Technical Paper: I - 11/2011 Seite 1/9 RPM: J.Bäcker

ESS Technology

The ESS technology is related to all HOPPECKE products in the AGM (absorbent glassmatt) design and represents an advancement in this base technology. ESS meansenhanced stability standard and has to be understood like an action plan tailored for eachproduct range applied.

power.com XC / HC / SB / solar.bloc /trak.bloc

net.power

Improvements in the active mass and conductivity of the current arrestors, as well as geladditives in the electrolyte are essential components of this engineering and design.Depending on the requested battery characteristics high current or cycling ability, eachproduct will get their individual setup out of the above mentioned arrangements.

In the following each design feature and their impact on the battery performance arediscussed in detail:

Active mass:The active mass is the material in the electrodes, which on electrochemical way receiveselectric energy during charging and delivers while discharging. The active mass is veryimportant for the performance of the battery and can be adjusted via the porosity.While batteries in high current applications require a high porosity in their active mass(high reaction surface), this characteristic can be adverse for cyclisation and chargeacceptance after deep discharges.

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Current Arrestor:AGM batteries provide due to their compact design the highest energy density of all leadacid batteries. The electrolyte is fixed in the absorbent glass matt (AGM) by capillarypower like in a sponge and is only available between the plates. All current arrestors areexposed to the gassing room above the plate set and have correspondingly no directcontact to the electrolyte like in vented or VRLA gel batteries. Hence, cooling effects viaelectrolyte can be neglected for this components.Having additionally in mind that the heat capacity of the limited sulphuric acid is around10,7 times higher than the value of lead an accurate thermal consideration of all currentarrestors within AGM batteries are reasonable. Arrangements based on the ESS conceptprovides for each product range and their main scope of application a tailor made solutionto achieve an optimal performance associated with a max. service life.

Electrolyte with Gel Additives:

An absorbent glass matt is a wovennetwork of glass fibres with differentthickness (0,25 - 3 μm). Between thefibres is a pore system with differentdiameters to absorb the electrolyte bycapillary power. While smaller pores arefilled with electrolyte, the bigger poresare available for the gas transfer.As a result of a woven fibre network thepore system is usually non-homogenousover the whole glass matt with theconsequence of an unbalanceddistributed electrolyte within a batterycell. Drying out effects and electrolytestratification by normal operation canreinforce this situation further.Standard AGM batteries are thereforeapplied to:

· Higher voltage spread· Interfered heat dissipation and

higher operating temperatures· Capacity losses· Lower service life

The appropriate module within the ESS technology eliminate this essential disadvantagesof the AGM design by adding gel additives to the electrolyte. A homogenous pore system

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will be achieved, which ensures a uniform electrolyte distribution in the glass matt overthe entire lifetime of the battery. One pleasant side effect of this arrangement is theenhanced thermal conductivity of the battery cell. Taking into account that the averageoperating temperature has a significant influence on the battery lifetime (Arrhenius Law),thus the ESS technology provides an important contribution.

ESS Technology providing an outstanding performance:

Thermal RunawayStandard AGM batteries are exposed to thermal runaway aspects, especially duringovercharging at voltages above 2,40 V/Cell. Figure 1 displays the temperaturedevelopment of a power.com battery equipped with the ESS technology during anovercharge at 2,65 V/Cell for about 160 hours. It can be clearly noticed that thetemperature rise settled down at a certain difference above ambient temperature anddecreases also in value accordingly. The low temperature sensitivity makes thisadvancement available for operation in harsh environmental condition.

Figure 1 - Temperature development on power.com batteries with ESS technologyat 160 h overcharging with 2,65 V per cell

Float OperationThe ESS Technology is designed for continuous float charge operation. Depending onthe product range the recommended float charge settings are like follows:

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- 2,25 VpC at +20°C/+77°F(power.com HC, SB, net.power 12V 100 & 150, solar.bloc)

- 2,27 VpC at +20°C/+77°F(power.com XC, net.power 12V 92 & 170)

Battery life and charging characteristics are affected by temperature. Every increase intemperature of about 10°C/18°F will half the battery life (Arrhenius Law). The optimumbattery life will be achieved when the battery is operating at +20°C/+77°F (see figure 2).

Figure 2 – Impact of stress temperature 55°C – power.com SB 12V 100 acc. toDIN EN 60896-21 (item 6.16)

CyclingThe individual ESS setup for cycling application is focussed on a long lifecharacteristic under extreme conditions where cyclic duty predominates. Figure 3 and4 display the cycle endurance test in photovoltaic application according to EN 61427.Within this test the battery will be exposed to a large number of shallow cycles at atemperature of 40°C, but at different state of charges. Whereas solar.bloc providesan outstanding cycle performance of more than 2500 cycles under this condition, alsothe standby front access battery net.power is able to overcome such extremecondition in an excellent manner.

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Figure 3 - Cycle endurance test in PV application on solar.bloc with ESS technologyacc. DIN EN 61427 (extreme conditions)

Figure 4 - Cycle endurance test in PV application on net.power 12V 170 withESS technology acc. DIN EN 61427 (extreme conditions)

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Design and construction details

power.com HC / SB / XC

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Design and construction details

net.power

Technical Paper: I - 10/2014 Seite 8/9 RPM: J.Bäcker

Technical details

Components Remark

Electrodes positive flat plate / negative flat plate

Grid Alloy PbCa

Separator AGM

Electrolyte Sulphuric acid with gel additives

Container & Lid High stability polypropylene;flammability class UL 94 HB;lid and container welded together, 100 % gas- and electrolyte –tight;Integrated handles

Pole Bushing 100% gas- and electrolyte-tight, compoundpole, welded to the lid

Terminal Moulded, plastic coated, lead screw terminalwith M8 brass insert

Valve Integrated central degassing system with flame arrestor

Kind of Protection IP 25 regarding DIN 40050. touch protectedaccording VBG 4

Terminal Screw M8 screw with insulated head and provision forsingle cell voltage measurement

Connector System Insulated, rubber moulded, solid copperConnector

Design Life power.com XC10 - 12 years (High Performance) at 20°C inaccordance to EUROBATpower.com HC12 years (High Performance) at 20°C inaccordance to EUROBATpower.com SB / net.power / solar.bloc12 years+ (Long Life) at 20°C in accordance to EUROBAT

Charging IU-characteristic: I max without limitationFloat: U = 2.25 V/cell ± 1 %Boost: U = 2,35 – 2,40 V/cell, time limitedCharging current: Typical up to 1x I10

Self Discharge approx. 2 - 3% per month at 20°C

Operational Temperature -20°C to 45°C; recommended 10°C to 30°C

Ventilation requirement f1=0.2according to DIN 50272 part 2 (valve regulatedbatteries)Tests according IEC 60896-21/22

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General specification of batteries with HOPPECKE ESS technology

Type C10/1.8 VAh

C5/1.77 VAh

C3/1.75 VAh

C1/1.70 VAh

C1/2/1.65 VAh

C1/6/1.60 VAh

weightkg

Length Lmm

Width Wmm

Height Hmm

power.com XC 121300 51 48 44 36 31 22 22.1 229 177 230power.com XC 121700 64 60 55 45 38 28 22.7 229 177 230power.com XC 122100 66 64 60 52 46 36 25.3 229 177 230power.com XC 122600 86 82 78 66 57 42 37.1 344 177 230power.com XC 123000 99 94 89 76 65 48 37.7 344 177 230power.com XC 123400 104 100 95 81 73 56 38.4 344 177 230power.com XC 124100 146 137 126 102 88 63 50.7 498 177 230power.com XC 124400 152 142 132 110 95 69 54.2 498 177 230power.com XC 125100 157 151 141 121 108 81 55.9 498 177 230power.com XC 21100 236 218 205 173 147 96 16,1 88,5 181 310power.com XC 21600 360 329 309 257 220 150 21,3 181 127 310power.com XC 21900 435 398 371 302 264 189 25,0 181 154 310power.com XC 22700 655 604 563 459 389 259 36,0 181 225 310

power.com HC 121200 45 42 40 41 28 21 22.0 229 177 230power.com HC 121600 56 53 49 48 35 26 22.6 229 177 230power.com HC 122000 61 58 55 62 43 34 25.2 229 177 230power.com HC 122400 78 76 72 71 54 40 37.0 344 177 230power.com HC 122800 89 87 83 75 62 46 37.6 344 177 230power.com HC 123200 94 89 86 93 67 52 38.3 344 177 230power.com HC 123800 132 124 116 103 80 59 50.5 498 177 230power.com HC 124200 138 129 122 114 88 66 54.0 498 177 230power.com HC 125300 143 136 130 111.0 101 77 55.8 498 177 230

Type C10/1.8 VAh

C5/1.77 VAh

C3/1.75 VAh

C1/1.70 VAh

C1/2/1.65 VAh

C1/6/1.60 VAh

weightkg

Length Lmm

Width Wmm

Height Hmm

power.com SB 12V 50 53 53 50 41 36 27 26.0 229 177 230power.com SB 12V 60 63 59 55 45 40 30 26.5 229 177 230power.com SB 12V 80 98 91 85 71 61 46 37.5 344 177 230power.com SB 12V 100 101 92 86 72 62 47 38.0 344 177 230power.com SB 12V 110 112 112 105 88 76 55 52.0 498 177 230power.com SB 12V 130 131 119 112 93 81 59 52.5 498 177 230power.com SB 12V 140 144 131 123 102 89 64 54.5 498 177 230power.com SB 6V 170 161 149 139 115 99 71 32.0 242 170 275power.com SB 6V 220 220 184 171 142 122 85 41.0 308 170 275power.com SB 2V 230 232 216 203 167 141 93 17.0 88.5 181 310power.com SB 2V 330 343 322 302 251 219 146 21.7 181 127 310power.com SB 2V 400 411 382 358 298 256 178 25.0 181 154 310power.com SB 2V 600 604 562 529 447 385 263 36,0 181 225 310

Type C10/1.8 VAh

C5/1.75 VAh

C3/1.70 VAh

C1/1.70 VAh

C1/2/1.65 VAh

C1/6/1.60 VAh

Max weightkg

Length Lmm

Width Wmm

Height Hmm

net.power 12V 92 91 85 79 66 56 40 30.0 396 105 273net.power 12V 100 108 102 95 78 68 50 42.8 541 125 217net.power 12V 150 163 154 145 120 104 73 61.9 541 125 302net.power 12V 170 170 160 150 126 107 75 64.5 541 125 302

Type C100/1.85 VAh

C48/1.80 VAh

C24/1.80 VAh

C10/1.00 VAh

Max weightkg

Length Lmm

Width Wmm

Height Hmm

solar.bloc 12V 58 60 57 55 48 19,0 232 177 190solar.bloc 12V 70 70 69 67 58 23,0 267 177 190solar.bloc 12V80 80 79 75 66 24 303 177 190solar.bloc 12V 90 90 89 84 76 28,0 342 177 190solar.bloc 12V 105 100 104 98 87 38,0 344 177 230solar.bloc 12V 135 130 129 122 111 46,0 344 170 275solar.bloc 12V 150 150 149 146 133 55 498 177 230solar.bloc 6V 200 190 189 182 167 32,0 242 170 275solar.bloc 6V 250 250 254 242 229 41,0 308 170 275