Hoppecke Trak bloc - User Manual

Observe the usage instructions
and install in a visible position
at the charging bay. Only trained
personnel may perform work on
batteries.
Wear protective goggles, protec-
tive gloves and protective clo-
thing when working on batteries!
Observe the accident preventi-
on regulations as well as DIN
EN 50110-1 and IEC 62485-3.
During installation/commissio-
ning, maintenance, cleaning and
disassembly wear additional face
protection (impact-resistant visor
according to EN 166 Class F).
Smoking is prohibited. There
must be no naked flames,
embers or sparks in the vicinity of
the battery, as this poses a risk
of explosion and a fire hazard.
Keep children away from bat-
teries!
Rinse eyes or skin splashed with
acid using plenty of clean water.
Then consult a doctor immedia-
tely. Wash clothing contaminated
with acid with plenty of water.
Electrolyte is highly corrosive.
Contact with electrolyte is not
possible during normal operation.
Risk of explosion and fire, avoid
short circuits!
Only use approved lifting and
transportation equipment, e. g.
lifting gear in accordance with
VDI 3616. Lifting hooks must
not cause any damage to cells,
connectors or connecting cables.
Dangerous electrical voltage.
Attention: Metallic parts of the battery cells
are always live. Therefore, no foreign objects
or tools may be placed on the batteries.
Warranty claims will no longer be valid in
the event of non-observance of the usage
instructions, repairs using non-original
spare parts or unauthorised intervention.
1. Start-up
The battery must be checked to ensure that
it is in mechanically perfect condition. The
installation area must be cleaned prior to
installation.
Only interconnect battery blocks with the
same charge state (same open-circuit vol-
tage, tolerance as per the following table).
Never power electrical consumers via a part
of the battery.
The battery terminal end must be connected
with the correct polarity and with reliable
contact. Otherwise, the batteries, the vehic-
le or the charging device may be destroyed.
Following assembly, the terminals must be
greased to protect against corrosion. The
battery must be recharged as per Item.
Tightening torque for pole screws on the
terminal ends and connectors:
2. Operation
The regulations in accordance with Standard
EN 62485 – Safety requirements for
secondary batteries and battery installations
– Part 3 apply for the operation of vehic-
le batteries. Traction batteries for electric
vehicles.
2.1 Discharging
The battery valves must not be closed or
covered. Electrical connections (e. g. plug
connectors) must only be opened or closed
when in de-energised state.
In order to achieve an optimal service life,
discharge of over 60 % of the rated capacity
should be avoided. Discharge of over 80 %
of the rated capacity is a deep discharge
and is not permissible. These significantly
reduce the service life of the battery. Only
those discharge state indicators that have
been approved by the battery manufacturer
may be used.
Discharged batteries must be charged
immediately and must not remain in dischar-
ged state. This also applies to batteries in a
state of deep discharge. Otherwise, the
service life of the battery will be significantly
reduced. The battery may freeze when in
discharged state.
2.2 Charging
Batteries must only be charged with direct
current. The charging methods in accor-
dance with DIN 41773-1 must only be
applied in the modification approved by the
manufacturer HOPPECKE. Therefore, only
those chargers that have been approved by
the battery manufacturer HOPPECKE may
be used. In order to prevent overloading
of the electrical cables and contacts and
impermissible gas formation, the battery
must only be connected to the allocated
charger that is permissible for the respective
battery size.
Operating instruction
trak
®
bloc
Lead-acid batteries with closed grid plate cells (trak
®
bloc)
Rated values
1. Rated capacity: see type plate
2. Rated voltage: see type plate
3. Discharge current: C
5
/5 h or C
20
/20 h
4. Rated temperature: 30 °C
trak
®
bloc batteries are closed batteries with suspended electrolytes that must not be topped
up with water for the entire duration of the service life. Pressure relief valves are used as
sealing plugs. These valves stop oxygen getting into the cells and drain off any excess charging
gases. The valves must not be removed. During operation, the same safety requirements apply
to the closed batteries as to batteries with liquid electrolyte in order to prevent electric shock
and explosion of the electrolytic charging gases and to avoid the risk of corrosive electrolytes
if the cell container is destroyed.
Rated
voltage
module
[V]
6
12
Maximum deviation
from mean value -
U
bloc
[V]
± 0,035
± 0,049
Cone terminal
Screw terminal M6/M8
Flat terminal M6
8 ± 1 Nm
20 ± 1 Nm
6 ± 1 Nm

Summary

Battery Startup Procedures

Initial Battery Inspection

Ensure battery is in perfect mechanical condition and installation area is clean before installation.

Interconnecting Battery Blocks

Connect battery blocks with the same charge state and correct polarity for reliable contact.

Terminal Greasing

Grease battery terminals after assembly to protect against corrosion.

Battery Operation and Maintenance

Discharging Batteries

Avoid discharging over 60% of rated capacity. Deep discharge over 80% reduces service life.

Charging Batteries

Use only approved chargers and ensure correct polarity. Charge only when temperature is below 35°C.

Equalising Charge

Used to guarantee service life and capacity, performed after normal charging or deep discharge.

Temperature Considerations

30°C is rated temperature; higher temps reduce service life, lower temps reduce capacity.

Electrolyte Properties

Electrolyte is suspended sulphuric acid; density cannot be measured.

Daily Maintenance

Charge the battery immediately after every discharge.

Weekly Maintenance

Perform a visual inspection for contamination and mechanical damage.

Quarterly Maintenance

Measure and record total and individual block voltages after full charge.

Yearly Maintenance

Check insulation resistance of vehicle and battery by a specialized electrician.

Battery Care

Keep battery clean and dry to prevent leakage currents.

Battery Storage

Store fully charged in a dry, frost-free location. Apply quarterly full charging.

Fault Reporting

Contact Customer Service immediately if any faults are detected on the battery or charger.

REACH Statement Pb-Metal

Informs about SVHC substances like Lead-metal in batteries.

General Safety Precautions

Electrical Hazard Warning

Dangerous electrical voltage. Metallic parts are live; do not place objects on batteries.

Fire and Explosion Risk

No naked flames, embers, or sparks near batteries. Avoid short circuits.

Personal Protective Equipment

Wear protective goggles, gloves, and clothing. Use face protection during installation/maintenance.

Handling and Lifting

Use approved lifting equipment. Avoid damage to cells, connectors, or cables.

Corrosive Electrolyte

Electrolyte is corrosive. Rinse splashed skin/eyes with water and seek medical attention.

Unauthorized Intervention

Warranty claims invalid for unauthorized repairs or non-original spare parts.

Children Safety

Keep children away from batteries.

Gas Emissions

Batteries have low gas emissions but require effective drainage of charging gases.

Temperature Limits

Upper limit temperature is 45°C; avoid exposure to direct sunlight.

Disposal of Batteries

Used batteries are waste; do not dispose with household waste. Agree return/recycling with manufacturer.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The HOPPECKE trak® bloc is a lead-acid battery with closed grid plate cells, designed for traction applications in electric vehicles. These batteries feature suspended electrolytes and are maintenance-free, as they do not require water topping up throughout their service life. Pressure relief valves act as sealing plugs, preventing oxygen ingress into the cells and venting any excess charging gases. These valves must not be removed.

Function Description:

The trak® bloc battery provides direct current power for electric vehicles. It operates under the principle of lead-acid electrochemistry, where chemical energy is converted into electrical energy during discharge and vice versa during charging. The closed design with suspended electrolyte minimizes gas emissions and eliminates the need for electrolyte density measurements. The battery is designed for a rated temperature of 30 °C and should ideally operate within a specific temperature range to ensure optimal service life and capacity.

Important Technical Specifications:

• Rated Capacity and Voltage: These are specified on the type plate of the individual battery.
• Discharge Current: C5/5 h or C20/20 h.
• Rated Temperature: 30 °C.
• Tightening Torques for Pole Screws:
  • Cone terminal: 8 ± 1 Nm
  • Screw terminal M6/M8: 20 ± 1 Nm
  • Flat terminal M6: 6 ± 1 Nm
• Open-Circuit Voltage Tolerance for Interconnection:
  • 6V module: ± 0.035 V from mean value (Ubloc)
  • 12V module: ± 0.049 V from mean value (Ubloc)
• Upper Limit Temperature: 45 °C, which is not permissible as an operating temperature.
• Minimum Insulation Resistance: Not below 50 Ohm per Volt of rated voltage (for batteries in a steel trough). For batteries with a rated voltage of 20 V, the minimum value is 1000 Ohm.
• Charging Voltage Limit: Must not exceed 2.6 V per cell.
• Equalisation Charging Current: Maximum 0.8 A per 100 Ah C5 rated capacity.

Usage Features:

• Safety: Adherence to EN 62485-3 and DIN EN 50110-1 is crucial. Users must wear protective goggles, gloves, and clothing. Smoking, naked flames, embers, or sparks are prohibited near the battery due to explosion and fire hazards. Children must be kept away. In case of acid contact, rinse immediately with water and seek medical attention.
• Installation: The battery must be checked for mechanical integrity before installation. The installation area must be clean. Only battery blocks with the same charge state (within specified open-circuit voltage tolerances) should be interconnected. Never power electrical consumers via a part of the battery. The battery terminal end must be connected with correct polarity and reliable contact. Terminals should be greased after assembly to prevent corrosion.
• Discharging: Avoid discharging over 60% of rated capacity. Deep discharge (over 80%) is not permissible as it significantly reduces service life. Only manufacturer-approved discharge state indicators should be used. Discharged batteries must be charged immediately to prevent freezing and reduced service life.
• Charging: Batteries must only be charged with direct current using HOPPECKE-approved chargers and charging methods in accordance with DIN 41773-1. The battery must be connected to the allocated charger suitable for its size to prevent overloading and impermissible gas formation. Charging should only begin when the battery temperature is below 35 °C and at least 15 °C. If temperatures are consistently above 40 °C or below 15 °C, constant voltage regulation may be required, applying a correction factor of -0.003 V/Z per K. Gas emissions are low but present, so effective ventilation is required.
• Equalising Charge: This is performed after normal charging, deep discharge, or repeated insufficient charging to maintain service life and capacity. It should be carried out quarterly with constant current (max. 0.8 A per 100 Ah C5) for a maximum of 5 hours, ensuring the charge voltage does not exceed 2.6 V per cell and the limit temperature is not exceeded.
• Temperature Considerations: 30 °C is the rated temperature. Higher temperatures reduce service life, while lower temperatures reduce available capacity. The battery must not be exposed to direct sunlight.
• Storage: If taken out of operation for extended periods, batteries must be stored fully charged in a dry, frost-free location. Quarterly full charging (as per Item 2.2) is required. If consumers are connected, full charging every 14 days may be necessary. A self-discharge rate of 2% per month is expected.

Maintenance Features:

• No Water Topping Up: The trak® bloc batteries are maintenance-free in terms of water topping up. The valves must never be opened or removed.
• Daily Maintenance: Charge the battery immediately after every discharge.
• Weekly Maintenance: Perform a visual inspection for contamination and mechanical damage.
• Quarterly Maintenance: After the battery has been fully charged and allowed to rest for at least 12 hours, measure and record the total voltage and individual voltage of the block batteries. Significant changes or differences between measurements require contacting Customer Service for further testing or repairs.
• Yearly Maintenance (for batteries in a steel trough): A specialized electrician must check the insulation resistance of the vehicle and the battery in accordance with EN 62485-3 and EN 1987-1.
• Cleaning: The battery must be kept clean and dry to prevent leakage currents. Cleaning should be performed in accordance with the ZVEI data sheet "Cleaning batteries."
• Faults: If any faults are detected on the battery or charger, contact HOPPECKE Customer Service immediately (+49 (0) 2963 61-591). Measured data from quarterly checks aid in troubleshooting.
• Environmental Considerations: Used lead-acid batteries are waste requiring special monitoring. They must not be disposed of with household waste but returned for recycling in accordance with Section 8 of the German Battery Ordinance (BattV) and agreed upon with the manufacturer. These batteries contain Lead-metal (CAS. Nr. 7439-92-1), an SVHC substance, exceeding 0.1 weight %. MSDS is available upon request.

Hoppecke Trak bloc Specifications

General

Brand	Hoppecke
Model	Trak bloc
Category	Camera Accessories
Language	English