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: 22/35
This document is uncontrolled when printed. For the most current and official copy, check the server.
Rail Engineering
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8.3
Capacity test
List of tools for this service action:
Designation
Comments
Charger and Discharge Resistor
With matching voltage, currents and
connection to your system
Digital voltmeter
with thin measuring tips
(Measuring hole connector cover
2mm)
DC voltage measurement
with display precision 0.001 V at cell voltage
Tool for accessing
According to documents of the corresponding
battery box
With a capacity test you can verify the functionality of a battery system. A battery with
standard design is operational if the current battery capacity C
act
is greater than 80% of
the rated capacity C
r
(Testing according IEC/EN 60689-21/22).
The most informative battery check is a periodic capacity test.
The test discharge is stressing the battery and the
voltage of individual
cells must not fall below 1.6 Vpc
.
Secure rapid full charge of the battery before and after the test.
Test the fully charged battery after a pause of 6 hours with a constant current C
10
for 8h
(test of functionality, less stressing) or down to the final voltage representing 1.8Vpc (test
for actual capacity).
8.4
Service life of the battery
The 2V ZeMa
Rail
single cells for rolling stock batteries have a limited service life. Cyclic
operation consumes the active mass of the positive plates and continuous charge will
lead to drying out of the electrolyte.
The end of the battery life is reached when the available capacity at fully charged
condition corresponds to only 80 % of the rated capacity. The reduced capacity is
indicated by how quickly the voltage drops during battery operation (discharge).The Ah -
meter of the battery management system BMS can determine the reduced capacity and
will display the end of the service life.
The ZeMa batteries must be operated at all times under the following conditions:
• Maximum energy throughput: Project related
• Average temperature: 20 ° C - 25 ° C
• Maximum operating temperature: up to + 40 ° C
In addition, the requirements, instructions and documentation of the manufacturer of the
ZeMa batteries must be complied with at all times.
The ZeMa batteries work in the entire temperature range of EN 50125-1, Table 2, Class
T3 (-25 ° C - + 45 ° C). At low temperatures, the charge consumption is reduced and the