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Hoppecke rail power PzS Assembly & Operating Instructions

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Implementing
Responsible
department:
department:
SVA
SVA
Created/modified (current index):
2024-11-07, W.Pickart
Checked (current index):
2024-11-08, M. Stumpf
Released (current index):
2024-11-08, Dr D. Mahl
rail | power PzS batteries
Operating and assembly instructions
PzS_Rail_allgemein_EN_00.docx
Document type:
Technical documentation
Operating and assembly instructions
File name:
PzS_Rail_allgemein_EN_00.docx
Status
Confidentiality:
Public
Doc. status:
Released
Revision:
Languag
00
e:
EN
Page:
1

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Summary of Contents for Hoppecke rail power PzS

  • Page 1 Implementing Responsible Document type: Status department: department: Technical documentation Confidentiality: Public Created/modified (current index): Doc. status: 2024-11-07, W.Pickart Released Operating and assembly instructions Checked (current index): 2024-11-08, M. Stumpf Released (current index): File name: Revision: Languag Page: 2024-11-08, Dr D. Mahl PzS_Rail_allgemein_EN_00.docx rail | power PzS batteries Operating and assembly instructions...
  • Page 2 Version overview Revision date Status Name Chapter Reason for change 2024-11-07 Created W. Pickart New creation 2024-11-08 Tested M. Stump 2024-11-08 Released Dr D. Mahl PzS_Rail_allgemein_EN_00.docx...
  • Page 3 Please note that the version of the battery manual was up to date at the time of delivery, but the latest version of the manual should still be downloaded from the Hoppecke homepage at: https://www.hoppecke.com/de. This is the only way to ensure that the technical information is up to date.

  • Page 4: Table Of Contents

    Table of contents ABOUT THESE INSTRUCTIONS 1.1. Target group of this document 1.2. Means of presentation 1.2.1. Symbols and signal words 1.2.2. Graphic symbols / pictograms on the battery system 1.3. Notation of nominal data 1.4. Abbreviations and definitions 1.5. Warranty, test reports Maintenance SAFETY INSTRUCTIONS 2.1.
  • Page 5 6.1. Transport of undamaged batteries 6.2. Transport of damaged batteries NOTES ON STORAGE 7.1. Storage period 7.2. Storage with permanent float charge 7.3. Storage with regular recharging 7.4. Storage with built-in battery ASSEMBLY / COMMISSIONING 8.1. Checking the delivery 8.2. Installation and connection MAINTENANCE 9.1.
  • Page 6 13.2.3.1. Maintenance - Measuring the charging voltage 13.2.3.2. Maintenance - Cleaning 13.2.3.3. Maintenance - Measuring the insulation resistance PzS_Rail_allgemein_EN_00.docx...

  • Page 7: About These Instructions

    About these instructions These operating and installation instructions are intended to help you optimise the operation, installation and maintenance of the HOPPECKE rail | power PzS cells used. This is the only way to achieve maximum service life. Contact your local contract partner, •...

  • Page 8: Graphic Symbols / Pictograms On The Battery System

    About these instructions 1.2.2. Graphic symbols / pictograms on the battery system The following graphic symbols are used in these operating and maintenance instructions and on the product: EN ISO 7010 - W012 Warning of electrical voltage EN ISO 7010 - W026 Warning of danger from charging batteries EN ISO 7010 - W023 Warning of corrosive substances...

  • Page 9: Notation Of Nominal Data

    The CAS number (also CAS registration number and CAS registry number, CAS = Chemical Abstracts Service) is an international labelling standard for chemical substances. Electrolyte HOPPECKE rail | power PzS cells are sealed lead-acid batteries with a liquid electrolyte consisting of diluted sulphuric acid. PzS_Rail_allgemein_EN_00.docx...

  • Page 10: Warranty, Test Reports Maintenance

    About these instructions 1.5. Warranty, test reports Maintenance This must be documented as proof that the maintenance has been carried out correctly. 13.2 Maintenance log on page 57 you will find table templates for this documentation. The maintenance documentation must be kept together with the other documentation for the battery/battery system.

  • Page 11: Safety Instructions

    Safety instructions Safety instructions Observe the safety instructions when handling the batteries and their components. Hint When handling batteries and their components, please also observe the information sheets of the ZVEI (German Electrical and Electronic Manufacturers' Association): • Information on the safe handling of lead accumulators (lead batteries) •...
  • Page 12 Safety instructions • Use hand lamps with mains cable without switch (protection class II) or hand lamps with battery (protection class IP54). PzS_Rail_allgemein_EN_00.docx...

  • Page 13: 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: • Tensions • Electric shocks There is an imminent danger with a high risk that will result in death or serious injury if it is not avoided.

  • Page 14: Toxic Substances

    REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals In accordance with the REACH regulation, we would like to point out that HOPPECKE rail | power PzS cells contain the SVHC substance lead metal (CAS.No. 7439-92-1) with more than 0.1 % by weight (SVHC = Substance of Very High Concern).

  • Page 15: Fire

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

  • Page 16: 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 imminent danger with a high risk that will result in death or serious injury if it is not avoided.

  • Page 17: Labelling On The Product

    Use of the product 2.3. Labelling on the product The type plate of a battery is attached to the container for the battery cells (container, trough, carrier). On the type plate you will find the serial number, date of manufacture, type, nominal voltage, number of battery cells and nominal capacity ( ) of the battery.

  • Page 18: Non-Intended Use

    Improper use of the batteries can lead to personal injury and damage to property. HOPPECKE Batterie Systeme GmbH accepts no responsibility or liability for personal injury or damage to property resulting directly or indirectly from handling the batteries if they are not used as intended.

  • Page 19: Directives, Laws And Standards

    Directives, laws and standards Directives, laws and standards Please observe the latest editions of the following regulations: • Accident prevention regulations • DIN EN ISO 20345 ("Personal protective equipment - Safety footwear") • DIN VDE 0105 ("Operation of electrical installations"), regulates in particular the quality and qualification requirements for work on electrical installations (DIN VDE 0105-100) and on railway electrical installations (DIN VDE 0105-103).

  • Page 20: Function And Structure

    | power PzS batteries are available as single cells (2 V). The following picture shows an example of the structure of a HOPPECKE rail | power PzS cell: Hoppecke...

  • Page 21: Charging Procedure For Rail | Power Pzs Cells

    Function and structure 5.3. Charging method for rail | power PzS cells 5.3.1. Single-stage charging with constant current, constant voltage (IU) In this charging process, both the current (I) and the voltage (U) are limited. At the start of charging, the charging current is limited and the charging voltage rises slowly. When a defined voltage is reached, this is kept constant by the charger.

  • Page 22: 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 single-stage charging. First the current is limited, then the voltage is kept constant once a certain value has been reached.

  • Page 23: Technical Data

    Function and structure 5.4. Technical data An overview of the available rail | power PzS cells is available on the Hoppecke website (www.hoppecke.com). 5.4.1. Technical details etails • Cells according to EN 60254 - 2 Construction / Design • HOPPECKE rail | power PzS cells are sealed lead-acid batteries with a liquid electrolyte consisting of diluted sulphuric acid.

  • Page 24: Battery Charging Characteristics

    Function and structure 5.4.3. Battery charging characteristics Like all chemical reactions, the charging/discharging processes in the cell are subject to a temperature effect. In general, chemical reactions are faster when the temperature rises and slower when the temperature falls. For this reason, temperature compensation is used for the charging voltage.
  • Page 25 Function and structure Hint The charging curve describes a wide temperature range (based on EN50547) in order to ensure a safe energy supply to the vehicle by the charger at all times. The specified temperature range is permissible for a few days, but should not be understood as a permanent operating temperature for the battery.

  • Page 26: Two-Stage, Temperature-Compensated Charging (Iu0U Charging)

    Function and structure 5.4.3.2. Two-stage, temperature-compensated charging (IU0U charging) A two-stage charge (constant current / constant voltage) is recommended for rail | power PzS batteries. In addition, a temperature-compensated charging characteristic is required to avoid excessive currents at high ambient temperatures and to fully charge the batteries at low temperatures.
  • Page 27 Function and structure The switchover from the low voltage level (trickle charge) to the higher voltage level (boost charge) takes place when the charging current is exceeded. The switchover from the higher voltage level (high charge) to the lower voltage (trickle charge) takes place when the charge current falls below the same level.

  • Page 28: Instructions For Transport

    Instructions for transport Instructions for transport Observe the regulations for the transport of batteries specified in the following sections. Hint Observe the safety instructions, see 2 Safety on page 6.1. Transport of undamaged battery n Filled batteries are not treated as dangerous goods if all of the following points apply: •...

  • Page 29: Transport Of Damaged Batteries

    Instructions for transport 6.2. Transport of damaged battery n Filled batteries are treated as dangerous goods if one of the following points applies: • Damaged • Leaking • Contaminated by acid The battery must be packed and transported in a container made of stainless steel or solid plastic.

  • Page 30: Notes On Storage

    Notes on storage Notes on storage The service life of the batteries begins with delivery ex works HOPPECKE. The storage times are to be fully counted towards the service life period. Hint Observe the safety instructions, see 2 Safety on page 11.

  • Page 31: Storage Period

    • The service life of the battery(ies) begins with the delivery of the filled and charged batteries ex works HOPPECKE. Storage times are to be fully counted towards the service life. • A storage period of 24 months must not be exceeded.

  • Page 32: Storage With Permanent Float Charge

    Notes on storage 7.2. Storage with permanent float charge The following applies to trickle charging: Charge permanently with current limitation to I5= Cn/5 h with 2.25 V per cell at 20°C ± 5°C. 7.3. Storage with regular recharging The following applies for regular recharging: Charge the battery for 24 hours at a constant voltage with current limitation to Cn/5 h at 2.40 V per cell.

  • Page 33: Assembly / Commissioning

    Assembly / commissioning Assembly / commissioning Objective: The battery is connected for use in the vehicle. Hint Observe the safety instructions, see 2 Safety on page 11. DANGER! Danger due to a short circuit between the positive and negative terminals of a battery. If the positive and negative terminals of a battery are short-circuited, there is a risk of overheating and explosion.

  • Page 34: Checking The Delivery

    • Write a short defect report on the delivery note before you sign it. • Ask the forwarding agent for an inspection and note the name of the inspector. • Draw up a defect report and send it to HOPPECKE Batterie Systeme GmbH and the carrier within 14 days.

  • Page 35: Installation And Connection

    Assembly / commissioning 8.2. Installation and connection Objective: The battery is connected for use in the vehicle. DANGER! Danger due to a short circuit between the positive and negative terminals of a battery. If the positive and negative terminals of a battery are short-circuited, there is a risk of overheating and explosion.
  • Page 36 Assembly / commissioning For delivery of so-called battery kits (cells, connectors, terminal screws): • Install the cells in the battery compartment of the vehicle according to your customer's installation drawing. • Install the connector. • Connect end poles. Hint Cells and ribbed panels are always installed from the outside inwards (and as specified in the construction drawing).
  • Page 37 Assembly / commissioning Hint When making the screw connections, observe the tightening torque of 25 Nm for the M10 terminal screws. 1. Connect the positive terminal of the battery to the positive terminal of the vehicle electrical system or charger. 2.

  • Page 38: Maintenance

    Follow the instructions in chapter 2 Safety on page 11. Have the batteries serviced regularly and properly by HOPPECKE specialist personnel or personnel authorised by HOPPECKE Batterie Systeme GmbH. To ensure that the battery is in optimum condition, follow the maintenance schedule:...

  • Page 39: Visual Inspection Of The Battery

    Battery and container Check the battery and In the event of mechanical container for mechanical damage: Contact the depot damage. manager or HOPPECKE Service. Connectors, screws, cables Connectors, screws and Tighten screws on cables or cables must not be loose. connectors.

  • Page 40: Check Electrolyte Level

    Maintenance 9.1.2. Check electrolyte level Objective: The electrolyte level of the battery cells is checked. 1. Disconnect the battery from the vehicle electrical system. 2. Open the hinged lid plugs. 3. Check the electrolyte level. (The markings for the minimum and maximum fill level can be seen on the inside of the hinged lid plugs, where the upper and lower electrolyte levels are indicated by a dotted line) Basket top...

  • Page 41: Measuring The Charging Voltage

    Maintenance 9.1.3. Measuring the charging voltage Objective: The charging voltage of the battery is measured and checked. The measurement of the voltages is used for fault detection. Logging the measured voltages helps with this. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design.

  • Page 42: Clean Battery

    Maintenance Example of a rail | power PzS cell: A cell voltage of 2.40 V at 20°C must be measured for heavy charging. 5. Note the measured values in the maintenance log, see 13.2 Maintenance log on page Result: The charging voltage of the battery is measured and checked. 9.1.4.

  • Page 43: Measuring The Insulation Resistance

    Hint Use an insulation tester with a test voltage of 500 V for rail | power PzS batteries. Suitable measuring device, e.g. Fluke 1507 (HOPPECKE mat. no.: 4141201237), with the settings 500 V/DC. CAUTION! Risk of damage to the vehicle's electrical system.
  • Page 44 42). 6. Measure the insulation resistances again according to steps 2 and 3. Hint If the insulation test fails again, contact HOPPECKE Service. 7. Enter activities in the maintenance log, see 13.2 Maintenance log on page 57. Result: The insulation resistance of the battery has now been measured.

  • Page 45: Refilling Deionised / Distilled Water

    Maintenance 9.1.6. Refill with deionised / distilled water Objective: The battery is topped up with deionised / distilled water. WARNING! Contact with the electrolyte may occur when checking the electrolyte level. There is a possible medium-risk hazard that could result in death or serious injury if not avoided. The electrolyte can cause severe skin burns and serious eye damage.

  • Page 46: Corrective Maintenance

    Maintenance 9.2. Corrective maintenance Hint Follow the instructions in chapter 2 Safety on page 11. 9.2.1. rail | power PzS cell n replace Target: rail | power PzS cells are replaced. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design.
  • Page 47 Maintenance Hint If rail | power PzS cells are defective, a maximum of 10% of the cells in the entire battery can be replaced. If more cells are defective, all cells must be replaced. Tools required: • Torque spanner with suitable spanner sizes for M10 screws 1.

  • Page 48: Replacing The Connector

    Maintenance 9.2.2. Replace connector Objective: A defective connector is replaced. Tools required: • Torque spanner with suitable spanner sizes 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 fit the pole screws. Hint Replace the M10 pole screws with plastic heads with new ones, as the screw connection is secured with a micro-encapsulated adhesive.

  • Page 49: Replacing The Temperature Sensor

    Maintenance 9.2.3. Replace temperature sensor The temperature sensor is installed as an L-piece in a special pole screw. Objective: A defective temperature sensor is replaced. 1. Disconnect the Cannon plug. 2. Remove the defective temperature sensor by pulling it out of the special pole screw. Temperature sensor Pole screw...

  • Page 50: Sources Of Error

    Error sources Error sources Hint Observe the safety instructions, see 2 Safety on page 11. 10.1. Capacity too low If the battery capacity is too low, proceed as follows: Possible cause Remedy Loosened or oxidised poles Check all connections, replace connectors if necessary (the spring washers must be replaced) Temperature sensor is defective -...

  • Page 51: No Battery Voltage

    Error sources 10.3. No battery voltage If you cannot measure any voltage at the battery, proceed as follows: Possible cause Remedy Battery plug not plugged in Insert battery plug Battery plug defective Replace battery plug Cable break Replace cable Cell connector defective Replace the cell connector (the spring washers must be replaced) 10.4.

  • Page 52: Disassembly / Assembly Of Rail | Power Pzs Cells And Accessories

    Disassembly / assembly of rail | power PzS cells and accessories Disassembly / assembly of rail | power PzS cells and accessories Objective: The rail | power PzS cells are replaced. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design.
  • Page 53 Disassembly / assembly of rail | power PzS cells and accessories 1. Switch off all chargers and consumers on the vehicle. If present, disconnect the battery from the vehicle electrical system and charger using the corresponding isolator switch. 2. Loosen the screws that connect the trough to the container. 3.

  • Page 54: Waste Disposal

    Note Used batteries with this symbol are recyclable economic goods and must be returned to the recycling process. Use the HOPPECKE recycling system. Used batteries are collected and recycled. Contact HOPPECKE Service for further information. Note Dispose of lead batteries that are not recycled as hazardous waste in compliance with all regulations.

  • Page 55: Appendix

    Additional tools for maintenance and service are listed below: Tool Description of the Voltmeter/multimeter (Picture shows an example) Current clamp DC (Picture shows an example) Insulation tester: Fluke 1507 (HOPPECKE mat.no.: 4141201237) Charger/discharger (Picture shows an example) Contact thermometer (Picture shows an example) PzS_Rail_allgemein_EN_00.docx...
  • Page 56 Appendix Fully insulated torque spanner (HOPPECKE mat. no. 4142500121) PzS_Rail_allgemein_EN_00.docx...

  • Page 57: Maintenance Log

    Appendix 13.2. Maintenance log Hint Enter the activities and the measured values in the maintenance log as proof in the event of a warranty claim. Seriennummer des Batteriesystems :___________________________________________ Number of the train: ___________________________________________ Date of commissioning: ___________________________________________ PzS_Rail_allgemein_EN_00.docx...

  • Page 58: Quarterly Maintenance Interval

    Appendix 13.2.1. Quarterly maintenance interval 13.2.1.1. Maintenance - visual inspection of the entire battery system Interval Visual inspection date Auditor (name) (years) Done (tick the appropriate box) 0,25 0,75 1,25 1,75 2,25 2,75 3,25 3,75 4,25 4,75 5,25 5,75 6,25 6,75 PzS_Rail_allgemein_EN_00.docx...

  • Page 59: Maintenance - Checking The Electrolyte Level

    Appendix 13.2.1.2. Maintenance - Check electrolyte level Interval Electrolyte level date Auditor (name) (years) checked (tick) 0,25 0,75 1,25 1,75 2,25 2,75 3,25 3,75 4,25 4,75 5,25 5,75 6,25 6,75 PzS_Rail_allgemein_EN_00.docx...

  • Page 60: Half-Yearly Maintenance Interval

    Appendix 13.2.2. Half-yearly maintenance interval 13.2.2.1. Maintenance - Refilling deionised / distilled water Interval Top up with date Auditor (name) (years) water - Done (tick the appropriate box) PzS_Rail_allgemein_EN_00.docx...

  • Page 61: Annual Maintenance Interval

    Appendix 13.2.3. Annual maintenance interval 13.2.3.1. Maintenance - Measuring the charging voltage Interval Voltage Current Temperature date Auditor (name) (years) [°C] 13.2.3.2. Maintenance - Cleaning Interval Cleaning - Done date Auditor (name) (years) (tick the appropriate box) 13.2.3.3. Maintenance - Measuring the insulation resistance Interval Insulation date...

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