Rail Power FNC Manual en

Executive Responsible Document type: State of
department: department: Technical Documentation confidentiality:

SVA SVA External
Created/changed (current index): Document state:
2021-10-04, W. Pickart Operating and Installation Manual Approved
Checked (current index):
2021-10-04, I. Fuhrmann
Approved (current index): File name: Revision: Language: Page:
2021-10-11, Dr. D. Mahl FNC_Rail_Manual_en10.docx 10 EN 1
Batteries FNC®-Rail
Operating and Installation Manual
FNC_Rail_Manual_en10.docx
Version overview
Revision Date Status Name Chapterl Reason for Change

01 2014-01-14 Created I.Fuhrmann - first issue
2014-01-21 Checked F. Mengeringhausen
2014-01-28 Approved Dr. Gutzeit
02 2015-03-15 Changed I.Fuhrmann divers divers updates
2015-03-17 Checked T. Schreckenberg
07 2019-04-01 Changed W. Pickart all update according to
2019-04-02 Checked I. Fuhrmann documentation-check
08 2019-09-12 Changed W. Pickart all update according to review
09 2021-03-09 Changed W. Pickart • 1.6 • Description of formats
2021-03-09 Checked F. Mengeringhausen added
2021-03-09 Approved Dr. D. Mahl • 5.5 • Note Box added in 5.5.
• 7.3 • Added chapter "Storage
with built-in battery"
• 8 • Note for commissioning
charge before regular
operation added
• 8.4 • Recommissioning after
test / parking operation
added
• 9.1.7.1 • Note "Paper towel" added
• 11 • Title changed
10 2021-10-04 Changed W. Pickart • 4 • DIN EN IEC 62485-3
2021-10-04 Checked I. Fuhrmann added
2021-10-11 Approved Dr. D. Mahl • 5.3 • Added note
• 11 • Added details
Foreword
Dear Customer,
Thank you very much for having decided in favour of a product bearing our brand name.
Please read this documentation carefully before working on the batteries or their
components. It contains important information on safe and proper unpacking, storage,
installation, commissioning and on operation and maintenance of FNC® rail batteries.
Amendments to this documentation are subject to change without prior notice. Our products
undergo continuous advanced development. As a result, there may be deviations between
the illustrations given in this documentation and the purchased product. This installation
manual is not covered by any change service.
Keep this documentation in such a manner that it is available immediately to all those who
need to carry out work in connection with the battery system or its components.
HOPPECKE Batterie Systeme GmbH Service hotline Germany:

Business Unit Special Power 0800 246 77 32
Postfach 11 80, D-59914 Brilon
Bontkirchener Str.1, D-59929 Brilon International service hotline:
+49 (0) 180 5 22 9999
Telefon: +49 (0) 29 63 61 1412
Fax: +49 (0) 29 63 61 1452
Internet: www.HOPPECKE.com
Email: [email protected]
Copyright HOPPECKE Batterie Systeme GmbH
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.
Table of Contents
1. USING THIS MANUAL 7
1.1. Target group of this document 7
1.2. Icons and signal words 7
1.3. Notation of nominal data 8
1.4. Graphic symbols / pictograms on the battery system 9
1.5. Nameplate information on the product 10
1.6. Definitions of terms 10
1.7. Other applicable documents 10
2. SAFETY INSTRUCTIONS 11
2.1. Potential hazards 11

2.1.1. Explosive gas mixture 11
2.1.2. Electrical voltage 12
2.1.3. Electrolyte 13
2.1.4. Toxic substances 14
2.1.5. Fire 14
2.1.6. Improper transport 15
2.1.7. Notes on disassembly 15
2.2. Personal protective equipment 16
2.3. Markings on the product 16
3. USE OF THE PRODUCT 17
3.1. Intended use 17
3.2. Unintended use 17
4. DIRECTIVES, LEGISLATION AND STANDARDS 18
5. FUNCTION AND STRUCTURE 19
5.1. Battery 19
5.2. FNC® rail cell 19
5.3. Low pressure water refilling system 21
5.4. Charging procedures for FNC rail cells 23

5.4.1. Charging with constant current (I) 23
5.4.2. Single-stage charging with constant current, constant voltage (IU) 24
5.4.3. Two-stage charging with constant current, constant voltage (IU0U) 25
5.5. Temperature compensation 26
6. INSTRUCTIONS FOR TRANSPORT 30
6.1. Surface transport (Road/Rail) according to ADR/RID 30
6.2. Transport by sea according to the IMDG Code 30
6.3. Air freight 31
7. STORAGE INSTRUCTIONS 31
7.1. General instructions 31
7.2. Storage period 32
7.3. Storage with built-in battery 33
8. COMMISSIONING/INSTALLATION 34
8.1. Checking the delivery 35
8.2. Measures prior to initial commissioning 35

8.2.1. Preparation 35
8.2.1.1. Replacing the battery cell transport plugs 36
8.2.1.2. Recommendation of additional measures 36
8.2.1.3. Preparation of batteries with unfilled cells 37
8.2.2. Commissioning charge 39
8.2.2.1. Preparation 40
8.2.2.2. Execution 41
8.2.2.3. Follow-up work 42
8.3. Installation and connection 43
8.4. Recommissioning after test or parking operation 44
9. MAINTENANCE 45
9.1. Preventive maintenance 45

9.1.1. Perform visual inspection 46
9.1.2. Checking the electrolyte level 47
9.1.3. Measuring the charging voltage 49
9.1.4. Fill up the electrolyte level with distilled water 51
9.1.4.1. Fill up distilled water manually 52
9.1.4.2. Refill distilled water with the central water refilling system 52
9.1.4.3. Refill distilled water with the water refill cart for single cells 53
9.1.5. Cleaning the battery 54
9.1.6. Testing the insulation resistance 55
9.1.7. Reconditioning 57
9.1.7.1. Preparation 59
9.1.7.2. Execution 61
9.1.7.3. Follow-up work 64
9.2. Corrective maintenance 65

9.2.1. Change of FNC® cells 65
9.2.1.1. Prepare the FNC® rail cell(s) to be replaced 66
9.2.1.2. Replace one or more FNC® rail cell(s) 68
9.2.2. Exchange of the temperature sensor 71
9.2.3. Exchanging a cell connector 73
10. TROUBLESHOOTING 75
10.1. Insufficient capacity 75
10.2. Insufficient insulation resistance 75
FNC_Rail_Manual_en10.docx 5
10.3. No battery voltage can be measured 76
10.4. Malfunction of the water refilling system 77
10.5. Malfunction of the temperature sensor 78
11. DISASSEMBLY / ASSEMBLY OF FNC® RAIL CELLS AND ACCESSORIES 79
11.1. Disassembly of FNC® rail cells and accessories 79
11.2. Assembly of new FNC® rail cells and accessories 83
12. DISPOSAL 88
13. APPENDIX 89
13.1. Additional tools 89
®
13.2. Commissioning protocol for HOPPECKE FNC rail batteries 91
13.3. Maintenance protocol for HOPPECKE FNC ® rail batteries 93

13.3.1. Half-yearly maintenance interval 94
13.3.1.1. Maintenance - Visual inspection of the battery system 94
13.3.1.2. Maintenance - Check electrolyte level 95
13.3.2. Yearly maintenance interval 96
13.3.2.1. Maintenance - Measurement of the charging voltage 96
13.3.2.2. Maintenance - Fill up electrolyte level 97
13.3.2.3. Maintenance - Cleaning 98
13.3.2.4. Maintenance - Measurement of the insulation resistance 99
13.3.3. Maintenance Interval every 5 years 100
13.3.3.1. Maintenance - Reconditioning 100
13.3.3.2. Maintenance - Measurement of voltage of single FNC® rail cells 101
Using this manual
1. 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.
Please contact your local authorised dealer if:

• You have any queries on this documentation
• There are local regulations or provisions that are not covered by this documentation or
are contrary to its contents
1.1. Target group of this document

All work on the FNC® rail cells may only be carried out by trained, fully qualified, authorised
personnel (ideally by qualified electricians):
• Personnel authorised by the safety officer of the train manufacturer
• Personnel authorised by the safety officer of the train operator
• Personnel authorised by HOPPECKE
• HOPPECKE specialist personnel
Untrained personnel may not carry out any work on the FNC® rail cells.
1.2. Icons and signal words

The following icons and signal words are used in this operating and installation manual:
DANGER!
Denotes an immediate hazard with a high level of risk that could lead to death or severe physical
injury if it is not prevented.
WARNING!
Denotes a potential hazard with a medium level of risk that could lead to death or severe
physical injury if it is not prevented.
CAUTION!
Denotes a hazard with a low level of risk that could lead to minor or medium degree of physical
injury if it is not prevented.
Note
Denotes important instructions to make best use of the product.
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

Un Nominal voltage 1.2 V multiplied by the number of cells connected in
series
Cn Nominal capacity C5 (according to IEC EN 60623)
available capacity at discharge at I5 (see nameplate)
down to 1.0 V for each cell connected in series at
nominal temperature
In Nominal current I5 (see nameplate) = Cn/5h
Tn Nominal 20 °C
temperature
d Electrolyte density 1.19 kg/l or higher according to project specific
requirements
D Torque of terminal M8: 20 Nm ± 1 Nm
screws M10: 25 Nm ± 1 Nm
U0 Open-circuit voltage 1.3 V ... 1.35 V, fully charged
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

Warning against explosive substances
EN ISO 7010 - P003

Fire, open light and smoking prohibited
EN ISO 7010 - M002

Follow instructions for use
EN ISO 7010 - M004

Use eye protection
EN ISO 7010 - M009

Use hand protection
EN ISO 7010 - M010

Use protective clothing
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 (C5 = Cn) of the battery.
If battery kits are supplied (individual cells with accessories), the nameplate of the battery
must be attached by the customer.
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. The last four digits indicate the production
week and year.
Example:
xxxxx2619 => production week 26; production year 2019
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.
Float charging The charge of an accumulator to compensate for its self-discharge
with the aim of keeping the accumulator fully charged.
Boost charging Indicates the charging of an accumulator with increased voltage
and a defined current in order to charge the accumulator as quickly
as possible.
Electrolyte FNC® rail batteries are NiCd batteries and contain potassium
hydroxide (KOH) as electrolyte with an addition of lithium hydroxide
(LiOH). When handled properly, FNC® rail batteries are safe.
Contact with the electrolyte is excluded.
Formats FNC® rail cells are delivered in different formats:
• R2 (format 2)
• R3 (format 3)
• R4 (format 4)
1.7. Other applicable documents

Document name Description
D00001-300-en<version Instructions for refilling water with an automatic low-
number>-Water-Refilling.pdf pressure water refill system
Electrolyte_Mixing.pdf Instructions for mixing liquid electrolyte
Safety instructions
2. 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:

• Explosions
• Fires
• Blast waves
• Hot or molten substances flying around
These hazards may be caused by the following ignition sources:

• Short circuits
• Electrostatic charges and discharges
• Smoking
• Open flames / fire, embers and sparks near batteries
• Electrical sparks through switches or fuses
• Hot surfaces with temperatures above 300 °C
There is an immediate, high risk situation which, if not avoided, will result in death or serious
injury.
Measures to avert the danger:

• Work with insulated, non-sparking tools.
• Ensure sufficient ventilation of the battery room in accordance with DIN EN IEC 62485-2
so that the potentially explosive gas mixture is removed.
• Avoid electrostatic charging:
- Do not rub batteries with plastic housings with a dry cloth or a cloth made of synthetic
material!
- Only clean batteries with a cotton cloth moistened with water. Wiping with a cotton cloth
moistened with water does not generate any electrical charge.
- Wipe batteries damp (with water) before removing or tearing off a label.
- Wear shoes and clothing which, due to their special surface resistance, prevent the
formation of electrostatic charges. (see 2.2 Personal protective equipment on page 16)
• Use hand lamps with mains cable without switch (protection class II) or hand lamps with
battery (protection class IP54).
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
injury.

• Be very careful when working on the batteries.
• Never place tools or other metal objects on a battery.
• Take off watches and jewellery before working on the batteries.
• Do not touch bare battery parts, connectors and terminals.
Safety instructions
2.1.3. Electrolyte
FNC® rail cells are NiCd cells and contain potassium hydroxide (KOH) as electrolyte with an
addition of lithium hydroxide (LiOH).
The following hazards exist:

• When working on open FNC® rail cells, contact with the electrolyte may occur.
• Electrolyte may escape as a result of damage to the housing of a cell.
• Polarity reversal of the battery or of individual cells can result in overheating and thus
electrolyte leakage.
• The electrolyte can cause severe burns.
There is a potentially hazardous medium-risk situation which, if not avoided, could result in
death or serious injury.
Measures to avert danger:

• Always wear protective goggles and gloves when working on batteries.
• Clothes contaminated with electrolyte should be washed with water.
• Check correct polarity before making connections.
Take the following first aid measures if contact with electrolyte has occurred:
Electrolyte on the skin or hair

• Dab the electrolyte with a cotton or paper towel, do not rub off.
• Remove contaminated clothing, avoiding contact with unaffected body parts.
• Rinse affected areas under running water for longer periods of time.
Lye in the eye

• Rinse eye gently with eye wash for a few minutes or rinse under running water. Avoid
excessive water pressure. If possible, remove any contact lenses and rinse further.
• Seek medical advice immediately.
Lye in the body

• Rinse mouth. DO NOT induce vomiting.
• Seek medical attention or hospitalization immediately.
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.

• Avoid contact with toxic substances.
• Wear personal protective equipment (see 2.2 Personal protective equipment on page
16).
2.1.5. Fire
In the event of fire there is danger from:
• Hot or molten substances
• Short circuits
• Open flames / fire, embers and sparks
• Hot surfaces with temperatures above 300 °C
injury.

• Wear personal protective equipment against caustic solution (see 2.2 Personal
protective equipment on page 16), also use breathing protection with self-sufficient
breathing air supply for large battery systems. In the event of contact with water, there is
a risk of reactions with the electrolyte (caustic solution) and consequently of violent
spraying.
• Disconnect the battery electrically.
• Extinguish incipient fires with CO2.
• When extinguishing electric fires with water in low-voltage systems (up to 1 kV), maintain
a spray jet distance of 1 m and a full jet distance of 5 m.
• Extinguish at short intervals. Otherwise there is danger of explosion due to possible
static charging on the battery housing.
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
• Leaking electrolyte
injury.

• Use safety shoes and goggles.
• Do not tilt batteries.
• Always lift the batteries by the handles or lifting points provided for lifting devices and
never carry them by the terminals of the battery or cells.
• Only use approved lifting and transport equipment, e.g. lifting gear. Lifting hooks must
not cause damage to cells, connectors or connecting cables.
• Always carefully remove batteries to avoid damage.
• Use suitable transport equipment.
• Carefully secure the load during transport to prevent damage to the battery housing.
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.
injury.

• Before starting to dismantle the batteries to be replaced, disconnect the supply lines
(fuses).
Due to the content of cadmium and caustic potash solution, FNC ® rail batteries must not be
disposed of with garbage or deposited in a landfill at the end of their service life. (see 12
Disposal on page 88)
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.
The conductivity of textiles and shoes must have the following properties in order to avoid
electrostatic charging:
• an insulation resistance ≥ 105 Ohm
• a surface resistance < 108 Ohm
2.3. Markings on the product

The type plate of a battery is attached to the container for the battery cells (container, tray,
carrier). On the type plate you will find the type, nominal voltage, number of battery cells and
nominal capacity (C5 = Cn) of the battery.
When battery kits (individual cells with accessories) are supplied, the type plate of the
battery must be attached by the customer.
Use of the product
3. Use of the product

3.1. Intended use
The FNC® rail cells of the battery are used to store and release electrical energy in rail
vehicles.
Use only in rail vehicles for:

• Buffering and supply of the low-voltage vehicle electrical system
• Provision of energy in emergencies
• Provision of energy for the maintenance and start-up of vehicles
• Start of the vehicle drive motors
Intended use includes the following requirements:

• Operation of the batteries only in perfect condition
• No deactivation or dismantling of safety devices
• Compliance with all instructions in this operating and maintenance manual
3.2. Unintended use
DANGER!
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. The risks associated with improper use are borne solely by the operator.
Any other use than described under "Intended use" is not intended and therefore not
permitted.
The improper use of the product includes in particular:

• Operation in potentially explosive atmospheres
• Operation in safety-relevant applications, unless these applications are expressly
specified or permitted in the product documentation.
• Operation without permanent/insufficient fastening
• Operation outside the technical data
• Operation or storage outside the specified environmental conditions
• The electrical connection does not correspond to the documentation supplied with the
battery.
• Operation with unauthorized changes or modifications to the product
Directives, legislation and standards
4. 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")
• DIN VDE 0105 ("Operation of electrical equipment"), in particular, governs the
requirements for quality and qualification for working on electrical equipment
(DIN VDE 0105-100) and on electrical equipment for railways (DIN VDE 0105-103).
• DIN VDE 100/IEC 60364 ("Erection of low-voltage installations")
• DIN EN 50110/VDE 0105 ("Operation of electrical installations")
• DIN EN 50155 ("Railway applications - Electronic equipment used on rolling stock")
• DIN EN IEC 62485-2: ("Safety requirements for secondary batteries and battery
installations") especially applicable for the calculation of the necessary ventilation of
battery rooms (in DIN EN IEC 62485-2).
• DIN EN IEC 62485-3: ("Safety requirements for secondary batteries and battery
installations") Part 3: Traction batteries for electric vehicles
• DIN EN 50547 Railway applications - Batteries for auxiliary power supply systems
• DIN EN 60077 ("Railway Applications - Electric equipment for rolling stock")
• DIN EN 60623/IEC 60623 ("Secondary cells and batteries containing alkaline or other
non-acid electrolytes. Vented nickel-cadmium prismatic rechargeable single cells"),
applicable primarily to the testing of cells (type test, series production test and field test).
Based on mutual agreement, the tests may also be conducted in accordance with the
French standard for rolling stock, NF F 64-018.
• DIN EN 60993/IEC 60993 ("Electrolyte for vented nickel-cadmium cells")
• DIN 43530-4 ("Water and refilling water for lead acid batteries and alkaline batteries")
• DIN VDE 0119-206-4: State of railway vehicles - Electric and traction systems, train
electric equipment - Part 206-4: Batteries
• ADR/RID: European Treaty on the international transport of hazardous goods by road /
Ordinance on the international transport of hazardous goods by rail
• IATA-DGR: Dangerous goods regulations - international air transport association.
German: Gefahrgut-Bestimmungen - Internationale Flug-Transport-Vereinigung
• IMDG Code: International Maritime Code for Dangerous Goods, German:
Gefahrgutkennzeichnung für gefährliche Güter im Seeschiffsverkehr
• Ordinance on the supervision of waste and residual materials (German Federal Law
Gazette, 1996)
In addition, observe and follow all applicable territorial, corporate and project-specific
regulations.
Function and structure
5. Function and structure

5.1. Battery
Batteries are interconnected from FNC® rail 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
• - Provision of energy in emergencies
• - Provision of energy for the maintenance and start-up of vehicles
• - Start of the vehicle drive motors
5.2. FNC® rail cell

FNC® rail cells are nickel-cadmium cells manufactured using fiber structure technology
using an extremely porous, three-dimensional nickel-metallised polypropylene fleece.
Decisive features are:

• Best volume/weight ratio due to 90% volume filling of the fiber electrodes with active
material
• High to very high currents possible during discharge and charging
• No carbonates are formed in the electrolyte
• Long service life and many charging cycles even under extreme temperature conditions
• Resists highest shock and vibration demands
• Cell vessels optionally made of:
- Polypropylene (PP)
- Flame retardant polypropylene (PP-V0)
- Polyethersulfone (PES)
• Wide variety of designs from high and extremely flat to low with large footprint
The following drawing shows the internal structure of a FNC rail 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 12 - Negative fiber structure electrode
6 - Terminal nut 13 - Separator
7 - Cell terminal
Note
The electrolyte used in the cells of the FNC® rail batteries is potassium hydroxide (KOH) with an
addition of lithium hydroxide (LiOH). The standard alkali density is 1.19 ± 0.02 kg/litre.
Depending on the ambient temperature, different alkaline densities may be necessary for specific
projects.
In contrast to the lead-acid battery, the alkaline density is not a measure of the state of charge.
5.3. Low pressure water refilling system

A water refill system can be an optional part of your battery. The low pressure water refilling
system allows the electrolyte levels of the FNC® rail cells to be filled with distilled water.
It consists of water refill plugs in the FNC® rail cells, hoses and a backfire protection unit.
The following picture shows a water refill plug:
The following picture shows a backfire protection unit (example):
The following picture shows an example of a battery with a coloured water refill system
(tubing = red; backfire protection = blue, water refill plugs = green):
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. This must be observed
during all work on the water refill system.
5.4. Charging procedures for FNC rail cells

5.4.1. Charging with constant current (I)
With this charging method, the cell is charged with the constant current I 5 = Cn/5h. The
charging voltage is not limited. However, there is a time limit so that a defined capacity is
charged into the cell.
Plateau
Voltage
Current
Time
At the end of the charging process, relatively high cell voltages occur (up to 1.9V / cell). In
this phase (also called "plateau" or gassing phase) the charging current decomposes water
into hydrogen and oxygen. This results in high water consumption.
The IEC60623 standard describes this charging procedure to prepare the cells for
subsequent discharge tests. The current limitation is at rated current and the time is in the
range of 7 to 8 hours. With this charging method a fully charged state (100%) can be
achieved. At the same time, all cells of a battery connected in series are balanced. This
method is therefore used for commissioning charging and reconditioning FNC ® rail cells.
This charging method is not used for the daily operation of the batteries due to the strong
gassing and the high water consumption. Furthermore, the resulting high voltage is well
above the permissible operating voltage of the on-board electrical system.
5.4.2. 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. The current then drops
automatically to a low value.
Constant current Constant voltage
Voltage
Current
Time
The setting of the charging voltage always represents a compromise between the
achievable state of charge and water consumption. The higher the voltage, the higher the
state of charge, but the higher the remaining charge current, the higher the water
consumption.
In accordance with the limited charging voltage, a reduced state of charge must be
assumed for the operation of the battery. Normally a value of 90% of the nominal capacity is
assumed (EN 50547). In extreme applications (very high or very low temperatures, cyclic
use) this value may also be lower.
5.4.3. 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. This first voltage threshold is called the "boost voltage".
When the boost voltage is reached, the charge current decays. When a certain charge
current is reached (usually I20 = Cn/20h), the voltage is reduced to a lower value. This
voltage value is referred to as the "float voltage".
Boost-Voltage Float-Voltage
Voltage
Strom
Current
Time
The advantage is that the boost voltage can be selected higher than with a single-stage
charge. This extends the constant current phase, resulting in a better state of charge in a
shorter time.
After reaching the current threshold (I20), which indicates that the battery has been
sufficiently charged, the voltage is switched to the float voltage. This voltage is significantly
lower than the voltage at single-stage charging. This keeps water consumption to a
minimum while maintaining the state of charge.
If there has been a discharge of the battery, the charging current will increase again. When
the switch-over point (I20) is reached, the charging voltage is reset to the boost value to
quickly recharge the battery. Then the charging current drops again and the charger
switches back to float voltage.
As a result, this charging process eliminates the compromise between water consumption
and state of charge of the single-stage charge.
In the case of two-stage charging, a reduction in the state of charge must also be taken into
account when the battery is designed. The value is usually in the same range as for single-
stage charging.
5.5. 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.
This compensation is used equally for the single-stage (IU) and the two-stage (IU0U)
charging process.
Note
Depending on the specific mode of operation of a vehicle and the resulting special load
requirements, individual values may differ from those listed below.
Charging Voltage at 20 °C in V per cell connected in

series
Cell- Single Stage Two Stage Two Stage Temperature
Performance Charging (IU) Charging Charging kompensation
Class acc. EN (IU0U), (IU0U), in V/°C/Cell;
60623 Float-Charge Boost-Charge starting from 20 °C
L 1.52 *) 1.50 1.60 -0.003
M 1.52 *) 1.50 1.60
H 1.47 *) 1.45 1.55
X 1.45 *) 1.40 1.50
*): Guide values; may vary depending on the project
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° C

see table
Charging Voltage [V]
Charging current limitation recommended: I = 1.5 x I5 = 1.5 x Cn/5h
Elektrolyte Temperature [°C]
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 ≤ I20
Boost Charge
Charging Voltage at 20°C
Charge voltage [V]
see table
Float Charge
Switchover from Float Charge to Boost Charge

at I ≥ I20
Charge current limitation recommended: I = 1.5 x I5 = 1.5 x Cn/5h
Elektrolyte temperature [°C]
The following conditions apply to the characteristic curve shown:
• Switching from float charge to boost charge:

The current permanently exceeds a value of I20 = Cn/20h.
• Switching from boost charge to float charge:
The current permanently falls below a value of I20 = Cn/20h.
• Current limitation 1.5 x I5 = 1.5 x Cn/5h (recommended value, deviations to higher or
lower currents are possible)
• At a temperature of ≥ 45 °C, a boost charge is not possible. Select the hysteresis in such
a way that the switch back to boost charge does not occur until a temperature of ≤ 40 °C
is reached.
Note
If the battery temperature ≥ is 60 °C, the charging process must be interrupted to prevent
damage to the cells. Select a control that does not resume charging until the battery temperature
has dropped to ≤ 55 °C.
Note
You can assume that the temperature 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 45°C.
The on-board charging device should generate a SERVICE message to indicate that you must
replace the temperature probe within a few days.
Instructions for transport
6. 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 11.
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):
New batteries, if: They are secured against sliding, turning over or damage.
They are provided with carrying facilities, unless, for example,
they are stacked on pallets.
They do not have hazardous traces of caustic solutions or
acids on the outside; they are protected against short-circuit.
Used batteries, if: Their housing is not damaged.
They are protected against leakage, sliding, turning over or
damage, for example, stacked on pallets.
They do not have hazardous traces of caustic solutions or
acids on the outside.
They are protected against short-circuit.
"Used batteries" are those that are transported for the purpose of recycling after normal use.
If the conditions of special regulation 598 are not complied with, declare and transport new
and used batteries as hazardous goods as follows:
UN hazardous goods class 8

UN no. (material number) 2795
Designation and description BATTERIES, WET, FILLED WITH CAUSTIC
SOLUTION
Packaging group Not assigned to any packaging group
Hazard label 8
ADR tunnel restriction code E
6.2. Transport by sea according to the IMDG Code

Declare FNC® rail battery systems for sea freight as follows:

Proper shipping name BATTERIES, WET, FILLED WITH CAUSTIC
SOLUTION
Hazard label 8
EmS F-A, S-B
Packing instructions P801
Storage instructions
6.3. Air freight

Declare FNC® rail battery systems for air freight as follows:

Proper shipping name BATTERIES, WET, FILLED WITH CAUSTIC
SOLUTION
Hazard label 8
Packing instruction 870
7. 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
7.1. General instructions

Unpack the battery system as soon as possible after delivery, install it and put it into
operation, see chapter 8 Commissioning on page 34.
In case this is not possible:

• Store the batteries in a clean, dry and frost-free room.
• Protect the batteries against mechanical damage and contamination.
• Do not expose the batteries to direct sunlight.
• Do not stack the batteries on top of each other.
• Observe and follow project-specific regulations applicable, if any.
Note
The minimum storage temperature is -25 °C.
The ideal storage temperature is +20 °C.
Higher storage temperatures lead to faster self-discharge and premature aging of the battery.
The maximum storage temperature is +60 °C.
During storage, a maximum relative humidity of 90% is permissible.
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.
Note
The date of manufacture of the FNC® rail cells is stamped on the top of each cell.
Each cell has a 9-digit cell code on top of the cell lid. The last four digits indicate the production
week and year.
Example:
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 5 (= Cn / 5h).

Discharge until the battery voltage averages 1 V per cell connected in series.
Result: Now the battery is ready for storage.
Note
Recommissioning:
Charge the battery system for recommissioning as described in 8.2.2 Commissioning charge on
page 39
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.
Disconnect the battery electrically from the electrical system of the vehicle to prevent
permanent consumers discharge the battery.
Parking has to be considered as normal operation for maintenance purposes. Carry out the
regular maintenance intervals and works, see 9 Maintenance on page 45.
Note
When the parking period exceeds 3 months, perform a commissioning before enter revenue
service, see 8.2.2 Commissioning charge on page 39.
Commissioning/Installation
8. Commissioning/Installation
Note
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.
• Complete battery containers that contain the battery and other electrical components fully
assembled. The containers are installed on/in the vehicle by the customer.
Project specific additional information can be included in a separate documentation.
The batteries are usually delivered filled and charged. They can be connected and
commissioned within three months of the date of manufacture (stamped on top of the
battery cells) without any special preparations.
In the following cases, a commissioning charge must be carried out before installing and
commissioning the batteries (see 8.2.2 Commissioning charge on page 39):
• The date of manufacture was more than 3 months ago when the batteries were
commissioned.
• Batteries delivered unfilled and uncharged should be put into operation. Carry out the
commissioning charge after the batteries have been filled with caustic solution (see
8.2.1.3 Preparation of batteries with unfilled cells on page 37).
• Filled and uncharged batteries should be put into operation.
• The vehicle in which the batteries are used should be put into operation after a long
period of standing or transport for the regular route operation, see 8.4 Recommissioning
after test or parking operation on page 44.
8.1. Checking the delivery

HOPPECKE Batterie Systeme GmbH packages your delivery with the greatest possible
care so that it arrives undamaged.
Check the delivery immediately:
• Completeness (comparison with the delivery note)
• Transport damages
• Make a note of:
- Damage to the outer packaging
- Visible stains or moisture that would indicate leaking electrolyte.
If the delivery is incomplete or there is damage in transit:

• 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.
Check the goods for defects:

• Observe the instructions in 2 Safety instructions.
• After delivery, unpack the batteries and check them for defects by performing a visual
and functional inspection.
• Document any existing defects and send them in text form to Hoppecke Batterie
Systeme GmbH within 14 days.
Note
If you notify the freight forwarder too late of defects or incompleteness, this may result in the loss
of your claims.
8.2. Measures prior to initial commissioning

8.2.1. 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
types:
water refilling-
plug (low
yellow transport plug white vent plug
pressure
System)
Note
The yellow transport plugs prevent the cells from being ventilated and can cause the individual
cells to be destroyed when the battery is charged.
If the cells are delivered with yellow transport plugs, replace them with the vent / water refilling
plugs supplied separately.
Note
The installation of a water refill system is described in a documentation supplied separately with
the battery if required.
8.2.1.2. Recommendation of additional measures

It is recommended to carry out the following additional measures before installing and
commissioning each battery:
• Check the cell connectors and their screw connections for tightness.
• Check the insulation resistance of the battery (see 9.1.6 Testing the insulation resistance
on page 55).
• Create a commissioning protocol for the battery (see 13.2 Commissioning protocol for
HOPPECKE FNC ® rail batteries on page 91).
8.2.1.3. Preparation of batteries with unfilled cells

Target: The unfilled battery is prepared for use in the vehicle.
WARNING!
There is danger through:
• Work on opened FNC® rail cells. Contact with the electrolyte may occur.
• Damage to the housing. Electrolyte may escape from the affected cell.
• Reverse polarity of the battery or of individual cells. It can cause overheating and thus
electrolyte leakage.
There is a potential medium-risk hazard which, if not avoided, could result in death or serious
injury.
The electrolyte can cause severe skin burns and eye damage.
• Always wear protective goggles and gloves when working on batteries.
• Clothing contaminated with electrolyte should be washed with water.
• Check correct polarity before making connections.
Observe the first aid measures, see 2.1.3 Electrolyte on page 13.
Note
• Filling with acid destroys the cells of the FNC® rail batteries. If caustic potash solution is not
mixed in accordance with regulations, the battery performance will be impaired.
• Only use electrolyte in accordance with IEC EN 60993 to fill the battery cells.
1. Remove the unfilled battery from storage and set it up in a suitable battery workshop for
wet chemistry.
2. Do not remove the yellow transport plugs and allow the battery to acclimatise for 6 hours
if the temperature difference between the storage and the battery workshop is more than
10 °C.
Note
Preparation and handling of the electrolyte are described in a separate documentation of
HOPPECKE Batterie Systeme GmbH. (see document: "Electrolyte_Mixing.pdf")
An electrolyte change is not necessary during the entire service life of the battery.
3. Remove the yellow transport plugs immediately before filling the battery.
4. Fill each cell of the battery with electrolyte up to approx. 1cm above the minimum mark.
5. Fit the supplied vent plugs (or the water refill plugs and tubing if the water refill system is
present).
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 4143180100) on each cell.
9. Charge the battery with the constant current I5 for 7.5 hours.
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.
If the battery reaches a temperature of 45 °C again before the 7.5 hour charging time has been
completed, interrupt charging again, etc.
10. Let the battery rest for at least 8 hours, preferably overnight.
11. Disconnect the charger/discharger from the battery.
12. Remove the gas venting tubes.
13. Manually fill the electrolyte levels of the cells with electrolyte up to the maximum mark.
Battery cell format Maximum electrolyte level according to measuring glass tube [mm]
R2 36 ± 2 (3.5 rings)
R3
R4 55 ± 2 (5.5 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 47. The measuring glass tube
contains a ring scale at which the electrolyte level can be read in rings.
14. Refit the vent plugs or the water refill system.
Result: The battery is now ready for use in the vehicle.
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.
- The date of manufacture (calendar week and year) of the battery is noted on the
nameplate.
- Furthermore, the date of manufacture of the FNC® rail cells is stamped on the top of each
cell. Each cell has a 9-digit cell code at the top of the cell cover. The last four digits provide
information about the production week and year.
Example:
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:
• open flames or fire
• smoking
• glowing sparks
• flying sparks during grinding work
• electrical sparks through switches or fuses
• hot surfaces with temperatures above 300 °C
• electrostatic discharges
Work with insulated, non-sparking tools.
Ground yourself when working directly on the battery.
Ensure sufficient ventilation of the container compartment in accordance with DIN EN IEC
62485-2 so that any explosive gas mixture that may be produced is discharged.
Note
The charge for commissioning is a constant current charge, see 5.4.1 Charging with constant
current (I) on page 23.
Required tools:
• suitable loading/unloading equipment
• measuring glass tube
• digital Multimeter
• gas venting tube
• contact thermometer
Perform the following activities in the order given here:
Activity Description
Prepare commissioning charge 8.2.2.1 Preparation on page 40
Execute commissioning charge 8.2.2.2 Execution on page 41
Follow-up work after commissioning 8.2.2.3 Follow-up work on page 42
charge
8.2.2.1. Preparation
Target: The cells are prepared for carrying out charging for commissioning.
Note
Carry out measures on the dismantled battery - i.e. mechanically separated from the vehicle -
before initial operation.
Note
It is strongly recommended that the charging be carried out for commissioning in an air-
conditioned working area at 20 °C (±5 °C).
1. Remove the hinged lid plugs from each FNC® rail cell or, if present, remove the tubing
and the water refill plugs.
2. Remove the insulation profiles.
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: 4143180100) on each FNC® rail
cell.
Result: Now the cells are prepared for carrying out the charge for commissioning. Continue
with the execution.
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 32.
1. Discharge the battery using a charger/discharger at rated current I5 until the voltage of
the battery has dropped to 1V per cell.
2. Leave the unloaded battery to rest for at least 4 hours.
3. Measure the temperature of the battery, e.g. with a contact thermometer.

The cell to be measured should be installed in the middle of the battery in order to detect
the warmest part of the system.
4. Charge the battery at constant current I5 for 7.5 hours.
Note
If the charger used requires a voltage limit to be entered, set this to 2 V per cell.
Note
Result: The cells are now charged. Continue with the follow-up work.
8.2.2.3. 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.
- Close the upper opening of the measuring glass tube with your index finger.
- Remove it from the cell until the scale is visible.
3. Read off the electrolyte level in the cell using the electrolyte remaining in the measuring
glass tube and allow the electrolyte in the measuring glass tube to flow back into the cell.
4. Fill the cells with distilled water to the maximum level.
1 = Glass tube for measuring
2 = MAX electrolyte level
3 = Top of separator
4 = MIN electrolyte level
H1 = Height from open cell plug to

MAX electrolyte level
H2 = Reserve of electrolyte between

MIN and MAX label
H3 = Measurable electrolyte height

range
R2 36 ± 2 (3.5 rings)
R3
R4 55 ± 2 (5.5 rings)
5. Insert the vent plugs again or reinsert the water refill plugs and restore the tubing.
6. Thoroughly remove any impurities from the battery with a clean, damp cloth.
test report. If the individual cell voltages deviate more than ± 50 mV from the average of
all cell voltages, contact HOPPECKE Service.
8. Remount the insulation profiles.
Result: The cells are now ready for operation again.
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.
There is an immediate, high-risk hazard which, if not avoided, will result in death or serious
injury.
Never short-circuit the positive and negative terminals of a battery.
DANGER!
Danger when connecting a battery to the consumer.
Polarity reversal of batteries may cause overheating and caustic leakage.
injury.
Always check the correct polarity before making connections.
Ensure that all loads in the vehicle and the charger are disconnected or switched off.
Note
If the terminals of a battery are damaged, the battery can no longer be used.
Do not damage the terminals of the batteries.
Note
Observe the project-specific electrical circuit diagram.
1. Connect the positive terminal of the battery to the positive terminal of the on-board power
supply or charger.
2. Connect the negative terminal of the battery to the negative terminal of the on-board
power supply or charger.
3. If available, connect control cables (e.g. temperature sensors, middle-voltage taps, etc.).
4. Check the battery connection, for example by checking the charging voltage and the
control signals.
Result: The battery is now connected for use in the vehicle.
8.4. Recommissioning after test or parking operation

Experience has shown that long test and parking periods of more than 3 months can occur
between the first commissioning of the batteries and the handover of the vehicle for regular
operation. In such cases, a new commissioning charge must be carried out, see 8.2.2
Commissioning charge on page 39.
Maintenance
9. Maintenance
9.1. Preventive maintenance
Note
If you cannot carry out the maintenance yourself, have the batteries serviced regularly and
properly by HOPPECKE qualified personnel or personnel authorised by HOPPECKE
Batterie Systeme GmbH.
To ensure the optimal state of the battery system, follow the maintenance plan:
Activity Interval Description

Visual inspection 6 months 9.1.1 Perform visual inspection on page 46
Check electrolyte level 6 months 9.1.2 Checking the electrolyte level on page 47
Measuring the charge 1 year *) 9.1.3 Measuring the charging voltage on page 49
voltage
Top up with distilled water 9.1.4 Fill up the electrolyte level with distilled water
on page 51
Cleaning the battery 9.1.5 Cleaning the battery on page 54
Measurement of the 9.1.6 Testing the insulation resistance on page 55
insulation resistance
Reconditioning charge 5 years *) The reconditioning charge includes:
• Checking the electrolyte level
• Measuring the single cell voltages
9.1.7 Reconditioning on page 57
Replacement of the FNC® 15 years *) 11 Disassembly / Assembly on page 79
rail cells and the
attachments
*) 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 FNC ® rail batteries on page 93.
Maintenance
9.1.1. Perform visual inspection

Target: The battery is visually inspected.
1. Inspect the battery against the following criteria:
Test object Test criterion Remedy

Contamination Check battery cells, screws, Thoroughly remove dirt from
connectors and cable lugs for battery cells, screws, connectors
dirt. and cable lugs with a clean, damp
cloth, as dust and moisture can
lead to leakage currents.
Ventilation Check ventilation openings for Clear the ventilation openings.
free passage
Mechanical damage Check battery and container Contact the depot manager or
for mechanical damage HOPPECKE Service.
Tight fit of connectors, Connectors, screws, cables Tighten connectors, screws,
screws and cables must not be loose. cables.
Electrolyte level of the The electrolyte level must be If necessary top up with distilled
battery cells between the min and max water, see 9.1.4 Fill up the
mark. electrolyte level with distilled water
on page 51
Tight fit of the temperature Check temperature sensor, if Attach the temperature sensor
sensor present, for proper mounting properly.
Contamination by electrolyte Plugs must be tight (no stains Check plugs for tight fit, correct if
of electrolyte on the plugs or necessary.
on the cells)
Tight fit of the water refill Water refill systems must be Check hoses and plugs for tight
system correctly installed if present fit, correct if necessary.
(no loose hoses or plugs).
Seals 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 FNC ® rail batteries on page 93.
Result: The visual inspection was completed.
Maintenance
9.1.2. Checking the electrolyte level

Target: The electrolyte level of the battery cells is checked.
When a battery is overcharged, electrolysis decomposes the electrolyte water into gases
(H2 and O2). This causes the electrolyte level to drop. The amount of decomposed water
depends on the charging voltage, the charging time per day and the temperature.
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.
Wear protective goggles and gloves when working on the batteries. (Five-finger latex or PVC
gloves).
Required tools:
Cells for use in railway vehicles often have flame-retardant polypropylene vessels (PP-V0)
through whose walls the electrolyte levels are not visible. With translucent standard
polypropylene vessels (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.
1. Open the vent plugs or remove the water refill plugs from 10% of the battery cells. For
example, 8 cells in an 80 cell battery.
Maintenance
2. Keep the upper opening of the measuring glass tube free and insert it into the respective
cell until it encounters resistance.
- Remove the measuring glass tube from the cell until the scale is visible.


MIN and MAX label

range
3. Read off the electrolyte level in the cell using the electrolyte remaining in the measuring
Note
The rings count upwards from the lower edge of the measuring glass tube.
• If the electrolyte level is more than 2 rings (R2 and R3) or more than 3 rings (R4), no distilled
water should be added. Continue with step 4.
• If the electrolyte level in one of the FNC® cells is less than or equal to 2 rings (R 2 and R3)
or less than or equal to 3 rings (R4), top up distilled water to the maximum level. (see 9.1.4
Fill up the electrolyte level with distilled water on page 51)
• If the electrolyte levels of the FNC® cells differ by more than 2 rings, contact HOPPECKE
Service.
If the electrolyte level of one or more cells exceeds 5 rings (R2 and 3) or 7 rings (R4), contact the
HOPPECKE service.
4. Close the vent plug again or insert the water refill plug again.
Result: Now the electrolyte level of the battery cells has been checked.
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.
DANGER!
When establishing access to the battery system, contact with sharp edges and/or live
components may occur due to the design.
injury.
• - Be very careful when carrying out any work on the batteries.
• - Wear personal protective equipment, see 2 Safety instructions on page 11.
Pre-condition
The battery system is connected to the vehicle's onboard charger and is being charged.
Required tools:
• Digital Multimeter
• current clamp
1. Measure the charging voltage of the battery system with a suitable multimeter.
2. Measure the charging current of the battery system with a suitable current clamp.
3. Measure the temperature of the battery system with a suitable thermometer (e.g. contact
thermometer).
4. Check the measured value against the charging characteristic, see 5.5 Temperature
compensation on page 26.
It applies:
Measured Current (I) Measured Voltage

Battery < I20 Float-Charge
More than I20 but lower (1.5 x I5) Boost-Charge
≥ (1.5 x I5) I-Phase; no statement possible.
Wait until U = const, i.e. until Boost- or Float-
Charging is available
Example using an FNC cell of power class M:

For rapid charging, a cell voltage of 1.60 V at 20 °C must be measured.
Maintenance
Note
If the measured voltage deviates from the setpoint by more than ± 1.5%, troubleshoot the
temperature sensor or charger.
Result: The charging voltage of the battery has been checked.
Maintenance
9.1.4. Fill up the electrolyte level with distilled water

Target: The battery is refilled with distilled water.
WARNING!
or serious injury.
Wear protective glasses and gloves (five-finger latex or PVC gloves) when working on the
batteries.
Note
Always check the electrolyte level before this maintenance step, see 9.1.2 Checking the
electrolyte level on page 47.
Note
• Filling with acid destroys the FNC® rail cells.
• Tap water is not allowed and will affect your battery performance.
• Only use distilled / deionised water according to EN 60993 or DIN 43530-4 to refill the FNC®
rail cells.
The refilling of distilled water can be done with 3 different methods:
Method Description
Fill up water manually 9.1.4.1 Fill up distilled water manually on page 52
Fill up water with the central water refill system 9.1.4.2 Refill distilled water with the central water
refilling system on page 52
Fill up water with the water refill cart for single 9.1.4.3 Refill distilled water with the water refill cart for
cells single cells on page 53
Result: The electrolyte levels of the battery are filled with distilled water.
Maintenance
9.1.4.1. Fill up distilled water manually

Required tools:
• funnel or pipette for filling the distilled water into the cells
1. Open all vent plugs.
2. Fill each FNC® rail cell with distilled water to maximum level.
For the cell types R2, R3 and R4 (the type information is a part of the cell designation, see
label on each cell), observe the following table when refilling distilled water:
R2 36 ± 2 (3.5 rings)
R3
R4 55 ± 2 (5.5 rings)
3. Close all vent plugs.
4. Clean the battery system if necessary, see 9.1.5 Cleaning the battery on page 54.
9.1.4.2. Refill distilled water with the central water refilling system
Note
If a water refill system is installed on the battery, the following applies:
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
Maintenance
9.1.4.3. Refill distilled water with the water refill cart for single cells
Note
If a water refill cart for single cells is available, the following applies:
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
Maintenance
9.1.5. Cleaning the battery

Target: The battery is cleaned.
A clean battery is essential to avoid accidents and property damage, as well as shortened
life and availability.
Cleaning the FNC® rail cells and the tray or container is necessary to maintain the
necessary insulation of the cells against each other, against earth or foreign conductive
parts. Damage caused by corrosion and leakage currents is also avoided.
Cleaning the battery is not only necessary to ensure high availability, but is also an essential
part of accident prevention regulations.
Note
Improper cleaning may damage the batteries.
Avoid damaging the battery:
• Do not use solvents or wire brushes for cleaning.
• Prevent penetration of cleaning water and dirt particles into the cells. The vent plugs must
be closed.
1. Clean the battery with a clean cloth and with water without adding any detergents or
cleaning agents.
2. Let the surfaces dry or use compressed air.
Note
Any liquids which entered the battery tray must be extracted and disposed of in accordance with
waste monitoring guidelines.
Result: The battery is now cleaned.
Maintenance
9.1.6. Testing the insulation resistance

Target: The insulation resistance of the battery is measured.
The insulation resistance of a battery in the rolling stock is a measure of the conductivity
between the battery terminal posts and the chassis of the vehicle. The conductivity is a
result of moisture and contamination of the battery between the battery terminal posts and
the chassis of the rolling stock vehicle. Ideally, no conductivity should take place here. The
ideal insulation resistance of the battery should be infinitely large.
When commissioning a new battery, the insulation resistance must be > 1 MΩ . It decreases
with the operating time (due to aerosols from the batteries, condensation, dust) and may not
fall below the following values depending on the nominal battery voltage:
Battery nominal voltage Norm Insulation Resistance (minimum value)

below 100 V DIN VDE 0119-206-4 10 kΩ
between 100 V and 120 DIN EN IEC 62485-2 100 Ω per Volt nominal voltage
V
Above 120 V, DIN EN 62485-3 09/2015 Number of cells x 1.2 V nominal voltage x 500
i.e. from 100 cells Ohm/V
If this minimum value is not reached, a possibly existing insulation monitor may detect an
error, an undesired increased discharge and loss of battery performance may occur.
Note
For FNC® rail 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.
An insulation test voltage of 500 V may damage other components connected to the battery.
Disconnect the battery from the on-board network, positive and negative terminal.
WARNING!
When carrying out measurements with an insulation measuring instrument, there is a risk of
electric shock.
There is a potential medium risk which, if not avoided, could result in death or serious injury.
Observe the safety precautions described in the documentation of the insulation measuring
instrument.
Required tools:
• Insulation measuring instrument (e.g. Fluke 1507)
Maintenance
1. Check the function of the insulation measuring device by measuring any metal part of the
battery tray / battery container against any metal part of the vehicle chassis. The
measured resistance must be 0 Ohm.
2. Measure the insulation resistance between positive terminal of the battery and one
metallic part of the rolling stock vehicle chassis (battery compartment or central earthing
point).
3. Measure the insulation resistance between the negative terminal and a metallic part of
the rolling stock vehicle chassis.
4. Check the function of the insulation measuring device by measuring any metal part of the
battery tray / battery container against any metal part of the vehicle chassis. The
measured resistance must be 0 Ohm.
5. Clean the battery if the measurements fall below the minimum value (see 9.1.5 Cleaning
the battery on page 54).
6. Measure insulation resistances again according to steps 2 and 3.
Note
If the isolation test fails again, contact HOPPECKE service.
Result: The insulation resistance of the battery is now measured.
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. This can lead to the formation of a hydrogen-oxygen gas
mixture (oxyhydrogen gas), which explodes even at low energy input.
Keep any source ignition away from the battery system:
• Open flames or fire
• Smoking
• Glowing embers
• Flying sparks during grinding work
• Electrical sparks caused by switches or fuses
• Hot surfaces with temperature above 300°C
• Electrostatic discharges
Work with electrically insulated tools that do not create sparks.
Ground yourself when working directly on the battery system.
Make sure that there is adequate ventilation in the battery room in accordance with DIN EN IEC
62485-2, so that the potential explosive gas mixture is discharged.
WARNING!
or serious injury.
Wear protective glasses and gloves (five-finger latex or PVC gloves) when working on the
batteries.
Note
• Carry out reconditioning when the battery system is uninstalled, i.e. mechanically separated
from the vehicle
• Recondition in an air-conditioned working area at 20 °C (±5 °C).
Note
The reconditioning charge is a constant current charge, see 5.4.1 Charging with constant current
(I) on page 23.
Required tools:
• suitable charging/discharging equipment
• torque wrench with matching wrench sizes for M8/M10 screws
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
Prepare reconditioning 9.1.7.1 Preparation on page 59
Execute reconditioning 9.1.7.2 Execution on page 61
After reconditioning 9.1.7.3 Follow-up work on page 64
Maintenance
9.1.7.1. Preparation
Target: The cells are prepared for reconditioning.
1. Remove the vent plugs or the water refill plugs and their tubing from each FNC® rail cell.
2. Clean the vent plugs or the water refill system in warm water, i.e. place it in warm water
and allow it to act during the reconditioning period. Then rinse with fresh water.
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.
- Remove the measuring glass tube from the cell until the scale is visible.


MIN and MAX label

range
6. Read off the electrolyte level in the cell from the electrolyte remaining in the measuring
Maintenance
Note for FNC-Cells in format 2 and 3

• If the electrolyte level of one or more cells is higher than 4 rings (counted from bottom to
top):
- take the battery out of service
- contact the HOPPECKE Service.
• The electrolyte level must be at least 1.5 rings. If necessary, fill the cell up to this level with
distilled water.
- Continue with the reconditioning, see step 7.
• If the electrolyte levels in the FNC® cells are above 3.5 but below 4 rings:
- Continue with reconditioning, see step 7.
- greater contamination (ejection of electrolyte) must be expected.
- Prevent contamination by laying out with a highly absorbent paper towel.
• If the electrolyte levels of the selected FNC® cells are equal to or below 3.5 rings:
Note for FNC-Cells in format 4

• If the electrolyte level of one or more cells is higher than 6 rings (counted from bottom to
top):
- take the battery out of service
- contact the HOPPECKE Service.
• The electrolyte level must be at least 2.5 rings. If necessary, fill the cell up to this level with
distilled water.
- Continue with the reconditioning, see step 7.
• If the electrolyte levels in the FNC® cells are above 5.5 but below 6 rings:
- greater contamination (ejection of electrolyte) must be expected.
- Prevent contamination by laying out with a highly absorbent paper towel.
• If the electrolyte levels of the selected FNC® cells are equal to or below 5.5 rings:
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: 4143180100) on each FNC® rail
cell.
9. Connect the charger/discharger to the main terminals of the battery.
Note
• M8 Torque: 20 Nm ± 1 Nm
• Use new spring washers.
Maintenance
Result: Now the cells are prepared for reconditioning. Continue with the execution.
9.1.7.2. Execution
Target: The cells are reconditioned.
The following graphic illustrates the steps necessary for reconditioning:
Carry out
Reconditioning
1.Discharge Battery
2.Let battery rest

for 4h
3. Measure
Temperature
Check
temperature
4. Charge Battery interrupt
charging if
necessary
5. .Let battery rest

for 2h
no 6. Discharge Battery
Contact
Hoppecke- Iterations > 5
Service yes
7.Let battery rest
for 4h
Discharge Time
<= 4,5h?
yes
no
Check
temperature
Charge Battery interrupt
charging if
necessary
9. Let battery rest

for 2h
Reconditioning
finalized
Maintenance
The individual steps are described in detail in the following instructions:
1. Discharge the battery at rated current I5 until the voltage of the battery has dropped to
1.0 V per cell, e.g. 80 V for an 80 cell battery.
2. Let the unloaded battery rest for at least 4 hours, preferably overnight.
3. Measure the temperature of the battery, e.g. with a contact thermometer.

The cell to be measured should be installed in the middle of the system in order to detect
the warmest part of the system.
Record the measured value.
Note
6. Discharge the battery at rated current I5 until the voltage of the battery has dropped to
1.0 V per cell and measure the time. This is the capacity test.
Note
If the battery system takes 5 hours to drop to 1.0 V per FNC® rail cell its capacity is 100 %. It
applies:
• 5 hours -> 100 %
• 4.5 hours -> 90 %
• 4 hours -> 80 %
• 3,5 hours -> 70 %
…

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.
Maintenance
Note
Result: The cells are now reconditioned. Continue with the follow-up work.
Maintenance
9.1.7.3. Follow-up work

Target: The cells are made ready for operation again after reconditioning.
3. Check the electrolyte level at each cell and manually fill the electrolyte level to the
maximum with distilled water, see 9.1.4.1 Fill up distilled water manually on page 52
4. Thoroughly remove any impurities from the battery with a clean, damp cloth.
5. Measure and record the individual cell voltages with a digital multimeter.
Note
If the individual cell voltages vary by more than ± 50 mV from the mean of all cell voltages,
contact HOPPECKE service.
6. Mount the insulation profiles.
7. Insert the vent plugs or the water refill plugs back into each FNC® rail cell.
8. Restore the hose system of the water refilling system, if present.
9. Measure the insulation resistance of the battery, see 9.1.6 Testing the insulation
resistance on page 55.
Result: The cells are now ready for operation again and can be installed in the vehicle.
Maintenance
9.2. Corrective maintenance
Note
9.2.1. Change of FNC® cells
DANGER!
injury.
• Be very careful when carrying out any work on the batteries.
• Wear personal protective equipment, see 2.2 Personal protective equipment on page 16.
DANGER!
Loose connections on the terminal screws can become very hot and cause inflammation or
explosions.
Use each screw and washer only once.
• First tighten the terminal screws by hand only.
• Align batteries and connectors again if necessary.
• Then tighten the terminal screws to the prescribed torque.
Note
• Switch off all consumers and chargers from the battery system before starting maintenance
work.
• A battery always has a voltage at the terminals.
• A battery must not be earthed or short-circuited.
• Batteries are very heavy. Carry the battery carrier with a sufficient number of persons or use
suitable lifting equipment and means of transport.
If FNC® rail cells are defective, you can replace a maximum of 10% of the total number of
cells in the entire battery system with new, unused cells of the same type. If more cells are
defective, all cells must be replaced.
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. Replace the cells to be replaced as described under 9.2.1.2 Replace one or
more FNC® rail cell(s) on page 68.
• If stored cells older than 3 months are used, a commissioning charge must first be
carried out for these cells, see 9.2.1.1 Prepare the FNC® rail cell(s) to be replaced on
page 66.
The date of manufacture of the FNC® rail cells is stamped on the top of each cell. Each cell
has a 9-digit cell code at the top of the cell cover. The last four digits indicate the production
week and year.
Example: xxxxx2619 => production week 26; production year 2019
9.2.1.1. Prepare the FNC® rail cell(s) to be replaced

Target: The new exchange cells are prepared for operation in the vehicle.
Required tools:
• suitable charging/discharging equipment

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:
• M8 or M10 cable lug
• M8: 20 Nm Tightening torque / M10: 25 Nm Tightening torque
Maintenance
3. Attach a gas venting tube to each FNC® rail cell (HOPPECKE material number:
4143180100).
4. Connect the exchange cells connected in series with a suitable charger/discharger.
Note
Use a suitable cable to connect the charger/discharger:
• M8 or M10 cable lug
• M8: 20 Nm Tightening torque / M10: 25 Nm Tightening torque
• Use new spring washers
terminal screw
cable lug spring washer
5. Discharge exchange cells using the discharger with rated current I5 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. Charge exchange cells with constant current I5 for 7.5 hours.
Note
9. Allow exchange cells to rest for at least 4 hours, preferably overnight.
10. Disconnect the charger/discharger from the exchange cells.
12. Manually fill up the distilled water of the exchange cells to the maximum, see 9.1.4.1 Fill
up distilled water manually on page 52.
13. Remount the vent plugs or water refilling plugs.
Maintenance
14. Thoroughly remove any contamination from the battery with a clean, damp cloth.
test report.
Result: The exchange cells are now prepared for operation in the vehicle.
9.2.1.2. Replace one or more FNC® rail cell(s)

Target: The defective cells are replaced with new exchange cells.
Required tools:
• - digital multimeter
• - cell lifter
• - torque wrench with matching wrench sizes for M8/M10 screws
1. Disconnect chargers and loads from the battery system.
2. Open the battery container, if available.
3. Remove the vent plugs or water refilling plugs and the tubing of the cell to be replaced.
4. Remove the insulating profiles.
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.
Maintenance
7. 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 FNC® rail cell(s) to be replaced on page 66.
Note
The date of manufacture of the FNC® rail cells is stamped on the top of each cell.
Each cell has a 9-digit cell code on top of the cell lid. The last four digits give information about
the production week and the production year.
Example:
xxxxx2610 => Production week 26; Production year 2010
Maintenance
8. Install the cell connectors.
Terminal screw
Terminal screw
Spring washer
Spring washer
Cell connector
Note
9. Install the insulating profiles.
10. Reinsert the vent plug or water refill plug and install the tubing.
11. 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.
12. Document exchange and number of cells.
Result: Now the defective cells have been replaced by new exchange cells.
Maintenance
9.2.2. Exchange of the temperature sensor

Target: A defective temperature sensor is replaced with a new one.
DANGER!
injury.
Note
work.
suitable lifting equipment and means of transport
Required tools:
• torque wrench with matching wrench sizes for M4 and M8/M10 screws
1. Disconnect the plug connection of the temperature sensor.
2. If available, remove the water refilling tube above the affected cell connector.
3. Remove the insulation profile above the affected cell connector.
4. Remove the cell connector.
5. Remove the temperature sensor from the cell connector by loosening the M4 screws.
6. Mount a new temperature sensor on the cell connector (torque: 2 Nm)
7. Mount the cell connector.
Note
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 49.
Result: Now the defective temperature sensor has been replaced with a new one.
Maintenance
9.2.3. Exchanging a cell connector

Target: A defective cell connector is replaced with a new cell connector.
DANGER!
injury.
DANGER!
Loose connections on the terminal screws can become very hot and cause inflammation or
explosions.
Use each screw and washer only once.
• First tighten the terminal screws by hand only.
• Align batteries and connectors again if necessary.
• Then tighten the terminal screws to the prescribed torque.
Note
work.
suitable lifting equipment and means of transport
Required Tools:
1. If available, remove the water refilling tube above the affected cell connector.
2. Remove the insulation profile of the affected cell connector.
3. Remove the terminal screws.
4. Remove the defective cell connector.
Maintenance
5. Install a new cell connector.
Terminal screw
Terminal screw
Spring washer
Spring washer
Cell connector
Note
6. Install the insulation profile.
7. If available, install the water refilling tube.
Result: The defective cell connector has now been replaced with a new cell connector.
Troubleshooting
10. Troubleshooting
Note
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
Loose or oxidised terminal(s) Check all connector(s), replace the
connector(s) if required (use new spring
washer(s))
Excessive cyclisation (many charge- Perform a reconditioning charge
/ deep discharge cycles)
Temperature sensor has a defect. Check the temperature sensor if available, see
That causes incorrect charge 10.5 Malfunction of the temperature sensor on
parameters. page 78.
10.2. Insufficient insulation resistance

When commissioning a new battery, the insulation resistance must be > 1 MΩ . It decreases
with the operating time (due to aerosols from the batteries, condensation, dust) and may not
fall below the following values depending on the nominal battery voltage:
Battery nominal Norm Insulation Resistance (minimum value)

voltage
below 100 V DIN VDE 0119-206-4 10 kΩ
between 100 V DIN EN IEC 62485-2 100 Ω per Volt nominal voltage
and 120 V
Above 120 V, DIN EN 62485-3 09/2015 Number of cells x 1.2 V nominal voltage x
i.e. from 100 500 Ohm/V
cells
If these minimum values are not reached, a possibly existing insulation monitor of the
vehicle may response, an undesired increased discharge and loss of battery performance
may occur.
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
FNC® rail cell(s) is/are leaking Remedy the problem or replace the cell if
necessary
Water refilling system is leaking Remedy the problem or replace the
plugs/hoses if necessary
10.3. No battery voltage can be measured

If no battery voltage can be measured, proceed as follows:
Cause Remedy
Main plug of the battery system is Connect the main plug
not inserted
Main plug of the battery system is Replace the main plug
defect
Cable breakage Replace the cable
Cell connector(s) is/are defect Replace the connector(s) (use new spring
washer(s))
Troubleshooting
10.4. Malfunction of the water refilling system

- if available -
If malfunctions arise during refilling of water, proceed as follows:
Effect Cause Remedy

Cells are not refilled Dirt in the water refilling Clean water refilling plug(s) with
plug(s) warm water or replace it/them if
necessary.
Then check all cells manually and

refill distilled water manually to
ensure an even level in all cells. At
the next maintenance interval, you
can use the water refill system again
for refilling.
Water leakage during The connection between the Check connection and replace water
refilling hose and the water refilling refilling plug and/or hose if necessary
plug is faulty / water leakage
during refilling
O-rings are damaged or Replace O-rings
shifted
Cell(s) is/are filled above Operating error during the -
maximum level refilling of water
Note:
Start the filling operation only
once a maintenance interval.
You overfill the cells if you
start the filling operation many
successive times, comparable
with the filling process of a
fuel tank of a car that can be
overfilled.
A hose is bent Remedy the cause of the problem.
The return line of the water Connect the water refilling cart
refilling cart is not connected correctly.
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.
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 5.5 Temperature compensation on page 26.
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 => 10 kΩ @ 20 °C).
Proceed as follows:
Possible Cause Remedy

Temperature sensor defect Replace the temperature sensor, see 9.2.2
Exchange of the temperature sensor on page
71
Plug defective Replace plug
Plug not inserted Insert plug
Cable breakage in the extension Replace cable
cable
Disassembly / Assembly of FNC® rail cells and accessories
11. Disassembly / Assembly of FNC® rail cells and

accessories
11.1. Disassembly of FNC® rail 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.
Carry out the prescribed safety measures that apply to the required installation works on the
rolling stock, see 2 Safety instructions on page 11.
DANGER!
• Battery racks/trays are very heavy.
• A battery should not be grounded or shorted. Carry the battery racks/trays with an adequate
number of persons or use suitable hoisting gear and transport equipment.
DANGER!
Use only fully insulated tools when working on batteries.
Note
• For rework, the battery system has to be accessed and dismounted from the vehicle.
Depending on the installation situation (container on the roof, underfloor container,
installation sidewards in the train), the deinstallation must be done specifically.
• The deinstallation of the battery system out of the train must be carried out by the train
manufacturer / train operator.
• After deinstallation, the battery system should be brought into a battery workshop for rework.
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.
This has to be done depending on the specific installation situation.
4. Disconnect the mechanical connection between battery system and vehicle and
dismount the battery system. Use suitable lifting equipment (forklift, lifting gear) to lift the
battery.
5. Bring the battery to stand on a safe ground in a battery workshop.
6. Dismount the water refilling system (plugs and tubes) if the battery is equipped with it,
and clean it in warm water without adding any detergents.
7. Dismount the insulation profiles.
8. Loosen the terminal screws of the main terminals and lay the cables aside.
9. Remove the connectors between the cell rows first in the order given in the following
example illustrations.
8 7
3
5 6
4 3 2
2
1
1
Note
The illustration above is an example. When working on the battery, the project-specific drawings
must be used.
10. Then remove the connectors between the cells in the rows.
Note
For removing the connectors keep the following sequence:
• Loosen the terminal screws on the cell, but leave the last few turns in. Do not remove the
terminal screws in this first step.
• Twist out the terminal screws the last few turns by hand and lay them aside for reuse.
• Lift out the connectors by hand and lay them aside for reuse.
DANGER!
• A battery cell always has a voltage at the terminals.
• Always remove the connectors very carefully in such a manner, that they do not shortcut the
cell or adjacent cells.
• When removing the second screw of a connector, always hold the connector in the foreseen
direction. This is to avoid shortcuts from rotation of the connector.
11. Lift out the cells one after the other.
Note
12. Lift out the spacer material if available (ribbed plates) and clean it in warm water without
adding any detergents.
13. Prepare the tray or container for reuse by cleaning as follows on a suitable washing
place:
In case of low contamination by electrolyte:

• Protect additional electrical components against liquid by using a plastic bag.
• Clean the tray under flowing water.
• Wash out any contamination with a clean, damp cloth without adding any detergents.
• Dry the tray with compressed air.
In case of strong contamination by electrolyte:

• Protect additional electrical components against liquid by using a plastic bag.
• Clean the tray by using diluted citric acid (5%).
• Clean the tray under flowing water.
• Wash out any contamination with a clean, damp cloth without adding any detergents.
• Dry the tray with compressed air.
11.2. Assembly of new FNC® rail 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.
Carry out the prescribed safety measures that apply to the required installation works on the
rolling stock, see 2 Safety instructions on page 11.
DANGER!
• Battery racks/trays are very heavy.
• A battery should not be grounded or shorted. Carry the battery racks/trays with an adequate
number of persons or use suitable hoisting gear and transport equipment.
Note
The cells are delivered sealed with yellow transport plugs. Keep the yellow transport plugs on the
cells during the installation procedure until the vent plugs or water refilling plugs are installed.
1. Install the new cells according to the technical drawing. Use the ribbed plates if available
to separate the cells from each other and from the tray, see following illustration.
Information about the thickness of the ribbed plates can be taken from the drawings and
parts lists.
Insulation Profile
Ribbed Plate
Cell
Note
The illustration above shows an example installation with ribbed plates.
Note
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. For crate installations of only one row, the middle cells should also be
installed at the last position.
Proceed with the next row in direction to the middle of the tray and so on until all cells are placed:
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:
1 2
1
4 3
5 6 2
7
3
8
Note
The illustration above is an example. When working on the battery, the project-specific drawings
must be used.
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.
• Twist in the terminal screws the first turns by hand on both sides of the connector.
• Align the cells again finely.
• Tighten the terminal screws with a torque wrench.
DANGER!
• A battery cell always has a voltage at the terminals.
• Always install the connectors very carefully in such a manner, that they do not shortcut the
cell or adjacent cells.
• When installing the first screw of a connector, always hold the connector in the foreseen
direction. This is to avoid shortcuts from rotation of the connector.
Note
• M8 torque: 20 Nm ± 1 Nm
• M10 torque: 25 Nm ± 1 Nm
• Use new spring washers
3. Reinstall the insulation profiles.
4. Dry the water refilling system if available (plugs and tubes) with compressed air.
5. Remount the water refilling system if available (plugs and tubes) or the vent plugs
according to the technical drawing.
6. Reconnect the main cables by remounting the terminal screws of the main terminals.
Disposal
7. Check the function of the battery according to the test specification in the separate
document: PVE 10-20-General-00_Battery_Tray_rev<version-number>.pdf
8. Reinstall the battery into the vehicle and restore the mechanical connection. Use suitable
lifting equipment (forklift, lifting gear) to lift the battery.
9. Reconnect the electrical connection of the battery to the surrounding parts of the battery
system (electric parts in the e-box or similar) and the vehicle on all terminals. This has to
be done depending on the specific installation situation.
Note
The reinstallation of the battery system to the train must be carried out by the train manufacturer
/ train operator.
10. Switch on the battery main switch.
11. Connect the loads to the battery system.
12. Disposal
Note
Note
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.
Note
Dispose of nickel cadmium batteries, which are not recycled, as special waste in compliance with
all regulations.
Because of the cadmium and potassium hydroxide content, FNC® Rail cells must never be
disposed of with household waste or landfilled at the end of their service life.
Please observe the country-specific regulations and regulations for disposal separately
Appendix
13. Appendix
13.1. Additional tools
The following lists additional tools for maintenance and service:
Tool Description
Voltmeter/multimeter
(illustration shows an example)
Current clamp DC
Contact thermometer
Insulation tester: Fluke 1507

HOPPECKE Mat. No.: 4141201237
External charge/discharge unit

Appendix
Waterfilling cart for central low pressure refilling

system
• HOPPECKE Mat. No.:
4147000230 230 V
4147000235 115 V
Waterfilling cart for single cells of format 1-5:
4147000210 230 V
4147000215 115 V
Waterfilling cart for special cells with adjustable
pistol
4147000225 115V
4147000220 230V
Glass tube for measuring

Gas venting tube

Cell lifter
Format 3, 4, 5
M10: HOPPECKE Mat. No.: 4141900003
Format 1, 2
M8, HOPPECKE Mat. No.: 4141900002
Fully insulated torque wrench

Appendix
®
13.2. Commissioning protocol for HOPPECKE FNC rail 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
Charging time: from: __________ o'clock until: __________ o'clock
Measurement of the single cell voltages: see table on following sheet
Measurement of the electrolyte temperature (one cell):
Time after
start of
charging / h
Temperature /
°C
Name: ______________________________________
Signature: ______________________________________
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 1 2 Zellen 1 2 Zellen 1 2

Nr. [V] [V] Nr. [V] [V] Nr. [V] [V]
1 28 55
2 29 56
3 30 57
4 31 58
5 32 59
6 33 60
7 34 61
8 35 62
9 36 63
10 37 64
11 38 65
12 39 66
13 40 67
14 41 68
15 42 69
16 43 70
17 44 71
18 45 72
19 46 73
20 47 74
21 48 75
22 49 76
23 50 77
24 51 78
25 52 79
26 53 80
27 54 *1)
*1) If the battery system consists of more than 80 cells, expand the table accordingly.
Appendix
13.3. Maintenance protocol for HOPPECKE FNC ® rail 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: ___________________________________________
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)
0.5
1.5
2.5
3.5
4.5
5.5
6.5
7.5
8.5
9.5
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
Appendix
13.3.1.2. Maintenance - Check electrolyte level

Interval Check electrolyte Date Inspector (Name)
(years) level
done (mark with
cross)
0.5
1.5
2.5
3.5
4.5
5.5
6.5
7.5
8.5
9.5
10
10.5
11
11.5
12
12.5
13
13.5
14
14.5
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
1
10
11
12
13
14
Appendix
13.3.2.2. Maintenance - Fill up electrolyte level

Interval Fill up electrolyte Date Inspector (Name)
(years) level done (mark
with cross)
1
10
11
12
13
14
Appendix
13.3.2.3. Maintenance - Cleaning

Interval Done (mark Date Inspector (Name)
(years) with cross)
1
10
11
12
13
14
Appendix
13.3.2.4. Maintenance - Measurement of the insulation resistance

Interval Measured Date Inspector (Name)
(years) value in
Ohm
1
10
11
12
13
14
Appendix
13.3.3. Maintenance Interval every 5 years

13.3.3.1. Maintenance - Reconditioning
Intervall Done (mark Date Inspector (Name)
(years) with cross)
5
10
Appendix
13.3.3.2. Maintenance - Measurement of voltage of single FNC® rail cells

Interval 5 years:
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 ± 50 mV from the average of all
cell voltages, contact HOPPECKE service.
Cell 1* 2* 3* Cell 1* 2* 3* Cell 1* 2* 3*

No. [V] [V] [mV] No. [V] [V] [mV] No. [V] [V] [mV]
1 28 55
2 29 56
3 30 57
4 31 58
5 32 59
6 33 60
7 34 61
8 35 62
9 36 63
10 37 64
11 38 65
12 39 66
13 40 67
14 41 68
15 42 69
16 43 70
17 44 71
18 45 72
19 46 73
20 47 74
21 48 75
22 49 76
23 50 77
24 51 78
25 52 79
26 53 80
27 54 *1)
Date: ______________________ Inspector: ______________________
Appendix
Interval 10 years:
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 ± 50 mV from the average of all
cell voltages, contact HOPPECKE service.
Cell 1* 2* 3* Cell 1* 2* 3* Cell 1* 2* 3*

No. [V] [V] [mV] No. [V] [V] [mV] No. [V] [V] [mV]
1 28 55
2 29 56
3 30 57
4 31 58
5 32 59
6 33 60
7 34 61
8 35 62
9 36 63
10 37 64
11 38 65
12 39 66
13 40 67
14 41 68
15 42 69
16 43 70
17 44 71
18 45 72
19 46 73
20 47 74
21 48 75
22 49 76
23 50 77
24 51 78
25 52 79
26 53 80
27 54 *1)
Date: ______________________ Inspector: ______________________

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Executive Responsible Document type: State of

department: department: Technical Documentation confidentiality:

Operating and Installation Manual

Revision Date Status Name Chapterl Reason for Change

HOPPECKE Batterie Systeme GmbH Service hotline Germany:

Copyright HOPPECKE Batterie Systeme GmbH

1. USING THIS MANUAL 7

1.1. Target group of this document 7

1.2. Icons and signal words 7

1.3. Notation of nominal data 8

1.4. Graphic symbols / pictograms on the battery system 9

1.5. Nameplate information on the product 10

1.6. Definitions of terms 10

1.7. Other applicable documents 10

2.1. Potential hazards 11

2.2. Personal protective equipment 16

2.3. Markings on the product 16

3. USE OF THE PRODUCT 17

3.1. Intended use 17

3.2. Unintended use 17

4. DIRECTIVES, LEGISLATION AND STANDARDS 18

5. FUNCTION AND STRUCTURE 19

5.2. FNC® rail cell 19

5.3. Low pressure water refilling system 21

5.4. Charging procedures for FNC rail cells 23

5.5. Temperature compensation 26

6. INSTRUCTIONS FOR TRANSPORT 30

6.1. Surface transport (Road/Rail) according to ADR/RID 30

6.3. Air freight 31

7.1. General instructions 31

7.2. Storage period 32

7.3. Storage with built-in battery 33

8.1. Checking the delivery 35

8.2. Measures prior to initial commissioning 35

8.3. Installation and connection 43

8.4. Recommissioning after test or parking operation 44

9.1. Preventive maintenance 45

9.2. Corrective maintenance 65

10.1. Insufficient capacity 75

10.2. Insufficient insulation resistance 75

10.4. Malfunction of the water refilling system 77

10.5. Malfunction of the temperature sensor 78

11. DISASSEMBLY / ASSEMBLY OF FNC® RAIL CELLS AND ACCESSORIES 79

11.1. Disassembly of FNC® rail cells and accessories 79

11.2. Assembly of new FNC® rail cells and accessories 83

13.1. Additional tools 89

13.3. Maintenance protocol for HOPPECKE FNC ® rail batteries 93

1. Using this manual

Please contact your local authorised dealer if:

1.1. Target group of this document

1.2. Icons and signal words

1.3. Notation of nominal data

Notation Meaning Value

1.4. Graphic symbols / pictograms on the battery system

EN ISO 7010 - W012

EN ISO 7010 - W026

EN ISO 7010 - W023

EN ISO 7010 - W002

EN ISO 7010 - P003