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Hoppecke Batteries Rail Power Operating And Maintenance Manual

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Executive
Responsible
department:
department:
SVA
SVA
Created/changed (current index):
2020-06-09, W. Pickart
Checked (current index):
2020-10-06, F. Mengeringhausen
Approved (current index):
2020-10-06, Dr. D.Mahl
Batteries rail.power
Operating and Maintenance Manual
Batteries_Rail_Power_Manual_en02.docx
Document type:
Technical Documentation
Operating and Installation Manual
File name:
Batteries_Rail_Power_Manual_en02.
docx
State of
confidentiality:
External
Document state:
Approved
Revision:
Language:
02
EN
Page:
1

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Summary of Contents for Hoppecke Batteries Rail Power

  • Page 1 Executive Responsible Document type: State of department: department: confidentiality: Technical Documentation External Created/changed (current index): Document state: 2020-06-09, W. Pickart Approved Operating and Installation Manual Checked (current index): 2020-10-06, F. Mengeringhausen Approved (current index): File name: Revision: Language: Page: 2020-10-06, Dr. D.Mahl Batteries_Rail_Power_Manual_en02.
  • Page 2 Version overview Revision Date State Name Chapter Reason for changes 2019-03-25 Created W.Pickart Initial version 2019-04-01 Checked T.Schreckenberg 2019-04-03 Approved Dr. K.Gutzeit 2020-02-05 Created W.Pickart Revision according to 2020-02-12 Checked T. Schreckenberg Documentation-Check 2020-03-18 Approved Dr. D.Mahl 2020-06-09 Created W.Pickart Chapter 7.3 "Storage with built- 2020-10-06 Checked...
  • Page 3 All rights reserved including those of patent and utility model applications. Disclosure of as well as copying this documentation and using or revealing its contents are not permissible unless this has been expressly approved in writing by HOPPECKE Batterie Systeme GmbH. Infringements will lead to liability for damages.

  • Page 4: Table Of Contents

    Table of Contents USING THIS MANUAL 1.1. Target group of this document 1.2. Means of representation 1.2.1. Icons and signal Words 1.2.2. Graphic symbols / pictograms on the battery system 1.3. Notation of nominal data 1.4. Abbreviations and glossary of terms SAFETY INSTRUCTIONS 2.1.
  • Page 5 NOTES ON STORAGE 7.1. Storage with permanent float charge 7.2. Storage with regularly recharge 7.3. Storage with built-in battery ASSEMBLY / COMMISSIONING MAINTENANCE 9.1. Preventive maintenance 9.1.1. Visual inspection of the battery 9.1.2. Measurement of the charging voltage 9.1.3. Cleaning the battery 9.1.4.

  • Page 6: Using This Manual

    This operating and installation manual is intended to assist with the optimal operation of the HOPPECKE rail.power blocks/cells used, as well as their installation and maintenance. This is the only way in which a maximum service life can be achieved.

  • Page 7: Graphic Symbols / Pictograms On The Battery System

    Using this manual 1.2.2. 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...

  • Page 8: Notation Of Nominal Data

    The CAS number (also called CAS registration number and CAS registry number, CAS = Chemical Abstracts Service) is an international identification standard for chemical substances. Electrolyte HOPPECKE rail.power blocks are valve-regulated lead-acid batteries. When handled correctly, rail.power batteries are safe and contact with the electrolyte is not possible. Batteries_Rail_Power_Manual_en02.docx...

  • Page 9: Safety Instructions

    Safety instructions Safety instructions Observe the following safety instructions when handling the batteries and their components. 2.1. Potential hazards 2.1.1. Explosive gas mixture Each time the batteries are charged, water is decomposed. This can form a hydrogen- oxygen gas mixture (oxyhydrogen gas), which explodes even at low energy input. There is danger through: •...

  • Page 10: Electrical Voltage

    Safety instructions 2.1.2. Electrical voltage Metal parts of the batteries are always live. High currents flow in the event of a short circuit. There is danger from: • Voltages • Electric shocks There is an immediate, high risk situation which, if not avoided, will result in death or serious injury.

  • Page 11: Toxic Substances

    REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) In accordance with the REACH regulation, we point out that HOPPECKE rail.power blocks/cells contain the SVHC substance lead metal (CAS.No. 7436-92-1) with more than 0.1 % by weight (SVHC = Substance of Very High Concern).

  • Page 12: Fire

    Safety instructions 2.1.5. Fire In the event of fire there is danger from: • Hot or molten substances • Short circuits • Open flames / fire, embers and sparks • Hot surfaces with temperatures above 300 °C There is an immediate, high risk situation which, if not avoided, will result in death or serious injury.

  • Page 13: Notes On Disassembly

    Safety instructions 2.1.7. Notes on disassembly If the connecting cables have not been disconnected before replacing the batteries, there is a risk of electric shock. There is an immediate, high risk situation which, if not avoided, will result in death or serious injury.

  • Page 14: Use Of The Product

    The improper use of the batteries can lead to personal injury 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.

  • Page 15: Directives, Legislation And Standards

    Directives, legislation and standards Directives, legislation and standards Please observe the latest edition of the following rules and regulations: • Accident prevention regulations • ISO 20345:2011 ("Personal safety gear – Safety boots") • DIN VDE 0105-103 (2014-10) ("Operation of electrical equipment"), in particular, governs the requirements for quality and qualification for working on electrical equipment (0105- 100) and on electrical equipment for railways (0105-103).

  • Page 16: Function And Structure

    (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: Opening for mounting a...

  • Page 17: Charging Methods For Rail. Power Blocks/Cells

    (dehydration). In accordance with the limited charging time in practice, HOPPECKE recommends a reduced state of charge of approx. 90% of the nominal capacity. For extreme applications (very high or very low temperatures, cyclical use) this value may be lower.

  • Page 18: Two-Stage Charging With Constant Current, Constant Voltage (Iu0U)

    Function and structure 5.3.2. Two-stage charging with constant current, constant voltage (IU0U) The two-stage charging process (IU0U) initially works according to the same principle as the single-stage charging process. First the current is limited, then the voltage is kept constant when a certain value is reached.

  • Page 19: Technical Data

    Function and structure 5.4. Technical data 5.4.1. Overview rail.power blocks/cells The following table shows an overview of the available rail.power blocks/cells: Designation Type Voltage Capacity Length Width Height Weigth Housing [Ah] [mm] [mm] [mm] [kg] material rail.power 12 V 58 Ah VRLA 23.0 rail.power 12 V 78 Ah...

  • Page 20: Battery Charging Characteristics

    Function and structure 5.4.3. Battery charging characteristics Like all chemical reactions, the charge / discharge processes in the cell are subject to a temperature effect. In general, chemical reactions run faster with rising temperature and slower with falling temperature. For this reason, temperature compensation is used for the charging voltage.

  • Page 21: Two Stage, Temperature Compensated Charging (Iu0U-Charging)

    Function and structure 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 if the battery charger is measuring temperatures above +80 °C or below -50 °C.
  • Page 22 Function and structure The switchover from the low voltage level (float charge) to the higher voltage level (boost charge) takes place when the charge current I is exceeded. The switchover from the higher voltage level (boost charge) to the lower voltage (float charge) takes place when the charge current falls below the same I To avoid battery damage, it is necessary to switch from boost charging to float charging at battery temperatures ≥...

  • Page 23: Notes For Transport

    Notes for transport Notes for transport Observe the regulations for the transport of batteries, which are specified in the following sections. Note Follow the safety instructions, see 2 Safety instructions on page 9. 6.1. Transportation of undamaged batteries Filled batteries are not defined as dangerous goods if all following points apply: •...

  • Page 24: Transportation Of Damaged Batteries

    If you follow the instructions of charging during storage, the battery system is always ready to use. The service life of the battery system begins with the delivery ex works from HOPPECKE. Storage periods must be taken into consideration in their entirety for the service life duration.

  • Page 25: Storage With Permanent Float Charge

    Notes on storage Note A too high storage temperature leads to faster self-discharge and a premature ageing of the battery system. The storage temperature must be in the range 0 °C … +40 °C. The optimum storage temperature is in the range +10 °C … +20 °C. 7.1.

  • Page 26: Storage With Built-In Battery

    Notes on storage 7.3. Storage with built-in battery Note Ideally, the battery should be stored separately from the vehicle in a clean, dry and frost-free room. If it is not possible to separate the battery from the vehicle and the vehicle is parked, make sure the battery will not deep discharge.

  • Page 27: Assembly / Commissioning

    Assembly / commissioning Assembly / commissioning Target: The battery is connected for use in the vehicle. Note Follow the safety instructions, see 2 Safety instructions on page 9. DANGER! Danger due to a short circuit between the positive and negative pole of a battery. If the positive and negative terminals of a battery are short-circuited, there is a risk of overheating and explosion.
  • Page 28 Assembly / commissioning Note When making the screw connections, observe the tightening torque of 20 Nm. M8 terminal screws with plastic head; Terminal screw M8 Wrench opening 22 mm Spring washer Pole shoe Connector 1. Connect the positive terminal of the battery to the positive terminal of the on-board power supply or charger.

  • Page 29: Maintenance

    Follow the safety instructions, see 2 Safety instructions on page 9. Have the batteries serviced regularly and properly by HOPPECKE qualified personnel or personnel authorised by HOPPECKE Batterie Systeme GmbH. To ensure the optimal state of the battery system, follow the maintenance plan:...

  • Page 30: Visual Inspection Of The Battery

    Clear the ventilation openings. free passage. Mechanical damage Check battery and container Contact the depot manager or the for mechanical damage. HOPPECKE Service Tight fit of connectors, Connectors, screws, cables Tighten connectors, screws, screws and cables must not be loose.

  • Page 31: Measurement Of The Charging Voltage

    Maintenance 9.1.2. Measurement of the charging voltage Target: The charging voltage of the battery is measured and checked. The measurement of the voltages is used for error detection. Logging the measured voltages helps here. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design.

  • Page 32: Cleaning The Battery

    Maintenance Example for a rail.power Cell: For Boost Charge a cell voltage of 2.35 V at 20 °C has to be measured. 5. Enter your activities in a maintenance protocol, see 13.2 Maintenance protocol on page Result: The charging voltage of the battery was measured and checked. 9.1.3.

  • Page 33: Measuring The Insulation Resistance

    Note For rail.power batteries, an insulation measuring instrument with a test voltage of 500 V must be used. Use a suitable measuring device, e.g. Fluke 1507 (HOPPECKE Mat.nr.: 4141201237), with the settings 500 V/DC. CAUTION! Risk of damage to the on-board network of the vehicle.
  • Page 34 32). 6. Measure insulation resistances again according to steps 2 and 3. Note If the isolation test fails again, contact HOPPECKE service. 7. Enter your activities in a maintenance protocol, see 13.2 Maintenance protocol on page Result: The insulation resistance of the battery is now measured.

  • Page 35: Measuring The Open-Circuit Voltage On Each Battery Block/Cell

    Repeat the measurement 4 hours after charging is complete. If the block/cell is then noticeable again, the entire battery must be replaced or you can contact HOPPECKE Service 3. Enter your activities in a maintenance protocol, see 13.2 Maintenance protocol on page Result: The open circuit voltages at each block/cell were measured.

  • Page 36: Corrective Maintenance

    Maintenance 9.2. Corrective maintenance Note Follow the safety instructions, see 2 Safety instructions on page 9. 9.2.1. Exchange of rail.power blocks/cells Target: rail.power blocks/cells are exchanged. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design.
  • Page 37 2 years old can be replaced by new rail.power blocks/cells • If the rail.power block/cell to be replaced is 2 years old or older, please contact the HOPPECKE service department. • If rail.power blocks/cells are defective, you can replace a maximum of 12% of the blocks/cells of the entire battery.

  • Page 38: Exchanging A Cell Connector

    Maintenance Note Note The pole screws M8 with plastic head must be replaced by new ones because the screw connection is secured with a micro-encapsulated adhesive. For connections with M8 pole screws without plastic head, you can reuse the screws, but must use new spring washers.

  • Page 39: Exchange Of The Temperature Sensor

    Maintenance Note Note The pole screws M8 with plastic head must be replaced by new ones because the screw connection is secured with a micro-encapsulated adhesive. For connections with M8 pole screws without plastic head, you can reuse the screws, but must use new spring washers.

  • Page 40: Troubleshooting

    Troubleshooting Troubleshooting Note Follow the safety instructions, see 2 Safety instructions on page 9. 10.1. Insufficient capacity If the capacity of the battery system is too low, proceed as follows: Cause Remedy Loose or oxidised terminal(s) Check all connector(s), replace the connector(s) if required (use new spring washer(s)) Temperature sensor has a defect.

  • Page 41: No Battery Voltage Can Be Measured

    Troubleshooting 10.3. No battery voltage can be measured If no battery voltage can be measured, proceed as follows: Cause Remedy Main plug of the battery system is Connect the main plug not inserted Main plug of the battery system is Replace the main plug defect Cable breakage...

  • Page 42: Disassembly

    Disassembly Disassembly Note Observe the disassembly instructions, see 2.1.7 Notes on disassembly 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.

  • Page 43: Disposal

    Old batteries bearing this sign are 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.

  • Page 44: Appendix

    Appendix Appendix 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) Batteries_Rail_Power_Manual_en02.docx...

  • Page 45: Maintenance Protocol

    Appendix 13.2. Maintenance protocol Hinweis For proof in case of warranty, enter the activities and the measured values in the maintenance log. Serial number of battery system: ___________________________________________ Number of train: ___________________________________________ Date of commissioning: ___________________________________________ 13.2.1. Half yearly maintenance interval 13.2.1.1.

  • Page 46: Yearly Maintenance Interval

    Appendix 13.2.2. Yearly maintenance interval 13.2.2.1. Maintenance - measurement of the charging voltage Interval Voltage Current Temperature Date Inspector (Name) (Years) [°C] 13.2.2.2. Maintenance - cleaning the battery Interval Cleaning - Done Date Inspector (Name) (Years) (mark with cross) 13.2.2.3. Maintenance - measuring the insulation resistance Interval Insulation-...

  • Page 47: Maintenance Interval 4 Years

    Appendix 13.2.3. Maintenance interval 4 years 13.2.3.1. Maintenance - measuring the open-circuit voltage on each battery block / cell Cell / Block No. Open-Circuit voltage *if more than 20 cells / blocks are installed, enlarge the table accordingly Date: ______________________ Inspector: ______________________ Batteries_Rail_Power_Manual_en02.docx...

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