Training D Battery - Hoppecke - EN

3rd Thai-German Community-based
Renewable Energy Conference 2018

8th February 2018, Eastin Grande Hotel Sathorn,
Surasak Ballroom, Bangkok
www.hoppecke.com HOPPECKE 1
Table of Contents
1) Site Storage Requirement
2) Parameters for Battery Sizing
3) Battery Depth of Discharge (DOD) & Life Cycles
4) Charging Parameters for Solar Application
5) Battery Maintenance
6) Optimized Battery System (AquaGen & ECS)
Table of Contents
1) Site Storage Requirement
2) Parameters for Battery Sizing
3) Battery Depth of Discharge (DOD) & Life Cycles
4) Charging Parameters for Solar Application
5) Battery Maintenance
6) Optimized Battery System (AquaGen & ECS)
Site Storage Requirement
- Storage Requirements
• The battery have to be fully charge

• The storage room must be dry and frost-free.
• Variations in the ambient temperature should be avoided in the battery storage room. In any
circumstances the temperatures must be below 40°C (104°F).
• Water condensation in the cells must be avoided.
• Direct sunlight must be avoided.
• Detergents, solvent material or its vapours as well as other chemicals are to be kept well apart
from the cells / blocks
• Cells / blocks are not to be stacked, to avoid mechanical damages
• For dry uncharged VLA cells / blocks: the plugs on the cell lid have to be removed only short time
before filling of the cells
- Maximum Storage Time and Recharge Requirements
• Dry uncharged VLA cells / blocks:

✓ Maximum storage time in dry condition should not exceed 24 months after delivery.
• Filled VLA cells / blocks:
✓ Maximum storage time should not exceed 3 months at 20°C after commissioning date at
manufacturing site.
• VRLA cells / blocks:
✓ Maximum storage time should not exceed 6 months at 20°C after commissioning date at
manufacturing site.
Note:
Recharge of the blocks / cells should be performed max. 2 times during storage time!
Thereafter the batteries must be connected to continuous float charge.
- VRLA @ Available Capacity vs Storage Time
- VLA @ Available Capacity vs Storage Time
- Improper storage will avoid manufacturer warranty
- Storage Warehouse without Air-conditioning System
Spacious area with high roof and air ventilation Rectifier System – Battery Charging Station
Table of contents
• Site Storage Requirement

• Parameters for Battery Sizing
• Battery Depth of Discharge (DOD) & Life Cycles
• Charging Parameters for Solar Application
• Battery Maintenance
• Optimized Battery System (AquaGen & ECS)
Parameters for battery sizing
- Temperature influence on battery capacity ?
▪ Capacity is smaller at low temperatures.

This effect is caused by an increase of acid viscosity (stickiness) and thus a slower diffusion
of acid into the plates.
▪ A low temperature increases acid viscosity. If acid viscosity increases, conductivity reduces.
▪ A low temperature leads to a slower exchange of interior & exterior sulphuric acid – the cell
voltage reduces earlier – the available current is smaller.
▪ Dependance of battery capacity on basis of 20°C:
at discharges below 3 h 1 % per 1 °C

at discharges above 3 h 0.6 % per 1 °C
Example: 250 Ah nominal capacity at 20°C is 250Ah / 80% = 312 Ah at 0°C
- Temperature influence – on capacity
2,15
6 OPzS 600
Discharge Current: 68,6A
2,10
2,05
2,00
Voltage U [V]
1,95
1,90
1,85
1,80
0C 20 C 40 C
1,75
0 100 200 300 400 500 600 700
Time T [min]
- Temperature influence – on capacity
- Temperature influence on self discharge and corrosion life time ?
▪ Self discharge is a continuous side effect. This is due to the decomposition of water.
▪ A monthly self discharge of 2 – 3 % is usual, based on nominal capacity.
▪ Chemical reactions depend on ambient temperature. A temperature increase of approximately

10 K (10 °C), increases the speed of chemical reaction by factor 2.
▪ An increase of ambient temperature by 10°C doubles the self-discharge rate, i.e. shortens the
shelf life of the battery and reduces its operational life by 50%, if no other aging effects, such as
drying out (sealed LA batteries) or mass softening due to under charge in cycle application
show up.
▪ Also ambient temperature has an adverse effect on the corrosion life of the positive plate and
limits its operational battery life, because plate corrosion can never be stopped.
- Temperature influence – on battery aging
Aging (of OPZV in standby application) as a function of ambient temperature
- Temperature influence – on cycle life
Cycle life time (of OPZV at 80% dod) as a function of ambient temperature
Temperature influence – freezing point
If a battery is discharged at 60% (dod), the ambient temperature must not fall below -23,4°C
- Important Info for Battery Sizing
When considering the battery sizing, the following parameters need to be considered:
i) Load – ampere / kilowatt (kW) / kilowatt hour (kWh)
ii) Back-up time – hours (hrs)
iii) Autonomy time – day(s)
iv) Battery system voltage - Vdc
v) Maximum Depth of Discharge - % DOD
vi) Minimum ambient temperature
vii) Inverter Efficiency
- Equations to determine battery capacity (Ah)
Total Ampere (A) x Back-up time (hrs)

i) Battery capacity (Ah) = ------------------------------------------------------------ x Autonomy days
(DC Load in Ampere) DOD x temp. correction (minimum)
Total Daily Energy Consumption (Wh) x Autonomy days

ii) Battery capacity (Ah) = -------------------------------------------------------------------------------------------
(AC Load in Wh)) Inv. Efficiency x Nom. Batt. Volt. x temp. correction (minimum) x DOD
Notes:
• Aging Factor - battery performance is relatively stable through out its life, dropping of rapidly towards the end. To ensure the
battery can meet the design requirements throughout its life the standard suggestions the initial capacity should be 125% of the
design capacity.
• Design Margin - to cater for unexpected circumstances (increased loads, poor maintenance, recent discharge, etc.) it is
common to allow a design margin of 10% to 15%.
- Example 1: Battery sizing in stand alone system (PV only without Genset)
Environment conditions:
• Current consumption 2 A for 5 hours over night
• Maximum period without any recharge: 4 days autonomy
• Maximum depth of discharge under extreme conditions: 50%
• Minimum ambient temperature: 10°C
Sizing Calculation:
• 2 Ampere x 5 hours = 10Ah
• 4 days x 10 Ah = 40Ah (extreme condition)
• 40Ah / 50% dod = 80Ah nominal capacity
• 80Ah / 0.9 = 89Ah (temperature correction 1% per 1K below 20°C)
• Result 89Ah C100 = 4 days
• Choose battery type from product brochure which can provide minimum capacity of 89Ah@C100
• Selected battery type: sun|power VRM 12-90
- Example 2: load profile of the customer: 499,77 kWh daily battery capacity
- Example 2: load profile of the customer: 499,77 kWh daily battery capacity
Environment conditions:
• Energy consumption: 500 kWh over night
• Battery System Voltage: 48 Vdc
• Maximum period without any recharge: 1 day autonomy
• Maximum depth of discharge under extreme conditions: 50%
• Minimum ambient temperature: 20°C
Sizing Calculation:
• 500 kWh / 0,9 (compensation efficiency losses) = 555.55 kWh
• (555.55 kWh x 1000) / 48V = 11,574 Ah dischargeable capacity on daily basis
• 11.574Ah / 50% dod = 23,148 Ah required nominal capacity C10
• Decide number of battery strings: e.g. 8 string
• Battery capacity Ah/string = 23,148 Ah / 8 ; minimum = 2,894 Ah @ C10
• Choose battery type from product brochure which can provide minimum capacity of 2,894Ah@C10
• 8 strings of 24 cells x sun|power VL 2-3980 (2,952Ah@C10)
Battery selection from manufacturer brochure / discharge data sheet
Battery datasheet
for example 1
Battery datasheet
for example 2
- Hoppecke Battery Engineering & Safety Tools (B.E.S.T)
BATTERY ENGINEERING & SAFETY TOOL (B.E.S.T.)
Language: Hotline
Choose tool:
INFO
INFO
INFO
INFO
Hydrogen Evolution
Ventilation acc. to EN 50272-2 Hydrogen Evolution Heat Dissipation
(IEEE Std 484-1996)
INFO
INFO
INFO
INFO
Genset Re-Charge Time Acid Gravity Sizing Solar Application
INFO
INFO
INFO
Aquagen Benefits Calculator Air-Pump Benefits Calculator Cable Dimensioning
Details / Comments
Calculation of ventilation and safety distance for battery installations 2

according EN 50272 part 2 (Applicable for projects within EU!) 3
1
Version 1.6.4 © 2014 HOPPECKE
- B.E.S.T Chart – Battery sizing with constant load (Amps)
INPUT REQUIREMENT INPUT RESULT S OUTPUT / RESULT
Parameters Diagram " Discharged capacity and accumulated capacity depending on discharge time"
Input 1: choose batt type (VLA / VRLA) Battery Type Vented VRLA
1200
Input 2: choose batt model (OPzS, Model
Discharged Capacity [Ah]

1000
OPzV & blocs battery) Nom inal s ys tem voltage
48 V 800
Input 3: Nom. Sys. Volt (12, 24, 36, 48V) Final dis charge voltage
600 Load graph at constant load profile
1.80 V / Cell 1.)
(ampere) input for 10 hours
Input 4: Nom. Final Disc. Volt (1.80 – Num ber of parallel battery s trings 400
Yes / No 1 2.)
1.95) 200
Com pens ation factor "Capacity vs Tem perature" 3.)
Input 5: Number of parallel strings 30 / 86 °C / °F 0
0 2 4 6 8 10 12
Com pens ation factor "Ageing" Yes / No 4.)
Autonomy [h]
Input 6: Operating Temperature Com pens ation factor "Lifetim e Yes / No 5.)
(T≥35°C (95°F) and DOD < 20% per day
Footnote
Utilization of the available capacity
Input 7: Ageing factor - optional 1200
Discharge Cap. accum. [Ah]

50 % 6.)
1000
Loadprofile Am pere / Watt 7.)
Input 8: Lifetime factor (Temp.= 35°C, Step Current [A] Discharge Time 800 Calculated capacity (Ah) @
DOD ˂ 20%) - optional 1 100.0 10.0
600 constant ampere input for 10
2
400
hours
Input 9: Targeted Depth of Discharge 3
3
200
(DOD) 4 8.)
5 0
0 2 4 6 8 10 12
Input 10: Load profile (amp. / watt., 6 Autonomy [h]
constant or variable load) – ampere & 7
constant load 8 Dis charged Capacity 1,000.0 Ah
9 Total dis charge tim e: 10.00 h

Propose number of battery strings
10 Power cons um ption (average): 4,800.00 Wh
and battery type / model
Recommended Battery: 1 x 24 cells 16 OPzV 2300 solar.power
Comments "Footnote" Diagram: "No. of cyles versus depth of discharge (DOD) based on the C10 capacity"
1.) Due to the long dis charge tim es in s olar application the final dis charge voltages s hould 16000
be s et like follows :
14000
Autonom y ≤ 20h - 1,8 V/Cell
Autonom y ≤ 100h - 1,85 V/Cell 12000
Autonom y > 100h - 1,9 V/Cell Calculated % Depth of Discharge
No. of cycles
2.) Selection only if num ber of s trings are pres cribed! 10000 (%DOD) and possible number of
3.) Com pens ation factor for capacity los s or benefit depending on the am bient tem perature.
4.) Com pens ationfactor 1,25 for ageing up to 80% of the nom inal capacity.
8000 life cycles before battery capacity
5.) Com pens ation factor for accelerated ageing at am bient tem perature > 35°C and 6000 has drop 20% from nominal
a m ax. depth of dis charge (DOD) of les s than 20% per day.
4000
capacity (Remaining capacity =
6.) To optim ize the cycling perform ance within a certain autonom y the m ax available battery capacity
can be adjus ted in a range between 0 - 80%. 2,401 Cycles
80%)
2000
7.) The loadprofile can be given in current [A] or power [W] values .
8.) The tim e fram e for each load s tep can be adjus ted individually! 0
0 10 20 30 40 50 60 70 80 90 100
Depth of discharge DOD [%] based on C10
OPzS po wer.bloc OPzS / OPzV sola r.p ower po wer.bloc OPzV sol ar.b loc Actu al
sol ar.p ower
- B.E.S.T Chart – Battery sizing with variable load (watt)
INPUT REQUIREMENT INPUT RESULT S
Parameters Diagram " Discharged capacity and accumulated capacity depending on discharge time"
Input 1: choose batt type (VLA / VRLA) Battery Type Vented VRLA
500
Input 2: choose batt model (OPzS, Model 450
Discharged Capacity [Ah]

OPzV & blocs battery) Nom inal s ys tem voltage
400
350
48 V
300
Input 3: Nom. Sys. Volt (12, 24, 36, 48V) Final dis charge voltage
250
Load graph at variable load profile
1.80 V / Cell 1.)
200 (watt) input for 10 hours
Input 4: Nom. Final Disc. Volt (1.80 – Num ber of parallel battery s trings 150
Yes / No 1 2.)
1.95) 100
Com pens ation factor "Capacity vs Tem perature" 3.) 50
Input 5: Number of parallel strings 30 / 86 °C / °F 0
0 2 4 6 8 10 12
Com pens ation factor "Ageing" Yes / No 4.)
Autonomy [h]
Input 6: Operating Temperature Com pens ation factor "Lifetim e Yes / No 5.)
(T≥35°C (95°F) and DOD < 20% per day
Footnote
Utilization of the available capacity
Input 7: Ageing factor - optional 1000
Discharge Cap. accum. [Ah]

50 % 6.) 900
Loadprofile Am pere / Watt 7.) 800
Input 8: Lifetime factor (Temp.= 35°C, Step Power [W] Discharge Time
700 Calculated capacity (Ah) @
DOD ˂ 20%) - optional 1 5000.0 2.0
600
500
variable load (watt) input for 10
2 3500.0 1.0 400 hours
Input 9: Targeted Depth of Discharge 3
3 7000.0 3.0 300
200
(DOD) 4 1200.0 1.5 8.) 100
5 3500.0 1.5 0
0 2 4 6 8 10 12
Input 10: Load profile (amp. / watt., 6 1250.0 1.0
Autonomy [h]
constant or variable load) – watt & 7
variable load 8 Dis charged Capacity 891.7 Ah
Propose number of battery strings
9 Total dis charge tim e: 10.00 h
and battery type / model
10 Power cons um ption (average): 4,280.00 Wh
Recommended Battery: 1 x 24 cells 16 OPzV 2300 solar.power
Comments "Footnote" Diagram: "No. of cyles versus depth of discharge (DOD) based on the C10 capacity"
1.) Due to the long dis charge tim es in s olar application the final dis charge voltages s hould 16000
be s et like follows :
14000
Autonom y > 100h - 1,9 V/Cell
12000 Calculated % Depth of Discharge
(%DOD) and possible number of
No. of cycles
2.) Selection only if num ber of s trings are pres cribed! 10000
3.) Com pens ation factor for capacity los s or benefit depending on the am bient tem perature.
8000 life cycles before battery capacity
4.) Com pens ationfactor 1,25 for ageing up to 80% of the nom inal capacity.
5.) Com pens ation factor for accelerated ageing at am bient tem perature > 35°C and 6000
has drop 20% from nominal
a m ax. depth of dis charge (DOD) of les s than 20% per day. capacity (Remaining capacity =
4000
6.) To optim ize the cycling perform ance within a certain autonom y the m ax available battery capacity
2,768 Cycles
80%)
can be adjus ted in a range between 0 - 80%. 2000
7.) The loadprofile can be given in current [A] or power [W] values .
8.) The tim e fram e for each load s tep can be adjus ted individually! 0
0 10 20 30 40 50 60 70 80 90 100
Depth of discharge DOD [%] based on C10
OPzS po wer.bloc OPzS / OPzV sola r.p ower po wer.bloc OPzV sol ar.b loc Actu al
sol ar.p ower
- B.E.S.T Chart – Charging at float voltage @ 2.25 Vpc
INPUT RESULTS
INPUT REQUIREMENT Parameters Diagram "Charging Curve Depending on Charging Voltage, Charging Current and Time" OUTPUT / RESULT
Battery Type 110
Input 1: Choose battery type Vented (Density: 1,22 - 1,24 kg/ltr.) 100 22.4 h 2.6 SOC Level
Vented (Density: > 1,24 kg/ltr.) 1.) (blue curve)
VRLA 90
Input 2: battery nominal capacity
Charging Current [A per 100 Ah]

Nominal Capacity (C10) 2000 Ah 2.) 80 2.4
Charging Voltage [V per Cell]

Input 3 : discharge capacity Discharged Capacity 1000 Ah 3.)
State of Charge SOC [%]

Charging time
70
Calculated battery DOD Depth of Discharge [DOD] 50.00 % required from 50%
Remaining Capacity 1,000 Ah 60 2.2 SOC to 100% SOC
Calculated remaining capacity State of Charge [SOC] 50.00 % with normal float
Calculated battery SOC charge @ 2.25 Vpc
Footnote
Charging voltage 50
Input 4: Charging Voltage 2.25 V 4.)

40 2.0
Requested SOC
Input 5: Target SOC 100 % 5.) 30
Charging Current
Charging Voltage
Input 6: Charging Currents 20 1.8
10 A per 100 Ah 6.)
(green curve)
200 A 10
Charging Factor
0 1.6
1 7.) 0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
Time [h] Charging Current
(red curve)
SOC [%] Current [ A / 100Ah] Actua l "" "" Vo lta ge [V/Cell]
Comments "Footnote" Details / Comments
1.) Battery type influences the acid density, the open circuit voltage as well as the available voltage High charging voltages benefits the mixture of the electrolyte and is therefore generally
window! recommended at deep discharges!
2.) Nominal capacity: Pb: C10 at 1,8 V/C; NiCd: C5 at 1,0 V/C, 20°C (68°F)
3.) Discharged capacity due to the load profile (Current x Time = Ah) Typical charging factors are like follows:
4.) Available charging voltage. Vented batteries: 1.20
5.) Required state of charging during recharging (State of charge [SOC] and the appropriate time VRLA batteries due to the capillar effect of the AGM /Gel: 1,05 - 1,10
will be shown in the diagram!)
Causion: By using the charging factor please set the state of charge [SOC] to 100%!
The time frame for each load step can be adjusted individually!
6.) Available charging current in [A per 100 Ah]
7.) The required charging factor is depending on the depth of discharge [DOD], cell height,
the electrolyte temperature and the charging voltage. For low charging voltages and low
depth of discharges increase the charging factor!
- B.E.S.T Chart – Charging at boost/equalize voltage @ 2.40 Vpc
INPUT RESULTS
Parameters Diagram "Charging Curve Depending on Charging Voltage, Charging Current and Time"
Battery Type 110
Vented (Density: 1,22 - 1,24 kg/ltr.) 100 7.5 h 2.6

Vented (Density: > 1,24 kg/ltr.) 1.)
VRLA 90

Nominal Capacity (C10) 2000 Ah 2.) 80 2.4

Discharged Capacity 1000 Ah 3.)

70
Depth of Discharge [DOD] 50.00 % Charging time
Remaining Capacity 1,000 Ah 60 2.2
required from 50%
State of Charge [SOC] 50.00 % SOC to 100% SOC
with charge (boost)
Footnote
Charging voltage 50
2.4 V 4.)
voltage of 2.40 Vpc
40 2.0
Requested SOC
100 % 5.) 30
Charging Current 20 1.8

10 A per 100 Ah 6.)
200 A 10
Charging Factor
0 1.6
1 7.) 0.0 2.0 4.0 6.0 8.0 10.0 12.0
Time [h]
SOC [%] Current [ A / 100Ah] Actua l "" "" Vo lta ge [V/Cell]
1.) Battery type influences the acid density, the open circuit voltage as well as the available voltage High charging voltages benefits the mixture of the electrolyte and is therefore generally
window! recommended at deep discharges!
2.) Nominal capacity: Pb: C10 at 1,8 V/C; NiCd: C5 at 1,0 V/C, 20°C (68°F)
3.) Discharged capacity due to the load profile (Current x Time = Ah) Typical charging factors are like follows:
4.) Available charging voltage. Vented batteries: 1.20
5.) Required state of charging during recharging (State of charge [SOC] and the appropriate time VRLA batteries due to the capillar effect of the AGM /Gel: 1,05 - 1,10
will be shown in the diagram!)
Causion: By using the charging factor please set the state of charge [SOC] to 100%!
The time frame for each load step can be adjusted individually!
6.) Available charging current in [A per 100 Ah]
7.) The required charging factor is depending on the depth of discharge [DOD], cell height,
the electrolyte temperature and the charging voltage. For low charging voltages and low
depth of discharges increase the charging factor!
Table of contents

Battery Depth of Discharge (DOD) & Life Cycles
Battery Terminology
• State of Charge (SOC)(%) – An expression of the present battery capacity as a percentage of maximum capacity. SOC is
generally calculated using current integration to determine the change in battery capacity over time.
• Depth of Discharge (DOD) (%) – The percentage of battery capacity that has been discharged expressed as a percentage of
maximum capacity. A discharge to at least 80 % DOD is referred to as a deep discharge.
• Terminal Voltage (V) – The voltage between the battery terminals with load applied. Terminal voltage varies with
SOC and discharge/charge current.
• Open-circuit voltage (V) – The voltage between the battery terminals with no load applied. The open-circuit
voltage depends on the battery state of charge, increasing with state of charge.
• Internal Resistance – The resistance within the battery, generally different for charging and discharging, also
dependent on the battery state of charge. As internal resistance increases, the battery efficiency decreases and
thermal stability is reduced as more of the charging energy is converted into heat.
• Nominal Voltage (V) – The reported or reference voltage of the battery, also sometimes thought of as the “normal”
voltage of the battery.
• Cut-off Voltage – The minimum allowable voltage. It is this voltage that generally defines the “empty” state of the
battery.
Battery Terminology
• Charge Voltage – The voltage that the battery is charged to when charged to full capacity. Charging schemes
generally consist of a constant current charging until the battery voltage reaching the charge voltage, then constant
voltage charging, allowing the charge current to taper until it is very small.
• Float Voltage – The voltage at which the battery is maintained after being charge to 100 percent SOC to maintain
that capacity by compensating for self-discharge of the battery.
• (Recommended) Charge Current – The ideal current at which the battery is initially charged (to roughly 70 percent
SOC) under constant charging scheme before transitioning into constant voltage charging.
• Capacity or Nominal Capacity (Ah for a specific C-rate) – The coulometric capacity, the total Amp-hours
available when the battery is discharged at a certain discharge current (specified as a C-rate) from 100 percent
state-of-charge to the cut-off voltage. Capacity is calculated by multiplying the discharge current (in Amps) by the
discharge time (in hours) and decreases with increasing C-rate.
• Cycle Life (number for a specific DOD) – The number of discharge-charge cycles the battery can experience
before it fails to meet specific performance criteria. Cycle life is estimated for specific charge and discharge
conditions. The actual operating life of the battery is affected by the rate and depth of cycles and by other conditions
such as temperature and humidity. The higher the DOD, the lower the cycle life.
- solar.bloc: Cycle life vs Depth of Discharge and Temperature
- OPzV solar.power: Cycle life vs Depth of Discharge and Temperature
- OPzS solar.power: Cycle life vs Depth of Discharge and Temperature
Table of contents

Charging Parameters for Solar Application
- Charging Stage/Phase in Solar Application
• Stage 1 – boost/bulk charge phase: this is a period of constant current and increased voltage that provides
most of the charge. Charging voltage runs up to the full-rated output of the battery charger for faster
charging. Limiting of charging voltage and charging currents required to protect the battery from overcharge.
• Stage 2 – absorption phase: also called the soak stage or topping stage. The charging currents drops during
this stage while the charging voltage remain at the same boost charge value. It is held for a controlled period
so the electrolyte solution has the opportunity to absorb the charge fully and completely. If a battery is left
at this charge stage, it will overcharge.
• Stage 3 – Float phase: A lower voltage “trickle” charge is delivered to maintain the battery’s fully charge
while not overcharging. In the float stage, the battery is at full charge (almost full charge) and ready for next
discharge.
• Stage 4 – Equalization phase: A battery bank consists of many individual battery cells connected in series
which all behave slightly different. Over time, this results in different charge levels in individual cells. This can
lead to premature failure, initially of individual cells, and finally to failure of the entire bank. Equalization
charge will bring up individual cell voltage at same levels.
- Charging with IU Characteristics (constant currents & constant voltage)
VOLTAGE / CURRENT
Constant Currents Phase (I phase) / Constant Voltage Phase (U phase) / Constant Voltage @
Bulk Phase Absorption Phase Float charge/phase
(Stage 1) (Stage 2 OR Stage 4 ) (Stage 3 )
i) Boost = 2.40V – 2.50V `
ii) Equalize = 2.55V
Float = 2.25 V
``
Voltage (V)
Curve
Max. = 6 x I10
Currents (I)
Curve
TIME
t1 = absorption phase (180 minutes)
t2 = equalizing phase (6 hours)
- Recommended Charging Parameters for VRLA, OPzV solar.power & solar.bloc
- Recommended Charging Parameters for VLA, OPzS solar.power
Table of contents

Battery Maintenance
Why battery maintenance and surveillance ?
It ensures maintaining the operation
It supports the extension of service life
Battery Maintenance
Battery maintenance / monitoring and life time
Battery maintenance / monitoring and life time
Maintenance
Random failures
Time t
Early failures Ageing failures
• Early failures : manufacturing quality and commission (Supplier)

• Random failures : operating conditions/ Stress-Factors (Customer)
• Ageing failures : dependant on care and maintenance (Customer)
Battery Maintenance
Maintenance
Take records of the type and scope of maintenance works performed,

(reference chapter 8 of maintenance handbooks Vented or VRLA). This is
helpful for
• troubleshooting
• claiming defects
1.Measure the room temperature (recommended between 10°C to 30°C)
2.Measure the surface temperature of each individual cell or monobloc (if

VRLA batteries are concerned) or the electrolyte temperature and density (if
Vented batteries are concerned). There must be a maximum deviation of +/-5 K
between individual cell or monobloc temperatures.
3.Do a visual inspection of the battery rack and battery cells (clean impression,
no dried particles, no deformation of poles).
Battery Maintenance
Measurement of Voltage (during float operation)
half-yearly:
Measure system voltage (Check the rectifier)
Tolerance of voltage: +/- 1 %
every year:
Measure single cell or bloc voltages
Range refers to the mean value of the average of measured total system voltage
Vented/flooded batteries
Voltage of the cell / bloc battery 2V 4V 6V 12V
Maximum allowed voltage -0,05 V -0,07 V -0,09 V -0,12 V
tolerances on float operation +0,10 V +0,14 V +0,17 V +0,25 V
Sealed/valve-regulated batteries
Voltage of the cell / bloc battery 2V 4V 6V 12V
Maximum allowed voltage -0,10 V -0,14 V -0,17 V -0,25 V
tolerances on float operation +0,20 V +0,28 V +0,35 V +0,50 V
Battery Maintenance
Measurement of acid density (during float operation)
half-yearly:
Measuring the density on pilot cells
Tolerance of density: +/- 0,01 kg/l
every year:
Measuring of individual cell densities
Tolerance: Lead, vented +/- 0,01 kg/l
Lead, valve-regulated not applicable
Each value with reference to the nominal acid density and room
temperature of the product
Battery Maintenance
Measurement of acid density (during float operation)
Influence of temperature on the acid density
Battery Maintenance
- Examination of tight connectors
➢ Check tight position of pole screw
Not
correctly
tightened
screw connections Result of an
cause insufficiently
tightened
overheating of
pole connection:
materials and
can cause
fire.
Battery Maintenance
- Examination of tight connectors
Screws are fixed with a torque of 20 Nm
All screws have a protection against self-loosening ( thread with lock-tight )
Protection against self-loosening

disappears with repeated installation
Protection against self-loosening
Battery Maintenance
- Keeping the battery surface clean
➢ Attention, electrostatic charge !!!
For cleaning of
batteries only use
absorbent cleaning
cloths, which
are moisted
with water.
Other cleaning
detergents can lead to
electrostatic
charge
or damage the
battery container.
Part EN 50272-2:2001
Battery Maintenance
➢ Example of grossly negligence !!!
Dangerous example
from the field …
Battery Maintenance
➢ Example of insufficient care !!!
With humidity a dust layor on the
battery leads to screeping currents !!!
Battery Maintenance
In order to avoid screeping currents, which cause a diversion of the

potentional or even evolve short circuits in an extreme situation.
Attention:
Clean the battery only

• With humid cloth
• Without cleaning detergents
Table of contents

Optimized Battery System
1) Benefit of AquaGen
vented batteries Valve regulated batteries
Long life time Recombination

Low sensitivity
Easy monitoring
Long life time

Low sensitivity
Easy monitoring
external
Recombination
Optimized battery system
Installation of AquaGen premium.top H possible

for batteries up to 350 Ah for higher capacities
AquaGen premium.top V have to be used
flash back protection
valve
opening permits escaping gas when

overloading
cover (roof) for the protection against falling
down drops
ceramic protection for the

catalyst
dome for the condensation of the water vapor
➢ Operation:
➢ Inside the batteries takes part as secondary reaction - water decomposition of

liquid electrolyte
➢ during the operation of the AquaGen® premium.top-recombination systems the

developed oxygen and hydrogen gas is moving to the AquaGen® plug
➢ by the integrated catalyst these gases recombined to the water vapour
➢ the water vapour condenses at walls of the dome of the AquaGen® premium.top-plug
➢ water drops flow themselves downward back into the battery
➢ Customer benefits:
➢ maintenance intervals are fully extended with even total freedom from maintenance
(up to 98 % recombination rate)
➢ no damage of the battery by refill of contaminated water
➢ Reduction of the ventilation requirements by 50 % small costs of room air engineering
➢ Prevention of a danger of explosion by outside flaming/spark effect with integration

of a backfire protection
➢ No significant escape of gas or of electrolyte fumes
➢ Decrease of maintenance and installation costs with increased safety
➢ high operational battery life time at low maintenance costs (topping up with water)
Calculation of the water consumption / maintenance costs at vented lead acid batteries
INPUT RESULT S
Parameters Comparison of CAPEX and OPEX with and without Aquagen ® premium.top
Currency €
16 OPzS solar.power 2900 Battery Type
Real Capacity (C10 at Uf=1,8 V/Cell) 2146 Ah

Des ign Life 20 Years 70000
Type Aquagen prem ium .top 48 PTV 1.)
60000
Aquagen recom bination efficiency 95 % 2.)
Depth of Discharge = 50% Depth of Dis charge [DOD] 50 % 3.) 50000
39222.65
No. of cells 24 OPEX
40000
Number of Cell = 24 (48V system) Actual Age of the Battery Sys tem
Expected Service Life of the Battery
0
10.0
Years
Years
4.)
5.)
CAP EX
30000
1634.28
Num ber of cycles per year
Number of cycles per year = 365 365 6.) 20000
Footnote
22,236.00 23,196.00
Tem perature 10000
Temperature - 30°C 30 / 86 °C / °F 7.)
Charging voltage 0
Charging Voltage = 2.4 V 2.4 V 8.) Without Aquagen s ys tem With Aquagen s ys tem Number of refilling interval
Rais ing of the Water Cons um ption over Battery Life Tim e
4 9.) Difference over the complete observed time ( cost reduction potential) 36628.37 €
Without AquaGen = 96
Price Aquagen prem ium .top PTH or PTV 20.00 € Accumulated cost reduction over the complete battery life time 59.60 % With AquaGen = 4
Price for Des tilled Water or Preparation of Water per Litre 1.50 €
Price Arrival / Departure / Provide Water Overal 40.00 € Without Aquagen With Aquagen
Price per hour Service Stuff 50.00 € Num ber of refilling intervals 96 4
Tim e to Refill one Battery String 5.40 h 10.) Am ount of refilled water during the com plete tim e 6,308.43 262.85 ltr.
Price of battery without Aquagen prem ium .top 22,236.00 € Service cos t including refilling + working tim e + arrival + water 39,222.65 1,634.28 €
Price of battery with Aquagen prem ium .top 23,196.00 € Sys tem price 22,236.00 23,196.00 €
Sys tem price including m aintenance cos ts 61,458.65 24,830.28 €
1.) Aquagen clas s ification will be done autom atically depending on battery capacity The water cons um ption of a lead acid battery can differ really m uch depending on the application.
2.) Aquagen recom binations rate - Default value 95% Batteries in s tandby operation will be kept in fully charged condition by a certain float charge current,
3.) Dis charge depth according load profile (Σ Dis charge Current x Tim e) which is going into the battery. This overcharging is the m ain reas on for the water cons um ption
4.) PbSb batteries increas es their water cons um ption over life tim e due to the antim ony pois ioning effect of the battery.
of the negative electrode. The cons equence will be higher cos ts s avings at aged PbSb batteries by Batteries in cyclic applications have quite often dis charge and charge cycles every day followed by
us ing the Aquagen recom biners . a s witch off. To elim inate the phenom enon of acid s tratification or to com pens ate charge los s es it is
neces s ary to put a certain overcharge capacity ins ide the battery. This m eans for vented lead acid
5.) Item 4.) and 5.) correlates with the tim e fram e for s izing of the OPEX cos ts . generally a charge factor of 1,20 at each fully recharge.
The expected s ervice life of a battery is depending on the des ign life or cycling ability, which
m eans that both values have to be correlated to each other!
6.) Dis charge and charge cycles increas e the water cons um ption due to the needed overcharge During overcharging 1 Ah decom pos e 0,3361g H2O und generates 0,449 ltr. hydrogen at 20°C /68°F
capacity to prevent acid s tratification. (Charge factor: 1,20)
7.) Operating tem peratures above 20°C leads to a higher water cons um ption if the charging voltage is
not tem perature regulated! (Arrhenius )
8.) Charging voltage which is m ainly us ed at the battery s ys tem . This will be for batteries in s tandby
operation generally 2,23 V/Cell, whereas cyclic application us es 2,40 V/Cell.
9.) Recom m ended ageing factor: PbSb = 4, PbCa = 1, NiCd = 1

10.) Inves tm ent- and operation- cos ts , which have to be adapted individually bas ed on cus tom ers
res pectively countries to calculate the appropriate cos ts s avings .
RESULTS
Comparison of CAPEX and OPEX with and without Aquagen ® premium.top
70000
60000
50000
39222.65 OPEX
40000
CAPEX
30000
1634.28
20000
22,236.00 23,196.00
10000
0
Without Aquagen system With Aquagen system
Number of refilling interval

Difference over the complete observed time ( cost reduction potential) 36628.37 €
Without AquaGen = 96
Accumulated cost reduction over the complete battery life time 59.60 % With AquaGen = 4
Without Aquagen With Aquagen

Number of refilling intervals 96 4
Amount of refilled water during the complete time 6,308.43 262.85 ltr.
Service cost including refilling + working time + arrival + water 39,222.65 1,634.28 €
System price 22,236.00 23,196.00 €
System price including maintenance costs 61,458.65 24,830.28 €
Details / Comments
➢ Comparison water consumption during battery life time – standby operation
4,2
3,8
per 100 Ah battery capacity 3,4

Water consumption [litre]
2,9
without AquaGen
2,5
2,1
1,7
1,3
0,8
with AquaGen
0,4
0,0
0 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228
Battery life time [months]
Installation with AquaGen
2) Benefit of Electrolyte Circulation System (ECS)
HOPPECKE Electrolyte Circulation System – Applications
Typical Applications:
Solar-/Off-grid applications
Power supply for remote off-grid applications and isolated
power networks, drinking water supply systems, healthcare
facilities
Telecommunications
Mobile phone stations, BTS stations, Off-grid/on-grid
solutions
Traffic Systems
Signaling systems, Lighting
HOPPECKE Electrolyte Circulation System – Benefits
Your benefits with the HOPPECKE Electrolyte

Circulation System:
Economic Recharge – cost reduction through increased

charging efficiency, significant reduced recharge time
Environmental-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
HOPPECKE Electrolyte Circulation System – Features
Operation Concept:
The HOPPECKE Electrolyte Circulations System pumps ambient air to the bottom of each
battery cell. Emerging air bubbles rise through the electrolyte, ensuring a homogeneous
electrolyte density distribution in each cell. The system is switched on and off automatically
and virtually maintenance free.
Features:
▪ Easy to install system components (plug & play).
▪ Pump is switched by µ-controller and works automatically.
▪ System can be retrofit.
▪ Maintenance free pump motor.
▪ Filter for air intake.
▪ Backpressure valve for protection of pump motor and control unit.
➢ HOPPECKE Electrolyte Circulation System – functional principle
and control electronics.

Wall-mounted housing
contains pump motor
A central tubing system
supplies air to all cells.
Emerging air bubbles

stir the electrolyte.
Air is blown into

every cell through
plastic pipes.
➢ HOPPECKE Electrolyte Circulation System – Overview Components
Air outlet with back Air intake with filter

pressure valve
Fuses
Air tube
Power Supply Cable
Current Sensor
Battery connection cable

(to loads resp. charger)
Air tube
➢ HOPPECKE Electrolyte Circulation System – Advantages
Increase of efficiency and cost savings:
Typically up to 120% of discharged energy need to be recharged in order to reach the initial
state of charge (vented lead acid battery types). This charging factor includes the elimination of
acid stratification.
Application of the HOPPECKE electrolyte circulation system reduces the required charging
factor significantly. Increase of efficiency is up to 15% compared to charging without
electrolyte circulation system.
Therefore less time and energy is required to recharge the battery and to achieve a
homogeneous electrolyte distribution.
The electrolyte circulation system reduces also service costs because of reduced water loss
compared to conventional charging.
Moreover the HOPPECKE electrolyte circulation system increases service life of the battery
and provides environmental and economical benefits for the entire battery system.
➢ Example for equalization recharge time without electrolyte pump
•Battery type: VLA

•DOD 50%
•Charge current: 10A /100Ah C10
•Charge voltage: 2,4 V/cell
•Target SOC: 100%
•Charging factor: 1,2
Voltage
Current
SOC
Best
➢ Example for equalization recharge time with electrolyte pump
110
100 7.7 h 2.6

•Battery type: VLA
90 •DOD 50%
•Charge current: 10A /100Ah C10
80 2.4 •Charge voltage: 2,4 V/cell
•Target SOC: 100%

70 •Charging factor: 1,05
60 2.2
50
40 2.0
30
Voltage
20 1.8
Current
10
SOC
0 1.6
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
Time [h]
B.E.S.T. Version 1.6.3. 2014
➢ Acid Stratification
Standby Cycling
application application At the Top:
Lower Specific Gravity
• corrosion
• overcharged
At the Bottom: Higher

Specific Gravity
• sulfation
Homogenous electrolyte • undercharged
• distributed over time
Key effects of electrolyte stratification:

1. Corrosion at the top lead due to low specific gravity
2. Electrode overcharge at the top of the cell
3. Undercharge in the lower part of the cell
4. Sulfation in the bottom of the cell due to high specific gravity
5. Premature capacity loss
6. Shortened cell life
➢ Acid Stratification
electrolyte distribution  homogeneous
electrolyte distribution  stratified
➢ Problem of acid stratification
▪ Excessive acid concentration causes sulphatation on the lower half of the

plates.
▪ Light acid restricts plate activation and supports corrosion which reduces
performance.
▪ A non-uniform acid-distribution causes an uneven depth of discharge of

the plates which leads to additional mass shedding.
▪ Differences in the electrical potential within the plates increase the self-
discharge of the cells.
OPzS Cycling – 8 h discharge / 16 h recharge (2,4 V per cell)

1,260
1,250
1,240
30 % depth of discharge
1,230
Acid density r [kg/l]
1,220
1,210
60 % depth of discharge
1,200
1,190
1,180
Danger of plate sulphatation at daily DOD ‘s beyond 50%
1,170
1,160
1,150
0 1 2 3 4 5
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3rd Thai-German Community-based

Renewable Energy Conference 2018

1) Site Storage Requirement

2) Parameters for Battery Sizing

3) Battery Depth of Discharge (DOD) & Life Cycles

4) Charging Parameters for Solar Application

6) Optimized Battery System (AquaGen & ECS)

1) Site Storage Requirement

2) Parameters for Battery Sizing

3) Battery Depth of Discharge (DOD) & Life Cycles

4) Charging Parameters for Solar Application

6) Optimized Battery System (AquaGen & ECS)

• The battery have to be fully charge

• Dry uncharged VLA cells / blocks:

• Site Storage Requirement

▪ Capacity is smaller at low temperatures.

▪ Dependance of battery capacity on basis of 20°C:

at discharges below 3 h 1 % per 1 °C

Example: 250 Ah nominal capacity at 20°C is 250Ah / 80% = 312 Ah at 0°C

▪ A monthly self discharge of 2 – 3 % is usual, based on nominal capacity.

▪ Chemical reactions depend on ambient temperature. A temperature increase of approximately

Aging (of OPZV in standby application) as a function of ambient temperature

Total Ampere (A) x Back-up time (hrs)

Total Daily Energy Consumption (Wh) x Autonomy days

BATTERY ENGINEERING & SAFETY TOOL (B.E.S.T.)

Calculation of ventilation and safety distance for battery installations 2

Version 1.6.4 © 2014 HOPPECKE

Discharged Capacity [Ah]

Discharge Cap. accum. [Ah]

constant load 8 Dis charged Capacity 1,000.0 Ah

9 Total dis charge tim e: 10.00 h

Discharged Capacity [Ah]

Discharge Cap. accum. [Ah]

Recommended Battery: 1 x 24 cells 16 OPzV 2300 solar.power

Charging Current [A per 100 Ah]

Charging Voltage [V per Cell]

State of Charge SOC [%]

Input 4: Charging Voltage 2.25 V 4.)

Comments "Footnote" Details / Comments

Battery Type 110

Vented (Density: 1,22 - 1,24 kg/ltr.) 100 7.5 h 2.6

Charging Current [A per 100 Ah]

Charging Voltage [V per Cell]

State of Charge SOC [%]

Charging Current 20 1.8

SOC [%] Current [ A / 100Ah] Actua l "" "" Vo lta ge [V/Cell]

Comments "Footnote" Details / Comments

• Site Storage Requirement

• Site Storage Requirement

i) Boost = 2.40V – 2.50V `

ii) Equalize = 2.55V

t2 = equalizing phase (6 hours)

• Site Storage Requirement

It ensures maintaining the operation

It supports the extension of service life

Battery maintenance / monitoring and life time

Early failures Ageing failures

• Early failures : manufacturing quality and commission (Supplier)

Take records of the type and scope of maintenance works performed,