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Foreword
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This draft Standard was prepared by the Ad Hoc Working Group 10 of TC9, Electromechanical
material on board of rolling stock, of Technical Committee TC 9, Electrical equipment and
systems for railways. It is submitted to the IEC enquiry.
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As grounding standards for Li-Ion industrial batteries (non-market specific, excluding road
applications), 2 standards are under development or finalization (as per IEC SC21A meeting in
th
th
Orlando on February 28 & 29 ):
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IEC 62620: Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Large format secondary lithium cells and batteries for use in
industrial applications,
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IEC 62619: Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Safety requirements for large format secondary lithium cells and
batteries for use in industrial applications.
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In addition, an integration standard for all energy storage technology is useful, especially
concerning the electrically connected ones. A call for expert had been issued in that direction,
as mentioned in the TC 9 CAG Recommendation 14/02 decided on April 18th, 2012. The
Japanese TC9 NC proposed convenor for this “NP on hybrid system with energy storage for
rolling stock”.
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It appeared that for EDLC type of energy storage units , the existing standardization has been
already created and can support the introduction of those technologies and is already started.
For Li-Ion batteries, although the battery part itself is under creation, a standard specifying the
specific rules to be applied for rolling stock would be requested, as done for EDLCs.
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The 1st Meeting of IEC/TC9/AHG7 on September 6th, 2012, in Erlangen, Germany, concluded,
as per convenor report:(point 4) that “As for energy storage systems, application standards for
traction batteries, flywheel, etc. are missing. Need of a new application standard of traction
batteries, especially Lithium-Ion, for TC9 was identified.”
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Therefore the current standard proposal was generated as per results of 9/1770/RQ
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Inquiry, on 2013-01-18, to answer the need to define complementally specific requirements for
Raiways considering:
35
on-board installation (for traction) as concluded at AHG7
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“Railways adaptations” versus those general standards
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This standard prIECxxxx shall be read in conjunction with PT 62864-1 “Railway applications – Rolling
stock – Power supply with onboard energy storage system - Part 1: Series hybrid system”.
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It should be mentioned that the auxiliary onboard battery type are not concerned in the present
document.
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This standardization project was derived from the EU-funded Research project CleanER-D.
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It is part of a series of standards, referring to each other. The hierarchy of the standards is intended to
be as follows in Railway specific area:
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and is grounded on global standards dealing with industrial Li-ion batteries:
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CONTENTS
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INTRODUCTION ..................................................................................................................... 5
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1
General ............................................................................................................................ 6
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2
1.1 Scope ...................................................................................................................... 6
Normative references........................................................................................................ 6
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3
Terms and definitionsr ...................................................................................................... 6
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4
3.1 Battery state of charge (SOC) .................................................................................. 7
3.2 8
hybrid ............................................................................................................................... 8
3.3 8
hybrid system vehicle ........................................................................................................ 8
Abbreviations .................................................................................................................... 9
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5
Parameter measurement tolerances ................................................................................ 10
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6
Selection of the most railways relevant regulations applicable to Li-ion railways
batteries ......................................................................................................................... 10
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6.1 Mechanical ............................................................................................................ 10
6.2 Environment .......................................................................................................... 10
6.3 Electrical ............................................................................................................... 11
6.4 Integration ............................................................................................................. 12
6.5 Fire protection ....................................................................................................... 12
6.6 Safety .................................................................................................................... 13
6.7 Electromagnetic compatibility EMC ........................................................................ 14
6.8 Software ................................................................................................................ 14
6.9 Miscellaneous / Sundries ....................................................................................... 14
Designation and marking ................................................................................................ 15
8
Battery designation ................................................................................................ 15
Battery termination ................................................................................................ 15
Marking ................................................................................................................. 15
7.3.1 Nameplate ................................................................................................. 15
7.3.2 Cells, Battery-pack, Tray, crate or other nameplates inside the battery ....... 16
7.4 Safety recommendations ....................................................................................... 16
7.4.1 Safety signs ............................................................................................... 16
Storage and transportation conditions ............................................................................. 18
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8.1 Transportation ....................................................................................................... 18
8.2 Storage of batteries ............................................................................................... 18
Dimensions ..................................................................................................................... 18
86
10 Electrical interface requirements ..................................................................................... 18
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10.1 Communication ...................................................................................................... 18
10.2 Dead start battery .................................................................................................. 19
11 Sizing requirements ........................................................................................................ 19
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11.1 Discharging requirements ...................................................................................... 20
11.1.1 Load profile ............................................................................................... 20
11.2 Requirements for battery sizing for emergency operations ...................................... 22
11.2.1 Long-time discharge .................................................................................. 22
11.2.2 Low temperature performance (if applicable) .............................................. 22
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7.1
7.2
7.3
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11.3 Charge retention (self discharge) ........................................................................... 22
11.4 Operationnal requirements (charge & discharge) .................................................... 22
11.5 Type of load profiles (duty cycles) requested to size the Railways traction
battery ................................................................................................................... 23
11.6 Functions considered (examples, eg auxiliary loads) .............................................. 23
11.7 Requests for cooling / heating (if requested, as per the sizing) ............................... 23
12 Electrical tests : specific (additionnal to 62619/620) testing requirements ........................ 23
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12.1 Specific (additionnal to 62619/620) testing requirements ........................................ 23
12.2 Specific operational conditions for Railways (eg long storage,…) ............................ 23
12.3 Load profile verification .......................................................................................... 23
12.3.1 General ..................................................................................................... 23
12.3.2 General methodology ................................................................................. 23
12.3.3 Sizing description (calculation, simulation or preliminary tests) ................... 24
12.3.4 Sizing documentation ................................................................................. 24
12.3.5 Operational verification (load profile test) ................................................... 24
12.3.6 Test report ................................................................................................. 25
12.4 Endurance ............................................................................................................. 26
12.4.1 Endurance in cycles ................................................................................... 26
13 Physical appearance ....................................................................................................... 26
114
14 Conditions for approval and acceptance .......................................................................... 27
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14.1 Type approval ........................................................................................................ 27
14.2 Batch acceptance .................................................................................................. 27
Bibliography ........................................................................................................................ 28
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Figure 1 – Safety signs outside the battery box ...................................................................... 16
120
Figure 1 – Safety signs inside the battery box ........................................................................ 17
121
Figure 1 - Example of load profile in emergency operation (standstill of the train) ................... 21
122
Figure 1 - Example of load profile in driving operation (driving without battery charging) ......... 21
123
Figure 1 - Example of speed limit profile attached to a specific track ...................................... 19
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Figure 1 Example of altitude profile attached to a specific track ............................................. 19
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Table 1a – Dimensions for vented nickel-cadmium prismatic cells in steel containersError! Bookmark not defin
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Table 1b – Dimensions for vented nickel- cadmium prismatic cells in plastic containersError! Bookmark not de
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Table 2 – Measurement tolerances in millimetres (valid for widths and lengths) .................... 18
129
Table 3 – Discharge performance at 20 °C ................................ Error! Bookmark not defined.
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Table 4 – Discharge performance at +5 °C ................................ Error! Bookmark not defined.
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Table 5 – Discharge performance at –18 °C .............................. Error! Bookmark not defined.
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Table 6 – High currents values .................................................. Error! Bookmark not defined.
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Table 7 – Endurance in cycles ................................................... Error! Bookmark not defined.
134
Table 8 – Constant voltage charging conditions ......................... Error! Bookmark not defined.
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Table 9 – Sequence of tests for type approval ........................... Error! Bookmark not defined.
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Table 10 – Recommended test sequence for batch acceptance . Error! Bookmark not defined.
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INTRODUCTION
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Concerning secondary lithium technology, as per the market started it development mainly with
portable batteries in the 90’s, existing standards are currently available focused on those
smaller batteries than considered in the present document:
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IEC 61960 Ed. 2: Secondary cells and batteries containing alkaline or other nonacid electrolytes - Secondary lithium cells and batteries for portable applications
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IEC 62133 Ed. 1: Secondary cells and batteries containing alkaline or other nonacid electrolytes - Safety requirements for portable sealed secondary cells, and for batteries
made from them, for use in portable application.
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Those standards are not covering the large cells and batteries for industrial applications, used
in railway applications, which are non-portable, with a mass of hundreds of kilograms.
Therefore, they will not be mentioned in the following parts.
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In March 2007, it was decided to start work on large capacity lithium cells & batteries, during
the general meeting of TC 21 & SC 21A in Beijing (China). Works done from then led to the
following standards under construction:
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IEC 62620: Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Large format secondary lithium cells and batteries for use in industrial
applications,
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•
IEC 62619: Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Safety requirements for large format secondary lithium cells and batteries for use
in industrial applications.
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It is on interest to mention that railways are specifically mentioned as an example in those
standards, to illustrate the scope difference versus portable.
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Li-ion railways batteries can be applied as pure traction Li-ion railways batteries, as pure
auxiliary Li-ion railways batteries, as Li-ion railways batteries to start a diesel engine or as a
combined Li-ion railways battery for two or even all three applications.
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Each application brings its own demands, often even its own standards. One has to
differentiate between standards on a component level (mainly valid for all three applications)
and standards on integration or function level.
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The latter standards are often generic and not direct linked to an Li-ion railways batteries
technology, but to the function the Li-ion railways batteries has to provide in a train. It can also
happen that these standards diminish limits set by other only component relevant standards.
For example a battery standard can allow a relative wide range of voltage, but due to the direct
connection to a train safety system this range is diminished by another standard.
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Every Li-ion railways batteries technology needs further components, not for storage of energy
but for control or safety functions – or for integration in the train like supporting frames. These
kind of additional components are normally not a new technology, in principle not even new for
train application. Therefore a wide range of standards can be applied on these components.
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In case an Li-ion railways batteries is built as a battery pack, some standards may by applied to
the whole battery pack, not just for the part the standard was originally written. An example for
that would be shock and vibration tests.
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RAILWAY APPLICATIONS – ROLLING STOCK EQUIPMENT –
ONBOARD LITHIUM-ION TRACTION BATTERIES
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1 General
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1.1 Scope
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This International Standard applies to Li-ion traction batteries for railway applications.
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It specifies the design, operation parameters, safety requirements, routine and type tests, as
well as marking, designation and dimensions.
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When there is an existing IEC standard specifying test conditions and requirements for
batteries used in special railway applications and which is in conflict with this standard, the
former shall take precedence.
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Possible use cases for the railway hybrid vehicle with onboard Li-ion traction batteries are
described in IEC 62864-1.
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2 Normative references
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The following normative documents contain provisions which, through reference in this text,
constitute provisions of this International Standard. For dated references, subsequent
amendments to, or revisions of, any of these publications do not apply. However, parties to
agreements based on this International Standard are encouraged to investigate the possibility
of applying the most recent editions of the normative documents indicated below. For undated
references, the latest edition of the normative document referred to applies. Members of IEC
and ISO maintain registers of currently valid International Standards.
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IEC 60050(486), International Electrotechnical Vocabulary – Chapter 486: Secondary cells and
batteries
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IEC 60051 (all parts), Direct acting indicating analogue electrical measuring instruments and
their accessories
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IEC 60410, Sampling plans and procedures for inspection by attributes
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IEC 60417 (all parts), Graphical symbols for use on equipment
211
IEC 60485, Digital electronic d.c. voltmeters and d.c. electronic analogue-to-digital converters
212
213
IEC 61438, Possible safety and health hazards in the use of alkaline secondary cells and
batteries – Guide to equipment manufacturers and users
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3 Terms and definitionsr
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For the purpose of this document, the terms and definitions given in IEC 60050-482 and
ISO/IEC Guide 51 as well as the following apply.
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3.1
capacity recovery
capacity that a cell or battery can deliver after the charge following the charge retention test
according to
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3.2
charge (capacity) retention
capacity that a cell or battery can deliver after storage, at a specific temperature, for a specific
time without subsequent recharging as a percentage of the rated capacity
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3.3
final voltage
end-of-discharge voltage
specified closed circuit voltage at which a discharge of a cell or battery is terminated
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3.4
nominal voltage
suitable approximate value of voltage used to designate or identify the voltage of a cell or
battery
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3.5
rated capacity
quantity of electricity C 5 Ah (ampere-hours) declared by the manufacturer which a single cell or
battery can deliver during a 5-h period, when charging, storing and discharging under the
conditions specified in 6.3.1
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3.1 Battery state of charge (SOC)
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residual capacity of battery available to be discharged, normally expressed as a percentage of
full charge
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3.6
Cell (secondary lithium)
a cell whose electrical energy is derived from the oxidation and the reduction of lithium. It is not
ready for use in an application since it is not yet fitted with its final housing, terminal
arrangement and electronic control device
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3.7
cell block
A group of cells connected together in parallel configuration. It is not ready for use in an
application since it is not yet fitted with its final housing, terminal arrangement and electronic
control device.
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3.8
module
A group of cells connected together either in a series and/or series/parallel configuration with
or without protective devices (e.g. fuse or PTC) and monitoring circuitry. It can be transported
and replaced when the battery system is maintained.
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See Note at Table 1.
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3.9
battery pack
A unit which incorporates one or more cells or modules. It incorporates adequate housing and
a terminal arrangement and may have protective devices or circuits. It gives control information
based on cell voltage to a battery system.
Note 1 the battery maker may provide the nominal voltage.
Note 2 the nominal voltage of a battery of n series connected cells is equal to n times the nominal voltage of a
single cell.
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3.10
battery system (equal to battery)
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A system which incorporates one or more cells, modules or battery packs. It has a battery
management unit to cut off in case of over charging, over current, and over heating. It may
have cooling or heating units.
In this particular standard, battery is restricted to xxx (take from PT 62864-1). TBD.
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3.2
273
hybrid
274
a system that combines two (or more) different types of components for a specific purpose
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An approach for using multiple motive power sources and one for using multiple electric power
sources exist for rolling stock applications.
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3.3
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hybrid system vehicle
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A vehicle that can store energy in an onboard energy storage system and is driven by using the
stored energy as well as electric power from a generator or overhead lines
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3.4
safety
freedom from unacceptable risk
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3.5
risk
a combination of the probability of occurrence of harm and the severity of that harm
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3.6
harm
physical injury or damage to the health of people or damage to property or to the environment
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3.7
hazard
potential source of harm
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3.8
intended use
use of a product, process or service in accordance with specifications, instructions and
information provided by the supplier
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3.9
reasonably foreseeable misuse
use of a product, process or service in a way which is not intended by the supplier, but which
may result from readily predictable human behaviour
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3.10
leakage
visible escape of liquid electrolyte
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3.11
venting
release of excessive internal pressure from a cell, module, battery pack, or battery system in a
manner intended by design to preclude rupture or explosion
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3.12
rupture
mechanical failure of a cell container or battery case induced by an internal or external cause,
resulting in exposure or spillage but not ejection of materials
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3.13
explosion
failure that occurs when a cell container or battery case opens violently and major components
are forcibly expelled
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3.14
fire
the emission of flames from a cell, module, battery pack, or battery system
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3.15
upper limit charging voltage
the highest charging voltage in the cell operating region from a safety stand point specified by
the cell manufacturer
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3.16
maximum charging current
the maximum charging current in the cell operating region from a safety stand point specified
by the cell manufacturer
327
3.17 ESS
328
3.18 ESU
329
3.19 BMS or BMU (requirement for this to be reflected in the text)
330
3.20 BTMS (requirement for this to be reflected in the text)
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4 Abbreviations
333
For the purpose of this document, the following abbreviations apply.
334
AC
Alternating Current
335
C5
Capacity at the 5-hour rate
336
DC
Direct Current)
337
DoD
Depth of Discharge
338
EMU
Electrical Multiple Unit
339
H
Height
340
HVAC
Heating, Ventilation, Air Conditioning
341
L
Length
342
LRU
Line replaceable Unit
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LVPS
Low Voltage Power Supply
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SOC
State of Charge
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W
Width
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5 Parameter measurement tolerances
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The overall accuracy of controlled or measured values, relative to the specified or actual
values, shall be within these tolerances:
351
a)
+1 %
for voltage;
352
b)
+1 %
for current;
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c)
+2 °C
for temperature;
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d)
+0,1 %
for time;
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e)
+1 %
for capacity.
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357
These tolerances comprise the combined accuracy of the measuring instruments, the
measurement techniques used, and all other sources of error in the test procedure.
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For assistance in selecting instrumentation see IEC 60051 for analogue instruments and IEC
60485 for digital instruments. The details of the instrumentation used shall be provided in any
report of results.
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6 Relevant railway standards
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6.1 Mechanical
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In the mechanical point of view, IEC 61373 “Railway applications - Rolling stock equipment.
Shock and vibration tests” appears as very relevant for energy storage systems.
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Also, EN 15085 "Railway applications - Welding of railway vehicles and components" is valid
for container and supporting frames.
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As for calculations for structures, the EN 12663 “Prescription for sizing of railways vehicles
structures” should be applied.
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6.2 Environment
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The following standards define environmental demands for railway components:
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IEC 60068-2-38: Environmental testing - Part 2-38: Tests - Test Z/AD: Composite
temperature/humidity cyclic test
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IEC 60068-2-1: Environmental testing - Part 2-1: Tests - Test A: Cold (2007)
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IEC 60068-2-2: Environmental testing - Part 2-2: Tests - Test B: Dry heat
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IEC 60068-2-27: Environmental testing - Part 2-27: Tests - Test Ea and guidance: Shock
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IEC 60068-2-30: Environmental testing - Part 2-30: Tests – Test Db: Damp heat, cyclic (12h +
12h cycle)
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IEC 60721-1: Railway application - Environmental conditions for equipment. Part 1: Equipment
on board rolling stock.
382
IEC 529: Degrees of protection provided by enclosures (IP Code)
383
is relevant for the enclosures of Li-ion railways batteries systems.
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IEC 60721-3-2 Classification of environmental conditions - Part 3: Classification of groups of
environmental parameters and their severities; section 2: Transportation
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6.3 Electrical
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Considering the electrical point of view, the following European railway standards applicable to
Li-ion railways batteries have been selected. One has to differentiate the potential of an Li-ion
railways batteries component when applying these standards. Some are only valid for low
voltage (e.g. 24 V DC for controllers), some are valid for mid voltage (e.g. 750 V DC link). The
latter should be applied for electric Li-ion railways batteries like batteries, EDLCs or flywheels
as these Li-ion railways batteries interfere with existing technologies like traction converters,
what for the standards have been written.
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IEC 62497-2: Railway application - Insulation coordination. Part 1: Basic requirements.
Clearances and creepage distances for all electrical and electronic equipment
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398
EN 61991: Railway applications. Rolling stock. Protective provisions relating to electrical
hazards
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400
This regulation takes an important place considering an electrical storage supplying traction
power in rolling stock. Protective provision have to be taken.
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IECC 60721-1 Railway applications - Electronic equipment used on rolling stock
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403
This standard is mainly valid for the low voltage components, but it also refers to environment
standards and defines applicable limits depending on the place of integration.
404
IEC 60850: Railway applications - Supply voltages of traction systems
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406
407
408
409
This regulation is related to the EN 50153 about storage system used to supply traction power.
Regulation EN 50163 gives the requirement to guarantee quality of voltages supplied by the
storage system. This standard and its voltage ranges could be applied to electric Li-ion
batteries as per extension (currently, it is not applicable as only directly connected equipment
are concerned)
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IEC 61287-1: Railway applications – Electronic power converter for rolling stock
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IEC 60050-826: Low-voltage installations - Part 200: Definitions
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IEC 60077-1: Railway applications - Electric equipment for rolling stock - Part 1: General
service conditions and general rules
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415
IEC 60077-2: Railway applications - Electric equipment for rolling stock - Part 2:
Electrotechnical components; General rules
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IEC 60364-5-56: Low-voltage electrical installations - Part 5-56: Selection and erection of
electrical equipment - Safety services
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EN 60439: Low-voltage switchgear and control gear assemblies
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This regulation has to be taken into account in the case of a storage system used to supply
auxiliaries connected to the low-voltage bus.
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IEC 60571: Electronic equipment used on rail vehicles
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IEC 60893-1: Insulating materials - Industrial rigid laminated sheets based on thermosetting
resins for electrical purposes - Part 1: Definitions, designations and general requirements
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UIC 550: Power Supply Installations for Passenger Stock
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Cabling Installation
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EN 50343: Railway application - Rolling stock. Rules for installation of cabling.
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Cables standards:
430
EN 50264-1, EN 50264-2 , EN 50264-3
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EN 50306-1, EN 50306-2, EN 50306-3, EN 50306-4
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EN 50355
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434
All these standards refer to Railway applications - Railway rolling stock cables having special
fire performance.
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436
EN 50382-1, EN 50382-2, EN 50382-3, Railway applications – Railway rolling stock high
temperature power cables having special fire performance
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6.4 Integration
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Considering integration of embedded energy storage, regulation EN 50272-3 titled “Safety
requirements for secondary batteries and battery installations. Traction batteries” is very
relevant for traction batteries. However, it doesn’t appear the same regulation about other type
of energy storage system (only lead-acid & alkaline batteries are concerned, with mention of
possible other technologies that could be added).
444
6.5 Fire protection
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450
Considering exported safety, the series of regulation “EN/TS 45545 / prEN 45545” under vote
procedure about fire protection is very relevant about the requirement on the material and
components in the train. Specially the two series prEN/TS 45545-2 and prEN/TS 45545-4 titled
“Railway applications. Fire protection on railway vehicles. Requirements for fire behaviour of
materials and components” and “Railway applications. Fire protection on railway vehicles. Fire
safety requirements for railway rolling stock design”.
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452
453
Li Ion batteries and EDLC, with metallic components and no plastic do not have specific testing
in these standards. This is a gap and should be considered in future updates of EN 45545 or
with application rules in the current Li-ion traction battery standard.
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WARNING: This part is not developed enough and should be discussed in the working group
with participation of experts from the sector (operators, OEMs, manufacturers). This is key for
railways industry, especially after the events that did occur in aviation sector and are
generating questions from operators, with possible use of rolling stocks in long tunnels.
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460
461
6.6 Safety
462
The IEC 62619 should be considered as a basis.
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464
465
466
467
In addition for railways, this theme is more generic and has to be considered especially on the
integration level. For all new and modified railway vehicles the "Commission Regulation (EC)
No 352/2009 of 24 April 2009 on the adoption of a common safety method on risk evaluation
and assessment as referred to in Article 6(3)(a) of Directive 2004/49/EC of the European
Parliament and of the Council" has to be considered.
468
469
470
471
472
473
In this regulation common safety methods (CSM) for risk evaluation are defined. This CSM
shall be applied not only on a component level, but also on an integration and functional level.
Here it is a big difference whether an Li-ion railways batteries is for traction only or also
providing onboard power supply for e.g. safety relevant components like train controller or
radio. A risk evaluation and assessment provides the necessary safety integrity level (SIL) for
each function and finally each component.
474
475
476
477
478
For batteries it will be also important which cell type is used, as some types (e.g. lithium iron
phosphate base) could show lower risks to have cell opening or flames in abusive situations
than others. The FP7 project OSIRIS launched in January 2012 will have a specific part
concerning safety if Li-ion cells, and will allow selecting the Li-ion electrochemistry taking into
consideration such point.
479
*** Regulation examples to be inserted as an annex ***
480
481
482
483
484
485
486
487
488
489
As an EC regulation the - COMMISSION REGULATION (EC) No 352/2009 of 24 April 2009 on
the adoption of a common safety method on risk evaluation and assessment as referred to in
Article 6(3)(a) of Directive 2004/49/EC of the European Parliament and of the Council - may not
be transferred to national law. Nevertheless national authorities may decree national rules how
to apply it. In Germany for example this was done by the Eisenbahn Bundesamt (EBA) by the
"Hinweise für die Anwendung der Verordnung (EG) Nr. 352/2009 der Kommission vom
24.04.2009 über die Festlegung einer gemeinsamen Sicherheitsmethode für die Evaluierung
und Bewertung von Risiken gemäß Artikel 6 Abs. 3 Buchstabe a der Richtlinie 2004/49/EG des
Europäischen Parlaments und des Rates durch das Eisenbahn-Bundesamt " (reference to
apply the EC 352/2009 …).
490
491
492
493
494
Based on the CSM the EBA together with the sector has developed the SIRF method
("Sicherheitsrichtline Fahrzeug", in English "safety rule vehicle"), which has to be applied in
Germany since 2011, as a detailed definition of the CSM. NeverthelLi-ion railways batteries
EBA also allows performing safety analysis according comparable standards like ISO 13849 or
EN 61062.
495
496
497
498
WARNING: This part is not developed enough and should be discussed in the working group
with participation of experts from the sector (operators, OEMs, manufacturers). This is key for
railways industry, especially after the events that did occur in aviation sector and are
generating questions from operators, with possible use of rolling stocks in long tunnels.
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499
500
6.7 Electromagnetic compatibility EMC
501
The common EMC standards for rail should be applied to Li-ion railways batteries:
502
503
IEC 62236: Railway application - Electromagnetic compatibility (all parts), especially the IEC
62236-3-2
504
505
6.8 Software
506
Software in Li-ion railways batteries components must fulfil the common rail standards:
507
508
EN 50126: Railway Applications - The Specification and Demonstration of Reliability,
Availability, Maintainability and Safety (RAMS)
509
510
IEC 61508: Functional safety of electrical, electronic programmable electronic safety-related
systems
511
IEC 62279: Railway Applications - Software for railway control and protection systems
512
513
6.9 Miscellaneous / Sundries
514
The following standards do not fit in the above structure, but should be applied as well:
515
516
ISO 3095 or 3381 “Railways application – acoustics – measurement of noise inside railbound
vehicles”
517
IEC 62079: Preparation of instructions - Structuring, content and presentation
518
519
Instructions and manuals are an important input for safety analysis, as the manufacturer has to
describe here risks and how to deal with them during operation.
520
IEC 61123: Reliability testing; compliance test plans for success railways batteries ratio
521
522
This standard can be important if a risk assessment is asking for a certain reliability for an Liion battery.
523
UIC 640 Motive power units - Inscriptions, marks and signs
524
Here are the correct labels (e.g. "Danger, high voltage") described.
525
526
EN 50215: Railway applications. Rolling stock. Testing of rolling stock on completion of
construction and before entry into service
527
This standard describes the test procedures for the complete train.
528
EN 50272-2-3: Ventilation requirements on batteries
529
530
531
Although this standard is not valid for Li Ion batteries, ventilation might be a topic for this type
of batteries as well. At present there is no rail standard dealing with this topic, this could be an
issue for future standardisation.
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9/1884/NP
532
533
Verwaltungsrichtlinie für Überwachungsbedürftige Anlagen (administrative regulation for safety
relevant components)
534
535
536
537
538
539
In this regulation the EBA defined rules for homolgation and operation of components with
safety aspects like pressure vessels (brake), fuel tanks or batteries. The latter were included
due to the risk of explosive gases (H2 and O2) which can occur with lead acid batteries.
Although Li-ion batteries show a much lower risk of producing explosive gases, at the moment
the complying with this regulation has to be discussed with the EBA, as there are no rail
standards for this topic. Especially the annex 4.7 and 6 should be considered.
540
541
542
543
Common regulations in Europe are very poor as each country has its own railway regulation.
Even if these regulations are very similar, they are not necessary regrouped in one European
regulation. Considering France, it exist many railway regulations applicable to EES that could
be relevant in this study.
544
545
546
547
548
549
550
Not a standard, but nevertheless a regulation to be observed is UN38.3 “Classification
Procedures, Test Methods and Criteria Relating to Class 9, Lithium Batteries” (UN transport
testing for lithium batteries) issued by the United Nations. Since Li-ion railways batteries for
railway systems will typically consist of (redundant) battery branches, which are made up of
several battery modules, which in turn consist of several battery cells, some clarification would
be welcome as to what units (cells/modules/battery branch/complete battery system) need to
pass the tests specified herein.
551
552
553
7 Designation and marking
554
7.1 Battery designation
555
556
Each battery by the unit that is installed or maintained shall carry clear and durable markings
giving the following information as per the IEC 62620.
557
558
559
In addition, the total energy content shall be provided; it shall be calculated based on the
current & voltage integration of the IEC 62620 nominal conditions for discharge, from cell or
module data to battery content by proportional rule.
560
561
7.2 Battery termination
562
This standard does not specify cell termination.
563
7.3 Marking
564
7.3.1 Nameplate
565
566
567
Each battery shall carry durable markings (considering railways harsh environment) giving the
minimum information as requested in IEC 62620, on a visible & non removable surface.
In addition, the following marking information is requested for Railways.
568
The nameplate of the battery shall be included following information:
569
570
571
− serial number;
− part number;
− weight;
9/1884/NP
572
573
574
575
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Future 62XXX/Ed1/NP IEC(E)
− revision level (if applicable);
− name of manufacturer.
− Battery energy as defined in 7.1.
576
7.3.2 Cells, Battery-pack, Tray, crate or other nameplates inside the battery
577
578
579
580
The nameplate tray, crate or other nameplates inside the box shall comply with EN 50272-3.
In case of multiple trays, the number and position of trays shall be given either on the trays or
in the instruction manual if trays reference cannot generate misassembling.
581
7.4 Safety recommendations
582
583
The manufacturer shall provide recommendations for the safe handling of the battery. See also
IEC 61438 and IEC 62620.
584
7.4.1 Safety signs
585
7.4.1.1 Outside the box
586
587
As a minimum ffollowing safety signs shall be placed outside the box:
Warning signs (according to EN ISO 7010):
588
-
W012 - Warning; Electricity
589
-
W026 - Warning; Battery Charging
590
Prohibition sign (according to EN ISO 7010):
591
-
P003 - No open flame; Fire, open ignition source and smoking prohibited
592
593
594
Figure 1 – Safety signs outside the battery box
595
596
7.4.1.2 Tray, crate or other places inside the box
597
598
Following Safety signs shall be placed inside the box:
Warning signs (according to EN ISO 7010):
599
-
W012 - Warning; Electricity
600
-
W026 - Warning; Battery Charging
601
-
W002 – Warning; Explosive material
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Future 62XXX/Ed1/NP IEC(E)
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602
Prohibition sign (according to EN ISO 7010):
603
-
604
Mandatory action signs (according to EN ISO 7010):
605
-
M002 – Refer to instruction manual/booklet
606
-
M004 – Wear eye protection
607
-
M009 – Wear protective gloves
608
-
M010 – Wear protective clothing
609
If the safety signs fixed on the tray or crate, the signs can be in black and white or colour.
P003 - No open flame; Fire, open ignition source and smoking prohibited
610
611
612
613
614
Figure 2 – Safety signs inside the battery box
9/1884/NP
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Future 62XXX/Ed1/NP IEC(E)
615
8 Storage and transportation conditions
616
8.1 Transportation
617
618
According to EN 50272-2 or the valid regulations of the respective country and the battery
manual. This should accompany the batteries.
619
8.2 Storage of batteries
620
621
622
623
624
625
626
For storage batteries shall be placed in a frost-free, dry room. The battery shall not be exposed
to direct sunlight.
in order to protect the battery, the battery shall be recharged in regular intervals. For Li-ion
batteries this can be up to 12 months. The battery manufacturer has to specify the charging
methods and intervals to be applied. For further details please refer to the battery manual. The
battery manufacturer has to specify the method of storage in his manual.
627
COMMISSIONING AFTER LONG STORAGE
628
629
630
631
632
After a long storage, some checks must be done before using the battery:
- With the diagnostic tools, checks for alarms (no alarm should be declared except the low
SOC one)
- Recharge with the external charger under IMR current until the SOC reaches at least 95% for
optimum balancing
633
634
If there are some difficulties or doubt for commissioning, please contact the manufacturer.
635
9 Dimensions
636
637
.
638
639
Table 2 – Measurement tolerances in millimetres
(valid for widths and lengths)
Up to and including 60 mm
0 to –2
Above 60 mm, up to and including 120 mm
0 to –3
Above 120 mm
0 to –4
640
641
10 Electrical interface requirements
642
10.1 Communication
643
644
There are different means for communication; the choice should be the subject of agreement
between the customer and the manufacturer at contractual stage.
645
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Future 62XXX/Ed1/NP IEC(E)
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646
10.2 Dead start battery
647
648
In case of a fully discharge battery, the power to revive the Li-ion battery traction electronics
shall be available at train level.
649
11 Design requirement
650
12 12.1 Design energy & power calculation methodology
651
There are different sizing requirements (for the battery to deliver a specified load profile):
652
− Emergency or seldom happening requirements, that are not regularly repeated
653
− Repetitive requirements, when the rolling stock is operated on a regular type of route.
654
655
656
657
658
659
The batteries will be sized in order to perform the required profiles, at beginning as well as at
the end of their operating life. It is therefore necessary to have a clear definition of the different
profiles, as well as of their expected repetition over daily operation (with possible insertion of
emergency profile at some point). It is to be noted that those profiles could be season
dependant (eg winter / summer / mid-season variations, especially when comfort auxiliaries
take a significant part of the global profile).
660
661
662
Sizing is key in order the battery can fulfil its role without going to area outside of their intended
use (meaning a loss of operational availability with safety protection features activation if
necessary).
663
664
665
666
Responsibilities are shared from the operator to train and battery manufacturers in order to
define such operational profiles. In order to clarify the impact of each of the parties, the
expected outputs are defined below, as these profiles are highly dependent of the specific
requirement for each track, as well as of the vehicle design selected by the train manufacturer.
667
668
669
Identification of the track constraints (operator level):
Speed limit
160
velocity in km/h
140
120
100
80
60
40
20
0
0
20 000
30 000
40 000
50 000
60 000
70 000
80 000
distance in m
670
671
672
673
10 000
Figure 3 - Example of speed limit profile attached to a specific track
With possible impact of the altitude (operator level):
height in m
alternative height
160
140
120
100
80
60
40
20
0
0
10 000
20 000
30 000
40 000
50 000
60 000
70 000
80 000
distance in m
674
675
Figure 4 Example of altitude profile attached to a specific track
9/1884/NP
676
677
678
679
680
– 20 –
Future 62XXX/Ed1/NP IEC(E)
With a target timetable to reach within such constraints, the train manufacturer can then define
the driving profile to be applied to its rolling stock, which will serve as a basis for the traction
calculation:
681
682
Figure 5 - Example of load profile as defined per the train manufacturer
683
684
685
686
687
688
689
690
691
The train manufacturer, based on the acceleration level selected & the repartition of the
requested power between the different energy sources, can then define the power requested
along the profile at Li-ion battery level.
In order to harmonize the sign conventions with those existing already for auxiliary batteries,
the positive power at battery level is defined as corresponding to the train acceleration (taking
energy from the battery to accelerate or power the auxiliaries for example), when the negative
power at battery level corresponds to a deceleration (and recuperation of the energy into the Liion battery).
692
The following sub-chapters provide some examples of such type of profiles.
693
12.1 Discharging requirements (emergency profiles or unusual operation)
694
There are different discharging requirements:
695
− load profile (emergency or driving operation);
696
− long-time discharge;
697
− low temperature discharging requirements;
698
− self discharge;
699
The requirements are described at the following subclauses.
700
12.1.1 Load profile
701
Several typical load profiles requirement are possible:
702
− emergency auxiliary operation (see Error! Reference source not found.);
703
− driving operation (see Error! Reference source not found.).
704
705
706
Error! Reference source not found. and Error! Reference source not found. show typical
load profiles for emergency operation for trains with restarting operation, or without in case of a
forced continued operation.
20
Future 62XXX/Ed1/NP IEC(E)
707
– 21 –
9/1884/NP
12.1.1.1 Emergency load profiles (eg auxiliaries back-up)
Loads
All
Loads
(1)
Start up (5)
Important
loads
(2)
Emergency
loads
(3)
Longtime discharging
(4)
708
709
Time
Figure 6 - Example of load profile in emergency operation (standstill of the train)
Loads
All
Loads
(1)
710
711
Important loads
(2)
Time
Figure 7 - Example of load profile in driving operation (driving without battery charging)
712
713
12.1.1.2 Traction emergency load profile
714
Two different types of load profiles are possible:
715
− emergency operation (see Error! Reference source not found.);
716
717
− driving operation (see Error! Reference source not found.), eg operation to exit /enter the
depot.
9/1884/NP
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Future 62XXX/Ed1/NP IEC(E)
718
719
720
12.2 Requirements for battery sizing for emergency operations
721
Train manufacturer shall define the following parameters:
722
723
724
725
SOC in emergency condition;
ambient temperature in emergency condition;
load profile (see 12.1.1) including auxiliaries if necessary;
minimum voltage at battery level for the whole load profile.
726
Battery manufacturer shall define
727
728
-
729
as the emergency profile shall be possible at the battery end of life
730
731
732
733
SOC and ageing factors shall be taken into account for battery sizing, depending on battery
technology and operating conditions. The selected values are typically between 60 % and
100 %. The manufacturer shall state the expected SOC and ageing behaviour for a given
specification and provide evidence of the expected battery behaviour.
ageing factor,
expected battery life impact under specified conditions,
734
735
12.2.1 Long-time discharge
736
737
Long-time discharge is for example a discharging time longer than four days with a defined
consumption. Such discharge cannot entirely be excluded.
738
739
Li-ion Batteries shall be able to withstand deep discharge without permanent damage see also IEC
62619.
740
741
742
The operator shall define the maximum duration until the battery will be recharged after such event, in
order that the proper energy is kept in the battery to accept such duration, as well as some possible
profiles (eg restart of the train system).
743
12.2.2 Low temperature performance (if applicable)
744
745
746
The admissible battery temperature is typically -18°C or as agreed with the customer. At this
temperature, the charged battery shall still be able to supply a “deep temperature load profile” as
specified by the customer.
747
In addition, no permanent damage shall occur at this temperature.
748
12.2.3 Charge retention (self discharge)
749
750
The reversible loss of capacity shall be maximum 10 % of the rated capacity after 30 days of storing at
o
20 C for Li-ion railways batteries.
751
For storage of batteries see 8.2.
752
12.3 Operational requirements (charge & discharge)
753
There are different discharging requirements:
754
− Regular repeated operation profile (driving operation);
755
756
− Non-regular but expectable operation profiles (eg in case of a congestion seldom happening
for non isolated tracks);
757
758
− Some specific pre-identified degraded modes (eg in case of a failure of some components
not preventing continuation of operation);
22
Future 62XXX/Ed1/NP IEC(E)
759
760
761
762
763
– 23 –
9/1884/NP
All those requirement shall be précised in terms of repetitions (eg for a round trip or a back &
forward trip: Nd of trips expected per day & Nb of operation days per year), as well as possible
interactions (eg position of a congestion profile within a day among repetitive profiles).
Variations of those profiles for seasons could be considered if having a significant impact on
the load profile.
764
765
12.3.1 Functions considered (examples, eg power boost & regenerative braking)
766
767
12.3.2 Type of load profiles (duty cycles) requested to size the Railways traction battery
768
769
12.3.3 Positionning / interaction of the load profiles over operation duration
770
771
772
12.4 Requests for cooling / heating (if requested, as per the battery manufacturer
recommendations)
773
774
13 Electrical tests : specific (additionnal to 62619/620) testing requirements
775
776
Specific testing requirement for railways are expected in addition to 62619 and 62620. They
are detailed in the following sub-capters.
777
13.1 Specific (additionnal to 62619/620) testing requirements
778
779
13.2 Specific operational conditions for Railways (eg long storage,…)
780
781
13.3 Load profile verification
782
783
13.3.1 General
784
785
786
787
788
This Chapter is applicable for the specification and verification of battery aptitude to supply
requested load profiles, if specified by the customer. The aim is to control conformity of design
and later of realization with the relevant specification. It is recommended that the number of
tests is limited to those which are proven to be necessary.
NOTE
789
13.3.2
790
791
The procedure and the parameters shall be specified by agreement between the battery
manufacturer and the customer including
792
• cumulated discharged energy vs. load profile,
793
• power available vs. load profile.
A load profile and the operating conditions may be optimized during the project.
General methodology
9/1884/NP
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Future 62XXX/Ed1/NP IEC(E)
794
Also realistic train operation has to be taken into account
795
• environment (e.g. temperature), and
796
• operational requirements (e.g. minimum voltage).
797
798
799
800
An important part is the charge level of the battery and its ageing.
This process requires a well defined and harmonised methodology for specification and
verification of the load profile compliance (as contractually defined). The selected approach
has two steps:
801
802
803
• simulation by calculation or testing of the compliance of the battery vs. load profile of the
train, for one or several specific load profiles over a defined environment (temperature)
under defined operational conditions (voltages);
804
805
• measurements on real battery for the verification of the compliance vs. load profile shall be
realized under simulation conditions;
806
807
808
• profiles shall be initially requested by the operator or by the train system integrator,
including adjustments to take into account final release of architecture and equipments
installed on the train (eg energy reserve of 20% or power reserve of 5%).
809
810
811
812
In case several profiles are requested, all load profiles shall be calculated or
tested. Each battery manufacturer shall provide to the customer his sizings for all requested
load profiles in the tendering phase. Those sizings shall be available for the operator on
request. If acceptable by the customer it may be sufficient to do the worst case only.
813
13.3.3
814
815
816
817
818
819
The battery sizing shall be done by the battery manufacturer, in order to make sure that the
required profile will be met in all identified discharge conditions agreed (e.g. environment,
sizing factors for charge or ageing). This can be done through numerical calculation (e.g.
simulation) or laboratory testing – or both in case numerical calculation is not considered
precise enough.
820
13.3.4
821
822
The results of the calculations and simulations shall be documented in a report. The minimum
requirements for the contents of the report are
823
824
• key data for the battery: technology, type, capacity & quantity of cells for the whole train,
electrical architecture as initially defined by the train system integrator,
825
826
827
• description of the battery behaviour over discharge time, with indication of compliance vs.
requested conditions (e.g. minimum voltage) for each profile segment in their occurrence
order,
828
829
• environmental conditions (e.g. temperatures for charging, discharging) and derating factors
(e.g. ageing, initial SOC depending on charging condition).
830
13.3.5
831
832
833
834
As the main concept of this standard is to allow for standardization of batteries, it is essential
that the final design data document (initial or updated) is filed: load profile test to be realized as
defined in agreement between operator, train system integrator and cell or battery
manufacturer:
835
• test temperature corresponding to selected sizing;
836
837
838
839
• minimum representative quantity of cells or monoblocs for performance tests (typically over
10% of the total cell quantity connected in series respectively a corresponding number of
monoblocs): in case paralleling profile will be adjusted proportionally, in representative
arrangement of cells. This will be referred later on as “battery” for the testing purposes.
Sizing description (calculation, simulation or preliminary tests)
Sizing documentation
Operational verification (load profile test)
24
Future 62XXX/Ed1/NP IEC(E)
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9/1884/NP
840
841
842
• minimum representative quantity of cells or monoblocs for functionnal : tiotal battery system.
in case paralleling profile cannot be adjusted proportionally. This will be referred later on as
“complete battery” for the testing purposes.
843
•
844
The following tolerances are admitted for performance tests:
845
• ambient temperature: ± 5K;
846
847
• cell temperature dispersion in the battery at test start: ± 2K. The test shall not start before
reaching the testing temperature for at least 1 h.
848
Battery preparation:
849
• cells or battery could be submitted to a suitable number of pre-activation cycles;
850
• complete charge as per IEC62620;
851
852
853
854
• application of the derating factors as mentioned in agreed simulation / calculation / lab.
testing stage, through partial discharge in relation to the rated capacity C n (e.g. 90 % ageing
and 90 % SOC => 90 %*90 %=81 % initial situation, thus 19 % partial discharge) for
emergency tests;
855
856
• cells or battery should then immediately be installed to reach temperature situation (agreed
temperature), until stable temperature is obtained.
857
858
859
860
Profile should then be realized as mentioned in agreed simulation / calculation / lab. testing
stage, and all load profile parameters (time, voltage, current, temperature) should be recorded.
The test plan shall be agreed between at least train & battery manufacturers prior to the tests.
This plan especially contains
861
• the conditions for preparation,
862
• the conditions for the specific test,
863
864
865
• the scaling factor if needed (number of representative cells).
Acceptance criterion: compliance with minimum Voltage (depending form battery type) all along
the testing profile.
866
13.3.6
867
868
869
The results of the verification measurements shall be documented in a report that should
remain attached with the train documentation. The minimum requirements for the contents of
the report are
870
871
• key data for the battery: technology, type, capacity and quantity of cells for the whole train,
electrical architecture,
872
873
874
• description of the battery behaviour over operation time, with indication of compliance vs.
requested conditions (e.g. minimum voltage) for each profile segment in their occurrence
order,
875
• tested sample manufacturing traceability (identification as per chapter at minimum).
876
877
• environmental conditions (e.g. temperatures) and derating factors (e.g. ageing, initial SOC
of tested battery),
878
• description of the measurement equipment used, with calibration certificates,
879
880
• any observations during the tests which might have an effect on the interpretation of the test
results.
881
882
In case of scaling, it might be necessary to apply a factor to compare test to the load profile.
This should then be clearly mentioned.
Test report
9/1884/NP
883
13.3.7
884
TBD
– 26 –
Future 62XXX/Ed1/NP IEC(E)
Lifetime projections
885
886
13.4 Endurance
887
13.4.1 Endurance in cycles
888
889
Endurance tests are extremely long & resources consuming. Moreover, their result is an
entrance point for battery sizing. Therefore they cannot be applied on a specific profile basis.
890
891
892
893
The endurance test is therefore extended from the IEC 62620 endurance testing at cell level,
with results not only after 500 cycles, but to be continued especially as some cells can be
specifically designed in order to provide a higher number of cycles. As an option, such cells or
batteries could be identified as such with mention of the class of cycle rating for those cells.
894
895
This mention will be provided with the NC followed by the class of endurance expressed in
cycles.
896
The following steps should then be realized after completion of the test in chapter 4.4.1:
897
898
Step 1 - The decrease rate shall be calculated from the rated capacity and the capacity
measured in step chapter 4.4.1 or in step 5.
899
900
901
Step 2 – If the capacity after additional 100 cycles is higher than 60% of the rated capacity, the
endurance tests in table 7 can be repeated until the capacity during the cycling test reaches
62.5% of the rated capacity.
902
Step 3 – The capacity at 0,2 I t A is determined according to 4.2.1
903
904
905
Step 5 – If the capacity is higher than 60% of the rated capacity, step 2 to step 3 are repeated
100 times followed by step 3. If the capacity is lower or equal to 60% of the rated capacity, go
to step 5.
906
Step 5 – End of cycling test
907
908
909
The cycle life of the cell or battery is given by the total number of cycles performed to reach
60% of the initial capacity at the 0,2 I t A rate. When the battery fails to reach 60% of the rated
capacity, the number of cycles shall be rounded to the nearest multiple of 100 (eg 800, 1500).
910
911
14 Mechanical tests
912
15 14.1Physical appearance
913
914
915
Visual inspection shall be performed on samples submitted to tests. No cracking, damage or
corrosion shall be apparent. Any deformation shall be within the tolerances of the dimensions
specified in the manufacturer’s drawings.
26
Future 62XXX/Ed1/NP IEC(E)
– 27 –
9/1884/NP
916
16 14.2 Shock & vibration
917
17 14.3 Safety
918
18 Conditions for approval and acceptance
919
18.1 Type approval
920
921
922
The type test shall be done on conditions to be agreed by train & battery manufacturer, to
validate the performance of the battery. It shall be done accordingly to chapter 12.3.5 and
12.3.6.
923
18.2 Sampling
924
925
This test shall ensure that the technical characteristics are maintained. They can be done on a
partial of more than 10% of the battery.
926
9/1884/NP
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Bibliography
927
928
929
930
IEC 61434,
Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Guide to designation of current in alkaline secondary
cell and battery standards
931
932
IEC 60050-482
International Electrotechnical Vocabulary - Part 482: Primary and
secondary cells and batteries
933
934
___________
28