EnerSys ZeMa200P18 User manual

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

Operation Manual

for 2V ZeMa Cells

Concern: Operation Manual for Rolling Stock VRLA TPPL+Sn Single cells:

ZeMa200P18, ZeMa270P12, ZeMa340P12 and ZeMa450P21

Author: Gordon Babock

Global Product Manager MP Specialties

File: EMEA-EN-OM-2VZeMa-CELLS-0123

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 2/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

Table of contents

1. About this document 3

1.1 General Information 3

1.2 Definitions and Abbreviations 3

1.3 Reference documents 4

2. Safety 4

2.1 General Safety information 4

2.2 Intended use 6

2.3 Leaflet "Information for the safe handling of lead-acid batteries" 6

2.4 Classification of warnings 6

3. Product description 7

3.1 Rolling Stock Single Cells 7

3.2 Illustration and Parts of a Cell 8

3.3 Charge and Discharge Parameters 9

3.4 Operating modes and special operating modes 9

4. Transport and storage 10

4.1 Receiving 10

4.2 Storage Conditions and Time 10

5. Mounting 12

5.1 Preparing for installation 12

5.2 Installation works 12

5.3 Assembly inspection, Connection 13

6. Commissioning 13

7. Operation 14

7.1 Operation modes 14

7.2 Charging of the rolling stock battery 15

7.3 Battery operation 18

8. Service 18

8.1 Inspection 19

8.2 Cleaning and visual inspection 21

8.3 Capacity test 22

8.4 Service life of the battery 22

8.5 Replacement of the battery 23

8.6 Repair and refurbishing (Curative service) 23

9. Decommissioning in the vehicle 28

9.1 Preparation for storage 28

10. Disassembling 28

10.1 Disassembling 28

11. Recycling and Disposal 29

11.1 Recycling 29

11.2 Disposal 29

12. Troubleshooting 30

13. Validation 32

14. Document History 32

15. Remark on the Classification 32

16. Appendices 33

Appendix A6: Decision tree for analysis of voltage deviations (2V ZeMaRail monoblocs and

cells under continuous charge) 34

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 3/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

1. About this document

1.1 General Information

This document provides instructions and technical information for the operation and

service of rolling stock single cell batteries in Railway applications. It covers the product

range of 2V ZeMaRail single cells with VRLA (AGM), TPPL+Sn Technology:

•ZeMa200P18

•ZeMa270P12

•ZeMa340P12

•ZeMa450P21

DO NOT commence operating or working on the battery until the “EMEA 2VZeMa Rail

Cells Operation Manual” instructions have been carefully read. Please file the documents

for future consultation. Additionally please study the technical documents about your

battery system and your application.

Additionally you study the technical documents about your battery system and your

application.

Paying close attention to these instructions will avoid possible hazards that can be

caused by batteries, it will also reduce future repair and/or down time and will help

increase the service life of the battery. Ignoring the operating instructions and repairing

batteries with non-original parts will void the battery warranty. All failures, malfunctions or

faults of the battery, the charger or any other accessories, must be notified to our After

Sales Service immediately.

1.2 Definitions and Abbreviations

AGM Absorbent Glass Mat

PbSn Lead tin (Alloy)

BMS Battery Monitoring System

DOD Depth of Discharge

NTC Negative Temperature Coefficient

OCV Open Circuit Voltage

TPPL Thin Plate Pure Lead (EnerSys Technology)

TPPL+Sn Thin Plate Pure Lead with PbSn (EnerSys Technology)

SOC State of charge

Vpc Volt per cell

VRLA Valve Regulated Lead Acid (battery)

V-0 Fire protection classification acc. UL-94 or EN 60695-11-10

(EnerSys uses V0 in type designation)

ZeMa Zero Maintenance

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 4/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

1.3 Reference documents

EN 62485-2 : 2019 «Safety requirements for secondary batteries and

EN 62485-3 : 2015 battery installations» (European Standard)

Part 2 : Stationary batteries

Part 3 : Traction batteries

EN 60077-1 : 2018 «Railway applications - Electrical equipment for rolling stock»

Part 1 : General service conditions and general rules

EN 50547 : 2013 «Railway applications –

Batteries for auxiliary power supply systems»

Leaflet Information for the Safe Handling of Lead-Acid Batteries

(EnerSys, Dec_2016)

2. Safety

2.1 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.

In principle, the internal instructions of the railway companies shall apply.

A full list of warning & information sign is listed in chapter 16 Appendix 7.

Follow instructions

Operation manual must be handed over to the competent personnel.

A copy shall be available at the charging location.

Work on batteries only after instruction by qualified personnel.

First aid

If any Acid splashes into eyes or onto skin rinse under clear running

water. After contact with eyes seek immediate advice from a medical

doctor, please also contact your doctor after serious skin contact.

If Electrolyte Splashes reach the eyes,

Clothing contaminated by acid should be washed with water and soap.

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 5/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

Pay attention to the hazards that can be caused by

batteries.

Pay attention to the dangers posed by batteries like stored energy,

short circuit, DC current, explosive gases and electrolyte leakage.

Dangerous electrical voltage !

All exposed metal parts of the battery cells are permanently live.

Danger of injury by electric shock.

Touch the battery only on the plastic surfaces.

Electrolyte is highly corrosive !

If Electrolyte Splashes reach the eyes, immediately wash the eyes with

plenty of clean water. In case of accident consult a doctor immediately!

In normal operation, a contact with the electrolyte is excluded. At

destruction of the cell vessels, the released fixed electrolyte (gelled

sulphuric acid) is as corrosive as liquid.

Avoid the risk of explosion and fire hazard, short circuits !

Attention! Metal parts of the battery cells are always hot, no tools or

foreign objects are to be placed on the battery.

Under all operating conditions, hydrogen can escape through the

ventilation Cap. Ventilate rooms and cabinets sufficiently.

Systemic health hazards !

Indicates several serious hazards for internal organs, e.g.: Respiratory

sensitisation. Aspiration hazard. Carcinogenicity, germ cell mutagenicity or

reproductive toxicity (CMR).

The installation in non-vented sealed housing is not permitted.

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.

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 6/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

Use protective glasses and clothes !

Use protective glasses and clothes when working on batteries. Pay

attention to the accident prevention rules as well as DIN EN 62485-3

and VDE 0105 part 1.

No Smoking !

Do not expose batteries to naked flames, glowing embers or sparks,

as it may cause the battery to explode.

2.2 Intended use

The rolling stock single cells ZeMaXX are intended for use as a back-up battery in rolling

stock vehicles like coaches and multiple power units.

Improper use can result in danger to people and objects. Assembly, operation and

service of the batteries must be performed by qualified personnel.

2.3 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.

2.4 Classification of warnings

Always observe the warnings under "2.1 General Safety information" when handling the

battery. This will reduce the risk of personal injury and the risk of property damage or

damage to the environment.

More warnings in this operation manual indicate hazards as well as dos and don’ts that

have to be observed and followed in the corresponding modes of operation or during the

work described.

Structure of safety instructions:

Icon

Warning (= Icon name)

Bold

Warning text

Tags in bold

Notes

Standard format

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 7/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

3. Product description

3.1 Rolling Stock Single Cells

These Instructions are valid for the following VLRA AGM Single Cells:

•ZeMa200P18

•ZeMa270P12

•ZeMa340P12

•ZeMa450P21

3.1.1 Common Technical Data of the rolling stock single cells ZeMaXXPxx

Technology : VRLA (AGM), TPPL+Sn

Nominal Voltage : 2 V

Flame retardant battery case : PC+ABS FR or Estaprop, halogen free

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 C10

Part number : SR70770206

Dimensions (WxDxH) : 125 x 157 x 259 mm

Terminals : M10 x 20 deep, female thread

Weight : 14.5 kg ±2%

For more technical data take reference to the data sheet:

•Hawker_ZeMaRail_ZeMa200P18_Brochure_01_EN_2021-03-V2.pdf

3.1.3 Technical Data: Rolling Stock Single Cells ZeMa270P12

Rated Capacity : 270 Ah C10

Part number : 1896504V0CP

Dimensions (WxDxH) : 83 x 198 x 370 mm

Terminals : M10 x 22 deep, female thread

Weight : 16.3 kg ±2%

For more technical data take reference to the data sheet:

•Hawker_ZeMaRail_ZeMa270P12_Brochure_01_EN_2022-09-V1.pdf

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 8/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

3.1.4 Technical Data: Rolling Stock Single Cells ZeMa340P12

Rated Capacity : 340 Ah C10

Part number : 1898204V0CP

Dimensions (WxDxH) : 83 x 198 x 435 mm

Terminals : M10 x 22 deep, female thread

Weight : 19.5 kg ±2%

For more technical data take reference to the data sheet:

•Hawker_ZeMaRail_ZeMa340P12_Brochure_01_EN_2022-09-V1.pdf

3.1.5 Technical Data: Rolling Stock Single Cells ZeMa450P21

Rated Capacity : 450 Ah C10

Part number : 1890507V0CHA

Dimensions (WxDxH) : 137 x 198 x 370 mm

Terminals : M10 x 22 deep, female thread

Weight : 27.9 kg ±2%

For more technical data take reference to the data sheet:

•Hawker_ZeMaRail_ZeMa450P21_Brochure_01_EN_2017-12-V1.pdf

3.2 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

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 9/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

3.3 Charge and Discharge Parameters

ZeMaRail Single Cells ZeMaXXPxx

Nominal voltage

C10

Ah Rated capacity to 1.8 V at 20°C

until 1.8 V

I10

XX/10

Discharge current for C

ILoad :

acc.

Load profile

A Discharge current acc. Customer load profile

Ufinal

1.8

End of charge voltage at I10 (until 1.8 V)

ICharge max

0.45*XX

Charge current for IU or IU0U-charging (minimum for cyclic use: 0.25*XXA)

UBoost

2.4

Boost level voltage setting at 20°C (2.40 V)

URail

2.3

Lower level or constant voltage setting for rail applications at 20°C,

2.30 … 2.35 V (low … high cyclic use)

to 2.35

V ± 1%

Iswitch

0.012*XX

Ufloat

2.29

V ± 1%

Float level voltage at 20°C, 2.29 V (> 24h)

Manual temperature compensation of the charge voltage:

-4

mV/°C

Electrolyte – temperature between -20°C till +45°C (-4 mV/per cell)

3.4 Operating modes and special operating modes

Further information about these modes can also be found in chapter 7.1 “Operation

modes”.

3.4.1 Standby (parallel) operation (charge)

As long as the power supply is ensured via the main power supply, the backup battery is

continuously charged. The charging current will be determined by the charging status of

the battery. With continuous charging the current drops to very small values to maintain

the battery fully charged.

3.4.2 Battery operation (discharge)

When the power supply is switched off or fails, the supply to DC loads will come from the

battery. The backup time will depends current demand from the DC loads.

To avoid damaging deep discharge, the loads must be separated before reaching the

final discharge voltage of the battery.

3.4.3 Storage and workshop operation (recharge, capacity testing, etc.)

During storage or service, the battery can be disconnected from charging and any loads,

the battery will show its open-circuit voltage on its terminals.

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.

Manual

Operation Manual for

ZeMa Single Cells

Prepared on: 23-11-2022

Prepared by: GBA

Released on: 04.01.2023

Released by: -

Revised on: -

Index: _-

Distributed to: customer (public)

Pages: 10/35

This document is uncontrolled when printed. For the most current and official copy, check the server.

Rail Engineering Tel. +49 (0) 2331/372 591

Dieckstrasse 42 Fax +49 (0) 2331/372 804

DE-58089 Hagen www.enersys.com

4. Transport and storage

4.1 Receiving

Upon receipt of a shipment, check that the items delivered are undamaged and match the

carrier’s Bill of Lading. Report any damage or shortages to the carrier. Your supplier is

not responsible for shipment damage or shortages that the receiver does not report to the

carrier.

4.2 Storage Conditions and Time

If a battery cannot be installed immediately it should be stored in a clean, cool, dry area.

4.2.1 The batteries must not be stacked. We recommend, for simple handling during transport

and storage, to place the cells on a pallet and fix them. Protect the cells from dust and

contamination with a plastic cover.

4.2.2 The relative humidity of max. 90% RH (non-condensing) should not be exceeded.

4.2.3 The storage ambient temperature should be between -15°C and 30°C, details see also

4.2.5.

4.2.4 Do not expose the cells and batteries permanently to direct sunlight.

Care must be taken on cleanliness. When cleaning, please note the remarks in chapter:

Cleaning and visual inspection.

4.2.5 During storage batteries lose capacity through self-discharge.

High temperature increases the rate of self-discharge and reduces the storage life.

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

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