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Batteries_Rail_Power_Manual_en02.docx

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Graphic symbols / pictograms on the battery system

Following graphic symbols are used in this operating and installation manual:

EN ISO 7010 - W012
Warning of electrical voltage

EN ISO 7010 - W026
Warning about danger from batteries

EN ISO 7010 - W023
Warning of corrosive substances

EN ISO 7010 - W002
Warning against explosive substances

EN ISO 7010 - P003
Fire, open light and smoking prohibited

EN ISO 7010 - M002
Follow instructions for use

EN ISO 7010 - M004
Use eye protection

EN ISO 7010 - M009
Use hand protection

EN ISO 7010 - M010
Use protective clothing

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Summary of Contents for Batteries Rail Power

Page 1: ...lity External Created changed current index 2020 06 09 W Pickart Operating and Installation Manual Document state Approved Checked current index 2020 10 06 F Mengeringhausen Approved current index 2020 10 06 Dr D Mahl File name Batteries_Rail_Power_Manual_en02 docx Revision 02 Language EN Page 1 Batteries rail power Operating and Maintenance Manual ...

Page 2: ...2019 04 01 Checked T Schreckenberg 2019 04 03 Approved Dr K Gutzeit 01 2020 02 05 Created W Pickart Revision according to Documentation Check 2020 02 12 Checked T Schreckenberg 2020 03 18 Approved Dr D Mahl 02 2020 06 09 Created W Pickart 7 3 Chapter 7 3 Storage with built in battery added 2020 10 06 Checked F Mengeringhausen 2020 10 06 Approved Dr D Mahl ...

Page 3: ...nual is not covered by any change service Keep this documentation in such a manner that it is available immediately to all those who need to carry out work in connection with the battery system or its components HOPPECKE Business Unit Special Power Postfach 11 80 D 59914 Brilon Bontkirchener Str 1 D 59929 Brilon Telefon 49 0 29 63 61 1412 Fax 49 0 29 63 61 1452 Internet www HOPPECKE com Email hbs ...

Page 4: ...gs on the product 13 3 USE OF THE PRODUCT 14 3 1 Intended use 14 3 2 Unintended use 14 4 DIRECTIVES LEGISLATION AND STANDARDS 15 5 FUNCTION AND STRUCTURE 16 5 1 Battery 16 5 2 rail power blocks cells 16 5 3 Charging methods for rail power blocks cells 17 5 3 1 Single stage charging with constant current constant voltage IU 17 5 3 2 Two stage charging with constant current constant voltage IU0U 18 ...

Page 5: ...ng a cell connector 38 9 2 3 Exchange of the temperature sensor 39 10 TROUBLESHOOTING 40 10 1 Insufficient capacity 40 10 2 Insufficient insulation resistance 40 10 3 No battery voltage can be measured 41 10 4 Malfunction of the temperature sensor 41 11 DISASSEMBLY 42 12 DISPOSAL 43 13 APPENDIX 44 13 1 Additional tools 44 13 2 Maintenance protocol 45 13 2 1 Half yearly maintenance interval 45 13 2...

Page 6: ...cians Personnel authorised by the safety officer of the train manufacturer Personnel authorised by the safety officer of the train operator Personnel authorised by HOPPECKE Batterie Systeme GmbH HOPPECKE experts Untrained personnel must not carry out any work on rail power blocks cells 1 2 Means of representation 1 2 1 Icons and signal Words The following icons and signal words are used in this op...

Page 7: ...012 Warning of electrical voltage EN ISO 7010 W026 Warning about danger from batteries EN ISO 7010 W023 Warning of corrosive substances EN ISO 7010 W002 Warning against explosive substances EN ISO 7010 P003 Fire open light and smoking prohibited EN ISO 7010 M002 Follow instructions for use EN ISO 7010 M004 Use eye protection EN ISO 7010 M009 Use hand protection EN ISO 7010 M010 Use protective clot...

Page 8: ... with 20 A for a 100 Ah battery IXX Discharge Current Named as Ixx based on rated capacity Example I5 for a 100 Ah battery 100 Ah 5 h 20 A Tn Nominal Temperature Tn Reference temperature for capacity D Tightening torque terminal screws D M8 20 Nm 1 Nm 1 4 Abbreviations and glossary of terms The following table describes abbreviations and terms that are used in this operating and installation manua...

Page 9: ...is an immediate high risk situation which if not avoided will result in death or serious injury Measures to avert the danger Work with insulated non sparking tools Ensure sufficient ventilation of the battery room in accordance with DIN EN IEC 62485 2 so that the potentially explosive gas mixture is removed Avoid electrostatic charging Do not rub batteries with plastic housings with a dry cloth or...

Page 10: ...onsist of grid structure electrodes Each positive electrode is wrapped in a fleece The electrolyte is fixed in this fleece Electrolyte may leak if the housing of a block cell is damaged Reversed polarity of the battery or of individual cells can cause overheating and thus leakage of electrolyte Electrolyte is very corrosive During normal operation contact with the electrolyte is excluded If the ho...

Page 11: ...iting Seek medical attention or hospitalization immediately 2 1 4 Toxic substances Rail power blocks cells contain lead Symbol Pb CAS Number 7439 92 1 There is a low risk hazard which if not avoided could result in minor or moderate injury Measures to avert the danger Avoid contact with toxic substances Wear personal protective equipment see 2 2 Personal protective equipment on page 13 Note REACH ...

Page 12: ...e of 1 m and a full jet distance of 5 m Extinguish at short intervals Otherwise there is danger of explosion due to possible static charging on the battery housing 2 1 6 Improper transport The batteries may be damaged during improper transport Falling batteries can cause personal injury If the batteries are transported improperly there is a risk of damage Suspended loads Dropping batteries or part...

Page 13: ...on the batteries and their components Wear safety goggles Wear protective gloves Wear protective clothing preferably made of cotton to avoid electrostatic charging of clothing and body Wear safety shoes In the event of an accident injuries can thus be prevented or at least the consequences of injury mitigated The conductivity of textiles and shoes must have the following properties in order to avo...

Page 14: ... and damage to property HOPPECKE Batterie Systeme GmbH assumes no responsibility and no liability for personal injury or damage to property resulting directly or indirectly from handling the batteries if they are not used as intended The risks associated with improper use are borne solely by the operator Any other use than described under Intended use is not intended and therefore not permitted Th...

Page 15: ...06 4 Batteries ADR RID European Treaty on the international transport of hazardous goods by road Ordinance on the international transport of hazardous goods by rail IATA DGR Dangerous goods regulations international air transport association German Gefahrgut Bestimmungen Internationale Flug Transport Vereinigung IMDG Code International Maritime Code for Dangerous Goods German Gefahrgutkennzeichnun...

Page 16: ...id batteries VRLA and are specially designed for use in rail vehicles rail power batteries are available as single cells 2V as well as block batteries 6 V 12 V The following figure shows an example of the structure of a HOPPECKE rail power block A block consists of 3 6 V block or 6 12 V block cells They are installed in a single housing The individual cells consist of grid structure electrodes Eac...

Page 17: ...tting of the charging voltage always represents a compromise between charging time and aging As the current decays when the voltage limit is reached due to the natural behaviour of the battery the charging process is slowed down Although higher voltage extends the constant current phase and shortens the charging time ageing is also accelerated by irreversible water loss dehydration In accordance w...

Page 18: ... shorter time After reaching the current threshold I50 which indicates that the battery has been sufficiently charged the voltage is switched to the float voltage This voltage is significantly lower than the voltage at single stage charging This keeps water consumption to a minimum while maintaining the state of charge If there has been a discharge of the battery the charging current will increase...

Page 19: ...308 170 275 41 0 PP rail power 2 V 220 Ah VRLA 2 220 183 90 310 14 4 ABS rail power 2 V 308 Ah VRLA 2 308 183 129 310 21 7 ABS rail power 2 V 375 Ah VRLA 2 375 183 155 310 25 0 ABS Block cell also in ABS FR Flame Retardent available fulfilling the UL94 V0 standard 5 4 2 Technical details Construction Design Cells according to EN 60896 21 22 VRLA Battery with electrolyte fixed in a glass fibre flee...

Page 20: ...5 4 3 1 One stage temperature compensated charging IU charging For rail power batteries a temperature compensated charging characteristic is required to avoid excessive currents at high ambient temperatures and to fully charge the batteries at low temperatures Starting from the charging parameters at design temperature the charging voltage is increased or decreased depending on the measured batter...

Page 21: ...ure sensor should be replaced within a few days 5 4 3 2 Two stage temperature compensated charging IU0U charging A two stage charge constant current constant voltage is recommended for rail power batteries In addition a temperature compensated charging characteristic is required in order to avoid excessive currents at high ambient temperatures and to fully charge the batteries at low temperatures ...

Page 22: ...recommended maximum charge current is 1 0 x I5 Charge voltages at 20 C Float charge 2 25 V per Cell Boost charge 2 35 V per Cell Note If the battery temperature is 60 C the charging process must be interrupted to prevent damage to the cells Select a control that does not resume charging until the battery temperature has dropped to 55 C Note You can assume that the temperature sensor is defective i...

Page 23: ...he sender packer and shipping agent have to care for following packaging For transportation of the battery a solid palette has to be used The battery has to be covered on top with a paperboard of the size of the battery to protect it against short circuits Afterwards the battery has to be tightened with non metallic straps plastics in horizontal and vertical direction to fix it on the palette An a...

Page 24: ... works HOPPECKE The storage periods are to be fully counted towards the service life Note Follow the safety instructions see 2 Safety instructions on page 9 Unpack install and commission batteries as soon as possible after delivery see 8 Assembly commissioning on page 27 In case this is not possible Store the batteries in a clean dry and frost free room Protect the batteries against mechanical dam...

Page 25: ...ls 6 75 V per block in case of 6 V blocks 13 5 V per block in case of 12 V blocks 7 2 Storage with regularly recharge Regularly recharge means Charge the battery system for 24 hours with current limitation of the nominal charging current I5 Cn 5h with following constant voltages 2 35 V per cell in case of 2 V single cells 7 05 V per block in case of 6 V blocks 14 1 V per block in case of 12 V bloc...

Page 26: ... the vehicle is parked make sure the battery will not deep discharge Disconnect the battery electrically from the electrical system of the vehicle to prevent permanent consumers discharge the battery Parking has to be considered as normal operation for maintenance purposes Carry out the regular maintenance intervals and works see 9 Maintenance on page 29 Note Perform regular recharging during the ...

Page 27: ...to the load Reversed battery polarity can cause overheating and acid leakage There is an imminent danger with a high risk that will result in death or serious injury if not avoided Always check the correct polarity before making connections Make sure that all consumers in the vehicle and the charger are switched off Note If the terminals of a battery are damaged the battery can no longer be used D...

Page 28: ...t the negative terminal of the battery to the negative terminal of the on board power supply or charger 3 If applicable connect existing control lines e g temperature sensors medium voltage taps etc 4 Check the battery connection for example by checking the charging voltage and the control signals Result The battery is connected for use in the vehicle M8 terminal screws with plastic head Wrench op...

Page 29: ...y on page 30 Measurement of the voltage of the entire battery 1 year 9 1 2 Measurement of the charging voltage on page 31 Cleaning the battery 9 1 3 Cleaning the battery on page 32 Measurement of the insulation resistance 9 1 4 Measuring the insulation resistance on page 33 Measurement of single block cell voltages 4 years 9 1 5 Measuring the open circuit voltage on each battery block cell on page...

Page 30: ...damage Check battery and container for mechanical damage Contact the depot manager or the HOPPECKE Service Tight fit of connectors screws and cables Connectors screws cables must not be loose Tighten connectors screws cables Tight fit of the temperature sensor Check temperature sensor for proper attachment if present Fix the temperature sensor properly Contamination by electrolyte Plugs must be ti...

Page 31: ...protective equipment see 2 Safety instructions on page 9 Precondition The battery system is connected to the vehicle s onboard charger and is being charged Required tools Digital Multimeter current clamp contact thermometer 1 Measure the charging voltage directly at the battery with a suitable multimeter 2 Measure the charging current directly at the battery with a suitable current clamp 3 Measure...

Page 32: ...ther extraneous conductive parts In addition damage caused by corrosion and leakage can be avoided Cleaning of batteries is not only necessary to ensure high availability required but is also an essential part of accident prevention regulations Note Improper cleaning may damage the batteries Avoid damaging the battery Do not use solvents or wire brushes for cleaning Prevent penetration of cleaning...

Page 33: ...EN 50272 Teil 2 100 Ω per Volt Nominal voltage above 120V DIN EN 62485 3 09 2015 No of cells x 2 0 V Nominal voltage Cell x 500 Ω V If this minimum value is not reached a possibly existing insulation monitor an undesired increased discharge and loss of battery performance may occur Note For rail power batteries an insulation measuring instrument with a test voltage of 500 V must be used Use a suit...

Page 34: ...the insulation resistance between the negative terminal and a metallic part of the rolling stock vehicle chassis 4 Check the function of the insulation measuring device by measuring any metal part of the battery tray battery container against any metal part of the vehicle chassis The measured resistance must be 0 Ω 5 Clean the battery if the measurements fall below the minimum value see 9 1 3 Clea...

Page 35: ...oltage values are valid for a temperature of 20 C 2 Calculate the mean value from the measured values Note If a rail power block Cell is more than 120 mV 12 V block 60 mV 6 V block 20 mV 2 V Cell below the calculated mean value you must charge the entire battery see following charging condition Charge the battery for 24 hours with current limited to I5 Cn 5h with following voltages 14 1 V per bloc...

Page 36: ...ork on the batteries Wear personal protective equipment see 2 Safety instructions on page 9 DANGER Loose connections at the terminal screws can heat up strongly and cause inflammations or explosions Use each screw and washer only once First tighten the pole screws only by hand Align batteries and connectors if necessary once again Then tighten the terminal screws to the prescribed torque Note Swit...

Page 37: ...entire battery If more blocks cells are defective all blocks cells must be replaced Required Tools Torque wrench with suitable widths for M8 screws 1 Remove the connectors to the adjacent blocks cells 2 Lift the rail power block cell to be replaced out of the tray container Note It is recommended to use a suitable suction lifting device for the removal and installation of the blocks cells 3 Lift t...

Page 38: ...but must use new spring washers Torque 20 Nm Result The rail power blocks cells are exchanged 9 2 2 Exchanging a cell connector Target A defect connector is exchanged Required tools Torque wrench with suitable widths for M8 screws 1 Loosen the terminal screws of the connector to be replaced 2 Remove the defective connector 3 Install the new connector and mount the pole screws Terminal screw M8 wit...

Page 39: ...Result The defect connector was exchanged 9 2 3 Exchange of the temperature sensor Target The defect temperature sensor is exchanged 1 Disconnect the Cannon plug 2 Remove the defective temperature sensor 3 Install the new temperature sensor 4 Reconnect the Cannon plug 5 Check the charging voltage see 9 1 2 Measurement of the charging voltage on page 31 Result The defect temperature sensor was exch...

Page 40: ...ation dust and may not fall below the following values depending on the nominal battery voltage Battery nominal voltage Norm Insulation Resistance minimum value below 100 V DIN VDE 0119 206 4 10 kΩ between 100 V and 120 V DIN EN IEC 62485 2 100 Ω per Volt nominal voltage Above 120 V i e from 100 cells DIN EN 62485 3 09 2015 Number of cells x 1 2 V nominal voltage x 500 Ω V If these minimum values ...

Page 41: ... the main plug Cable breakage Replace the cable Cell connector s is are defect Replace the connector s use new spring washer s 10 4 Malfunction of the temperature sensor If the temperature sensor does not provide plausible temperature values in the range lower 50 C or higher 80 C proceed as follows Possible Cause Remedy Temperature sensor defect Replace the temperature sensor Plug defective Replac...

Page 42: ...bly on page 13 1 Switch off all chargers and consumers on the vehicle 2 Establish access to the battery system 3 Disconnect the connecting cable between the battery and the vehicle 4 Remove the battery system from the vehicle 5 Loosen and remove cell connectors cables 6 Pull out the blocks cells Dispose of the individual parts separately ...

Page 43: ... recyclable economic goods and must be returned via the recycling process You can use the HOPPECKE recycling system The old batteries are picked up and returned to the recycling system Contact HOPPECKE Service for further information Note Arrange for the disposal of lead acid batteries that are not returned to the recycling process as special waste observing all regulations ...

Page 44: ...ix 13 1 Additional tools The following lists additional tools for maintenance and service Tool Description Voltmeter Multimeter Picture shows an example Insulation tester Fluke 1507 HOPPECKE Mat nr 4141201237 Charging Discharging device Picture shows an example ...

Page 45: ...ber of battery system ___________________________________________ Number of train ___________________________________________ Date of commissioning ___________________________________________ 13 2 1 Half yearly maintenance interval 13 2 1 1 Maintenance visual Inspection of the battery Interval Years Visual Inspection Done mark with cross Date Inspector Name 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 ...

Page 46: ...ng voltage Interval Years Voltage V Current A Temperature C Date Inspector Name 1 2 3 4 5 13 2 2 2 Maintenance cleaning the battery Interval Years Cleaning Done mark with cross Date Inspector Name 1 2 3 4 5 13 2 2 3 Maintenance measuring the insulation resistance Interval Years Insulation Resistance Ω Date Inspector Name 1 2 3 4 5 ...

Page 47: ... Maintenance measuring the open circuit voltage on each battery block cell Cell Block No Open Circuit voltage V 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 if more than 20 cells blocks are installed enlarge the table accordingly Date ______________________ Inspector ______________________ ...

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