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Operation Manual for Rolling Stock VRLA TPPL+Sn Single cells:
Concern:
ZeMa200P18, ZeMa270P12, ZeMa340P12 and ZeMa450P21
Author:
Gordon Babock
Global Product Manager MP Specialties
File:
EMEA-EN-OM-2VZeMa-CELLS-0123
Rail Engineering
Dieckstrasse 42
DE-58089 Hagen
Operation Manual
for 2V ZeMa Cells
www.enersys.com
Tel. +49 (0) 2331/372 591
Fax +49 (0) 2331/372 804
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Table of Contents
Related Manuals for EnerSys ZeMa200P18
Summary of Contents for EnerSys ZeMa200P18
- Page 1 Operation Manual for 2V ZeMa Cells Operation Manual for Rolling Stock VRLA TPPL+Sn Single cells: Concern: ZeMa200P18, ZeMa270P12, ZeMa340P12 and ZeMa450P21 Author: Gordon Babock Global Product Manager MP Specialties File: EMEA-EN-OM-2VZeMa-CELLS-0123 Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42...
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Page 2: Table Of Contents
Document History Remark on the Classification Appendices Appendix A6: Decision tree for analysis of voltage deviations (2V ZeMaRail monoblocs and cells under continuous charge) Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 3: About This Document
Depth of Discharge Negative Temperature Coefficient Open Circuit Voltage TPPL Thin Plate Pure Lead (EnerSys Technology) TPPL+Sn Thin Plate Pure Lead with PbSn (EnerSys Technology) State of charge Volt per cell VRLA Valve Regulated Lead Acid (battery) Fire protection classification acc. UL-94 or EN 60695-11-10... -
Page 4: Reference Documents
Batteries for auxiliary power supply systems» Leaflet Information for the Safe Handling of Lead-Acid Batteries (EnerSys, Dec_2016) Safety General Safety information Operation manual, nameplate and warning signs etc. must always be kept at the plant site and if possible made clearly visible in the battery compartment. - Page 5 To eliminate security risks, the ventilation requirements of EN 62485-2 : 2019 «Safety requirements for secondary batteries and battery installations. Stationary batteries» must be respected. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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Page 6: Intended Use
Leaflet "Information for the safe handling of lead-acid batteries" For more information on safe handling of lead-acid batteries please read the current EnerSys Information Leaflet "Instructions for the Safe handling of Lead-Acid Batteries". This guidance note provides advice and assistance for compliance with the statutory requirements. -
Page 7: Product Description
V-0 (UL 94), I3 / F2 (NF F 16-101) Shock and Vibration : Category 1, Class B (EN 61373) The single cells are delivered charged and ready for use. 3.1.2 Technical Data: Rolling Stock Single Cells ZeMa200P18 Rated Capacity : 208 Ah C Part number : SR70770206... -
Page 8: Illustration And Parts Of A Cell
Figure 1 : Parts of a 2V ZeMaRail Single Cell Pos. Subject Quantity Cell case Cell lid Terminals Flame barrier at vents Type label Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 9: Charge And Discharge Parameters
The state of charge is also to be monitored during the storage of the battery. Possibly you might hold it at full charge by a workshop charger operating with float voltage. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 10: Transport And Storage
The chart below shows the relationship between open-circuit voltages (OCV) and storage time at various temperatures: Figure 2 : Self-discharge: OCV per cell representing approx. % of SOC Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... - Page 11 If the voltage of the individual cells is reduced below 2.02 V, storage damage may have occurred. Before using such batteries, they should be recharged and tested in a workshop. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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Page 12: Mounting
Verify that during operation sufficient air circulation will ensure the dissipation of heat out of the compartment. Check that any ventilation filters are not blocked. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 13: Assembly Inspection, Connection
Fully recharge the battery immediately after the test and hold the battery for at least 48 hours on continuous charge. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 14: Operation
Figure 3 : Operating modes charge-discharge-charge with IU0U charging characteristic Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 15: Charging Of The Rolling Stock Battery
The battery will then get fully charged and a small charging current remains to compensate the self-discharge and recombination. The reference temperature is 20 ° C. Figure 4 : Charging characteristic IU0U charge for ZeMa200P18* Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42... - Page 16 Released by: - Index: _- Distributed to: customer (public) Pages: 16/35 This document is uncontrolled when printed. For the most current and official copy, check the server. Parameter ZeMa200P18* Cell 2V Battery 24V 108V 20°C Max. charging current* 80 A Boost level voltage U 2.40 V...
- Page 17 Practical tests show that an increase of 10 °C of the battery temperature from the nominal temperature of 20 °C causes a 50% reduction on service life. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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Page 18: Battery Operation
For a long lasting hassle-free operation it is important that the charging technology is correctly parametered to the operating conditions. Make yourself familiar with the Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 19: Inspection
Check the setting of the voltage controller of the charger every 6 to 12 months. Integrate this test in an inspection modus with an appropriate interval. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... - Page 20 This may indicate that there is an internal short circuit in one of the cells. During the service life expect higher cell voltage values to decline. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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Page 21: Cleaning And Visual Inspection
Take care that there is no water in the screw heads of the connectors and that the battery is thoroughly dry before re-commissioning. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 22: Capacity Test
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 Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 23: Replacement Of The Battery
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 (ZeMa200P18*: 20.8 A) and the trickle charging voltage of 2.29 Vpc. Rail Engineering Tel. - Page 24 The procedure applies for a limited period a small charging current (<10% I to the series-connected 2V cells. During this charge with constant-current the voltage limit is increased to 2.8 Vpc. Charging Equalization charge Duration current System ZeMa200P18 max. 2.08A ZeMa270P12 max. 2.70A max. 10 h 33.6V ZeMa340P18 max. 3.70A ZeMa450P21 max.
- Page 25 Recharge a completely discharged battery as soon as possible in the workshop at 20°C with a reduced current of I (ZeMa200P18*: 9.8 A) for 26 hours. Limit the charge voltage to 2.35 Vpc: After this step adjust the charging rectifier back to trickle charging voltage of 2.29 Vpc. A subsequent recharging for at least 72 hours will help to maintain the electrochemistry of your battery.
- Page 26 Pay attention to safe installation and use only suitable handling equipment and hoists. Special care is required when the battery tray has cracks or mechanical damages. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
- Page 27 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, 25.0 ± 0.9 ZeMa340P12, ZeMa450P21 The terminal screws should be tightened quickly when screwing, otherwise the screw lock cures and ordinary tightening can not be performed.
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Page 28: Decommissioning In The Vehicle
Use insulated tools. 10.1.5 Insulate and secure the connection cables of the vehicle during your work. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 29: Recycling And Disposal
Please contact our point of sale for supporting you in taking back spent batteries and render them to the secondary lead smelters for processing. Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... -
Page 30: Troubleshooting
10 completed days. Rate the cell voltages in accordance with the “Decision tree for analysis of voltage deviations” in 16 “ Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... - Page 31 Follow it to the information in Section 8.1.1 “Checking of charge and cell voltage” Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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Page 32: Validation
(public/restricted/confidential) and may only be disclosed with this note. Observe protective note DIN ISO 16016! © 2023 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. -
Page 33: Appendices
Information for the Safe Handling of Lead-Acid Batteries Title: Information for the Safe Handling of Lead-Acid Batteries File: Information_for_the_Safe_Handling_of_lead-acid_batteries_EN_Dec_2016.pdf 6 pages (First published Jan. 2013) Appendix A2: Data sheet ZeMaRail ZeMa200P18 Title: Data sheet ZeMaRail ZeMa200P18 Hawker_ZeMaRail_ZeMa200P18_Brochure_01_EN_2021-03-V2.pdf File: 4 pages, download from www.enersys.com... -
Page 34: Appendix A6: Decision Tree For Analysis Of Voltage Deviations (2V Zemarail Monoblocs And Cells Under Continuous Charge)
This document is uncontrolled when printed. For the most current and official copy, check the server. Appendix A6: Decision tree for analysis of voltage deviations (2V ZeMaRail monoblocs and cells under continuous charge) Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com... - Page 35 This document is uncontrolled when printed. For the most current and official copy, check the server. Appendix A7: Warning & Information signs on the tray Rail Engineering Tel. +49 (0) 2331/372 591 Dieckstrasse 42 Fax +49 (0) 2331/372 804 DE-58089 Hagen www.enersys.com...
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