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: 27/35
This document is uncontrolled when printed. For the most current and official copy, check the server.
Rail Engineering
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www.enersys.com
8.6.5 Replacement of battery segment or individual cells
Designation
Comments
Lifting and other mechanical tools
Depending on system design
Insulated torque wrench
Nuts according system design
Scotch Brite sponge
Cleaning of contact surfaces
An Assembly drawing and part list can be found in your system documentation.
If your system is composed of several batteries (E.g. in trays) or with individual cells in
series and you have to partial replace a segment or an individual cell in the service
workshop, please read the following information:
Combine only batteries or cells that are in the
same state of charge
. It is best to
undergo the various groups a previous 72h charge with float level charging voltage
and ensure that they all are fully charged.
Combine only batteries or cells with approximately the
same age
and when reusing
cells select cells from similar applications. Our experience shows that new cells prove
problematic when installed with batteries that have already been used for more than 2
years.
Work with
insulated tools
, when assembling the cells check the correct polarity and
mount the connectors correctly (Refer to system drawing). During assembly, make sure
that all contact surfaces are clean. Residues of the screw lock mass, can be removed
with a dry Scotch Brite sponge.
Use only new and unused terminal screws with screw lock (grey-blue mass in the thread).
Do not exceed the recommended
tightening torque
for the terminal screws:
Cells
Tightening torque
Unit
ZeMa200P18,
ZeMa270P12,
ZeMa340P12, ZeMa450P21
25.0 ± 0.9
Nm
The terminal screws should be tightened quickly when screwing, otherwise the screw lock
cures and ordinary tightening can not be performed.