The HOPPECKE traction cell

In Europe, the most comment power source for the battery electric trucks in the internal transport equipment are traction batteries with positive tubular plates and negative flat plates. They have proven to be reliable, highly efficient, with a long life expectation and an acceptable recharge time. The design of the HOPPECKE trak - traction battery has the unique trak Q traction cell technology inside. The trak Q traction cell has a compound seal pillar and an additional fleece envelope around the negative plates. This design is recognised in the market by many satisfied customer, who prefers the HOPPECKE batteries for their day in day out reliability. They need extremely little maintenance and have a proven long cycle life. The specific HOPPECKE design of its traction cells are the result of the continuous development and improvements over the last 20 years. It is not a surprise that the HOPPECKE traction batteries are nowadays in the top league for every battery powered application.

The outstanding features of the HOPPECKE trak Q traction cell

figure 1 - HOPPECKE trak Q traction cell

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The typical HOPPECKE pillar design with cast on compound sealing in polypropylene is absolute 100% leak poof!

figure 2 - HOPPECKE compound sealed pillar

Highly flexible and elastic woven gauntlet of the Hoppecke traction cell reduces the loss of active material to a minimum
Positive electrode Alloy woven gauntlet 9, 0 mm (outside diameter) PbSb (lead antimony)

figure 3 positive woven gauntlet

figure 4 Details of the woven positive gauntlet Version: PzS 13.08.06 English page 2/9 M. Schiemann / J.Scheffers

Specific HOPPECKE fleece envelopes around the negative plates to avoid any short circuits in the cell
Negative plate Alloy flat plate 4,5 mm (thickness) PbSb (lead Antimony)

figure 5 negative flat plate

figure 6 fleece envelopes around the negative plate

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After the thermoplastic welding of pillar / lid, it is 100% sealed and avoids any acid leakage. Together with the fully isolated flexible intercell connector the trak traction cell is fully isolated and it prevents any creeping current over the top of the battery.

figure 7 the unique HOPPECKE thermoplastic 100% compound pillar / lid sealing

Intercell connector Cell bolts Protection Classification

A flexible, fully isolated copper connector with a Santoprene cover A steel bolt M 10 with an isolated hexogen head and an reading point voltage measuring. IP 25 in accordance with DIN 40050 and the EN safety guidelines for the electrical protection of the user (VBG 3 VDE 0701/702)

Every traction cell is prepared for trak air (electrolyte circulation) at the assembly line in the factory

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figure 8 The basics of the HOPPECKE trak air Systems

The features of the trak air System? During the discharge of the battery, the specific gravity of the electrolyte will decrease. The electrolyte (diluted sulphuric acid) is participating in the chemical reaction. Both positive and negative plates will enlarge in size due to the absorption of the sulphate and there will be a stratification of the electrolyte. During the charge of the battery, this process will reverse. The sulphate, leaving the active plate material, will create on the spot a very high concentration of the specific gravity of the electrolyte and strengthen the stratification in the first stage of the charge process. The heavier electrolyte sinks towards the bottom. This has a negative effect on the charge acceptance of the plate, as the specific gravity is low at the top and high at the bottom. The mechanical stress on plates, the positive gauntlet material is high. There are two options to eliminate the stratification during the charge process. 1. The natural way in the second phase of the standard charge process. The charge current is not completely converted into ampere-hours. The battery is over charged The plates are producing hydrogen and oxygen gas. The gas bubbles will circulate the electrolyte and the stratification disappears. However, it means longer charge time. More over charge, more water losses and a temperature rise of ca.10 C.

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2. The best way is the usage of HOPPECKE trak air. It eliminates all the negative side effects as mentioned above. From the start of the charge process, air is pumped into each cell. It creates a homogenous specific gravity of the electrolyte and eliminates the stratification directly. This favourable trak air charge process also avoids the mechanical stress on the plates. That is, why each HOPPECKE trak Q cell is prepared for trak air electrolyte circulation at the assembly line in the factory. It gives the possibility to install the trak air system for electrolyte circulation on any standard trak basic battery; also afterwards at the customers site.

Key benefits of trak cells & batteries:

Longer life expectation Higher number of cycles Absolute no pillar corrosion Smooth and clean cell lids. Fully isolated, no creeping currents Highest possible protection against short circuits High flexibility in application & option for trak air (even afterwards)
HOPPECKE trak Q cells Cycle life time in dependence on depth of discharge

120

100 depth of discharge C5 [%]

80

60

40

20

0 0 500 1000 1500 2000 2500 3000 3500 cycle number

figure 9 HOPPECKE trak batteries cycle life related to the depth of discharge at 30C

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HOPPECKE traction cell ranges

trak standard cell range with 60 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 PzS L 120 3 PzS L 180 4 PzS L 240 5 PzS L 300 6 PzS L 360 7 PzS L 420 8 PzS L 480 9 PzS L 540 10 PzS L 600 120 180 240 300 360 420 480 540 600 L W H Weight dry charged [kg] 6,4 9,1 11,7 14,4 17,0 19,7 22,4 25,0 27,7 Weight filled & charged [kg] 8,0 11,6 14,9 18,4 21,9 25,3 28,9 32,3 35,8

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 372 372 372 372 372 372 372 372 372

trak standard cell range with 80 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 PzS L 160 3 PzS L 240 4 PzS L 320 5 PzS L 400 6 PzS L 480 7 PzS L 560 8 PzS L 640 9 PzS L 720 10 PzS L 800 160 240 320 400 480 560 640 720 800 L W H Weight dry charged [kg] 7,8 11,0 14,3 17,5 20,8 24,1 27,3 30,6 33,8 Weight filled & charged [kg] 9,9 13,9 17,9 22,0 26,2 30,3 34,3 38,4 42,4

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 432 432 432 432 432 432 432 432 432

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trak standard cell range with 90 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 PzS L 180 3 PzS L 270 4 PzS L 360 5 PzS L 450 6 PzS L 540 7 PzS L 630 8 PzS L 720 9 PzS L 810 10 PzS L 900 180 270 360 450 540 630 720 810 900 L W H Weight dry charged [kg] 9,0 12,6 16,3 19,9 23,6 27,3 30,9 34,6 38,2 Weight filled & charged [kg] 11,5 16,1 20,9 25,3 30,1 34,9 39,5 44,3 49,1

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 507 507 507 507 507 507 507 507 507

trak standard cell range with 110 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 PzS L 220 3 PzS L 330 4 PzS L 440 5 PzS L 550 6 PzS L 660 7 PzS L 770 8 PzS L 880 9 PzS L 990 10 PzS L 1100 220 330 440 550 660 770 880 990 1100 Nominal capacity C5 at 30 C [Ah] 2 PzS L 280 3 PzS L 420 4 PzS L 560 5 PzS L 700 6 PzS L 840 7 PzS L 980 8 PzS L 1120 9 PzS L 1260 10 PzS L 1400 280 420 560 700 840 980 1120 1260 1400 L W H Weight dry charged [kg] 10,7 15,1 19,5 23,9 28,3 32,7 37,1 41,5 46,0 Weight filled & charged [kg] 13,9 19,6 25,3 31,1 36,9 42,7 48,4 54,3 60,2

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 597 597 597 597 597 597 597 597 597

trak standard cell range with 140 Ah / positive plate Cell type L W H Weight dry charged [kg] 13,3 18,6 24,0 29,3 34,7 40,0 45,4 50,7 56,2 Weight filled & charged [kg] 17,5 25,0 32,6 39,8 47,4 54,6 62,3 69,9 77,3

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 750 750 750 750 750 750 750 750 750

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trak High performance cell range with 105 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 HPzS 210 3 HPzS 315 4 HPzS 420 5 HPzS 525 6 HPzS 630 7 HPzS 735 8 HPzS 840 9 HPzS 945 10 HPzS 1050 210 315 420 525 630 735 840 945 1050 L W H Weight dry charged [kg] 10,3 14,5 18,8 23,0 27,3 31,5 35,8 40,0 44,3 Weight filled & charged [kg] 12,8 18,4 24,0 29,4 35,0 40,6 46,2 51,6 57,2

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 577 577 577 577 577 577 577 577 577

trak High performance cell range with 125 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 HPzS 250 3 HPzS 375 4 HPzS 500 5 HPzS 625 6 HPzS 750 7 HPzS 875 8 HPzS 1000 9 HPzS 1125 10 HPzS 1250 250 375 500 625 750 875 1000 1125 1250 L W H Weight dry charged [kg] 11,1 15,9 20,7 25,5 30,3 35,1 39,9 44,8 49,6 Weight filled & charged [kg] 14,3 20,4 26,5 32,7 38,9 45,1 51,2 57,6 63,8

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 597 597 597 597 597 597 597 597 597

trak High performance cell range with 155 Ah / positive plate Cell type Nominal capacity C5 at 30 C [Ah] 2 HPzS 310 3 HPzS 465 4 HPzS 620 5 HPzS 775 6 HPzS 930 7 HPzS 1085 8 HPzS 1240 9 HPzS 1395 10 HPzS 1550 310 465 620 775 930 1085 1240 1395 1550 L W H Weight dry charged [kg] 13,3 18,6 24,0 29,3 34,7 40,0 45,4 50,7 56,2 Weight filled & charged [kg] 18,1 25,6 33,1 40,1 47,4 55,0 62,5 70,0 76,9

[mm] [mm] [mm] 47 65 83 101 119 137 155 174 192 198 198 198 198 198 198 198 198 198 750 750 750 750 750 750 750 750 750

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