HOPPECKE Lithium-ion battery systems Motive Power Systems Reserve Power Systems Special Power Systems Service Your benefits: Highly flexible due to modular system structure Highest possible level of operational safety thanks to integrated HOPPECKE battery management system Long cycle life up to 2,500 cycles at 80% depth of discharge Compact dimensions and lightweight structure due to high energy and power density Excellent failure safety through intelligent parallel connection of modules Typical applications for HOPPECKE lithium-ion battery systems Motive Power applications Reserve Power applications Energy storage from renewable sources Similar to the illustration
A wide variety of potential applications Examples for motive power, uninterruptible power supply and power generation Electric and hybrid buses Load management/smart Grid Industrial trucks Electric garbage trucks, electric and hybrid vehicles Automated guided vehicles Off-grid users Cleaning machines Rail and underground systems Self-consumption of PV energy
More than 1,000 possible configurations We design your individual battery system HOPPECKE lithium-ion battery systems have a modular structure and are comprised of 24V and 36V basic modules. These basic units are designed in such a way that they can be used as individual blocks or installed as a group consisting of several modules to form a larger battery system. The lithium-ion modules are available in High Energy (with high energy content) or High Power (with high current carrying capacity) versions. The HOPPECKE basic module soon available as a high-voltage module In addition to the 24V and 36V basic modules, the HOPPECKE high-voltage module will soon be available with a nominal voltage of 100V. This new module type will also be suitable for serial and parallel connection. Our HOPPECKE high-voltage modules will offer new solutions anywhere high voltages are needed, e.g. electric buses, railway vehicles or uninterrupted power supply systems. High level of flexibility thanks to scalable lithium-ion system High power outputs and capacities can be achieved through parallel and serial connection of the HOPPECKE modules. Technical data at a glance HOPPECKE trak LiOn module High Energy 24 V 36 V High Power High Energy High Power Nominal voltage in V 25.9 25.9 37 37 Nominal capacity in Ah (C 1 ) 50 40 50 40 Nominal energy content in kwh 1.3 1.0 1.9 1.5 Charging voltage in V 29.0 29.0 41.4 41.4 Final discharging voltage in V 22.4 22.4 32.0 32.0 Constant discharging current in A 100 240 100 240 Constant charging current in A 50 80 50 80 Cycle life (80% DOD) ) 2500 2500 2500 2500 Discharging temperature -10 to 50 C -10 to 50 C Charging temperature 5 to 45 C 5 to 45 C Storage temperature -10 to 50 C -10 to 50 C Weight in kg 11.5 10.5 15.5 14.0 Dimensions L x W x H in mm 228 x 128 x 289 228 x 170 x 289
Our quality standards for maximum safety and reliability HOPPECKE lithium-ion basic modules have to pass extremely strict quality controls. Before they leave the HOPPECKE plant in Zwickau, the capacity and safety mechanisms of each individual module are tested and examined. HOPPECKE lithium-ion modules are also UN38.3 ( Transport of lithium batteries ) and CE certified. UN38.3 test content Transport guidelines for lithium-ion batteries Height simulation Thermal test Vibration test Working closely with various certification bodies and test laboratories allows us to achieve applicationspecific system certifications for you. High IP protection classes can be achieved through the design and construction of suitable outer packaging (tubs, containers). Simply contact us and tell us what you need! Active and passive heating or cooling for an optimal performance HOPPECKE modules can be heated or cooled through a suitable structure of the peripheral devices, in order to increase the lifetime of the lithium-ion cells by a significant amount and guarantee an optimal performance. In this context, both passive and active processes can be used. Controls are either operated automatically by the modules or via the optional CAN interface (CAN2X Gateway). The HOPPECKE engineering team will be pleased to take over the task of designing systems such as these for you. Rapid charging systems with maximum operating safety Compared with conventional solutions, HOPPECKE lithium-ion systems can be charged using very high currents (2C). In cyclical applications, this special feature offers significant cost advantages, since no substitute batteries are required. The illustration below shows the capacity trend for a HOPPECKE lithium-ion system when daily idle times are used for interim charging. The rapid charging characteristics of the HOPPECKE system allow it to be used on a constant basis by the energy system or the consumer. With our HOPPECKE systems, you can enjoy increased operational safety. The intelligent parallel connection of the lithium-ion modules ensures a redundant system design. The system can be kept running even when a module is switched off. Another benefit is that the nominal capacity of a HOPPECKE lithium-ion module is available at all times: at both high and low discharging currents. This means that battery systems can be designed to be smaller than is possible with other battery technologies, which can only provide less than their nominal capacity at high discharging currents. Capacity [%] Charging current [C] 100 90 Battery charging during idle times 80 70 Capacity 60 2 50 40 30 1 20 Charging current 10 0 0 1 2 3 4 5 6 7 8 Capacity trend of a HOPPECKE lithium-ion system during 8-hour period of use Time [h]
Battery Management System (BMS) for double safety Battery management system (BMS) at module level Lithium-ion batteries must be monitored electronically on a constant basis in order to ensure their safe use and protect the lithium-ion cells against damage. These tasks are carried out by a battery management system (BMS). Each HOPPECKE battery module contains a BMS developed in-house. This monitors the module and prevents its use outside of the safe operating range defined before critical circumstances arise. Thus, each module is intrinsically safe. The BMS also facilitates communication with other modules in the battery system and with the user system connected to the battery via a CAN2X gateway. Four testing and monitoring functions, one goal: Maximum safety 1 Status display 5 2 High-power contact 6 3 4 Communication connection Connection measuring signals 5 7 8 1 Hardware safety Measuring shunt Control panel Power circuit 2 3 6 4 7 Intrinsic safety function Measures individual cell voltages, cell temperatures and cell current Monitors the safe operating range Shuts down the module by means of modern semiconductor components if maximum values are exceeded (e.g. overvoltage, overheating, etc.) Individual cell balancing function Structure of a basic module 8 Adjusts cell charging status through intelligent balancing Allows the maximum possible electrical energy to be extracted Status calculation function Algorithms developed in-house to calculate state of charge (SOC) and state of health (SOH) of the HOPPECKE lithium-ion cells Calculation based on measurement of the individual cell voltage and integration of the current flowing through the cell Communication function CAN-based communication function Transmission of individual module status and of measurements to the entire battery system
Battery Management System (BMS) for double safety Battery management system (BMS) at system level The BMS integrated into each battery module monitors the status of the module and measures the status variables (voltage, current, temperature, etc.) via the internal HOPPECKE CAN Bus so that each module is updated with the system status (Master- Master principle). In addition, the BMS facilitates communication with the superordinate user system via the CAN2X gateway module. In this context, the X stands for any customer communication protocols. HOPPECKE offers the CAN open standard exworks. Customer-specific adjustments can be made at any time. User Gateway BMS BMS + + + + + + Architecture of a full HOPPECKE system The module structure allows storage systems to be realised in a flexible manner with regard to voltage and capacity Module Structure of a HOPPECKE full system Module Battery system/tray Modules are connected serially in strings to achieve the required system voltage The battery capacity is achieved by parallelizing the strings Failure safety: the parallel connection of the modules ensures that the full system will continue to run even if a module fails Significant module parameters are exchanged via CAN bus on the basis of the Master-Master Principle Components in a HOPPECKE battery system Module (serial, connected in parallel) CAN2X-Gateway Cooling/heating (active or passive) Tub/housing in various protection classes Special high-voltage systems available on request Status variables that are relevant for the system (SOC, SOH, system temperature, current, voltage, warnings and error messages) are exchanged with the superordinate user application via CAN2X gateway Semi-active balancing of the modules at system level
HOPPECKE s recycling concept We go the extra mile For more than 40 years, we have been running our own metal plant (certified waste disposal operation) and, in this context, in line with the German Battery Directive, we offer our customers and the free market our own battery return and recycling system. We organise the collection of your used batteries directly at your site, regardless of the manufacturer or design, and ensure that all packaging and transport guidelines are adhered to. We guarantee that the batteries will be recycled correctly and will provide you with evidence to confirm this. You can enjoy absolute peace of mind that your batteries, which are subject to waste disposal regulations, will be treated properly. We have a comprehensive reverse logistics system in place in Germany and throughout Europe HOPPECKE lithium-ion recycling cycle Production of new batteries/systems Production of new cells Commissioning and use of batteries/systems Recycling and reprocessing of individual components Battery return Disassembly/separation of components HOPPECKE External HOPPECKE partners
Motive Power Systems Reserve Power Systems Special Power Systems Service HOPPECKE worldwide Industrial batteries - Complete energy systems - Full Service Your partner for sustainable energy solutions! Further information on www.hoppecke.com HOPPECKE Batterien GmbH & Co. KG Postfach 1140 D-59914 Brilon Bontkirchener Straße 1 D-59929 Brilon-Hoppecke Telefon +49(0)2963 61-0 Telefax +49(0)2963 61-449 Email info@hoppecke.com www.hoppecke.com Service hotline Germany 0800 246 77 32 International Service hotline +49(0)180 5 22 9999 Form Lithium-ion battery systems 8pp EN/08.13/K 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.