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Hoppecke Rail Power FNC-HT Operating And Installation Manual

Batteries (high temperature)
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Executive
Responsible
department:
department:
SVA
SVA
Created/changed (current index):
2025-05-05, W. Pickart
Checked (current index):
2025-05-07, I. Fuhrmann
Approved (current index):
2025-05-09, Dr. D. Mahl
Batteries rail | power FNC-HT (High Temperature)
Operating and Installation Manual
FNC_Rail_HT_Manual_en04.docx
Document type:
Technical Documentation
Operating and Installation Manual
File name:
FNC_Rail_HT_Manual_en04.docx
State of
confidentiality:
External
Document state:
Approved
Revision:
Language:
04
EN
Page:
1

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  • Page 1 Executive Responsible Document type: State of department: department: confidentiality: Technical Documentation External Created/changed (current index): Document state: 2025-05-05, W. Pickart Approved Operating and Installation Manual Checked (current index): 2025-05-07, I. Fuhrmann Approved (current index): File name: Revision: Language: Page: 2025-05-09, Dr. D. Mahl FNC_Rail_HT_Manual_en04.docx Batteries rail | power FNC-HT (High Temperature) Operating and Installation Manual...
  • Page 2 I. Fuhrmann environmental conditions 2024-05-03 Approved Dr. D. Mahl • 9.1.7.1 • Introduction of the new 13.1 degassing tube (Hoppecke Mat.-No. 4143180110) • 9.2.1 • Wording changed from 9.2.3 washer to spring washer and screw exchange removed • 9.2.1.2 • Sequence of action instruction changed •...
  • 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. Icons and signal words 1.3. Notation of nominal data 1.4. Graphic symbols / pictograms on the battery system 1.5. Nameplate information on the product 1.6. Definitions of terms 1.7.
  • Page 5 5.8. Alternating portion of the charging current INSTRUCTIONS FOR TRANSPORT 6.1. Surface transport (Road/Rail) according to ADR/RID 6.2. Transport by sea according to the IMDG Code 6.3. Air freight STORAGE INSTRUCTIONS 7.1. General instructions 7.2. Storage period 7.3. Storage with built-in battery COMMISSIONING/INSTALLATION 8.1.
  • Page 6 Assembly of new rail | power FNC-HT cells and accessories DISPOSAL APPENDIX 13.1. Additional tools 13.2. Commissioning protocol for HOPPECKE rail | power FNC-HT batteries 13.3. Maintenance protocol for HOPPECKE rail | power FNC-HT batteries 13.3.1. Half-yearly maintenance interval 13.3.1.1. Maintenance - Visual inspection of the battery system 13.3.1.2.

  • Page 7: Using This Manual

    This operating and installation manual is intended to assist with the optimal operation of the HOPPECKE nickel-cadmium batteries used, as well as their installation and maintenance. This is the only way in which a maximum service life can be achieved.

  • Page 8: Notation Of Nominal Data

    Using this manual 1.3. Notation of nominal data Nominal battery data is used in accordance with the following notation in this operation and installation manual: Notation Meaning Value Nominal voltage 1.2 V multiplied by the number of cells connected in series Nominal capacity (according to IEC EN 60623)

  • Page 9: Graphic Symbols / Pictograms On The Battery System

    Using this manual 1.4. 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 10: Nameplate Information On The Product

    Using this manual 1.5. Nameplate information on the product The nameplate of a battery is attached to the container for the battery cells (container, tray, carrier). On the nameplate you will find the type, the rated voltage, the number of battery cells and the nominal capacity (C ) of the battery.

  • Page 11: Definitions Of Terms

    Using this manual 1.6. Definitions of terms The following table explains the terms used in these operating and maintenance instructions: Abbreviation/Term Description Reconditioning Describes the defined discharge and subsequent charging of the battery with constant current. This can be used to eliminate or reduce operational capacity losses of the battery system.

  • Page 12: 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 ignites even at low energy levels. There is danger through: •...

  • 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: • Voltages • Electric shocks There is an immediate, high risk situation which, if not avoided, will result in death or serious injury.

  • Page 14: Electrolyte

    Safety instructions 2.1.3. Electrolyte rail | power FNC-HT cells are NiCd cells and contain natrium hydroxide (NaOH) as electrolyte with an addition of lithium hydroxide (LiOH). The following hazards exist: • When working on open rail | power FNC-HT cells, contact with the electrolyte may occur. •...

  • Page 15: Toxic Substances

    Safety instructions 2.1.4. Toxic substances Nickel-cadmium batteries contain toxic substances: • Battery cells contain more than 0.1% cadmium (Cd) There is a low-risk hazard which, if not avoided, could result in minor or moderate injury. Measures to avert the danger: •...

  • Page 16: Improper Transport

    Safety instructions 2.1.6. Improper transport The batteries may be damaged during improper transport. Falling batteries can cause personal injury. If the batteries are transported improperly, there is a risk of damage: • Suspended loads • Dropping batteries or parts of batteries •...

  • Page 17: Personal Protective Equipment

    Safety instructions 2.2. Personal protective equipment Always when working on the batteries and their components: • Wear safety goggles • Wear protective gloves • Wear protective clothing, preferably made of cotton, to avoid electrostatic charging of clothing and body • Wear safety shoes In the event of an accident, injuries can thus be prevented or at least the consequences of injury mitigated.

  • Page 18: 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 19: Directives, Legislation And Standards

    Directives, legislation and standards Directives, legislation and standards Observe the latest edition of the following rules and regulations: • Accident prevention regulations, especially DGUV Regulation 1: Accident prevention regulation; Principles of prevention • DIN EN ISO 20345 ("Personal safety gear – Safety boots") •...

  • Page 20: Function And Structure

    Function and structure Function and structure 5.1. Battery Batteries are interconnected from rail | power FNC-HT cells and used in rail vehicles. Here they fulfil one or more of the following functions: • - Buffering and supply of the low-voltage vehicle electrical system •...
  • Page 21 Function and structure The following drawing shows the internal structure of a rail | power FNC-HT cell: 1 - Positive terminal 8 - Negative electrode stack 2 - Negative terminal 9 - Positive electrode stack 3 - Cell container 10 - Positive fiber structure electrode 4 - Cell lid 11 - Tab 5 - Vent plug...

  • Page 22: Center Of Gravity Of The Battery

    Function and structure 5.3. Center of gravity of the battery Note Take the centre of gravity of the battery into account for all mechanical movements (e.g. lifting, forklift transport, etc.). 5.4. Environmental conditions for FNC rail cells Environmental conditions according to Description EN 50125-1 •...
  • Page 23 Function and structure Note For water refilling with a water refill system, refer to the separate document: D00001-300-en<version number>-Water-Refilling.pdf Note The hosing of the water refill system must follow the potential of the electrical wiring of the battery in accordance with EN 62485-3 in order to reduce the occurrence of leakage currents. See also the project-specific technical drawings of the water refill system.

  • Page 24: Charging Procedures For Rail | Power Fnc-Ht Cells

    Function and structure 5.6. Charging procedures for rail | power FNC-HT cells 5.6.1. Charging with constant current (I) With this charging method, the cell is charged with the constant current I /5h. The charging voltage is not limited. However, there is a time limit so that a defined capacity is charged into the cell.

  • Page 25: Single-Stage Charging With Constant Current, Constant Voltage (Iu)

    Function and structure 5.6.2. Single-stage charging with constant current, constant voltage (IU) This charging method limits both the current (I) and the voltage (U). At the beginning of charging, the charging current is limited and the charging voltage rises slowly. When a defined voltage is reached, it is kept constant by the charger.

  • Page 26: Two-Stage Charging With Constant Current, Constant Voltage (Iu0U)

    Function and structure 5.6.3. 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 27: Temperature Compensation

    Function and structure 5.7. Temperature compensation Like all chemical reactions, the charging and 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 28 The following figure shows the charging voltage per cell connected in series as a function of the battery temperature monitored by the charger (IU characteristic). Temperature compensated charge -3 mV/°C/cell starting from 20 °C for HOPPECKE NiCd batteries 1-stage constant voltage charge with current limitation: Charging Voltage at 20°...
  • Page 29 The following figure shows the charging voltage per cell connected in series as a function of the battery temperature monitored by the charger (IU characteristic). Temperature compensated charge -3 mV/°C/cell starting from 20 °C for HOPPECKE NiCd batteries 2-stage constant voltage charge with current limitation: Switchover from Boost Charge to Float Charge at I ≤...

  • Page 30: Alternating Portion Of The Charging Current

    Function and structure Note You can assume that the temperature probe of the battery system is defect, if the on-board charger device detects temperatures above +80 °C or below -50 °C. You have to set the on-board charging device in such a way, that the charging voltage not exceeds the float charge voltage at 60°C.

  • Page 31: Instructions For Transport

    Instructions for transport Instructions for transport Observe the regulations for the transport of batteries specified in the following sections. Note Observe the safety instructions, see 2 Safety instructions on page 6.1. Surface transport (Road/Rail) according to ADR/RID Filled batteries having the UN numbers 2795 (batteries/rechargeable batteries, wet, filled with alkalis) are not classified as hazardous goods requiring declaration during transport, if the following requirements are met (according to the ADR special regulation 598, section 3.3):...

  • Page 32: Air Freight

    Not assigned to any packaging group Hazard label Packing instruction Storage instructions The service life of the batteries begins with delivery ex works HOPPECKE. Storage periods must be taken into consideration in their entirety for the service life duration. Note Observe the safety instructions, see 2 Safety instructions on page 7.1.

  • Page 33: Storage Period

    Storage instructions 7.2. Storage period Note The storage life of the battery must not exceed three months after manufacture. If the expected storage life exceeds three months, discharge the battery as described below. The battery system prepared in this way can be stored for three years. The date of manufacture of the FNC rail cells can be specified in 2 different ways: •...
  • Page 34 Storage instructions Steps to prepare the storage of the battery: Target: The battery is prepared for storage. 1. If the battery was supplied with yellow transport plugs, replace them with water refill plugs or vent plugs. 2. Discharge the battery using a charger/discharger with rated current I (= C / 5h).

  • Page 35: Storage With Built-In Battery

    Storage instructions 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 36: Commissioning/Installation

    Commissioning/Installation Commissioning/Installation Note Observe the safety instructions, see 2 Safety instructions on page Note Batteries can be supplied in various ways: • Individual cells with connectors and other accessories for installation by the customer. • Individual carriers installed by the customer in the battery compartment of the vehicle. The cells are already assembled in the carriers.
  • Page 37 Commissioning/Installation CAUTION! For the delivery of so-called battery kits with installation by the customer, observe the following points regarding the installation situation: • The FNC rail cells must be installed with a press fit in the carrier/container before they are put into operation.
  • Page 38 Commissioning/Installation The date of manufacture of the FNC rail cells can be specified in 2 different ways: • Production date until CW 15/2024 Note The date of manufacture of the FNC rail cells is stamped on the tops of each cell. Each cell has a 9-digit cell code on top of the cell lid.

  • Page 39: Checking The Delivery

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

  • Page 40: Measures Prior To Initial Commissioning

    Preparation Note Accessories such as glass tubes for determining the filling level, equipment for refilling water and chargers are part of the range of accessories offered by HOPPECKE Batterie Systeme GmbH. 8.2.1.1. Replacing the battery cell transport plugs When the batteries are delivered, the cells can be sealed with one of the following plug...

  • Page 41: Preparation Of Batteries With Unfilled Cells

    6. Let the battery rest for 12 hours. 7. Remove the hinged lid plugs or the water refilling system. 8. Mount the gas venting tubes (Hoppecke material number 4143180110) on each cell. 9. Charge the battery with the constant current I for 7.5 hours.
  • Page 42 Maximum electrolyte level according to measuring glass tube [mm] 36 ± 2 (3.5 rings) Note The electrolyte levels of the cells can be checked with the Hoppecke measuring glass tube (Mat- No.: 4144140010), see 9.1.2 Checking the electrolyte level on page 53.

  • Page 43: Commissioning Charge

    Commissioning/Installation 8.2.2. Commissioning charge Note • Batteries with unfilled cells must always receive an initial charge after filling. Cells delivered uncharged must also receive a commissioning charge. • Otherwise the following applies: If commissioning is carried out up to 3 months after the date of manufacture, the measures described here are not necessary.
  • Page 44 Commissioning/Installation DANGER! Explosion hazard due to formation of oxyhydrogen gas! When the cells are charged, water is decomposed and a hydrogen-oxygen gas mixture (oxyhydrogen gas) is formed, which explodes even at low energy input. Keep any ignition source away from the battery: •...

  • Page 45: Preparation

    3. Measure the individual cell voltages with a digital multimeter and record the values in a test report. Note If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE Service. 4. Insert a gas venting tube (HOPPECKE material number: 4143180110) on each rail | power FNC-HT cell.

  • Page 46: Execution

    Commissioning/Installation 8.2.2.2. Execution Target: The cells are set to the charged state. Note Steps 1 and 2 do not apply if the battery was purchased uncharged or if it was discharged beforehand in accordance with 7.2 Storage period on page 1.

  • Page 47: Follow-Up Work

    Target: After charging, the cells are made ready for operation again. 1. . Remove the gas venting tubes. 2. Measure the electrolyte level in each cell with the measuring glass tube (HOPPECKE material number: 4144140010). - Keep the upper opening of the measuring glass tube free and insert it into the cell until it encounters resistance.

  • Page 48: Installation And Connection

    Commissioning/Installation 8.3. Installation and connection Target: The battery is connected for use in the vehicle. DANGER! Danger of 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 49 Commissioning/Installation In case of 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 connectors. • Connect the end terminals. Note The installation of cells and ribbed panels is always carried out from the outside to the inside (and as specified in the construction drawing).

  • Page 50: Recommissioning After Test Or Parking Operation

    Commissioning/Installation Note Observe the tightening torque when making the screw connections. • M8 torque: 20 Nm ± 1 Nm • M10 torque: 25 Nm ± 1 Nm • Use new spring washers. 1. Connect the positive terminal of the battery to the positive terminal of the on-board power supply or charger.

  • Page 51: Maintenance

    *) Intervals may vary depending on the project and/or the ambient temperature. Note In the event of a warranty claim, enter the activities and the measured values in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. FNC_Rail_HT_Manual_en04.docx...

  • Page 52: Perform Visual Inspection

    The seals of the container, if Replace damaged seals. any, must not show any mechanical damage. 2. Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. Result: The visual inspection was completed. FNC_Rail_HT_Manual_en04.docx...

  • Page 53: Checking The Electrolyte Level

    (PP) and polyethersulfone vessels (PES), individual electrolyte levels may not be visible due to the installation situation. In these cases, the measuring glass tube available from HOPPECKE (material number: 4144140010) must be used as an aid for electrolyte level control.
  • Page 54 4. Close the vent plug again or insert the water refill plug again. 5. Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. Result: Now the electrolyte level of the battery cells has been checked.

  • Page 55: Measuring The Charging Voltage

    Maintenance 9.1.3. Measuring the charging voltage Target: The charging voltage of the battery is checked by measurement. The controlled system temperature sensor-charger-battery is checked here. The measurement and logging of the measured charging voltage is used for error detection. For this purpose, the charging voltage is measured in float charge or boost charge and compared with the setpoint value.
  • Page 56 If the measured voltage deviates from the setpoint by more than ± 1.5%, troubleshoot the temperature sensor or charger. 5. Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. Result: The charging voltage of the battery has been checked. FNC_Rail_HT_Manual_en04.docx...

  • Page 57: Fill Up The Electrolyte Level With Distilled Water

    Maintenance 9.1.4. Fill up the electrolyte level with distilled water Target: The battery is refilled with distilled water. WARNING! When checking the electrolyte level, contact with the electrolyte may occur. There is a potentially hazardous medium-risk situation which, if not avoided, could result in death or serious injury.

  • Page 58: Fill Up Distilled Water Manually

    Fill up distilled water with the central water refill system. Instructions are described in the following document: D00001-300-en<version number>-Water-Refilling.pdf Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. FNC_Rail_HT_Manual_en04.docx...

  • Page 59: Refill Distilled Water With The Water Refill Cart For Single Cells

    Refill distilled water with the single cell water refill cart. Instructions are described in the following document: D00003-300-en<Version number>_Manual_SemiAutomaticWaterfilling.pdf Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. FNC_Rail_HT_Manual_en04.docx...

  • Page 60: Cleaning The Battery

    Any liquids which entered the battery tray must be extracted and disposed of in accordance with waste monitoring guidelines. 3. Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. Result: The battery is now cleaned. FNC_Rail_HT_Manual_en04.docx...

  • Page 61: Testing The Insulation Resistance

    Note For rail | power FNC-HT batteries, an insulation test 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 setting 500 V/DC CAUTION! Risk of damage to the on-board network of the vehicle.
  • Page 62 60). 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 report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101.

  • Page 63: Reconditioning

    Maintenance 9.1.7. Reconditioning Reconditioning can eliminate or reduce capacity losses of a battery system. It is carried out by repeatedly discharging/charging of the battery system with constant current. DANGER! Danger of explosion due to formation of oxyhydrogen gas! Water is decomposed during the commissioning charge of the batteries, during reconditioning and during charging in train operation.
  • Page 64 Maintenance For reconditioning, the battery is supplied with an electric charge of 1.5 Cn, where relatively high cell voltages can arise while charging (up to 1.9 V). For example, a battery charging voltage of 152 V may occur with an 80 cell battery. Perform the following activities in the order given here: Activity Description...

  • Page 65: Preparation

    3. Remove the insulation profiles on the connectors. 4. Clean the insulation rails with warm water. 5. Measure the electrolyte level in each cell with the measuring glass tube (HOPPECKE material number: 4144140010). - Keep the upper opening of the measuring glass tube free and insert it into the cell until it encounters resistance.
  • Page 66 7. Measure the individual cell voltages with a digital multimeter and record the values in a maintenance report. Note If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service. 8. Insert a gas venting tube (HOPPECKE material number: 4143180110) on each rail | power FNC-HT cell.

  • Page 67: Execution

    Temperature Check temperature 4. Charge Battery interrupt charging if necessary 5. .Let battery rest for 2h 6. Discharge Battery Contact Hoppecke- Iterations > 5 Service 7.Let battery rest for 4h Discharge Time <= 4,5h? Check temperature Charge Battery interrupt charging if necessary 9.
  • Page 68 If the discharge time is ≤ 4.5 hours, repeat the procedure from point 4. Note If the discharge time is still ≤ 4.5 hours after 5 repetitions of this procedure, contact HOPPECKE service. 8. Charge the battery at constant current I for 7.5 hours.
  • Page 69 Maintenance Note The battery must not exceed a temperature of 45 °C during charging. If a temperature of 45 °C is reached, interrupt charging. Note the remaining charging time. Do not continue charging until the cell temperature has dropped to 25 °C. Complete the charging time of 7.5 hours after the battery has cooled down.

  • Page 70: Follow-Up Work

    10. Enter your activities in a maintenance report, see 13.3 Maintenance protocol for HOPPECKE rail | power FNC-HT batteries on page 101. Result: The cells are now ready for operation again and can be installed in the vehicle.

  • Page 71: Corrective Maintenance

    Maintenance 9.2. Corrective maintenance Note Observe the safety instructions, see 2 Safety instructions on page 9.2.1. Change of rail | power FNC-HT cells DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design. There is an immediate, high-risk hazard which, if not avoided, will result in death or serious injury.
  • Page 72 Maintenance Note The mixing of cells from different used batteries into one total battery is not allowed. The exchange cells must be cells in a charged state. The lid code of the cells must be observed: • If the cells have been manufactured within the last 3 months, no commissioning charge is required.

  • Page 73: Prepare The Rail | Power Fnc-Ht Cell(S) To Be Replaced

    1. Measure the individual cell voltages of the exchange cells with a digital multimeter and record the values in a test report. Note If the open-circuit voltage of a cell < 1.2 V, contact the HOPPECKE service. 2. Connect exchange cells in series with suitable connecting cables or cell connectors. Note Use a suitable cable to connect the cells: •...

  • Page 74: Replace One Or More Rail | Power Fnc-Ht Cell(S)

    Maintenance 5. Discharge exchange cells using the discharger with rated current I until the voltage has dropped to 1.0 V per cell. 6. Allow load-free exchange cells to rest for at least 4 hours. 7. Measure the temperature of at least one of the exchange cells. 8.
  • Page 75 Maintenance 5. Remove the cell connectors. (M8 / M10 screws) Note To lift the cell, use the Hoppecke cell lifter. (M8: HOPPECKE material number: 4141900002 / M10: HOPPECKE material number: 4141900003). 6. Remove the cell from the container / tray.
  • Page 76 Maintenance 8. Install the exchange cell in the container / tray. Insulation Profile Ribbed Plate Exchange Cell Note If the exchange cells are older than 3 months, preparation must be carried out before, see 9.2.1.1 Prepare the rail | power FNC-HT cell(s) to be replaced on page FNC_Rail_HT_Manual_en04.docx...
  • Page 77 Maintenance The date of manufacture of the FNC rail cells can be specified in 2 different ways: • Production date until CW 15/2024 Note The date of manufacture of the FNC rail cells is stamped on the tops of each cell. Each cell has a 9-digit cell code on top of the cell lid.
  • Page 78 12. Check the total voltage of the battery. Note If the total voltage is less than the number of cells x 1.2 V, contact HOPPECKE Service. 13. Document exchange and number of cells. Result: Now the defective cells have been replaced by new exchange cells.

  • Page 79: Exchange Of The Temperature Sensor

    Maintenance 9.2.2. Exchange of the temperature sensor Target: A defective temperature sensor is replaced with a new one. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design. There is an immediate, high-risk hazard which, if not avoided, will result in death or serious injury.
  • Page 80 Maintenance 8. Mount the insulation profile. 9. Reinstall the water refilling tubes if available. 10. Connect the plug connection of the temperature sensor. 11. Check charge voltage, see 9.1.3 Measuring the charging voltage on page Result: Now the defective temperature sensor has been replaced with a new one. FNC_Rail_HT_Manual_en04.docx...

  • Page 81: Exchanging A Cell Connector

    Maintenance 9.2.3. Exchanging a cell connector Target: A defective cell connector is replaced with a new cell connector. DANGER! When establishing access to the battery system, contact with sharp edges and/or live components may occur due to the design. There is an immediate, high-risk hazard which, if not avoided, will result in death or serious injury.
  • Page 82 Maintenance 5. Install a new cell connector. Terminal screw Terminal screw Spring washer Spring washer Cell connector Note • M8 Torque: 20 Nm ± 1 Nm • M10 Torque: 25 Nm ± 1 Nm • Use new spring washers. 6. Install the insulation profile. 7.

  • Page 83: Troubleshooting

    Troubleshooting Troubleshooting Note Observe the safety instructions, see 2 Safety instructions on page 10.1. Insufficient capacity If the capacity of the battery system is too low, proceed as follows: Cause Remedy Charging process too short Check onboard Charger, Perform a reconditioning charge Different Electrolyte levels Correct electrolyte level...

  • Page 84: No Battery Voltage Can Be Measured

    Troubleshooting If the insulation resistance is too low, leakage currents can reduce the available capacity. This can also cause differences in voltage between the cells. Regular cleaning prevents these leakage currents. Cause Remedy Contamination Cleaning rail | power FNC-HT cell(s) is/are Remedy the problem or replace the cell if leaking necessary...

  • Page 85: Malfunction Of The Water Refilling System

    There are one or more leaking Remedy the cause of the problem, cells replace the cell(s) if necessary O-rings are damaged or Replace O-rings shifted Note If cells are filled above the maximum level, contact the HOPPECKE service. FNC_Rail_HT_Manual_en04.docx...

  • Page 86: Malfunction Of The Temperature Sensor

    Troubleshooting 10.5. Malfunction of the temperature sensor If the temperature sensor does not provide plausible temperature values, the battery may be undercharged or overcharged. Compare the measured charging voltages and the measured temperature values, see 5.7 Temperature compensation on page A defect of the temperature sensor can be detected by a resistance measurement with simultaneous temperature measurement using the data sheet of the temperature sensor (e.g., Ntc 10k =>...

  • Page 87: Disassembly / Assembly Of Rail | Power Fnc-Ht Cells And Accessories

    Disassembly / Assembly of rail | power FNC-HT cells and accessories Disassembly / Assembly of rail | power FNC-HT cells and accessories 11.1. Disassembly of rail | power FNC-HT cells and accessories DANGER! Depending on installation conditions, there can be a risk of death or severe injuries when establishing access to or accessing the battery system, caused by the rolling stock or parts thereof, or the battery system.
  • Page 88 Disassembly / Assembly of rail | power FNC-HT cells and accessories 1. Disconnect all loads from the battery system. 2. Switch off the battery main switch. 3. Disconnect the electrical connection of the battery from the surrounding parts of the battery system (electrical parts in the e-box or similar) and the vehicle on all terminals.
  • Page 89 Disassembly / Assembly of rail | power FNC-HT cells and accessories 9. Remove the connectors between the cell rows first in the order given in the following example illustrations. Note The illustration above is an example. When working on the battery, the project-specific drawings must be used.
  • Page 90 Disassembly / Assembly of rail | power FNC-HT cells and accessories Note To lift the cell, use the Hoppecke cell lifter. (M8: HOPPECKE material number: 4141900002 / M10: HOPPECKE material number: 4141900003). 12. Lift out the spacer material if available (ribbed plates) and clean it in warm water without adding any detergents.

  • Page 91: Assembly Of New Rail | Power Fnc-Ht Cells And Accessories

    Disassembly / Assembly of rail | power FNC-HT cells and accessories 11.2. Assembly of new rail | power FNC-HT cells and accessories DANGER! Depending on installation conditions, there can be a risk of death or severe injuries when establishing access to or accessing the battery system, caused by the rolling stock or parts thereof, or the battery system.
  • Page 92 Disassembly / Assembly of rail | power FNC-HT cells and accessories Note The illustration above shows an example installation with ribbed plates. Note To lift the cell, use the Hoppecke cell lifter. (M8: HOPPECKE material number: 4141900002 / M10: HOPPECKE material number: 4141900003). FNC_Rail_HT_Manual_en04.docx...
  • Page 93 Disassembly / Assembly of rail | power FNC-HT cells and accessories Note To achieve a “press fit” installation of the cells into the tray keep the sequence of installation as described in following photos (example from a project): Start at the main plus terminal and line up the cells on the outside wall of the tray according to the technical drawing.
  • Page 94 Disassembly / Assembly of rail | power FNC-HT cells and accessories 2. Install the cell connectors according to the technical drawing. Use new spring-washers. First install the connectors in the cell rows, then install the connectors between the cell rows in reverse order to the deinstallation, see following example illustrations: Note The illustration above is an example.
  • Page 95 Disassembly / Assembly of rail | power FNC-HT cells and accessories Terminal screw Terminal screw New Spring / Safety washer New Spring / Safety washer washer Cell connector Note For remounting the connectors keep the following sequence: • Place the connector in the required position. •...

  • Page 96: 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 97: Appendix

    The following lists additional tools for maintenance and service: Tool Description Voltmeter/multimeter (illustration shows an example) Current clamp DC (illustration shows an example) Contact thermometer (illustration shows an example) Insulation tester: Fluke 1507 HOPPECKE Mat. No.: 4141201237 External charge/discharge unit (illustration shows an example) FNC_Rail_HT_Manual_en04.docx...
  • Page 98 Glass tube for measuring HOPPECKE Mat. No.: 4144140010 Gas venting tube HOPPECKE Mat. No.: 4143180110 Cell lifter Format 3, 4, 5 M10: HOPPECKE Mat. No.: 4141900003 Format 1, 2 M8, HOPPECKE Mat. No.: 4141900002 Fully insulated torque wrench HOPPECKE Mat. No.: 4142500121 FNC_Rail_HT_Manual_en04.docx...

  • Page 99: Commissioning Protocol For Hoppecke Rail | Power Fnc-Ht Batteries

    Appendix 13.2. Commissioning protocol for HOPPECKE rail | power FNC-HT batteries Vehicle: __________ Date: __________ Batterie No.: __________ Cell Type: __________ Number of cells: __________ Open circuit voltage (battery): __________ V Charging voltage at start of charging: __________ V Charging voltage at end of charging: __________ V...
  • Page 100 Appendix Single cell voltages ____ Commissioning charge ____ Reconditioning charge Column 1: Open circuit voltage before charging, Start of measurement: Date _______ Time________ Column 2: Open circuit voltage after charging, Start of measurement: Date _______ Time________ Zellen Zellen Zellen *1) If the battery system consists of more than 80 cells, expand the table accordingly. FNC_Rail_HT_Manual_en04.docx...

  • Page 101: Maintenance Protocol For Hoppecke Rail | Power Fnc-Ht Batteries

    Appendix 13.3. Maintenance protocol for HOPPECKE rail | power FNC-HT batteries Note In the case of a warranty claim, enter the activities and the measured values in the maintenance report Number of battery system: ___________________________________________ Number of train: ___________________________________________ Date of commissioning: ___________________________________________ FNC_Rail_HT_Manual_en04.docx...

  • Page 102: Half-Yearly Maintenance Interval

    Appendix 13.3.1. Half-yearly maintenance interval 13.3.1.1. Maintenance - Visual inspection of the battery system Interval Visual Inspection Date Inspector (Name) (years) done (mark with cross) 10.5 11.5 12.5 13.5 14.5 FNC_Rail_HT_Manual_en04.docx...

  • Page 103: Maintenance - Check Electrolyte Level

    Appendix 13.3.1.2. Maintenance - Check electrolyte level Interval Check electrolyte Date Inspector (Name) (years) level done (mark with cross) 10.5 11.5 12.5 13.5 14.5 FNC_Rail_HT_Manual_en04.docx...

  • Page 104: Yearly Maintenance Interval

    Appendix 13.3.2. Yearly maintenance interval 13.3.2.1. Maintenance - Measurement of the charging voltage Interval Measured Date Inspector (Name) (years) value in V FNC_Rail_HT_Manual_en04.docx...

  • Page 105: Maintenance - Fill Up Electrolyte Level

    Appendix 13.3.2.2. Maintenance - Fill up electrolyte level Interval Fill up electrolyte Date Inspector (Name) (years) level done (mark with cross) FNC_Rail_HT_Manual_en04.docx...

  • Page 106: Maintenance - Cleaning

    Appendix 13.3.2.3. Maintenance - Cleaning Interval Done (mark Date Inspector (Name) (years) with cross) FNC_Rail_HT_Manual_en04.docx...

  • Page 107: Maintenance - Measurement Of The Insulation Resistance

    Appendix 13.3.2.4. Maintenance - Measurement of the insulation resistance Interval Measured Date Inspector (Name) (years) value in FNC_Rail_HT_Manual_en04.docx...

  • Page 108: Maintenance Interval Every 5 Years

    Appendix 13.3.3. Maintenance Interval every 5 years 13.3.3.1. Maintenance - Reconditioning Intervall Done (mark Date Inspector (Name) (years) with cross) FNC_Rail_HT_Manual_en04.docx...

  • Page 109: Maintenance - Measurement Of Voltage Of Single Rail | Power Fnc-Ht Cells

    For the table headers applies the following: • 1*: Open circuit voltage before charging Note: If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service. • 2*: Open circuit voltage after charging • 3*: Deviation of the single cell voltage to the average single cell voltage (sum of all cell voltages divided by the number of cells) Note: If the individual cell voltages deviate more than ±...
  • Page 110 For the table headers applies the following: • 1*: Open circuit voltage before charging Note: If the open circuit voltage of a cell is < 1.2 V, contact HOPPECKE service. • 2*: Open circuit voltage after charging • 3*: Deviation of the single cell voltage to the average single cell voltage (sum of all cell voltages divided by the number of cells) Note: If the individual cell voltages deviate more than ±...

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