Manual
Operation Manual for
ZeMa Single Cells
Prepared on: 23-11-2022
Prepared by: GBA
Released on: 04.01.2023
Released by: -
Revised on: -
Index: _-
Distributed to: customer (public)
Pages: 23/35
This document is uncontrolled when printed. For the most current and official copy, check the server.
Rail Engineering
Tel. +49 (0) 2331/372 591
Dieckstrasse 42
Fax +49 (0) 2331/372 804
DE-58089 Hagen
www.enersys.com
battery can no longer be fully charged. Constantly high temperatures accelerate the aging
of the battery.
The time depends strongly on the real usage conditions (charging technology, influence
of heat, cyclic operation, ...).
For the evaluation of the battery state of health condition a C
5
or C
10
capacity test can be
conducted. Due to the long duration of the test in most cases the battery must be
dismounted from the vehicle.
The increase of the continuous charging current is an indicator of the advanced period of
use. But it is not a distinct sign of reaching the end of the service life.
We recommend that the rail operator defines a maximum expected service life of the
battery in their vehicles and operating conditions and to preventively replace the rolling
stock by this criterion.
8.5
Replacement of the battery
In order to achieve a short downtime of the vehicle in the event of faults, that cannot be
remedied within a short time or when the maximum period of use is reached, we
recommend a rapid exchange of the battery system in the vehicle.
8.5.1 Dismantling of the batteries
Follow the instructions in chapter 10.1 "Disassembling".
Log the operation counter data, which read at the BMS.
8.5.2 Installation of replacement batteries
Follow the instructions in chapter 5 “Mounting” and chapter 6 ”Commissioning”.
Reset the counters in the BMS (or to the intermediate values of the replacement battery).
8.6
Repair and refurbishing (Curative service)
Avoid the risk of explosion and fire hazard, short circuits!
Attention!
Metal parts of the battery cells are always hot,
no tools nor
foreign objects are allowed
to be placed on the battery.
Under all operating conditions, hydrogen can escape through the ventilation
Cap. Sufficiently ventilate rooms and cabinets.
It is
not permitted
to charge in closed and unventilated rooms.
To eliminate security risks, the ventilation requirements for workshop charging according
to
EN 62485-3:2015
“Safety requirements for secondary batteries and battery
installations, Part 3: Traction batteries” must be respected.
When working with a battery charger make sure you follow the instructions of this
equipment and verify correct parameter settings.
8.6.1 Recharging the battery in the workshop
For the recharging of the battery in the workshop at 20 ° C use a constant current
charging of minimum I
10
(
ZeMa200P18*: 20.8 A
) and the trickle charging voltage of 2.29
Vpc.