with a plastic housing for wall mounting. The air outlet of this unit is con-
nected to the air tubing (refer to Figure 2). For switching the air pump during battery charge periods an inductive
current sensor is connected to the pump- and control unit. The power supply for the pump- and control unit
comes from the battery (24V / 48V). Refer also to Figure 3 and Figure 4.
Note: For 48V battery systems with larger cells (18 OPzS solar.power 3250 up to 26 OPzS solar.power 4700)
two electrolyte circulation pumps are required (refer to Figure 5).
Figure 3: Schematic diagram
Figure 2: Pump and control unit
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Figure 4: System overview - Components
Figure 5: System setup for 48V battery systems with cells >= 18 OPzS solar.power 3250
(18 OPzS solar.power 3250 up to 26 OPzS solar.power 4700)
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Electrolyte Circulation System
7145240031 V1.1 (01.2013)
Figure 6: Inserted hard plastic tubes
Installation
The installation procedure in this section describes how to retrofit a HOPPECKE Electrolyte Circulation System
in an existing battery installation. It considers the default operating mode.
Before installation:
• Check if all required components have been delivered.
• Note: The Electrolyte Circulation System cannot be used with a recombination system (HOPPECKE AquaGen®
premium.top) simultaneously. Any recombination system plugs need to be replaced by the HOPPECKE
Labyrinth plugs (refer also to /3/).
• Please contact your HOPPECKE representative in case you want to use the Electrolyte Circulation System
together with an automatic water refill system.
Attention
Important note: Before starting the installation procedure make sure that all safety precautions
(refer to chapter Safety precautions) are fulfilled. That includes:
1. Use insulated tools only.
2. Wear insulating rubber gloves and rubber shoes.
3. Wear protective glasses.
Important note: Ensure that all electrical loads are switched off (separators, fuses, switches).
This must be carried out by qualified personnel.
Please consider that even after switching off all electrical loads metal parts of the battery are
always live. Never place tools or other objects on top of the batteries.
Step 1: Equip battery cells with air tubes
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