AquaGen® premium.

top

HOPPECKE Batterien GmbH & Co. KG · Bontkirchener Straße 1 · 59929 Brilon-Hoppecke

AquaGen® premium.top

Vented Batteries Valve Regulated Batteries

Long battery life time

Low sensitivity Recombination
Easy state detection

Long battery life time

Low sensitivity
Easy state detection
H+ H+
½ O2
Extern
Recombination
H2O

Optimized battery system

2012 Battery Seminar - AquaGen premium.top 2

AquaGen® premium.top - Function

Function HOPPECKE AquaGen® premium.top

 Inside lead acid or NiCd-batteries a secondary reaction called water

decomposition of the liquid electrolyte takes place.
 During the operation of the AquaGen® premium.top-recombination systems
the developed oxygen and hydrogen gas is moving to the AquaGen® plug.
 By the integrated catalyst these gases recombined to the water vapour.
 The water vapor condenses at the walls of the dome of the AquaGen®-
recombination system
 The water drops, which are formed in the AquaGen®-recombination system,
flow themselves downward back into the battery.

2012 Battery Seminar - AquaGen premium.top 3

HOPPECKE AquaGen® - Function
Condensation
1
During the charge and under
Water vapor float charge the (oxyhydrogen)
3 gas escapes through the cell
openings.
This is based on the
2 electrolysis of water by the over
Recombination charging current
2
By the integrated catalyst the
oxyhydrogen gas will be
recombined to water vapour.
Gas
3
This water vapour condenses
1 at the walls of the dome
4
4 4
Water drops flow back into the
Water cell

2012 Battery Seminar - AquaGen premium.top 4

HOPPECKE AquaGen® - Internal Construction

Flash back protection

Valve

Cover (roof) for the Opening permits escaping

protection against gas when overloaded
falling down drops

Ceramic protection
for the catalyst

Dome for the condensation

of the water vapor

2012 Battery Seminar - AquaGen premium.top 5

HOPPECKE AquaGen® - Internal Construction

Flash back protection

Ceramic protection
for the catalyst

Dome for the condensation

of the water vapor

2012 Battery Seminar - AquaGen premium.top 6

AquaGen® premium.top

Bidirectional valve integrated

 Increase of the retention time of the
water vapour in the system
 Positive pressure and negative
pressure security
 100% -test of the valve function

Active part cover

 Cover (roof) for the protection against
falling down drops
 Fixing of the active part (2-point-
bearing)

2012 Battery Seminar - AquaGen premium.top 7

AquaGen® premium.top

Identification of the AquaGen – Recombiners via DataMatrix Code

 Serial number
 Production date

2012 Battery Seminar - AquaGen premium.top 8

AquaGen® premium.top

Advantages of the HOPPECKE AquaGen® premium.top

 Maintenance intervals are fully extended with even total freedom from
maintenance(up to 98 % recombination rate)
 Extension of battery life time based on the constant electrolyte density
 None damages of the battery by refill of contaminated water
 Reduction of the ventilation requirements by 50%  low costs for the room air
engineering
 Prevention from a danger of explosion by outside flaming/spark effect with
integration of a backfire protection
 No significant escape of gas or electrolyte fumes
 Decrease of maintenance and installation costs with increased safety
 Visual display (Condensate formation in the recombiner)
 Improvement of the service work due to a separate service opening in each
single cell

2012 Battery Seminar - AquaGen premium.top 9

Diagnostic Opening in each Single Cell

Service opening for density and

temperature measurements

For a safe operation of the battery system a take off of the AquaGen®-
recombiner for inspection of the acid gravity is not necessary anymore!!!

2012 Battery Seminar - AquaGen premium.top 10

HOPPECKE AquaGen® - Operational Probation

Advantages of the HOPPECKE AquaGen® premium.top

Combination of the advantages of vented batteries with reduced maintenance

costs:

 High operating life and less maintenance costs

Extension of the topping up intervals
 High employment probation
In use since about 30 years
 None extra costs
No exchange during the whole battery operating life necessary
 Highest costumer acceptance
Over a million recombination systems in use

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Comparison Water Consumption
4,5

4,0
per 100Ah Battery Capacity [C10]
Water consumption [ltr./100Ah]

3,5

3,0 without AGS

2,5

2,0

1,5

1,0

with AGS
0,5

0,0
0 5 10 15 20
Service Life in Years
2012 Battery Seminar - AquaGen premium.top 12
AquaGen® premium.top

Installation of AquaGen premium.top H possible

for batteries up to 340 Ah.
For higher capacities above 340 Ah AquaGen
premium.top V has to be used.

2012 Battery Seminar - AquaGen premium.top 13

 AquaGen®

History, tests and references

HOPPECKE Batterien GmbH & Co. KG · Bontkirchener Straße 1 · 59929 Brilon-Hoppecke

HOPPECKE AquaGen® - History
History:

AquaGen types AquaGen AquaGen AquaGen®

5 Ampere, D30 & D48 premium.top
15 Ampere PTH & PTV

Production
1976 - 2000 2000 - 2006 from 2007 …
period
Development Introduction of the Flash back Increased
aim recombination as protection efficiency and over
function and charge protection
product

2012 Battery Seminar - AquaGen premium.top 15

HOPPECKE AquaGen®
International admissions

2012 Battery Seminar - AquaGen premium.top 16

Test Deutsche Bahn AG
(German railway - test 65509)

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Test Deutsche Bahn AG
(German railway - test 65509)
Test data of the test 65509 dd. 1977:

 Duration of the test: 362 days (without interruption)

 Charging voltage: 2,30 V/Cell

 Charging current: 0,38 A (Average value)

 Discharging current: 0,000 A

 Room temperature: (21 +/- 5) °C.

 Measurement at 4 cells 4 GK 200 (each with 2 normal plugs and 2 with a

AquaGen®-recombination system …“)

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Test Deutsche Bahn AG
(German railway - test 65509)
Results of the test 65509 from 1977:

„… During the duration of test the following quantities of water were refilled, in
each case up to the upper (maximum) marking line:

Type of plug Water quantity

Normal plug 1140 cm3/Cell

AquaGen® -
recombination system 70 cm3/Cell

The volume between both marks (min. - max.) is 700 cm3

The water consumption of the test cells equipped with AquaGen® plugs was only
6.14 % amount in comparison to the quantity of water used by two cells equipped
with normal plugs.

2012 Battery Seminar - AquaGen premium.top 19

Test Deutsche Bahn AG
(German railway - test 65509)

Evaluation to the test 65509 from 1977

„… The one year continued test has showed the water consumption of
stationary batteries can be substantially lowered by the employment by
AquaGen® plugs of the company HOPPECKE. About the operational life
time of the plugs still no experiences are available. According to statement
of the manufacturer they are there for 6 years without objection in the use
…“

2012 Battery Seminar - AquaGen premium.top 20

HOPPECKE AquaGen® – Norske Veritas 2007
Flash back test at Norske Veritas 2007:

2012 Battery Seminar - AquaGen premium.top 21

HOPPECKE AquaGen® – Norske Veritas 2007

2012 Battery Seminar - AquaGen premium.top 22

AquaGen® Admission Deutsche Telekom
2 x 60 V 4 OPzS 200 battery equipped with
30 cells x ceramic plug
30 cells x AquaGen plug D30
for the direct comparison of the water consumption

Result:
For the cells equipped with AquaGen® recombination plugs no change of
electrolyte level since more than 3 years!!!
2012 Battery Seminar - AquaGen premium.top 23
HOPPECKE AquaGen® – References

Installation 106 cells 12 GroE 300 with

AquaGen®-recombination systems at RWE
Mülheim for the substation of Thyssen
Stahlwerk – April 1984 (!)

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HOPPECKE AquaGen® – References
Reference letter E.on Ruhrgas – power distributor

Herewith we confirm, that we have operated following batteries of the company

HOPPECKE Batterien GmbH & Co. KG more than 16 years in our installation
side Emsbüren:
2 x 55 cells 14 GroE 350
2 x 12 cells 7 GroE 700
1 x 12 cells 8 GroE 200

All batteries were during the operational life time operated with the HOPPECKE
AquaGen recombination system. The system is used for catalytic recombination
of water, which is decomposed in the battery by electro-chemical processes.
By using of this AquaGen recombination system during the 16 years operation
time a refilling of demineralised water was totally not necessary, so the
maintenance costs have been significantly reduced.

Mit freundlichen Grüßen

Bernhard Temmen
E.ON Ruhrgas AG
Strooteweg 2
D-48488 Emsbüren
2012 Battery Seminar - AquaGen premium.top 25
HOPPECKE AquaGen® References

Hydropower plant Kaprun (Austria) – 9 OSP.HC 765

with AquaGen® recombination systems installed in December 2005

2012 Battery Seminar - AquaGen premium.top 26

HOPPECKE AquaGen® References

Installation 2 x 106 Zellen 9 GroE 900 with AquaGen®-recombiners

Polski Koncern Naftowy Orlen S.A. (PKN Orlen S.A.)
Installed in December 2005
2012 Battery Seminar - AquaGen premium.top 27
HOPPECKE AquaGen® References

Venezuela - MAN Ferrostaal

- ENELVEN gas and steam power plant
2 x 61 x 30 OSP.XC 3450 + AquaGen®
installed in June 2006

2012 Battery Seminar - AquaGen premium.top 28

HOPPECKE AquaGen® References

Installation:
13 cells + 186 cells 5 OSP.HC 425 and
108 cells 12 OSP.HC 1020 with
AquaGen®-Recombination plugs
in 2004 / 2005 in Leibstadt (NPP
Switzerland)

2012 Battery Seminar - AquaGen premium.top 29

HOPPECKE AquaGen® References

Installation Switzerland:
60 cells 8 OSP.HC 680
with AquaGen®-plugs in 2004 / 2005
in Beznau (NPP Switzerland)

2012 Battery Seminar - AquaGen premium.top 30

HOPPECKE AquaGen® References

Deutsche Telekom / Krefeld -

Germany 1632 cells
15 OSP.HC 1275 with AquaGen®
recombination plugs in the strategic
data processing center
Further Installations: in Bielefeld,
Bamberg and Kiel

2012 Battery Seminar - AquaGen premium.top 31

HOPPECKE AquaGen® References

German Telecom:
Order of more than 100.000 AquaGen® recombiners in year 2007

2012 Battery Seminar - AquaGen premium.top 32

HOPPECKE AquaGen® References

Installation Belgium ESA – Redú

2 x 204 cells 8 OSP.HC 280 +
AquaGen D30 March 2006, replaced
system of January 1994 OGi cell +
AquaGen

2012 Battery Seminar - AquaGen premium.top 33

HOPPECKE Reference list (extract)

ABB Ltd., AEG SVS

BASF AG, Bombardier Transportation
Cegelec,China Nuclear Energy Industry Corp.
DB Netz AG, DB Services
DB Telematik GmbH, DeTeImmobilien
E.ON Kernkraft GmbH, E.ON Netz GmbH, E.ON Wasserkraft GmbH
Frerk Aggregatebau GmbH
GUTOR ELECTRONIC Ltd.
Masterguard GmbH
MTU Friedrichshafen GmbH
Piller Power Systems GmbH
POWERQUATTRO
RWE Systems AG
SIEMENS AG (PUC)
– prescribed for all battery installations at power plants!!!
ThyssenKrupp Stahl AG

2012 Battery Seminar - AquaGen premium.top 34

 AquaGen®

Montage

HOPPECKE Batterien GmbH & Co. KG · Bontkirchener Straße 1 · 59929 Brilon-Hoppecke

AquaGen® premium.top
New ventilation plug (as standard) design also like an adapter for the
installation of AquaGen premium.top

Adapter bayonet 24 / S 21,5

 Modification of the standard

bayonet plug
 Redundancy of the
ventilation openings
 Modula accomplishment
by the removal of the
labyrinth, development
of the adapter for the
AquaGen

2012 Battery Seminar - AquaGen premium.top 36

AquaGen® premium.top
Removing of the labyrinth before new installation of adapter plug

2012 Battery Seminar - AquaGen premium.top 37

AquaGen® premium.top
Removing of the labyrinth at already installed adapter plug

2012 Battery Seminar - AquaGen premium.top 38

AquaGen® premium.top
Installation of AquaGen premium.top plug

2012 Battery Seminar - AquaGen premium.top 39

Thank You. . .

Thank you
for your
attention!

www.hoppecke.com

2012 Battery Seminar - AquaGen premium.top 40