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HOPPECKE

Operating Instructions
for vented FNC-T nickel cadmium batteries with fibre-structured
electrodes for use in automatic guided vehicles (AGV) and other
traction applications
Specifications: Explosion and fire hazard, avoid must be firmly seated. The following tor-
Nominal voltage UN: 1.2 V x number of short circuits! ques apply for screw connectors:
cells connected in series Caution! Metal parts of the bat- Thread size M8: 16 Nm  1 Nm
Nominal capacity CN = C5: tery cells are always live, do not Thread size M10: 20 Nm  1Nm
5-hr discharge with nominal current place items or tools on the bat-
(see type plate and techn. data in these tery! 1.2 With charger off and loads isolated
instructions) connect battery to the charger (positive ter-
CN Electrolyte is strongly corrosive! minal to positive post) maintaining correct
Nominal discharge current: IN = I5:
5h polarity.
Nominal final discharge volt. Us: 1.0 V/C Do not tip the battery!
Nominal temperature TN: 20°C Only use approved lifting and 2. Preparing unfilled batteries/cells
transport equipment, e.g. lifting
equipment in accordance with 2.1 The cells are filled with electrolyte up
Installed by: VDI 3616. to a level between the min. and max.
Lifting hooks must not damage mark. See the separate instructions on pre-
on: cells, connectors or connector paring and handling of electrolyte.
cables. Before filling with electrolyte remove the
Start-up by:
transport plugs.
Note: After filling, the supplied standard vent
on: Non-compliance with operating instruc- plugs are fitted onto the cells.
tions, repairs made with other than origi-
Safety marking nal parts, tampering or use of additives for Note:
affixed by: the electrolyte render the warranty null If Aqua Gen vent plugs are supplied, do
and void. not fit onto the cells until after initial char-
on:
ging.
Warning:
Observe operating instructions Never use acid or dilute acid solutions for 2.2 After filling and a waiting period of
and affix close within sight of the topping up. Acid destroys the battery. 12 hours carry out initial charging as de-
battery! Work on batteries only
scribed under section 3.2 and 3.3.
under instructions of skilled per- Caution:
sonnel! During and after charging the battery pro- 2.3 Not less than two hours after completi-
duces explosive gases. Ensure adequate on of initial charge the electrolyte level in
Smoking prohibited! ventilation under VDE 0150, Part 3. Up to the cells must be filled to the max. mark
Do not expose battery to open fla- 1 h after charging electric connections with electrolyte. If Aqua Gen vent plugs
me, heat or sparks as explosion must not be touched. No open flame, are supplied they are then fitted onto the
and fire hazard exists! heat, electric installations or carriers of sta- cells.
tic electricity which could produce sparks
When working on batteries wear must come near the battery! Metal parts of
protective glasses and clothing! the battery installation could be live. Use 3. Preparing filled cells for use
Observe the accident prevention insulated tools and suitable clothing. Do
rules as well as DIN VDE 0510, not wear rings, watches or metal objects 3.1 Replace the transport plugs with stan-
VDE 0105 Part 1! when working on the battery installation. dard vent plugs (flip-top vent plugs)

Lye splashes in the eyes or on the 3.2 Initial charging is carried out at the
skin must be washed out or off 1. General hints battery’s constant nominal charging cur-
with plenty of water. Then see a rent for 12 hours. The nominal charging
doctor immediately! Lye splashes 1.1 Before commissioning all cells must be current is calculated as CN/5 h.
on clothing must be washed out inspected for mechanical damage and Initial charging is not necessary if the
with water! correct polarity connection. Connectors cells / batteries are delivered filled and
charged and are put into operation as charger allocated and approved for the according to 41773. The following para-
described under section 4 within 2 months battery size. meters are adhered to:
of delivery. Following long transport or Charge current H types: 5 to 12.5 x I5
storage periods the filled and charged If the charger was not procured together X types: 5 to 20 x I5
cells / batteries should undergo an equali- with the battery, it is advisable to have it
zing charge as under section 4.6. checked for suitability by the battery ma- Charge voltage boost charge: 1.55 V/cell
nufacturer’s service department. to 1.65 V/cell
Note: Float charge: 1.4 V/cell to 1.45 V/cell.
Constant charging currents of up to 50% During charging it must be ensured that
of the nominal charging current are per- charge gases can escape unhindered. Re- With AGV operation battery gassing is
missible for initial charging if the charging move the battery-tray lid or open the cover largely avoided so that the battery can be
duration is set so that a quantity of electri- of the battery installation area. For batte- charged in the AGV. With AGV it must
city of 2.4 x CN is charged into the bat- ries in AGV systems see special parame- merely be ensured that no dangerous ac-
tery. ters, section 4.4.1. cumulation of charge gasses can occur.
The vent plugs remain on the cells.
During initial charging with constant cur- FNC-T batteries of type M are not recom-
rent, cell voltages of up to 1.9 v may oc- With the charger off the battery must be mended for use in AGV installations.
cur. The load must therefore be disconnec- connected, ensuring correct polarity (plus
ted from the battery, see section 1.2. on plus and minus on minus). The charger 4.4.2 General traction applications
During initial charging a higher quantity of is then switched on. FNC-T batteries are also used in hand-dri-
water is decomposed (gassing) than du- ven industrial trucks and fork-lift trucks. De-
ring normal battery operation. Sufficient pending on battery design the discharge
ventilation must therefore be ensured ac- 4.4 General operating parameters depth can reach up to 100% CN. By suffi-
cording to DIN VDE 0510. cient ventilation of the battery it must be
4.4.1 Operation in automatic guided ensured that the electrolyte temperature
3.3 After long battery transport periods or vehicle systems (AGV) does not exceed 35°C. A temperature of
storage periods of over 36 months, three With this method of operation the battery 45°C is also tolerated for short periods.
to four battery charges and discharges are is used for running an automatic guided
recommended. Charging is carried out vehicle. These vehicles serve to transport The battery loads in this operation are as
with the constant nominal charging current materials. follows:
and a charge factor of 1.0 v/cell. The fi- Constant driving current:
nal charge is an equalizing charge as de- The characteristic of this battery is a con- FNC-T H and X types: see section 4.4.1
scribed in section 4.6. stant cycle (charge - discharge) operation FNC-T M types: up to 1.5 x I5
where the battery is only charged with a
3.4 Not less than two hours after completi- charge factor of approx. 1.02 to 1.05. Peak current:
on of the charge the electrolyte level in the After a certain period of operation, usually FNC-T H and X types. see section 4.4.1
cells must be topped up to the max. mark between 3 and 12 months, depending on FNC-T M types: up to 10 x I5
with distilled water. After cleaning the the load applied to the battery, an equali-
cells, see section 5.2, the battery is ready zing charge as under section 4.6 is neces- Voltage range:
for operation. sary. 1 V to  1.2 V x number of cells connec-
ted in series
4. Operation For discharging the battery the following
general operational parameters apply: The battery is charged using the IUOU
4.1 For the assembly and operation of The maximum discharge depth with each characteristic or - preferably - using an
traction batteries DIN VDE 0510 Part 3 cycle is 30% CN. The daily capacity (in IUIa characteristic under DIN 41773 with
and DIN VDE 0117 apply. VDE 0100 and Ah per day) withdrawn from the battery the following parameters:
VDE 0105 must also be observed. can be up to 4 x CN at an ambient tem- Charge current, main charge
perature of up to 30°C without the necessi- X types: see section 4.4.1
4.2 Discharging ty for additional cooling. Should the daily H types: see section 4.4.1
Unless the manufacturer has specified capacity requirement exceed the above- M types: up to 7.5 x I5
otherwise, the battery may not be dischar- mentioned values, provision must be made
ged below the nominal final discharge vol- in the battery tray for ventilation. (convec- Additional charge (IUIa characteristic) for
tage. tion). If this is not possible or should the all types: 0.5 x I5
daily capacity drawn exceed 6 x CN for- Charge factor: 1.2
4.3 Charging ced ventilation must be provided for the Charge voltage: 1.55 V/cell to
Charge with direct current only. All char- battery. 1.65 V/cell
ging methods with their limit values may
be employed as under The battery loads are generally as follows: In the Ia part of the characteristic voltages
DIN 41773 Part 2 (IU characteristic) Constant driving current:1 to 2.5 x I5 of  1.75 V/cell can occur. Disconnect
DIN 41776 ( I characteristic) Peak current: 10 to 20 I5 the load from the battery.
Voltage range: 1 V to  1.2 V x number
In order to avoid overloading the electric of cells connected in series. 4.5 Special instructions for the operation
circuits and contacts and to prevent unac- of batteries in hazardous areas
ceptable gas formation and leakage of el- The battery is charged under an IUOU These are batteries which operate under
ectrolyte from the cells, only connect to a characteristic or an IUa characteristic VDE 0170/0171 EX I in firedamp con-
ditions or under EX II in areas where ex- 4.10 Electrolyte - carry out an equalizing charge as under
plosion hazard exists. The electrolyte consists of diluted caustic section 4.6
potash solution (KOH) with a lithium - measure the charge voltage of all cells
During charging and after-generation of hydroxide (LiOH) additive, see the instruc- just before end of charge
gas the container lids must be lifted or tions for mixing electrolyte and
opened such that any developing explosi- DIN 43 530 for permissible impurities. The 5.3.2 In an extended maintenance (every
ve gas mixture is neutralized by sufficient nominal electrolyte density of 1.19 kg/l 12 to 18 months, depending on the load)
ventilation.  0.02 kg/l is based on 20°C and an the following must be carried out in addi-
electrolyte level up to the max. mark in the tion to the standard maintenance checks:
4.6 Equalizing charge battery’s fully charged state. - check electrolyte temperature in a few
Equalizing charges serve to extend service Higher temperatures reduce the electrolyte cells
life and maintain capacity. They are neces- density, lower temperatures increase the - discharge the battery with nominal cur-
sary as part of important maintenance electrolyte density. The correction factor is rent before the equalizing charge
work and after exhaustive discharges and 0.0005 kg/l per °K. - check that connecting bolts are securely
repeated insufficient recharging. fastened
Important: - under VDE 0117 the insulation resistance
The battery is charged with constant cur- The electrolyte maintains efficiency throug- of the vehicle and the battery must be
rent as in initial charge (section 3.2). The hout the entire battery life. The electrolyte checked as required but at least once a
equalizing charge is completed when the never needs changing during the battery’s year by an electrician.
battery has reached a minimum voltage of service life. The check for insulation resistance must
1.75 V x number of cells connected in se- be conducted according to DIN 43 539
ries and has been charged at this voltage Important: Part 1.
for 4 hours. As it is possible to exceed the With nickel-cadmium batteries the electro- As specified under DIN VDE 0510, Part 3,
permissible load voltages, appropriate lyte density is no measure for the battery’s the battery insulation resistance recorded
measures must be taken, e.g. disconnect state of charge. should not be less than the value of 50 
the load from the battery. Sufficient ventila- per V nominal voltage. With batteries with
tion must be ensured (VDE 0510, Part 3). 5. Battery maintenance and control a nominal voltage of 220 V the minimum
(servicing) value is 1000 .
On exceeding the maximum charge tem-
perature of 45°C, charging must be inter- 5.1 Electrolyte level An extended maintenance comprises the
rupted to allow the battery to cool down. The electrolyte level must be checked following additional points:
regularly. If it has dropped to the min. - general condition of the battery
4.7 Superimposed alternating currents mark while in a charged state, it must be - charger running smoothly
Alternating currents superimposed on the topped up with distilled water under
battery’s direct current lead to additional DIN 43 530, Part 4, maximum conducti- 6. Tests
warming of the battery. When recharging vity 30 S/cm. Tests must be conducted according to EN
a battery using the methods described un- See section 4.10 on electrolyte density. 60 896, complemented by DIN 43 530
der sections 4.4 to 4.6 the actual value of If the electrolyte level drops due to water or also IEC 623.
the alternating current should not exceed a decomposition, the electrolyte density will
value of 20 A per 100 Ah battery nominal increase slightly. 7. Faults
capacity. With an equalizing charge a va- Electrolyte density should not be measured Should faults be detected in the batteries
lue of 5 A per 100 Ah should not be ex- just after topping up with distilled water. or charging devices, customer services
ceeded. must be called in immediately. Measure-
5.2 Cleaning/maintenance ment data under section 5.3 facilitate fault
4.8 Temperature To avoid leakage currents the battery must detection and removal.
The optimal operating temperature range be kept dry and clean. Cleaning the bat-
for nickel-cadmium batteries is 0°C to tery should be carried out as specified in 8. Storage and taking out of
30°C. The technical data apply for the no- the ZVEI pamphlet on battery cleaning. operation
minal temperature of 20°C. The operating The cell plugs must be closed.
temperature range lies between - 25°C Should cells or batteries be stored or ta-
and + 45°C for the types of operation un- Caution: ken out of operation for longer periods,
der sections 4.4 to 4.6. The operating Dangerous contact potential possible. they must be placed in a dry room. The
temperature range can be extended to cells can be stored unfilled or filled with
- 40°C if an original HOPPECKE special el- Plastic battery components, in particular electrolyte. Before storing, the filled cells
ectrolyte is used. Higher temperatures re- the cell containers, must only be cleaned must be discharged with nominal current
sult in reduced charge acceptance and with water containing no additives. The up to the nominal final discharge voltage.
shorten service life. Lower temperatures vent plugs can be cleaned in warm water.
reduce the available capacity. Note:
5.3 Checks at regular intervals Dangerous contact potential possible.
4.9 Temperature-related charge voltage Only insulated tools may be used. Never
A temperature-related adjustment of the 5.3.1 For a standard maintenance (every place tools on connectors: short circuit and
charge voltage can be made at an opera- 3 to 12 months, depending on the load) fire hazard.
ting temperature of above 30°C. The tem- the following must be carried out:
perature correction factor is - 0.002 v/cell - measure the open-circuit voltage of all For storage in excess of 6 months the cells
per °K. cells are discharged as described above. The
electrolyte is then emptied out and the The following table shows the different FNC-T 201 H 12 2.4 1.52
standard vent plugs (flip-top vent plugs) FNC-T cell types according to capacity FNC-T 202 H 23 4.6 1.77
are replaced by transport plugs. Following class: FNC-T 203 H 35 7.0 2.68
these preparations the cells can be stored FNC-T 204 H 46 9.2 3.00
indefinitely. 11.1 FNC-T type range X for very high lo- FNC-T 205 H 58 11.2 4.17
Before using stored cells follow instructions ads, at discharge times ranging from split FNC-T 206 H 69 13.8 4.36
as under sections 1 and 2. seconds to a few minutes FNC-T 207 H 80 16.0 4.58
FNC-T 208 H 93 18.6 5.58
9. Transport FNC-T Type X Nominal Nom. Cell FNC-T 209 H 104 20.8 5.78
capacity current weight FNC-T 210 H 115 23.0 6.91
Batteries which do not show any damage Ah A kg FNC-T 211 H 125 25.0 7.21
are not treated as dangerous goods under FNC-T 103 X 10 2.0 1.38 FNC-T 307 H 140 28.0 8.58
the German dangerous goods regulations FNC-T 106 X 19 3.8 2.46 FNC-T 308 H 160 32.0 9.16
- roads (GGVS) and dangerous goods re- FNC-T 110 X 33 6.6 3.74 FNC-T 309 H 180 36.0 9.24
gulations - railways (GGVE) as long as FNC-T 114 X 45 9.0 5.04 FNC-T 310 H 200 40.0 11.11
they are secured against short circuits, FNC-T 118 X 58 11.6 6.24 FNC-T 311 H 220 44.0 11.61
slipping, falling over or damage and are FNC-T 203 X 13 2.6 1.80
stacked and secured appropriately onto FNC-T 206 X 25 5.0 3.16 11.3 FNC-T type range M for average lo-
pallets. (German dangerous goods regula- FNC-T 210 X 43 8.6 4.83 ads, at discharge times ranging from 20
tions - roads (GGVS, Rand No 2801 a). FNC-T 214 X 60 12.0 6.31 minutes to a few hours
There must be no external traces of electro- FNC-T 218 X 77 15.4 7.84
lyte solution detectable on the goods to be FNC-T Type M Nominal Nom. Cell
transported. 11.2 FNC-T type range H for high loads, capacity current weight
at discharge times ranging from a few se- Ah A kg
10. Dismantling, disposal, recyc- conds to approx. 30 minutes FNC-T 201 M 20 4.0 1.54
ling of batteries FNC-T 202 M 40 8.0 2.58
FNC-T Type H Nominal Nom. Cell FNC-T 203 M 60 12.0 2.84
The dismantling and disposal of batteries capacity current weight FNC-T 204 M 80 16.0 4.16
may only be carried out by trained person- Ah A kg FNC-T 205 M 100 20.0 4.46
nel. The EC Directives 91156 (EEC) and FNC-T 101 H 9 1.8 1.2 FNC-T 206 M 120 24.0 5.56
9386 (EEC) must be observed. FNC-T 102 H 17 3.4 1.4 FNC-T 207 M 140 28.0 5.90
FNC-T 103 H 26 5.2 2.1 FNC-T 208 M 160 32.0 7.11
11. Technical data FNC-T 104 H 35 7.0 2.3 FNC-T 209 M 180 36.0 7.41
FNC-T 105 H 44 8.8 3.2 FNC-T 306 M 200 40.0 8.51
The battery’s nominal voltage, the number FNC-T 106 H 52 10.4 3.4 FNC-T 307 M 233 46.6 9.23
of cells, the nominal capacity (CN = C5) FNC-T 107 H 60 12.0 3.6 FNC-T 308 M 266 53.2 10.00
and the battery type are obtained from the FNC-T 108 H 70 14.0 4.4 FNC-T 309 M 300 60.0 10.94
type plate. Other capacities at different di- FNC-T 109 H 78 15.6 4.6
scharge currents can be obtained from the FNC-T 110 H 86 17.2 5.4
manufacturer’s type lists. FNC-T 111 H 95 19.0 5.6

Printed in Germany
Teil-Nr. 4240203001/0998/1 H

HOPPECKE Accumulatorenwerke HOPPECKE


Carl Zoellner & Sohn GmbH & Co KG
Phone (0 29 63) 61-0 · Fax (0 29 63) 6 14 49
http://www.HOPPECKE.de
Batterien P.O.Box 11 40 · D-59914 Brilon (Hoppecke e-Mail: hoppecke.IO@t-online.de

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