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0% found this document useful (0 votes)

66 views

Grid Power FNC Manual en

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Nguyễn Anh Danh

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Installation, commissioning and operating instructions

for stationary Fibre Nickel Cadmium Batteries grid | power FNC®

Similar to the illustration

Foreword
Dear Customer,
Thank you very much for having decided in favour of a product bearing our brand name.
Please read this documentation carefully before working on the batteries or their components. It contains important
information on safe and proper unpacking, storage, installation, commissioning and on operation and maintenance
of grid | power FNC®-batteries.
Amendments to this documentation are subject to change without prior notice. Our products undergo continuous
advanced development. As a result, there may be deviations between the illustrations given in this documentation
and the purchased product. This installation manual is not covered by any change service.
Keep this documentation in such a manner that it is available immediately to all those who need to carry out work
in connection with the battery system or its components.

HOPPECKE
Batterie Systeme GmbH Service-Hotline Germany:
P.O. Box 11 80 0800 24677-32
D-59914 Brilon

Bontkirchener Straße 1 International Service-Hotline:

D-59929 Brilon-Hoppecke +49 (0)180 5229999
Phone +49 (0)2963 61-1412
Fax +49 (0)2963 61-1452
Internet www.hoppecke.com
Email [email protected]

Installation, commissioning and operating instructions

for stationary Fibre Nickel Cadmium Batteries grid | power FNC®

Type, Design, Print: PRIOTEX Medien GmbH, 59609 Anröchte

© 2021 HOPPECKE Batterien GmbH & Co. KG

P.O. Box 11 40
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.

Installation, commissioning and operating instructions for stationary Fibre Nickel Cadmium Batteries grid | power FNC® Installation, commissioning and operating instructions for stationary Fibre Nickel Cadmium Batteries grid | power FNC®
V1.1 (06.2022) V1.1 (06.2022)

2 3
Table of Contents

1 Using this manual............................................................................................................................................................. 6 8.1.5. Ventilation Requirements�� 23

1.1. Target group of this document��6 8.2. Installing the Battery System�� 24
1.2. Means of Representation��6 8.2.1. Preliminary Work on Unfilled and Uncharged grid | power FNC®-cells�� 24
1.3. Notation of Nominal Data��7 8.2.2. Equipping the Rack or Cabinet�� 25
1.4. Abbreviations and Definitions��7 8.2.3. Connecting the Battery System�� 25
8.2.4. Labelling the Battery System�� 27
2 Safety��8
2.1. General Safety Instructions��8 9 Commissioning�� 27
2.2. Personal Protective Equipment��9 9.1. Charging Procedures for the Initial Commissioning�� 28
2.3. Specific Safety Instructions for grid | power FNC®-Battery Systems��9 9.1.1. Charging with Constant Current�� 28
2.3.1. Safety Instructions on Handling with Electrolyte��9 9.1.2. Charging with Constant Current and Constant Voltage (CCCV)�� 29
2.3.2. Safety Instructions on Charging the Battery System�� 10 9.2. Commissioning of Unfilled and Uncharged (UU) and Filled and uncharged (FU)
2.3.3. Protection against dangerous body contact currents�� 10 grid | power FNC®-cells�� 30
2.3.4. Special hazards in the event of fire�� 11 9.3. Commissioning Filled and Charged (FC) FNC®-cells�� 31
9.4. Capacity Testing of Batteries According to DIN IEC 60623�� 32
3 Intended/Unintended use.............................................................................................................................................. 11
3.1. Intended Use�� 11 10 Maintenance�� 32
3.2. Unintended Use�� 11 10.1. Checking for Cleanliness and Condition of the Battery System�� 33
10.2. Checking the Electrolyte Levels�� 34
4 Directives, Legislation and Standards.......................................................................................................................... 12 10.3. Measuring the Charging Voltage�� 36
10.4. Testing the Insulation Resistance�� 36
5 Product description........................................................................................................................................................ 12 10.5. Cleaning�� 37
5.1. grid | power FNC®-cell.................................................................................................................................. 12 10.6. Fill up the Electrolyte Level with Distilled Water�� 37
5.2. Cell Plugs for Different Use Cases�� 14 10.7. Reconditioning�� 39
5.3. Operation Modes (see also IEC 62485-2)�� 14
5.3.1. Standby parallel operation�� 14 11 Troubleshooting�� 42
5.3.2. Buffer operation�� 15 11.1. Over Consumption of Distilled Water�� 42
5.3.3. Switching mode (charge/discharge mode)�� 15 11.2. Dispersion of the Individual Cell Voltages�� 42
5.4. Battery Charging Characteristic�� 16 11.3. Available Battery Capacity is Low�� 42
5.5. Battery Capacity�� 17 11.4. Insulation Resistance is Low�� 43
11.5. Battery Voltage not Measureable�� 43
6 Transport�� 18
6.1. Surface Transport (Road/Rail) according to ADR/RID�� 18 12 Disassembly, Disposal and Recycling........................................................................................................................ 43
6.2. Transport by sea according to the IMDG Code�� 19
6.3. Air Freight�� 19 13 Appendix�� 44
6.4. Checking the delivery�� 20 13.1. Commissioning Record�� 44
13.2. Maintenance Log�� 47
7 Storage�� 20 13.2.1. Six-monthly Maintenance Interval�� 48
7.1. Storage of Filled and Charged (FC) Cells�� 21 13.2.1.1. Visual Inspection and Checking Electrolyte Level�� 48
7.2. Storage of Unfilled and Uncharged (UU) and Filled and Uncharged (FU) grid | power FNC®-cells�� 21 13.2.1.2. Measuring battery system voltage�� 49
13.2.2. Annual Maintenance Interval�� 50
8 Installation�� 22 13.2.2.1. Cleaning the battery system �� 50
8.1. Mounting a Rack or Cabinet�� 22 13.2.2.2. Insulation testing�� 51
8.1.1. Before Mounting a Rack or Cab�� 22 13.2.2.3. Filling up distilled water�� 52
8.1.2. Checking the Scope of Delivery�� 22 13.2.3. Maintenance Interval every 5 years�� 52
8.1.3. Mounting a Rack�� 23 13.2.3.1. Reconditioning�� 52
8.1.4. Mounting a Cabinet�� 23 13.2.3.2. Measuring of Single Cell Voltages�� 53
13.3. Useful tools�� 55

4 5
1 Using this manual 1.3 Notation of Nominal Data

This operating and installation manual is intended to assist with the optimal operation of the HOPPECKE nickel- Nominal battery data is used in accordance with the following notation in this operation and installation manual:
cadmium batteries used, as well as their installation and maintenance. This is the only way in which a maximum
service life can be achieved.
Notation Meaning Value
Please contact your local authorised dealer:
Un Nominal voltage 1.2 V multiplied by the number of cells connected in series
– If you have any queries on this documentation.
– If there are local regulations or provisions that are not covered by this documentation or are contrary to its contents. C5
Cn Nominal capacity available capacity at discharge at I5 (see nameplate) up to 1.0 V
for each cell connected in series at nominal temperature
1.1 Target group of this document In Nominal current I5 (see nameplate) = Cn/5 h

All work on the battery system and the grid | power FNC -cells must only be carried out by trained, fully qualified
® Nominal
Tn 20 °C
and authorised personnel: temperature
– Personnel trained by HOPPECKE
– HOPPECKE experts 1.4 Abbreviations and Definitions

The following table explains abbreviations and terms used in these installation, commissioning and operating
1.2 Means of Representation instruction:

The following icons and signal words are used in this operating and installation manual:
Abbreviation/Definition Explanation
While working on batteries wear face protection (impact resistant visor Describes the defined discharge and subsequent charging of the battery with
according to EN 166 class F or similar), protective eye-glasses, protective Reconditioning constant current. This allows the capacity losses of the battery system to be
gloves and clothing. eliminated or reduced.
Observe accident prevention regulations as well as EN 50110-1 and
The charge of an accumulator to compensate for its self-discharge with the aim
IEC 62485-2. Float Charging
of keeping the accumulator fully charged.
Indicates the charging of an accumulator with increased voltage and a defined
Boost Charging
Denotes an immediate hazard with a high level of risk that could lead to death or severe physical current in order to fully charge the accumulator as quickly as possible.
injury if it is not prevented. grid | power FNC®-batteries are NiCd batteries and contain potassium hydroxide
(KOH) as electrolyte with an addition of lithium hydroxide (LiOH). When handled
Danger! Electrolyte
properly, grid | power FNC®-batteries are safe. Contact with the electrolyte is
excluded.
Denotes a potential hazard with a medium level of risk that could lead to death or severe physical
injury if it is not prevented.

Warning!

Denotes a hazard with a low level of risk that could lead to minor or medium degree of physical injury
if it is not prevented.

Caution!

Denotes a hazard in which the product, other objects or the environment may get damaged if it is
not prevented.

Attention!

Denotes first-aid measures.

Denotes important instructions to make best use of the product.

6 7
2 Safety 2.2 Personal Protective Equipment

Observe the safety instructions while handling the battery system and its components. While working on batteries wear face protection (impact-resistant visor
according to EN 166 class F or similar), protective eye-glasses, protective
gloves and clothing!
2.1 General Safety Instructions Observe accident prevention regulations as well as EN 50110-1 and
IEC 62485-2.
Caused by:
– Explosions If working with lead-acid batteries, the following equipment must be provided at the very least:
– Pressure waves – Insulated tools
Danger! – Flying hot or molten substances – Rubber gloves
– Protective shoes
Avoid:
– Fire extinguisher
– Short-circuits
– Rubber apron
– Electrostatic charges and discharges
– Protective goggles
– Sparking or arcs
– Face protection (impact-resistant visor according to EN 166 class F or similar)
– Emergency eye wash
Caused by:
– Voltages
2.3 Specific Safety Instructions for grid | power FNC®-Battery Systems
Danger! – Electric shocks
2.3.1 Safety Instructions on Handling with Electrolyte
Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit.
– Please be very careful when doing any work on the batteries in order to prevent severe injuries grid | power FNC®-cells are NiCd batteries and contain caustic potassium hydroxide solution as electrolyte.
caused by electrical shocks or burns.
– Never place tools or other metallic objects on a battery. Contact with the electrolyte can occur if you work on open cells. Electrolyte can be discharged if the
housing of an grid | power FNC®-cell is damaged. It can cause severe burn injuries on the skin and
– Remove watches and jewellery before doing any work on the batteries.
to the eyes.
– Do not touch any exposed battery parts, connectors, terminals or poles.
Warning!
While working on batteries wear face protection (impact resistant visor
according to EN 166 class F or similar), protective eye-glasses, protective
Reverse polarity of batteries or cells can cause overheating and thereby result in the electrolyte being
gloves and clothing.
ejected from the cell vents. Check for correct polarity before making connections.
Observe accident prevention regulations as well as EN 50110-1 and
Danger! IEC 62485-2.

First-aid measures
The cells of the batteries contain more than 0.1 % cadmium by weight: Take the following actions if you have come into contact with the electrolyte:
– Symbol: Cd
Electrolyte solution on the skin or in the hair
Attention! – CAS number: 7440-43-9
– Dab it with a cotton or paper-based cloth, but do not wipe it off.
– Remove pieces of clothing that have been contaminated, and while doing so, avoid contact with the
affected parts of the body as far as possible.
– Rinse off the affected parts for a longer period of time under flowing water.

Electrolyte in the eyes

– Gently rinse off the eye for up to 15 minutes with an eyewash or wash the eye in flowing water.
Avoid excessive water pressure when doing so. Remove any contact lens as far as possible and
continue to rinse off the eye.
– Consult an eye specialist or physician immediately.

Electrolyte in the mouth

– Rinse the mouth with water. DO NOT induce vomiting.
– Contact a doctor immediately or look for a hospital.

Use water to wash off clothes contaminated with electrolyte.

8 9
2.3.2 Safety Instructions on Charging the Battery System 2.3.4 Special hazards in the event of fire

Danger of explosion due to formation of oxyhydrogen gas! –W ear personal protective equipment against alkaline solutions (2.2 Personal Protective Equipment
When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen on page 9), for large battery systems also use breathing protection with self-sufficient breathing
gas) is formed, which already explodes with low energy input. air supply.
Danger! Danger! – Disconnect battery electrically.
Keep any source ignition away from the battery system: – Extinguish incipient fires with CO2.
– Open flames or fire –W hen extinguishing electric fires with water in low-voltage systems (up to 1 kV), maintain a spray
– Smoking distance of 1 m and a full spray distance of 5 m.
– Glowing embers –W ear alkali-resistant protective clothing! In case of contact with water, there is a risk of reactions
– Flying sparks during grinding work with the electrolyte (caustic solution) and consequently of violent spraying.
– Electrical sparks caused by switches or fuses –E xtinguish in short intervals. Otherwise, there is danger of explosion due to possible static charging
– Hot surfaces with temperature above 300 °C on the battery housing.
– Electrostatic discharges Failure to do so may result in death or serious injury.

Work with electrically insulated tools that do not strike sparks. Ground yourself when working directly
on the battery system.
Make sure that there is adequate ventilation in the container room in accordance with IEC 62485-2, 3 Intended/Unintended Use
so that the potential explosive gas mixture is discharged.
3.1 Intended Use

The following instructions are meant to prevent explosions caused by electrostatic discharges The grid | power FNC®-cells of the battery system are used to store and release electrical energy in standby
(Source: ZVEI – German Electrical and Electronic Manufacturers‘ Association – Professional applications, for example, uninterruptible power supply.
Association for Batteries):
– Do not rub batteries with a plastic housing with a dry cloth or one made of synthetic material! Intended use includes the following requirements:
Rubbing plastic surfaces generates electrostatic charge. Clean the batteries only with a cotton – Operating the battery system only if it is in proper condition
cloth moistened in water. Wiping with a cotton cloth moistened in water does not generate – No deactivation or disassembly of safety devices
electrostatic charge.
– Compliance with all instructions given in this operating and installation manual
– Do not rub batteries with clothing e. g. made of cotton! This can generate electrostatic charge.
– Wear shoes and clothes that prevent the formation of electrostatic charge on account of their
special surface resistance (see chapter 2.2 Personal Protective Equipment on page 9). 3.2 Unintended Use
– Use hand-held lamps with a mains cable without a switch (Protection class II) or hand-held lamps
with a battery (Protection class IP54). Unintended use of the batteries can lead to personal injuries or damage to property.
– Moisten a label of a battery (with water) before you pull off a label. Pulling off plastic labels can In case of unintended use, HOPPECKE Batterie Systeme GmbH shall not assume any liability for
develop electrostatic charge. personal injuries or damage to property that result directly or indirectly from handling the batteries.
Danger! The operator shall be solely responsible for the risks arising from unintended use.

2.3.3 Protection against dangerous body contact currents Any other use than described under “Intended use” is not intended and therefore not permitted.

In stationary battery installations, measures must be taken to guard against direct and indirect contact. For battery The unintended use of the product includes in particular:
installations this protection can take the form of obstacles or distance. – Operation in explosion-endangered areas
–O peration in safety-relevant applications, unless these applications are expressly specified or permitted in the
According to IEC 62485-2:
product documentation
– Battery installations with a rated voltage of 60 V … 120 V must be accommodated in electrical operation areas.
– Operation without permanent/insufficient fastening
– Battery installations with a rated voltage of more than 120 V must be accommodated in enclosed, electrical
– Operation outside the technical data
operating areas.
– Operation or storage outside the specified environmental conditions
Doors of battery rooms and cubicles count as obstacles when they are identified by the following warning plates – The electrical connection does not correspond to the documentation supplied with the battery
(fitted externally):
– Warning plate “Dangerous Voltage”, if the battery voltage exceeds 60 V (see ISO 3864).
– Prohibition sign: “No fire, naked flame or smoking”.
– Warning plate “Battery Room” to indicate electrolyte, explosive gases, dangerous voltages and currents.

10 11
4 Directives, Legislation and Standards The following drawing shows the internal structure of a grid | power FNC®-cell:

Please observe the latest edition of the following rules and regulations:
– Accident prevention regulations, especially DGUV Regulation 1: Accident prevention regulation; Principles of
prevention
– DIN EN ISO 20345 (“Personal safety gear – Safety boots”)
– DIN VDE 0105 (“Operation of electrical equipment”), in particular, governs the requirements for quality and 1 = Positive pole
qualification for working on electrical equipment (DIN VDE 0105-100)
2 = Negative pole
– DIN VDE 100/IEC 60364 (“Erection of low-voltage installations”)
3 = Cell casing
– DIN EN 50110/VDE 0105 (“Operation of electrical installations”)
4 = Cell lid
– IEC 62485/VDE 0510 (“Safety requirements for secondary batteries and battery installations”), particularly
5 = Vent plug
applicable for calculating the air ventilation required in battery rooms (in IEC 62485-2)
6 = Pole nut
– DIN EN 60623/IEC 60623 (“Secondary cells and batteries containing alkaline or other non-acid electrolytes.
Vented nickel-cadmium prismatic rechargeable single cells”), applicable primarily to the testing of cells (type 7 = Cell pole
test, series production test and field test) 8 = Negative electrode stack
– DIN EN 60993/IEC 60993 (“Electrolyte for vented nickel-cadmium cells”) 9 = Positive electrode stack
– DIN VDE 0100-600 Low-voltage electrical installations – Part 6: Verification (IEC 60364-6:2006, modified); 10 = Positive fiber structure electrode
German implementation HD 60364-6:2007 11 = Current tab
– ADR/RID: European Treaty on the international transport of hazardous goods by road/Ordinance on the inter- 12 = Negative fiber structure electrode
national transport of hazardous goods by rail 13 = Separator
– IATA-DGR: Dangerous goods regulations – international air transport association. German: Gefahrgut-
Bestimmungen – Internationale Flug-Transport-Vereinigung
– IMDG Code: International Maritime Code for Dangerous Goods, German: Gefahrgutkennzeichnung für gefähr-
liche Güter im Seeschiffsverkehr
– Ordinance on the supervision of waste and residual materials (German Federal Law Gazette, 1996)
In addition, observe and follow all applicable territorial and national, corporate and project-specific regulations
and accident prevention regulations.
The electrolyte is a solution of potassium hydroxide (KOH) in distilled water with an addition of lithium hydroxide
(LiOH). The standard electrolyte is designed for use in temperatures of between -25 °C and +45 °C. The lithium
hydroxide in the electrolyte varies between the different cell types (X, H, M, L). DIN IEC 993 is valid for the production
of the electrolyte.
5 Product description
When the cells are in operation, the density of the standard electrolyte is 1.19 kg/l ± 0.01 kg/l at the reference
grid | power FNC®-cells are connected to form battery systems and are deployed in standby applications.
temperature of 20 °C (electrolyte density can be higher on delivery).
Here, they fulfil one or more of the following functions:
– Buffering and supply of the low-voltage networks The electrolyte density is no indicator for the state of charge of nickel cadmium batteries.
– Providing power in case of an emergency
– To start a standby gen set/engine
For most FNC®-products, HOPPECKE supplies on request a special electrolyte that allows operation in low tempe-
ratures down to -45 °C.
5.1 grid | power FNC®-cell

grid | power FNC®-cell are nickel-cadmium cells, which are produced with fiber structure technology. It uses an
extremely porous, three-dimensional synthetic fleece, metallized with nickel.

The particular characteristics are:

– The best volume/weight ratio by 90 % volume filling of the fiber electrodes with active material.
– High to very high values of current can flow during charging and discharging.
– No carbonates are formed in the electrolyte.
– The batteries have long service life and several charging cycles even under extreme temperature conditions.
– It withstands the most extreme of stress caused by shocks and vibrations.
– Cell housings made optionally either of polyether sulphone, polyamide or polypropylene.
– A large variety of constructions ranging from high and extremely flat to low with a large surface area.

12 13
5.2 Cell Plugs for Different Use Cases 5.3.2 Buffer operation

Cell Plug Description

Direct current source Load

Yellow transport plug:

grid | power FNC®-cells are sealed with yellow transport plugs at delivery.

Battery

Vent plug:
The vent plug is the standard plug for FNC®-standby applications. It provides easy access to
Characteristics of this operating mode are:
control and refill the electrolyte level. The lid contains a filter that works as backfire protection.
– Load, direct current source and battery are permanently connected in parallel.
– The charging voltage is the operating voltage of the battery and at the same time the system voltage.
– The direct current source (charging rectifier) is not able to supply the maximum load current at all times. The load
Valve regulated plug (VR): current temporarily exceeds the rated current of the DC source. During this time, the battery supplies current.
A low-pressure valve recombines oxygen and hydrogen gasses inside the cell with up to 90 % – The battery is therefore not fully charged at all times.
efficiency. – The charging voltage to be set is 1.45 ... 1.55 V per cell x number of cells connected in series (measured at the
No water addition or filling is required over a 20 year service life when operated on float charge end poles of the battery).
at 20 °C. Furthermore, the VR plug provides a backfire protection.

5.3.3 Switching mode (charge/discharge mode)

Furthermore, HOPPECKE provides grid | aquagen pro vent plugs that are described in a separate documentation.
Contact HOPPECKE for further information.

Direct current source Load

5.3 Operation Modes (see also IEC 62485-2)

5.3.1 Standby parallel operation

Charger Battery
Direct current source Load

Characteristics of this operating mode are:

– When charging, the battery is disconnected from the consumer.
Battery – The battery can be switched to the consumer as required.
– The charging voltage of the battery is max. 1.50 ... 1.60 V/cell (boost charge) or 1.40...1.45 V/cell (float charge),
see also Section 5.3.1.
– The battery also can be charged with constant current I5. A secure shutdown criterion is required for this.
Characteristics of this operating mode are: Voltages up to 1.9 V/cell can occur.
– Load, direct current source and battery are permanently connected in parallel. – The charging process must be monitored.
– The charging voltage is the operating voltage of the battery and at the same time the system voltage. – Secured shutdown criterion required (up to 1.9 V/cell).
– The direct current source (charging rectifier) is always able to supply the maximum load current and the battery
charging current.
– The battery only supplies power when the direct current source fails.
– The charging voltage to be set is 1.40 ... 1.45 V per cell x number of cells connected in series (measured at the
end poles of the battery). This is called float charging. The battery is permanently in the state of charging with
float charge voltage.
– To shorten the recharge time, a charging stage can be used where the charging voltage is set to 1.50 ... 1.60 V
per cell x number of cells connected in series. This is referred to as boost charging.
– After charging in boost charge, an automatic switchover to float charge takes place.

14 15
5.4 Battery Charging Characteristic The following conditions are applicable to the characteristic shown:
– Switch from float charge to boost charge:
In the temperature range from 10 °C up to 30 °C the battery system can be operated with the charging voltages The current permanently overshoots a value of I20 = Cn/20 h.
as given in the table below: – Switch from boost charge to float charge:
The current permanently undershoots a value of I20 = Cn/20 h.
Charging voltage at 20 °C in V per cell connected in series: –C urrent limit I5 = Cn/5 h (recommended value, there may be deviations to higher or lower values of current)
– It is necessary to switch from boost charge to float charge when battery temperature is ≥ +45 °C, to avoid
Temperature
Cell performance Single-stage charging 2-stage charging 2-stage charging damage to the battery. The hysteresis must be selected so that the switch to boost charge is only possible
compensation
class according to (IU) (IU0U), (IU0U), when the temperature is ≤ +40 °C.
in V/degrees/cell;
EN 60623 float charging Boost charge – If the battery temperature is ≥ 60 °C, the charging process must be switched off to prevent damage from cells.
starting from 20 °C
The hysteresis must be chosen in a way that charging is only switched on again when the temperature ≤ 55 °C.
L 1.55

M 1.52
1.45 1.55 … 1.60 5.5 Battery Capacity
H 1.48
-0.003 A battery‘s capacity is the amount of electric charge it can deliver at the rated voltage.
X 1.45

VR L 1.42 1.57 The capacity, that can be charged to and can be taken from a battery, depends on the electrolyte temperature.
– 1) This relationship is shown in the following illustration. It shows the charge acceptance of FNC®-cells (1: H type;
VR M 1.40 1.55 2: M and L types) charged with I5 as a function of the electrolyte temperature:

1)
It is not recommended to use the single stage charging as charging characteristic for grid | power FNC® VR-cells,
because you cannot achieve the advantages of the VR technology (no water addition or filling is required over the
service life).

If the operating temperature differ from the range mentioned above, it is recommended to use a temperature
compensated charging method.

Capacity [%]
The following diagram illustrates the charging voltage of each cell connected in series depending on the
temperature of the electrolyte monitored by the charger (constant voltage, constant current characteristic, with
current limitation).
Charge voltage [V]

Temperature of the electrolyte [°C]

A test of the battery‘s capacity is part of the reconditioning, refer to 10.7 Reconditioning on page 39.

Temperature of the electrolyte [°C]

1 = Float charge
2 = Boost charge

16 17
6 Transport If the conditions of special regulation 598 are not complied with, declare and transport new and used batteries as
hazardous goods as follows:
Batteries must be packed, marked and conveyed in accordance with the applicable transport regulations
(ADR, IMDG Code, IATA). The cells of the battery should be protected against short-circuiting, sliding, falling over
UN hazardous goods class 8
or damage and are to be secured to pallets by suitable means. There should be no dangerous traces of lye on the
outside of the packages. Any special national regulations are to be observed. UN no. (material number) 2795

Following receipt and inspection of batteries, the battery cells should be replaced in their original packing. This Designation and description BATTERIES, WET, FILLED WITH CAUSTIC SOLUTION
provides the battery with good protection against damage while it is in storage prior to installation.
Packaging group Not assigned to any packaging group

Hazard label 8
Damage to the battery housing can lead to spilling of electrolyte, resulting in chemical burns. Secure
the load carefully during transport to prevent the battery housing from becoming damaged. ADR tunnel restriction code E

Danger!

The batteries are very heavy and can cause injuries and be damaged if they fall. 6.2 Transport by sea according to the IMDG Code
Use safety boots.
Use suitable equipment for transport. Declare grid | power FNC®-battery systems for sea freight as follows:
Caution!

Observe and follow the regulations for the transport of batteries, which are provided in the following sections. UN hazardous goods class 8

UN no. (material number) 2795

6.1 Surface Transport (Road/Rail) according to ADR/RID Proper shipping name BATTERIES, WET, FILLED WITH CAUSTIC SOLUTION

Filled batteries having the UN numbers 2795 (batteries/rechargeable batteries, wet, filled with alkalis) are not Packaging group Not assigned to any packaging group
classified as hazardous goods requiring declaration during transport, if the following requirements are met Hazard label 8
(according to the ADR special regulation 598, section 3.3):
EmS F-A, S-B
they are secured against sliding, turning over or damage. Packing instructions P801
they are provided with carrying facilities, unless, for example,
New batteries, if: they are stacked on pallets.
they do not have hazardous traces of caustic solutions or acids on the outside;
6.3 Air Freight
they are protected against short-circuit.
their housing is not damaged. Declare grid | power FNC®-battery systems for air freight as follows:
they are protected against leakage, sliding, turning over or damage, for example,
Used batteries, if: stacked on pallets. UN hazardous goods class 8
they do not have hazardous traces of caustic solutions or acids on the outside.
UN no. (material number) 2795
they are protected against short-circuit.
Proper shipping name BATTERIES, WET, FILLED WITH CAUSTIC SOLUTION

“Used batteries” are those that are transported for the purpose of recycling after normal use. Packaging group Not assigned to any packaging group

Hazard label 8

Packing instruction 870

18 19
6.4 Checking the delivery 7.1 Storage of Filled and Charged (FC) Cells

HOPPECKE Batterie Systeme GmbH packages your delivery with the greatest possible care so that it arrives The storage period of the batteries should not exceed three month after manufacturing and delivery
undamaged. from the factory.
– Check the delivery immediately for completeness (comparison with the delivery note). If the foreseeable storage period exceed three month, discharge the batteries as described below.
– Check the goods for transport damage. The battery system prepared in this way can be stored for three years.
The manufacturing date of the grid | power FNC®-cells is stamped on the top of each battery cell.
– Make a note:
Each cell has a 9-digit cell code on top of the cell lid. The last four digits indicate the week and year
– Damage to the outer packaging
of production.
– Visible stains or moisture that would indicate leaking electrolyte
Example:
xxxxx2610 → Production week 26; Production year 2010
If the delivery is incomplete or there is damage in transit:
– Write a short defect report on the delivery note before you sign it.
Steps to prepare the battery system for storage:
– Ask the carrier for an inspection and make a note of the name of the inspector.
1. Remove the plug of each grid | power FNC®-cell.
– Write a defect report and send it within 14 days to HOPPECKE Batterie Systeme GmbH and the forwarding agent.

Inspect goods for defects: Valid for grid | power FNC® VR-cells:
– Follow the instructions in chapter 2 Safety on page 8. Remove a VR plug carefully. It is recommended to use the HOPPECKE plug opener (Mat. No.
4142500125).
– After delivery, unpack the batteries as soon as possible and check them for defects by visually inspecting them,
Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically
see 10.1 Checking for Cleanliness and Condition of the Battery System on page 33.
pull out the plug from the cell opening.
Wear personal protective equipment because grid | power FNC® VR-cells operate under pressure.
Removing a VR plug can release electrolyte spray.
If you notify the freight forwarder too late of defects or incompleteness, this may result in the loss of
your claims.
2. Discharge the batteries by using a charging/discharging device with nominal current I5 (nominal capacity C5/5 h)
until the battery voltage has dropped to 1.0 V per cell.

7 Storage 3. Seal each grid | power FNC®-cells with a yellow transport plug.

The service life of the battery system begins with the delivery ex works from HOPPECKE. Storage periods must be Filled and charged (FC) grid | power FNC®-cells prepared in this manner can be stored up to three
taken into consideration in their entirety for the service life duration. years.
After three years, a recondition charge is necessary, see 10.7 Reconditioning on page 39.
Unpack the battery system as soon as possible after delivery, install it and put it into operation, see 8 Installation
on page 22. If you want to put the stored grid | power FNC®-cells into operation, you have to charge the cells for
recommissioning. For information, refer to 9.2 Commissioning of Unfilled and Uncharged (UU) and
In case this is not possible: Filled and uncharged (FU) grid | power FNC®-cells on page 30.
– Store the batteries in a clean, dry and frost-free room.
– Protect the batteries against mechanical damage and contamination.
– Do not expose the batteries to direct sunlight. 7.2 Storage of Unfilled and Uncharged (UU) and Filled and Uncharged (FU) grid | power FNC®-cells
– Do not stack the batteries on one another. Please observe and follow project-specific regulations applicable, if any.
Ensure that the grid | power FNC®-cells are sealed with yellow transport plugs.
grid | power FNC®-cells (UU and FU) can be stored up to three years.
The ideal storage temperature is +20 °C. After three years the UU cells must be filled and a recondition charge is necessary, see 10.7
The maximum storage temperature is +60 °C. Reconditioning on page 39. If you store the grid | power FNC®-cells longer than three years, contact
A too high storage temperature leads to faster self-discharge and premature ageing of the battery HOPPECKE before you put the cells into operation.
system.
If you want to put the stored grid | power FNC®-cells into operation, you have to charge the cells for
recommissioning. For information, refer to 9.2 Commissioning of Unfilled and Uncharged (UU) and
Filled and uncharged (FU) grid | power FNC®-cells on page 30.

20 21
8 Installation 8.1.3 Mounting a Rack

Risk of serious injury or death caused by: Assemble the rack according the instructions delivered from the manufacturer.
– high voltages
Observe the minimum distances according to IEC 62485-2.
– electric shocks
Danger!
Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit.
– Be very careful when doing any work on the batteries in order to prevent severe injuries caused by
electrical shocks or burns.
– Never place tools or other metallic objects on a battery. Risk of serious injury or death caused by high voltages and electric shocks.
– Remove watches and jewelry before doing any work on the batteries. If component voltages in excess of 120 V are reached or if the rated voltage of the battery is above
this value, then a minimum distance of 1.5 m is to be maintained between non-insulated connections
– Do not touch any exposed battery parts, connectors, terminals or poles.
Danger! or connectors and earthed parts (e. g. water pipes, heating) and between the end terminals of the
Use insulated tools and wear personal protective equipment. battery.

8.1 Mounting a Rack or Cabinet 8.1.4 Mounting a Cabinet

8.1.1 Before Mounting a Rack or Cabinet Assemble the cabinet according to its documentation, if it is supplied in separate parts.

Before starting assembly it must be ensured that the battery room is clean and dry and has a door which can Observe the minimum distances according to IEC 62485-2.
be closed. The battery room must be provided with warning signs conforming to IEC 62485-2 (see also 2.3.3
Protection against dangerous body contact currents on page 10).

Particular attention should also be paid to the following:

– Ensure correct floor loading and floor quality (access routes and battery room).
8.1.5 Ventilation Requirements
– Ensure that the mounting surface (floor of the battery room or electrolyte tray) is resistant to electrolyte.
– Protection against sources of ignition (naked flame, glowing matter, electrical switches) in the vicinity of the cell Ensure that the battery room or cabinet has an adequate ventilation. The ventilation has to keep the hydrogen
opening, Calculate “filament distance” as specified in IEC 62485-2 (Chapter 7.7). concentration below the threshold of 4 % by volume during battery charging, in accordance with IEC 62485-2.
– Ensure adequate ventilation according to IEC 62485-2.
– Agreement with other persons working in the same room (ensures trouble-free installation). The volume of air which must be changed hourly may be calculated by the following formula:
– Provide for leakage resistances of the floor according to IEC 62485-2.
HOPPECKE will be pleased to help you in procuring suitable racking. Q = volume of air in m3 per hour
Q = 0.05 * n * I n = number of FNC®-cells of the battery system
I = charging current in ampere (A)
8.1.2 Checking the Scope of Delivery

Check all goods delivered for completeness and for any signs of damage. The battery room or cabinet can be natural or forced ventilated. If natural ventilation (airflow 0.1 m/s) is used the
inlet and outlet openings must have a minimum cross-section, that is calculated as follows:
Clean all parts if necessary.
A = cross-section of vent in cm2
Note and follow the accompanying documentation. This documentation should comprise an assembly drawing A = 28 * Q
Q = volume of air in m3 per hour
for the rack or cubicle, together with battery connection instructions. If the documents required for correct assembly
of the rack are missing, please follow the project documentation or ask for this before starting assembly.
Provide ventilation openings at suitable locations to obtain the most advantageous conditions for air exchange.
Only undamaged cells may be used, since otherwise the whole battery may be adversely affected by escaping
electrolyte.

22 23
8.2 Installing the Battery System 8.2.2 Equipping the Rack or Cabinet

Risk of serious injury or death caused by: 1. Check and clean each cell.
– high voltages The contact surfaces of the terminals and the connectors must be in a clean and proper condition.
– electric shocks
Danger! 2. Place the individual cells:
Metallic parts of the batteries are always live. High current flow occurs if there is a short-circuit. – one after the other
– with correct polarity (for verification use a suitable measuring instrument)
– Be very careful when doing any work on the batteries in order to prevent severe injuries caused by
– as shown on the connection drawing, and at right-angles to the horizontal support rails
electrical shocks or burns.
– Never place tools or other metallic objects on a battery.
You can place the individual cells without any clearance.
– Remove watches and jewellery before doing any work on the batteries.
A distance of at least 5 mm between the cells is recommend in warmer environments (> 35 °C).
– Do not touch any exposed battery parts, connectors, terminals or poles.

The grid | power FNC®-cells are delivered according to your order: 8.2.3 Connecting the Battery System
– Filled and charged (FC)
– Unfilled and uncharged (UU) Connect the grid | power FNC®-cells electrically after you have placed them to a rack or cabinet. Use only original
– Filled and uncharged (FU) HOPPECKE accessories.

The cells are supplied sealed with yellow transport plugs or the standard vent plugs are already mounted. Several grid | power FNC®-cells can form a row. One or more rows form the battery system.

grid | power FNC® VR-cells are supplied sealed with yellow transport plugs. The VR plugs are separately enclosed 1. The contacts must be clean and free from any traces of corrosion.
in the delivery.
2. Connect the grid | power FNC®-cells to each other to form a row.

It is recommended to leave the yellow transport plugs on the cells until you have completed the
connection and installation of the battery system.

8.2.1 Preliminary Work on Unfilled and Uncharged grid | power FNC®-cells 1 = screw
2 = spring washer
The electrolyte is a solution of potassium hydroxide (KOH) in distilled water with an addition of lithium
hydroxide (LiOH). 3 = connector
It is recommended to use electrolyte delivered by HOPPECKE. 4 = terminal
Attention! If this is not possible for some reasons contact HOPPECKE for instructions on mixing.

Fill immediately (within 1 hour) electrolyte to an unfilled and uncharged cell after you have removed
the yellow transport plug. Prolonged contact of atmospheric oxygen to the electrodes can negatively
influence the performance.
Attention!

1. Remove the yellow transport plugs. Use spring washers.

Spring washers ensure a permanent and secure fit of the connectors on the terminal posts.
2. Fill electrolyte to the each grid | power FNC®-cell up to the minimum level +10 mm. Torque:
M8 = 20 Nm ± 1 Nm
Topping-up with electrolyte to the maximum level takes place after the commissioning of the battery M10 = 25 Nm ± 1 Nm
system, see 9 Commissioning on page 27.

3. Let the cells rest for 1 hour.

4. Insert the yellow transport plugs again.

Wait at least 12 hours before you begin with the commissioning works, see 9 Commissioning on
page 27.

Attention!

24 25
3. Install isolation rails to the connectors. Ensure that the wiring of the row and end connectors is proof against short-circuits:
Use wiring material with at least 3 kV dielectric strength.
Let a distance in air of at least 10 mm between the wiring and electrically conductive parts.
Alternatively, additional insulation may be used.
Any mechanical loading of the end terminals is to be avoided by the fixing of the row and end con-
nectors.
Avoid any mechanical load on the terminals with connecting the row and end connectors. Use only
original HOPPECKE accessories.

8.2.4 Labelling the Battery System

You have to attach visible polarity labels to the end terminals of the battery. It is recommended to equip the
FNC®-cells with consecutive numbers (from the positive to the negative terminal of the battery).
Battery systems with a nominal voltage ≥ 75 V installed in the EU must carry a CE conformity marking.
Contact HOPPECKE for further information.
The isolation rails are available as a yard good, also in flame retardant material according to UL94-V0.
They can be used for 3 mm and for 6 mm standard connectors.

9 Commissioning
4. Connect the rows to each other.
Danger of explosion due to formation of oxyhydrogen gas!
When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen
Risk of damage to the battery system. gas) is formed, which already explodes with low energy input.
The cross section of the row connectors must match to the current strength. Danger!
Keep any source ignition away from the battery system:
Attention! – Open flames or fire
– Smoking
– Glowing embers
– Flying sparks during grinding work
– Electrical sparks caused by switches or fuses
– Hot surfaces with temperature above 300 °C
– Electrostatic discharges

Work with electrically insulated tools that do not strike sparks.

Ground yourself when working directly on the battery system.
Make sure that there is adequate ventilation in the container room in accordance with IEC 62485-2,
so that the potential explosive gas mixture is discharged.

Row or end connector: Row or end connector with connection bracket:

1 = cover cap 1 = cable with cable eye

2 = screw 2 = nut
3 = spring washer 3 = spring washer
4 = cable with cable eye 4 = screw
5 = terminal 5 = washer
6 = terminal
7 = connection bracket
8 = spring washer
9 = screw

26 27
9.1 Charging Procedures for the Initial Commissioning 9.1.2 Charging with Constant Current and Constant Voltage (CCCV)

9.1.1 Charging with Constant Current

The CCCV charging must not be used for unfilled and uncharged (UU) FNC®-cells.
It is highly recommended to charge the HOPPECKE grid | power FNC®-cells during initial commissioning with a
constant current for a defined period of time. Attention!

The diagram below exemplarily shows the charge voltage of one cell depending on time during charge with As an option, you can use the constant current, constant voltage charging method for initial commissioning of the
constant current I5 for 7.5 hours: battery system. This method takes longer to charge the battery system to approximately 100 % than the constant
current charging (see 9 Commissioning on page 27).

Charging current
Charging voltage [V]

Charging voltage

Charging time [h]

First, the grid | power FNC®-cells are charged with a constant charging current. The maximum current has to be
limited to ≤ I5 (e. g. for a 100 Ah battery the current I5 = 20 A).

As soon as the voltage limitation takes place, the charging current decreases automatically.

Charging time [h] The following table shows the specified charging time for charging with limited charging voltage:

Voltages up to 1.9 V per cell can occur during the initial charging with constant current. Voltage [V] Time [h] Current [A] Capacity [Ah] Description
If your battery charger cannot achieve this performance for the complete battery system, the system
has to be split into two or more groups. Charge the groups separately. This is the recommended charging method, see 9.1.1
7.5 I5
1.9 V/cell Charging with Constant Current on page 28.
If you decrease the constant current, the charging time is increased. 15 I10 –
Example:
– I5 = 7.5 hours 10.5 I5
1.85 V/cell
– I10 = 15 hours 21 I10
– I20 = 30 hours
13.5 I5
… 1.8 V/cell If you limit the charging voltage, the charging time must be
27 I10 extended. Every step of 0.05 V increases the charging time by
1.5 * Cn
3 hours if the charging current is I5.
16.5 I5
1.75 V/cell
33 I10
Initial commissioning is only possible with char-
19.5 I5 ging voltages ≥ 1.65 V to get the capacity of the
1.7 V/cell battery system to approximately 100 %.
39 I10

22.5 I5
1.65 V/cell
45 I10

28 29
9.2 Commissioning of Unfilled and Uncharged (UU) and Filled and uncharged (FU) grid | power FNC®-cells 9.3 Commissioning Filled and Charged (FC) FNC®-cells

Danger of explosion due to formation of oxyhydrogen gas! If the initial commissioning is within three months from the manufacturing date, the instructions in
When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen this chapter are not mandatory.
gas) is formed, which readily explodes with low energy input. The manufacturing date of the grid | power FNC®-cells is stamped on the top of each battery cell.
Danger! Each cell has a 9-digit cell code on top of the cell lid. The last four digits indicate the week and year
Keep any ignition source away from the battery system: of production.
– Open flames or fire Example:
– Smoking xxxxx2610 → Production week 26; Production year 2010
– Glowing embers
– Flying sparks during grinding work Danger of explosion due to formation of oxyhydrogen gas!
– Electrical sparks caused by switches or fuses When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen
– Hot surfaces with temperature above 300 °C gas) is formed, which readily explodes with low energy input.
Danger!
– Electrostatic discharges
Keep any ignition source away from the battery system:
Work with electrically insulated tools that do not create sparks. – Open flames or fire
Ground yourself when working directly on the battery system. – Smoking
Make sure that there is adequate ventilation in accordance with IEC 62485-2, so that the potential – Glowing embers
explosive gas mixture is discharged. – Flying sparks during grinding work
– Electrical sparks caused by switches or fuses
Valid for unfilled and uncharged (UU) grid | power FNC®-cells – Hot surfaces with temperature above 300 °C
After filling the electrolyte, wait at least 12 hours before you begin with the commissioning works. – Electrostatic discharges

Danger! Work with electrically insulated tools that do not create sparks.
Ground yourself when working directly on the battery system.
1. Remove the transport plug of each grid | power FNC -cell. ®
Make sure that there is adequate ventilation in accordance with IEC 62485-2, so that the potential
explosive gas mixture is discharged.
2. Recommended: Insert a gas venting tube on each grid | power FNC®-cell,
(HOPPECKE Mat. No.: 4143180100). 1. Measure the voltages of the individual cells using a digital multimeter and note the values in the commissioning
report see 13.1 Commissioning Record on page 44.
3. Measure the temperature of the battery system by inserting a suitable glass thermometer through the opening The open circuit voltage of a fully charged, non-defective cell at 20 °C must be ≥ 1.3 V.
of a cell. The cell to be measured should be installed in the center of the system, in order to capture the warmest
possible location of the system. The individual cell voltages should not vary by more than ± 50 mV from the mean of all cell voltages.
If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service.
4. Charge the battery system using a constant current of I5 for 7.5 hours.

The battery system must not exceed a temperature of 45 °C during charging. 2. Remove the transport plug of each grid | power FNC®-cell.
Once a temperature of 45 °C is reached, stop the charging process.
Make a note of the remaining charging time. 3. Recommended: Insert a gas venting tube on each grid | power FNC®-cell,
Attention! Only continue charging when the cell temperature has dropped below 25 °C. (HOPPECKE Mat. No.: 4143180100).
Complete the remaining charging time of the 7.5 hours after the battery system has cooled.
Should the battery again reach a temperature of 45 °C before the charging time of 7.5 hours is 4. Discharge the battery system by using a charging/discharging device with nominal current I5, until the voltage of
completed, interrupt the charging process again, and repeat as necessary. the battery system has dropped to 1.0 V per cell.

5. Allow the battery system to rest for at least 4 hours. 5. Allow the battery system to rest with disconnect load for at least 8 hours, ideally overnight.

6. Remove the gas venting tubes. 6. Measure the temperature of the battery system by inserting a suitable glass thermometer through the opening
of a cell. The cell to be measured should be installed in the center of the system, in order to capture the warmest
7. Thoroughly remove any contamination on the battery system with a soft, damp cloth with water. possible location of the system.

8. Refill the electrolyte level of each grid | power FNC®-cell with electrolyte to maximum. 7. Charge the battery system using a constant current of I5 for 7.5 hours.

9. Place the (vent/VR) plug vertically and insert it carefully to each FNC®-cell.

10. Keep a log of your actions, see 13.1 Commissioning Record on page 44.

30 31
Activity Interval Reference
The battery system must not exceed a temperature of 45 °C during charging.
Once a temperature of 45 °C is reached, stop the charging process. Visual inspection of the battery system 10.1 Checking for Cleanliness and Condition
Make a note of the remaining charging time. and the FNC®-cells of the Battery System
Attention! Only continue charging when the cell temperature has dropped below 25 °C.
Checking the electrolyte level 6 months 10.2 Checking the Electrolyte Levels on page 34
Complete the remaining charging time of the 7.5 hours after the battery system has cooled.
Should the battery again reach a temperature of 45 °C before the charging time of 7.5 hours is Measuring the charging voltage
10.3 Measuring the Charging Voltage on page 36
completed, interrupt the charging process again, and repeat as necessary. of the battery system
Testing the isolation resistance
8. Allow the battery system to rest for at least 4 hours. 10.4 Testing the Insulation Resistance on page 36
of the battery system

9. Remove the gas venting tubes. Cleaning the battery system and its parts 12 months 10.5 Cleaning on page 37
Filling up electrolyte level 10.6 Fill up the Electrolyte Level with Distilled Water
10. Thoroughly remove any contamination on the battery system with a soft, damp cloth with water. with distilled water on page 37
Measuring the individual cell voltage
11. Refill the electrolyte level of each grid | power FNC®-cell with distilled water to maximum. Is part of the reconditioning.
of all FNC®-cells 5 years
12. Place the (vent/VR) plug vertically and insert it carefully to each FNC -cell. ® Reconditioning 10.7 Reconditioning on page 39

13. Keep a log of your actions, see 13.1 Commissioning Record on page 44.
Enter the activities and the measured values in a maintenance report as evidence in the event of a
warranty claim.
9.4 Capacity Testing of Batteries According to DIN IEC 60623

The capacity test is part of the recondition charge, see 10.7 Reconditioning on page 39.
10.1 Checking for Cleanliness and Condition of the Battery System

A clean battery is absolutely necessary, in order to avoid reduced service life and availability of the battery. Cleaning
of cell carriers, trays, racks and insulators is necessary in order to maintain the required insulation of the cells from
10 Maintenance each other, from the earth, and from other extraneous conductive parts.
In addition, damage caused by corrosion and leakage can be avoided. Cleaning of batteries is not only necessary to
– Have the batteries serviced regularly and properly by HOPPECKE qualified personnel or personnel authorised by ensure high availability required, but is also an essential part of accident prevention regulations.
HOPPECKE Batterie Systeme GmbH.
– Observe the notes in chapter 2 Safety on page 8. 1. Keep the cells of the battery system clean and dry since dust and moisture can lead to leakage currents.
– Correct maintenance of the battery system and its components is a basic requirement to ensure a satisfactory
service life of the battery. 2. Keep screws, connectors and cable lugs clean.
– To ensure that your battery remains in optimum condition, the following maintenance programme must be fulfilled.
– It is also mandatory to keep maintenance records, that include details of the temperature in the room in which 3. Thoroughly remove any contamination using a clean, damp cloth.
the batteries are installed or stored.
4. Check the batteries according to the following criteria:
The following table shows the measures for preventive maintenance:
– Contamination: Battery cells must be clean
– Ventilation: Ventilation openings must be unobstructed
– Cells, the racks or cabinets must be free from mechanical damage
– Connectors, screws and cables must be tight
– Plugs are mounted correctly (no electrolyte stains on the plugs or on the cells)

5. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.

32 33
10.2 Checking the Electrolyte Levels 1 = Glass tube for measuring
2 = MAX electrolyte level
Valid for grid | power FNC® VR-cells 3 = Top of separator
No water addition or filling is required over the service life when operated on the recommended
4 = MIN electrolyte level
specific float charge voltage at 20 °C.
However, it is recommended to inspect the electrolyte levels every six months visually. H1 = Height from open cell plug to MAX electrolyte level
H2 = Reserve of electrolyte between MIN and MAX label
H3 = Measurable electrolyte height range
Contact with the electrolyte can happen when measuring the electrolyte level. It can cause severe
chemical burns to the skin and severe damage to the eyes.

You can see the level of the electrolyte from the outside, if the housing of the FNC®-cells are made of polypropylene
(PP).

If the following conditions are true, no further action is necessary:

– The electrolyte levels of all FNC®-cells are higher than the middle between minimum and maximum.
Otherwise, you have to refill the electrolyte levels with distilled water to the maximum level, refer
The following table shows the measured electrolyte level according to the cell type (distinguished by the enclosure
to 10.6 Fill up the Electrolyte Level with Distilled Water on page 37.
height):
– The difference between the FNC®-cells must be not greater than 5 mm.

Enclosure Level measured

Description
If the level of the electrolyte is not visible, use the glass tube for measuring height [mm] with the glass tube [mm]
(HOPPECKE Mat. No.: 4144140010) as described below. 5 Middle between Minimum and Maximum
217
1. Open or remove the plug of each grid | power FNC -cell. ® 19 Maximum level

15 Middle between Minimum and Maximum

276
Valid for grid | power FNC® VR-cells: 36 Maximum level
If you want to check the electrolyte level with the glass tube for measuring, remove the VR plug
carefully. It is recommended to use the HOPPECKE plug opener (Mat. No. 4142500125). 22.5 Middle between Minimum and Maximum
Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically 373
55 Maximum level
pull out the plug from the cell opening.
Wear personal protective equipment because grid | power FNC® VR-cells operate under pressure.
Removing a VR plug can release electrolyte spray.
5. If the level is higher than the middle between minimum and maximum level no further action is necessary.
It is recommended to use the glass tube for measuring Otherwise, you have to refill the electrolyte levels with distilled water to the maximum level, refer to 10.6 Fill
(HOPPECKE Mat. No.: 4144140010) to check the electrolyte. up the Electrolyte Level with Distilled Water on page 37.

2. C
heck the electrolyte level in each cell with the glass tube for measuring Use only distilled water in accordance with EN 60993 for topping up the battery cells.
(HOPPECKE Mat. No.: 4144140010). Filling the cells with acid or acidic water destroys the cells of the grid | power FNC®-batteries.
Tap water impairs the battery performance.
3. K
eep the top opening of the glass tube free and guide it into the cell until it meets some resistance. Warning!

4. Close the top opening of the glass tube with the index finger and remove it from the cell. 6. Close or remount the plugs.

7. Clean the battery system if necessary, see 10.5 Cleaning on page 37.

8. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.

34 35
1. Measure the insulation resistance between plus pole of the battery and one metallic part of the battery rack/
10.3 Measuring the Charging Voltage cabinet or central earthing point.

The measurement of the voltage values is used to detect and identify faults. Recording the voltage values measured 2. Measure the insulation resistance between the minus pole and a metallic part of the battery rack/cabinet or
helps in doing so. central earthing point.

Precondition 3. C
lean the battery system, if the measured values are lower than the minimum value (see 10.5 Cleaning).
The battery system is connected to a charging device and is being charged.
4. Measure the insulation resistance again according to step 1 and 2.

Depending on installation conditions, there can be a risk of death or severe injuries when establishing 5. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.
access to or accessing the battery system.
Carry out the prescribed safety measures that apply to the required maintenance works.
Danger! 10.5 Cleaning

1. Measure the charging voltage of the battery system. A clean battery is absolutely necessary, in order to avoid reduced service life and availability of the battery.

2. Measure the temperature of the battery system. Solvent and wire brushes can attack the walls of the battery cells.
Do not use solvents or wire brushes to clean the batteries.
3.
Control the measured charging voltage with the charging characteristic, refer to 5.4 Battery Charging
Characteristic on page 16. Attention!

4. Note the measured values, see 13.2 Maintenance Log on page 47. Cleaning water that penetrates into the battery or dirt particles can damage it.
While cleaning the battery, the battery cells must be sealed with the cell plugs or transport plugs.

10.4 Testing the Insulation Resistance Attention!

The insulation resistance of a battery is a measure of the conductivity. It results of moisture and contamination 1. C
lean the battery with a clean, damp cloth and with water without adding any detergents or cleaning agents.
of the battery between the battery poles and the chassis (rack/cabinet). Ideally, no conduction should take place
here if the insulation resistance of the battery is infinitely large. 2. R
inse off the cell plugs with water if this is necessary.

When commissioning a new battery, the insulation resistance must be > 1 MΩ. This value falls with the operating 3. Dry the surfaces of the battery after cleaning them using a clean, damp cloth or with the help of compressed air.
time (caused by aerosols from the batteries, condensation and dust) and, in accordance with IEC 62485-2, it should
not fall below the value of 100 Ω per volt of nominal voltage. 4. Any liquids which entered the battery rack or cabinet must be extracted and disposed of in accordance with
waste monitoring guidelines.
Minimum value for the battery system:
100 Ω x 1.2 V x number of cells of the battery connected in series. 5. To protect bare connectors and terminals against corrosion, a thin layer of neutral Vaseline or anti-corrosion
lubricant can be used.
For grid | power FNC®-batteries, an insulation resistance measuring instrument with a test voltage of
500 V/1000 V must be used (according to DIN VDE 0100-600). 6. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.
Use a suitable measuring device, e. g., GOSSEN METRAWATT METRISO 5000 D-PI.
Nominal battery voltage ≤ 500 V = set the measuring device to 500 V/DC, 1 minute
Nominal battery voltage > 500 V = set the measuring device to 1000 V/DC, 1 minute 10.6 Fill up the Electrolyte Level with Distilled Water

An insulation test voltage of 500 V/1000 V may damage other components connected to the battery. Valid for grid | power FNC® VR-cells
Disconnect the battery from the load if you measure the insulation resistance. No water addition or filling is required over the service life if the battery system operates on float
charge at 20 °C.
Attention! If, however, you have to fill up the electrolyte level with distilled water, remove the VR plug carefully.
It is recommended to use the HOPPECKE plug opener (Mat. No. 4142500125)
While carrying out measurements with an insulation resistance measuring instrument there is the Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically
risk of getting an electric shock. Observe and follow the safety precautions described in the pull out the plug from the cell opening.
documentation of the insulation resistance measuring instrument. Wear personal protective equipment because grid | power FNC® VR-cells operate under pressure.
Caution! Removing a VR plug can release electrolyte spray.

36 37
Contact with the electrolyte can happen when measuring the electrolyte level. It can cause severe Use only distilled water in accordance with EN 60993 for topping up the battery cells.
chemical burns to the skin and severe damage to the eyes. Filling the cells with acid or acidic water destroys the cells of the FNC®-batteries.
Tap water impairs the battery performance.
Warning! Attention!
While working on batteries wear face protection (impact resistant visor
according to EN 166 class F or similar), protective eye-glasses, protective 2. Clean the battery system if necessary, see 10.5 Cleaning on page 37.
gloves and clothing.
Observe accident prevention regulations as well as EN 50110-1 and 3. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.
IEC 62485-2.

10.7 Reconditioning
Precondition
You have checked the electrolyte level as described in 10.2 Checking the Electrolyte Levels on page 34. Reconditioning can eliminate or reduce capacity losses of a battery system.
It is carried out by repeatedly discharging/charging of the battery system with constant current.

1. Refill the electrolyte levels with distilled water to the maximum level.
Danger of explosion due to formation of oxyhydrogen gas!
When the cells are charged, water is decomposed and a hydrogen-oxygen-gas mixture (oxyhydrogen
1 = Glass tube for measuring gas) is formed, which readily explodes with low energy input.
2 = MAX electrolyte level Danger!
3 = Top of separator Keep any source ignition away from the battery system:
4 = MIN electrolyte level – Open flames or fire
H1 = Height from open cell plug to MAX electrolyte level – Smoking
H2 = Reserve of electrolyte between MIN and MAX label – Glowing embers
H3 = Measurable electrolyte height range – Flying sparks during grinding work
– Electrical sparks caused by switches or fuses
– Hot surfaces with temperature above 300 °C
– Electrostatic discharges

Work with electrically insulated tools that do not create sparks.

Ground yourself when working directly on the battery system.
Make sure that there is adequate ventilation in accordance with IEC 62485-2, so that the potential
explosive gas mixture is discharged.

Contact with the electrolyte can happen when measuring the electrolyte level. It can cause severe
chemical burns to the skin and severe damage to the eyes.

Warning!
While working on batteries wear face protection (impact resistant visor
according to EN 166 class F or similar), protective eye-glasses, protective
gloves and clothing.
Maximum electrolyte levels according to the cell type (to distinguish by the enclosure height): Observe accident prevention regulations as well as EN 50110-1 and
IEC 62485-2.
Enclosure Level measured
Description
height [mm] with the glass tube [mm]
Ensure that the battery room or cabinet has an adequate ventilation. The ventilation has to keep the
5 Middle between Minimum and Maximum hydrogen concentration below the threshold of 4 % by volume during battery charging, in accordance
217 with IEC 62485-2.
19 Maximum level Attention!
15 Middle between Minimum and Maximum
276 Precondition
36 Maximum level Check the electrolyte level in each cell:
The electrolyte levels must be higher than the middle between minimum and maximum.
22.5 Middle between Minimum and Maximum Fill up the electrolyte levels with distilled water to the middle between minimum and maximum if
373
55 Maximum level necessary. For instructions, refer to 10.2 Checking the Electrolyte Levels on page 34.

38 39
For reconditioning, the battery is supplied with an electric charge of 1.5 Cn, where relatively high cell voltages can If the battery system takes 5 hours to drop 1.0 V per grid | power FNC®-cell its capacity is 100 %:
arise while charging (up to 1.9 V). – 5 hours → 100 %
– 4.5 hours → 90 %
1. Remove the plugs at each grid | power FNC®-cell.
– 4 hours → 80 %
– 3 hours → 60 %
Valid for grid | power FNC® VR-cells …
Remove a VR plug carefully. It is recommended to use the HOPPECKE plug opener (Mat. No.
4142500125). 11. Allow the battery system to rest for at least 8 hours, preferably overnight. If the discharge time is ≤ 4.5 hours,
Alternatively use a small, slot screwdriver. Grab the plug with your hand and slowly twist and vertically repeat the process from point 8.
pull out the plug from the cell opening.
Wear personal protective equipment because grid | power FNC® VR-cells operate under pressure.
Removing a VR plug can release electrolyte spray. If the discharge time is still ≤ 4.5 hours after 5 repetitions of this procedure, contact HOPPECKE
service.
2. Remove the insulation profiles.

12. Charge the battery system using a constant current of I5 for 7.5 hours.

The battery system must not exceed a temperature of 45 °C during charging.

Once a temperature of 45 °C is reached, stop the charging process.
Make a note of the remaining charging time.
Attention! Only continue charging when the cell temperature has dropped below 25 °C.
3. Measure the voltages of the individual cells using a digital multimeter and note the values in the maintenance Complete the remaining charging time of 7.5 hours after the battery system has cooled.
log. The open circuit voltage of a fully charged, non-defective cell at 20 °C is ≥ 1.3 V. Should the battery again reach a temperature of 45 °C before the charging time of 7.5 hours is
completed, interrupt the charging process again, and repeat as necessary.

The individual cell voltages should not vary by more than ± 50 mV from the mean of all cell voltages.
If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service. 13. Allow the battery system to rest for at least 8 hours, preferably overnight.

14. Remove the gas venting tubes.

4. It is recommended to insert a gas venting tube on each grid | power FNC®-cell,
(HOPPECKE Mat. No.: 4143180100). This reduces the contamination by electrolyte. 15. Thoroughly remove any contamination on the battery system with a soft, damp cloth with water.

5. Discharge the battery system by using a charging/discharging device with nominal current I5, until the voltage 16. Refill the electrolyte level with distilled water to the maximum level, see 10.6 Fill up the Electrolyte Level with
of the battery system has dropped to 1.0 V per cell in the arithmetic middle (e. g., battery system with 54 cells Distilled Water on page 37.
→ 54 V).
17. Remount the plugs to the FNC®-cells.
6. Allow the battery system to rest open circuit for at least 8 hours, preferably overnight.
18. Measure the voltages of the individual cells using a digital multimeter.
7. Measure the temperature of the battery system by inserting a suitable glass thermometer. The cell to be
measured should be installed in the centre of the system, in order to capture the warmest possible spot of the
system. Record the measured value. If the individual cell voltages vary by more than ± 50 mV from the mean of all cell voltages, contact
HOPPECKE service.
8. Charge the battery system using a constant current of I5 for 7.5 hours.

The battery system must not exceed a temperature of 45 °C during charging. 19. Clean the battery system if necessary.
Once a temperature of 45 °C is reached, stop the charging process.
Make a note of the remaining charging time. 20. Mount the insulation profiles.
Attention! Only continue charging when the cell temperature has dropped below 25 °C.
Complete the remaining charging time of 7.5 hours after the battery system has cooled. 21. Measure the insulation resistance of the battery system, see 10.4 Testing the Insulation Resistance on page 36.
Should the battery again reach a temperature of 45 °C before the charging time of 7.5 hours is
completed, interrupt the charging process again, and repeat as necessary. 22. Keep a log of your maintenance activities, see 13.2 Maintenance Log on page 47.

9. Allow the battery system to rest for at least 2 hours.

10. Discharge the battery system by using a charging/discharging device with nominal current I5, until the voltage
of the battery system has dropped to 1.0 V per cell and measure the time elapsed. This is the capacity test.

40 41
11 Troubleshooting 11.4 Insulation Resistance is Low

Definition:
11.1 Over Consumption of Distilled Water
Minimum insulation resistance = 100 Ω x 1.2 V x number of FNC®-cells
During charging, electrolysis decomposes the water of the electrolyte into the gases 2H2 + O2. This leads to a
In case of an insulation fault, leakage currents may reduce the available capacity of the battery. This runs the risk
lowering of the electrolyte level. The volume of decomposed water depends on charging voltage, charging time per
of giving rise to different cell voltage. Regular cleaning can prevent these leakage currents and different cell
day and temperature.
voltages.
If you detect an over consumption of distilled water, proceed as follows:
Possible Cause Remedy
Possible Cause Remedy Contamination Cleaning
Charging voltage is too high Check the charger Correct the reason of the leakage;
Leaks in a cell
possibly exchange the cell
Dispersion of the individual cell voltages See next chapter

11.5 Battery Voltage not Measureable

11.2. Dispersion of the Individual Cell Voltages
If you cannot measure a voltage, proceed as follows:
If you detect that the individual cell voltages show variations of more than ± 50 mV from the mean of all cell
voltages, proceed as follows:
Possible Cause Remedy

Possible Cause Remedy A fuse has tripped Search for the fault; switch on/exchange the fuse

Variations in cell temperature Check the ventilation Broken cables Change the cable
The equalization must be performed by Defect connectors Change the connector (use new spring washers)
Differences in the electrolyte density of the cells
HOPPECKE service
Measure the individual cell voltages;
Plate short-circuits in one or more cells
Change the defect cells
Various charge states of the cells Run a reconditioning charge 12 Disassembly, Disposal and Recycling
Insulation resistance is too low See 11.4 Insulation Resistance is Low on page 43 Caused by:
– Voltages
– Electric shock
11.3 Available Battery Capacity is Low Danger!
Before starting to disassemble the battery, disconnect any supply and load cables (fuses).
Insufficient capacity may be due to the following causes:
Based on the content of cadmium and caustic potassium, grid | power FNC®-batteries must not be disposed of at
Possible Cause Remedy the end of their service life with household waste.
Check the local regulations and codes regarding storage of waste batteries.
Boost charging process is too short Run a reconditioning charge

Electrolyte levels are below minimum level Correct the electrolyte level Note
Old batteries bearing this sign are recyclable economic goods and must be returned via the recycling
Control all connections, change connectors if
Loose or oxidised terminals process.
necessary (use new spring washers)
You can use the HOPPECKE recycling system. The old batteries are picked up and returned to the
Insulation resistance is too low See 11.4 Insulation Resistance is Low on page 43 recycling system. Contact HOPPECKE Service for further information.

Note
Dispose of nickel-cadmium batteries, which are not returned to the recycling process, as special
waste in compliance with all regulations.
Cd

42 43
13 Appendix Charging current:

13.1 Commissioning Record Start of charging End of charging

A record should be made during commissioning of the battery: Charger current [A]

Customer:
Temperatures:
Order No.:
Where installed: Start of charging End of charging

Ambient [°C]

Electrolyte [°C]

of pilot cell number:

Supplier:

Battery No.: Loading time:

Cell type: from to

No. of cells: Date

Capacity [Ah]: Time [h]

Charging voltage (tick and fill out): Commissioning confirmation:

■
Charging with constant current I5
■
Charging with constant current
Commissioning carried out by
Date Signature

and constant voltage Acceptance (supplier) carried out by

Acceptance (customer) carried out by

Constant current [A]:

Maximum voltage [V]:

Battery voltages:

Start of charging End of charging

Open-circuit voltage [V]

Charging voltage [V]

44 45
Measurement of individual cell voltages: 13.2 Maintenance Log

End-of-charge voltage 15 min. Cut-off voltage after

Cell No. Open terminal voltage [V]
before end of charging [V] 5 hours discharge [V] Keep this maintenance log to provide a proof in case of warranty.

Number of the battery system:��

Commissioning date:��

Hint: Reproduce this page according to the number of cells of your battery system.

46 47
13.2.1 Six-monthly Maintenance Interval

13.2.1.1 Visual Inspection and Checking Electrolyte Level 13.2.1.2 Measuring battery system voltage

Interval Done (mark Interval Measured

Date Inspector (name) Date Inspector (name)
(years) with a cross) (years) value in Volt
0.5 0.5
1 1

1.5 1.5

2 2

2.5 2.5

3 3

3.5 3.5

4 4

4.5 4.5

5 5

5.5 5.5

6 6

6.5 6.5

7 7

7.5 7.5

8 8

8.5 8.5

9 9

9.5 9.5

10 10

10.5 10.5

11 11

11.5 11.5

12 12

12.5 12.5

13 13

13.5 13.5

14 14

14.5 14.5

48 49
13.2.2 Annual Maintenance Interval

13.2.2.1 Cleaning the battery system 13.2.2.2 Insulation testing

Interval Done (mark Interval Measured

Date Inspector (name) Date Inspector (name)
(years) with a cross) (years) value in Ohm
1 1
2 2

3 3

4 4

5 5

6 6

7 7

8 8

9 9

10 10

11 11

12 12

13 13

14 14

50 51
13.2.2.3 Filling up distilled water 13.2.3.2 Measuring of Single Cell Voltages

Interval Done (mark Interval Cell Measured Cell Measured Cell Measured
Date Inspector (name)
(years) with a cross) (years) number value in Volt number value in Volt number value in Volt
1 5

13.2.3 Maintenance Interval every 5 years

13.2.3.1 Reconditioning

Interval Done (mark

Date Inspector (name)
(years) with a cross)
5
10

Date: Inspector: ______

Hint: Reproduce this page according to the number of cells of your battery system.

52 53
13.3 Useful tools

In the following you find a list with tools which helps you in case of maintenance and service:

Interval Cell Measured Cell Measured Cell Measured Tool Description

(years) number value in Volt number value in Volt number value in Volt
10

Voltmeter/multimeter
(illustration shows an example)

Insulation tester
(illustration shows an example)

External charge/discharge unit

(illustration shows an example)

Waterfilling cart
230 V
(HOPPECKE Mat. No.: 4147000210)
115 V
(HOPPECKE Mat. No.: 4147000215)

Glass tube for measuring

(HOPPECKE Mat. No.: 4144140010)

Gas venting tube

(HOPPECKE Mat. No.: 4143180100)

Cell lifter
Format 3, 4, 5: M10
(HOPPECKE Mat. No.: 4141900003)
Date: ______________________________ Inspector: ____________________________________ Format 1, 2: M8
(HOPPECKE Mat. No.: 4141900002)

Hint: Reproduce this page according to the number of cells of your battery system.

Plug opener for cells with valve plug (VR plug)

(HOPPECKE Mat. No.: 4142500125)

54 55
Installation, commissioning and operating instructions

for stationary Fibre Nickel Cadmium Batteries grid | power FNC®

All details in this brochure are based on state-of-the-art technology. Our products are subject to constant development. We therefore reserve the right to make changes.
Printed in Germany

HOPPECKE Batterien GmbH & Co. KG

P.O. Box 1140 · D-59914 Brilon · Germany Phone +49(0)2963 61-0 Email [email protected]
Bontkirchener Straße 1 · D-59929 Brilon Fax +49(0)2963 61-270 www.hoppecke.com

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Grid Power FNC Manual en

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Grid Power FNC Manual en

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Installation, commissioning and operating instructions

for stationary Fibre Nickel Cadmium Batteries grid | power FNC®

Similar to the illustration

Bontkirchener Straße 1 International Service-Hotline:

Installation, commissioning and operating instructions

Type, Design, Print: PRIOTEX Medien GmbH, 59609 Anröchte

© 2021 HOPPECKE Batterien GmbH & Co. KG

Denotes first-aid measures.

Denotes important instructions to make best use of the product.

Electrolyte in the eyes

Electrolyte in the mouth

Use water to wash off clothes contaminated with electrolyte.

The particular characteristics are:

Cell Plug Description

Yellow transport plug:

5.3.3 Switching mode (charge/discharge mode)

Direct current source Load

5.3.1 Standby parallel operation

Characteristics of this operating mode are:

Temperature of the electrolyte [°C]

Temperature of the electrolyte [°C]

UN no. (material number) 2795

Packing instruction 870

8.1 Mounting a Rack or Cabinet 8.1.4 Mounting a Cabinet

Particular attention should also be paid to the following:

1. Remove the yellow transport plugs. Use spring washers.

3. Let the cells rest for 1 hour.

4. Insert the yellow transport plugs again.

8.2.4 Labelling the Battery System

Work with electrically insulated tools that do not strike sparks.

Row or end connector: Row or end connector with connection bracket:

1 = cover cap 1 = cable with cable eye

9.1.1 Charging with Constant Current

Charging time [h]

If the following conditions are true, no further action is necessary:

Enclosure Level measured

15 Middle between Minimum and Maximum

10.4 Testing the Insulation Resistance Attention!

Work with electrically insulated tools that do not create sparks.

The battery system must not exceed a temperature of 45 °C during charging.

14. Remove the gas venting tubes.

9. Allow the battery system to rest for at least 2 hours.

11.5 Battery Voltage not Measureable

13.1 Commissioning Record Start of charging End of charging

of pilot cell number:

Battery No.: Loading time:

Cell type: from to

No. of cells: Date

Capacity [Ah]: Time [h]

Charging voltage (tick and fill out): Commissioning confirmation:

and constant voltage Acceptance (supplier) carried out by

Acceptance (customer) carried out by

Maximum voltage [V]:

Start of charging End of charging

Open-circuit voltage [V]

Charging voltage [V]

End-of-charge voltage 15 min. Cut-off voltage after

Number of the battery system:�����������������������������������������������������������������������

Interval Done (mark Interval Measured

13.2.2.1 Cleaning the battery system 13.2.2.2 Insulation testing

Interval Done (mark Interval Measured

13.2.3 Maintenance Interval every 5 years

Interval Done (mark

Date: ______________________________ Inspector: ____________________________________

Interval Cell Measured Cell Measured Cell Measured Tool Description

External charge/discharge unit

Glass tube for measuring

Gas venting tube

Plug opener for cells with valve plug (VR plug)

for stationary Fibre Nickel Cadmium Batteries grid | power FNC®

HOPPECKE Batterien GmbH & Co. KG

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Number of the battery system:��

Date: Inspector: ______