BRITISH STANDARD BS EN 50272 3 2002 Incorporating Corrigendum No 1 Safety requirements for secondary batteries and battery installations — Part 3 Traction batteries The European Standard EN 50272 3 20[.]
BS EN 50272-3:2002 BRITISH STANDARD Incorporating Corrigendum No Safety requirements for secondary batteries and battery installations — Part 3: Traction batteries The European Standard EN 50272-3:2002 has the status of a British Standard ICS 29.220.20 ?? ? ? ????? ??????? ??? ?? ???????? ? ?? ? ?? ?? ?? ?????? ? ?? ? ? ?????? ? ??? ? ? ? ? ? ? ? ? ? ? BS EN 50272-3:2002 National foreword This British Standard is the official English language version of EN 50272-3:2002 It supersedes BS 6287:1982, which is withdrawn The UK participation in its preparation was entrusted to Technical Committee PEL/21, Secondary cells and batteries, which has the responsibility to: — aid enquirers to understand the text; — present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep UK interests informed; monitor related international and European developments and promulgate them in the UK — A list of organizations represented on this committee can be obtained on request to its secretary Cross-references The British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entitled “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application Compliance with a British Standard does not of itself confer immunity from legal obligations This British Standard, having been prepared under the direction of the Electrotechnical Sector Policy and Strategy Committee, was published under the authority of the Standards Policy and Strategy Committee on 24 October 2002 Summary of pages This document comprises a front cover, an inside front cover, the EN title page, pages to 16, an inside back cover and a back cover The BSI copyright date displayed in this document indicates when the document was last issued Amendments issued since publication © BSI 2006 ISBN 580 40642 Amd No Date 16575 29 September 2006 Addition of supersession details Corrigendum No Comments EUROPEAN STANDARD EN 50272-3 NORME EUROPÉENNE EUROPÄISCHE NORM October 2002 ICS 29.220.20 English version Safety requirements for secondary batteries and battery installations Part 3: Traction batteries Règles de sécurité pour les batteries et les installations de batteries Partie 3: Batteries de traction Sicherheitsanforderungen an Batterien und Batterieanlagen Teil 3: Antriebsbatterien für Elektrofahrzeuge This European Standard was approved by CENELEC on 2002-07-01 CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CENELEC member This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the Central Secretariat has the same status as the official versions CENELEC members are the national electrotechnical committees of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and United Kingdom CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung Central Secretariat: rue de Stassart 35, B - 050 Brussels © 2002 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members Ref No EN 50272-3:2002 E EN 50272-3:2002 -2Foreword This European Standard was prepared by the Technical Committee CENELEC TC 21 X, Secondary cells and batteries The text of the draft was submitted to the formal vote and was approved by CENELEC as EN 50272-3 on 2002-07-01 The following dates were fixed: - latest date by which the EN has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2003-07-01 - latest date by which the national standards conflicting with the EN have to be withdrawn (dow) 2005-07-01 - 3- EN 50272-3:2002 Contents Scope .4 Normative references .4 Definitions Protection against electric shock Prevention of short circuits and protection from other effects of electric current .8 Provisions against explosion hazards by ventilation Provision against electrolyte hazard .1 Battery containers and enclosures Accommodation for charging maintenance 10 Battery peripheral equipment/accessories 11 Identification labels, warning notices and instructions for use, installation and maintenance 12 Transportation, storage, disposal and environmental aspects 13 Inspection and monitoring Table EN 50272-3:2002 -4- Scope This standard applies to secondary batteries and battery installations used for electric vehicles, e.g in electric industrial trucks (including - lift trucks, tow trucks, cleaning machines, automatic guided vehicles), in battery powered locomotives, in electric road vehicles (e.g passenger and goods vehicles, golf carts, bicycles, wheelchairs) The nominal voltages are limited to 000 V a.c and 500 V d.c respectively and describe the principal measures for protection against hazards generally from electricity, gas emission and electrolyte It provides requirements on safety aspects associated with the installation, use, inspection, maintenance and disposal of batteries It covers lead-acid, nickel cadmium and other alkaline secondary batteries NOTE It is intended to amend this standard to include other battery systems when they become available Normative references This European Standard incorporates by dated or undated reference, provisions from other publications These normative references are cited at the appropriate places in the text and the publications are listed hereafter For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision For undated references the latest edition of the publication referred to applies (including amendments) EN 66 995 Personal eye-protection - Specifications EN 1 75-1 998 Safety of electrical trucks - Electrical requirements Part : General requirements for battery powered trucks EN 987-1 987 Electrically propelled road vehicles - Specific requirements for safety Part : On board energy storage EN 60204-1 986 Electrical equipment of industrial machines Part : General requirements EN 60900 993 Hand tools for live working up to kV a.c and ,5 kV d.c EN 61 40 2001 Protection against electric shock - Common aspects for installation and equipment (IEC 61 40:1 997) EN 61 429 + A1 1 996 998 Marking of secondary cells and batteries with the international recycling symbol ISO 7000-1 35 and indications regarding directives 93/86/EEC and 91 /1 57/EEC HD 22.1 S3 997 Rubber insulated cables of rated voltages up to and including 450 V/750 V Part : General requirements IEC 60364-4-41 992 Electrical installations of buildings Part 4: Protection for safety Chapter 41 : Protection against electric shock IEC 60050-486 991 International Electrotechnical Vocabulary Chapter 486: Secondary cells and batteries IEC/TR3 61 431 995 Guide for the use of monitor systems for lead-acid traction batteries ISO 7000 989 Graphical symbols for use on equipment - Index and synopsis - 5- EN 50272-3:2002 Definitions For the purposes of this European Standard the following definitions apply 3.1 (secondary) cell; (rechargeable) cell; single cell an assembly of electrodes and electrolyte which constitutes the basic unit of a secondary battery (see IEV 60050: 486-01 -02) NOTE This assembly is contained in an individual case and closed by a cover 3.2 lead-acid cell or battery a secondary battery in which the electrodes are made mainly from lead and the electrolyte is a sulphuric acid solution (H SO ) (see IEV 60050: 486-01 -04) 3.3 nickel-cadmium cell or battery an alkaline secondary battery in which the positive material is made mainly from nickel and the negative material is made mainly from cadmium (see IEV 60050: 486-01 -07) The electrolyte is an alkaline solution (potassium hydroxide, KOH) 3.4 vented (secondary) cell a secondary cell having a cover provided with an opening through which gaseous products may escape (see IEV 60050: 486-01 -1 8) 3.5 valve regulated (secondary) cell a secondary cell which is closed under normal conditions but has an arrangement which allows the escape of gas if the internal pressure exceeds a predetermined value The cell cannot normally receive addition to the electrolyte (see IEV 60050: 486-01 -20) 3.6 gas-tight sealed (secondary) cell a secondary cell which remains closed and does not release either gas or liquid when operated within the limits of charge and temperature specified by the manufacturer The cell may be equipped with a safety device to prevent dangerously high internal pressure The cell does not require addition to the electrolyte and is designed to operate during its life in its original sealed state (see IEV 60050: 486-01 -21 ) 3.7 secondary battery two or more secondary cells connected together and used as a source of electrical energy (see IEV 60050: 486-01 -03) 3.8 traction battery a secondary battery which is designed to provide the propulsion energy for electric vehicles 3.9 monobloc battery a secondary battery in which the plate packs are fitted in a multi-compartment container (see IEV 60050: 486-01 -1 7) 3.1 electrolyte a liquid or solid phase containing mobile ions which render the phase ionically conductive (see IEV 60050: 486-02-1 9) EN 50272-3:2002 -6- 3.1 gassing; gas emission the formation of gas produced by electrolysis of the electrolyte (see IEV 60050: 486-03-24) 3.1 charge; charging (of a battery) An operation during which a battery receives from an external circuit electrical energy which is converted into chemical energy (see IEV 60050: 486-01 -1 ) 3.1 equalisation charge extended charge which ensures complete charging of all cells in a battery 3.1 opportunity charging the use of free time during a work period to top up the charge and thus extend the work period of a battery whilst avoiding excessive discharge 3.1 overcharge; overcharging (of a cell or battery) continued charging after the full charge of a cell or battery (see IEV 60050: 486-03-35) 3.1 discharge; discharging (of a battery) an operation during which a battery delivers current to an external circuit by the conversion of chemical energy into electrical energy (see IEV 60050: 486-01 -1 2) 3.1 battery peripheral equipment equipment installed on the battery, which supports or monitors the operation of the battery, e.g central water filling system, electrolyte agitation system, battery monitoring system, central de-gassing system, battery connectors (plugs and sockets), thermal management system, etc 3.1 charging room a room or closed area intended specifically for recharging batteries The room may also be used for battery maintenance 3.1 charging area an open area designated and made suitable for recharging batteries The area may also be used for battery maintenance Protection against electric shock Measures shall be taken on batteries and in contact and indirect contact, or against both in detail in IEC 60364-4-41 specifying the 000 V a.c or 500 V d.c The following traction batteries in electrical vehicles 4.1 battery charging installations for protection against direct direct or indirect contact These measures are described protection against electric shock on installations up to clauses describe the typical measures to be taken for Protection again st both direct and indirect contact Protection against direct and indirect contact is simultaneously met by the use of safety extra low voltage (SELV) (24 V d.c.) or protective extra low voltage (PELV) (24 V d c.), as long as the whole installation corresponds to the conditions for SELV or PELV - 7- EN 50272-3:2002 For protection against direct contact the following protective measures apply: - protection by insulation of live parts; - protection by barriers or enclosures; - protection by obstacles (see I EC 60364-4-41 ,41 2.1 to 41 2.3) For protection against indirect contact the following measures can be selected: - protection by automatic disconnection or signalling; - protection by protective insulation; - protection by earth-free local equipotential bonding; - protective electrical separation 4.2 Protection against direct and indirect contact when discharging the traction battery on the vehicl e (battery d isconnected from charg er / main s) 4.2.1 Batteries with nominal voltages up to and including 60 V d.c not require protection against electric shock caused by direct contact, as long as the whole installation corresponds to the conditions for SELV and PELV However, for other reasons, e.g short circuits, mechanical damage, all batteries in electrical vehicles require protection against direct contact of live parts, even if the battery nominal voltage is 60 V d.c or less Batteries with nominal voltages from above 60 V d.c and up to and including 20 V d.c require protective measures against direct contact 4.2.2 NOTE Batteries with nominal voltages up to and including 20 V d.c are regarded as safe power sources for SELV-systems (safety extra low voltage) or PELV-systems (protective extra low voltage) (see I EC 60364-4-41 , 41 1 ) The following protective measures apply: a) insulation of live parts; b) barriers or enclosures; c) obstacles or placing out of reach If the protection against direct contact of live parts is ensured only by obstacles or placing out of reach, the battery accommodation shall have access restricted to trained and authorized personnel only, and shall be marked by warning labels Batteries having nominal voltages exceeding 20 V d.c require protective measures against both direct and indirect contact Battery compartments with batteries having nominal voltages exceeding 20 V d.c shall be locked and have restricted access for trained and authorized personnel only and shall be marked by warning labels (see Clause 1 ) For batteries with nominal voltages exceeding 20 V d.c the following protective measures against indirect contact can be selected: - protective electrical insulation; - protection by earth-free equipotential bonding; - protection by automatic disconnection or signalling EN 50272-3:2002 4.3 -8- Protection again st direct and indirect contact when ch arging th e traction battery If battery chargers with safe separation from the feeding mains are used (in accordance to EN 61 40), the protective measures SELV or PELV are applicable If the nominal voltage of the battery does not exceed 60 V d.c protection against direct contact is not required, as long as the total installation corresponds with the conditions of SELV or PELV When the battery charger does not comply with these requirements, the protective measures against direct and indirect contact apply (see I EC 60364-4-41 ) However, for other reasons, e.g short circuits, mechanical damage, all batteries in electrical vehicles (see also EN 1 75-1 ) require protection against direct contact of live parts, even if the battery nominal voltage is 60 V d.c or less Prevention of short circuits and protection from other effects of electric current 5.1 Cables and cell connectors Cables and cell connectors shall be insulated to prevent short circuits Protection against short circuits cannot be provided by overcurrent protection devices for battery-specific reasons, therefore connecting cables between charger, respective battery fuse, and battery, and between battery and vehicle must be protected against short circuit and earth fault For these cables EN 60204-1 applies Where trailing cable is used, the protection against short circuits shall be improved by the use of single core cable generally equal to EN 60204-1 However where the battery nominal voltage is less or equal to 20 V d.c the trailing cables may be of grade H01 ND2 minimum (see HD 22.1 S3) because of higher flexibility The battery terminal cables shall be fixed in a manner that prevents tensile/torsional strain on the battery terminals Insulation shall be resistant to the effects of ambient influences such as temperature, electrolyte, water, dust, commonly occurring chemicals, gasses, steam and mechanical stress 5.2 Protective measures during maintenance When working on live equipment, the use of appropriate procedures will reduce the risk of injury The regulations according to EN 60900 apply Only insulated tools shall be used During maintenance operation where people work close to an exposed battery system the risk of injury shall be minimized To minimize the risk of injury, the following measures shall be observed: - batteries shall not be connected or disconnected without first isolating the circuit; - battery terminal and connector covers shall be provided which allow routine maintenance whilst minimising exposure of energized conductive parts; - all metallic personal objects shall be removed from the hands, wrists and neck before starting work; - for battery systems where the nominal voltage is above 20 V d.c., insulated protective clothing and/or local insulated coverings will be required to prevent personnel making contact with the floor or parts bonded to earth NOTE For maintenance purposes, batteries having a nominal voltage above 20 V d.c should be divided into sections consisting of 20 V d.c (nominal) or less - 5.3 9- EN 50272-3:2002 Battery insulation A new battery shall have a minimum insulation resistance of M Ω when measured between a battery terminal and metallic tray, vehicle frame or other conductive supporting structure Where the battery is fitted into more than one container, this test shall be carried out with the sections (including metal battery containers) electrically connected 5.3.1 5.3.2 The insulation resistance of a disconnected battery taken out of service, when measured between a battery terminal and metallic tray, vehicle frame or other conductive supporting structure, shall be at least 50 Ω multiplied by the nominal battery voltage and not less than kΩ Where the battery is fitted into more than one container, this test shall be carried out with the sections (including metal battery containers) electrically connected Test voltage - The insulation resistance of the vehicle and traction battery shall be checked separately The test voltage for the battery shall be greater than the nominal voltage, which is minimum the open circuit voltage of the battery, but not more than 00 V d.c or three times the nominal voltage (see EN 1 75-1 ) 5.3.3 For test procedure see EN 987-1 , subclause 6.2.1 Provisions against explosion hazards by ventilation 6.1 Gas generation During charge, gases are evolved from all secondary cells and batteries using aqueous electrolytes This is a result of the electrolysis of the water by the charging current Gases produced are hydrogen and oxygen When emitted into the ambient atmosphere an explosive mixture may be created if the hydrogen concentration exceeds % hydrogen by volume in air NOTE When a cell reaches its fully charged state water electrolysis occurs according to Faraday's law Under standard conditions (N.T.P.) ): - Ah decomposes H2O into: - decomposition of cm (1 g) H2O requires : Ah - 26, Ah decomposes H2O into: g H2+ 8g O2 0, 42 l H2+ 0, 21 l O2, When the operation of the charge equipment is stopped, the emission of gas from the cells will substantially subside within one hour However, precautions are still necessary after this time, as gas trapped within the cells can be released suddenly due to movement of the battery when it is refitted to the vehicle or when the vehicle moves in service 6.2 Ventilation requirements Whether the battery is charged on or off the vehicle, the ventilation requirements of this subclause shall be met The purpose of ventilating a battery location or enclosure is to maintain the hydrogen concentration below the % hydrogen threshold Battery accommodation rooms are to be considered as safe from explosions, when by natural or artificial ventilation the concentration of hydrogen is kept below this safe limit 1) N.T.P.= Normal Temperature and Pressure, T=273 K, P=1 01 hPa EN 50272-3:2002 - 10 - The necessary ventilation airflow for a battery location or compartment shall be calculated by the following formula: Q = v q s n I gas C n / 00 [m 3/h] ⋅ ⋅ ⋅ ⋅ ⋅ where Q v q s n I gas Cn ventilation air flow [m 3/h]; necessary hydrogen dilution factor = 24; 0,42 -3 [m 3/Ah] generated hydrogen; safety factor = 5; number of cells; current producing gas during the gassing phase of charge [A/1 00Ah] (see Table ) nominal capacity [Ah] = = = = = = = ⋅ The ventilation formula can be resolved into the following: Q = 24 0,42 -3 n I gas C n / 00 [m 3/h] ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ Q = 0,05 n I gas C n / 00 [m 3/h] ⋅ ⋅ ⋅ Where standard chargers are used and no detailed information regarding the charge characteristic is provided, I gas C n / 00 shall be calculated as 25 % minimum of the rated charger output current ⋅ For detailed calculation of the required ventilation air flow use the value of the gas producing current I gas given in Table , which corresponds with the end of charge current for different charger types expressed in A/1 00 Ah rated capacity Where a so-called ‘fast charger’ is used, a specific value for I gas should be obtained from the manufacturer When charging more than one battery in the same room the ventilation must be calculated as the sum of the individual ventilation air flow Table - Gas producing current I gas respectively typical end of charge current in A per 00 Ah rated capacity, when charging with IU, IUI, or taper chargers Charger characteristic IU charging IUI charging Taper charging a b c d I gas for lead-acid battery I gas for lead-acid battery I gas for NiCd battery a vented cells valve regulated cells (voltage limit 2,4 V/c) (voltage limit 2,4 V/c) (voltage limit ,55 V/c) b b 5b current in rd charging current in rd charging current in rd charging step step step max max ,5 max minimum 25 % of nominal charger current at 2,6 V/c, d d typical values are in the range of to c For NiCd gas recombination type cells, consult the manufacturer Because of the large variations which can exist in battery design and installation, consult the manufacturer For simple taper charger without change-over of characteristic Taper charging is not typical for these batteries For application consult the battery manufacturer The specified values are typical for worst case conditions to ensure that ventilation is adequate to all kinds of vented or valve-regulated batteries During the first few cycles of operation the recombination process in VRLA batteries may not be completely established, and batteries may behave similar to vented batteries in terms of gassing - 6.3 11 EN 50272-3:2002 - Natural ventilation The required air flow shall preferably be ensured by natural ventilation, otherwise by forced (artificial) ventilation Battery rooms, areas and enclosures require an air inlet and outlet, each with a minimum free area of opening calculated by the following formula: [cm 2] A = 28 Q ⋅ where Q = ventilation air flow [m 3/h] NOTE For the purpose of this calculation the air velocity is assumed to be 0,1 m/s In open air, in large halls and in well ventilated rooms an air velocity of adequate air ventilation is ensured ≥ 0,1 m/s can be assumed and Well ventilated rooms shall have a free volume of at least 2,5 Q [m 3] ⋅ The air inlet and outlet shall be in the best possible location for the exchange of air, i.e - openings on opposite walls, - minimum distance apart of m when openings in the same wall The air extracted from the charging area/room shall be exhausted to the atmosphere outside the building 6.4 Forced ventilation Where the airflow Q can not be obtained with natural ventilation, forced ventilation shall be used to secure the required exchange of air for the mode of operation Interlocking of chargers and ventilation fans shall be considered The air extracted from the charging area/room shall be exhausted to the atmosphere outside the building 6.5 Close vicinity to the battery In the close vicinity of the battery the dilution of explosive gases is not always secured, therefore a safety distance of minimum 0,5 m through the air without flames, sparks, arcs or glowing devices (max surface temperature 300 °C) must be observed 6.6 Ventilation of battery compartment 6.6.1 Where removable covers are provided for the battery and when appropriate, the covers shall be removed prior to charging in order to ventilate gas produced and aid battery cooling 6.6.2 Suitable ventilation openings shall be provided in the battery container, compartment or cover so that during discharge or rest periods, dangerous accumulations of gas not occur when the equipment is used in accordance with manufacturer's instructions The ventilation opening area shall be at least: A = 0,005 n C5 ⋅ ⋅ [cm 2] where A = total cross-sectional area of ventilation holes required [cm 2] n = number of cells in battery C5 = capacity of battery at the 5h rate [Ah] EN 50272-3:2002 Provision against electrolyte hazard 7.1 Electrolyte and water - 12 - Electrolyte used in lead-acid batteries is an aqueous solution of sulphuric acid Electrolyte used in NiCd batteries is an aqueous solution of potassium hydroxide Distilled or demineralized water is used for topping up the cells 7.2 Protective clothing In order to avoid personal injury from electrolyte splashes, when handling electrolyte and / or vented cells or batteries, protective clothing shall be worn, such as - protective glasses (see EN 66) or masks for eyes or face, - protective gloves and aprons for skin protection In the case of valve-regulated or gastight batteries at least protective glasses and gloves shall be worn 7.3 Accidental contact , "First Aid" Both electrolytes cause burns to eyes and skin 7.3.1 Eye contact In the event of accidental contact with electrolyte immediately flood the eyes with large quantities of water for an extended period of time of at least In all cases get immediate medical attention ! 7.3.2 Skin contact In the event of accidental contact with electrolyte, wash the affected parts with large quantities of water or with neutralising aqueous solutions, such as soap water for sulphuric acid or a mild acidic solution for alkaline electrolyte If irritation of skin persists obtain medical attention 7.4 Battery accessories and maintenance tools Materials used for battery trays, battery accessories and components inside battery charging rooms shall be resistant to or protected from the chemical effects of the electrolyte In the event of electrolyte spillage remove the liquids with absorbing material; neutralising material is preferred Maintenance tools, such as funnels, hydrometers, thermometers, etc, which are in contact with electrolyte shall be separately dedicated to the lead-acid or NiCd-batteries and shall not be used for any other purpose Battery containers and enclosures 8.1 The battery accommodation, trays, crates and compartments shall have adequate mechanical strength and be constructed either of electrolyte resistant materials or be protected against the damaging effects of electrolyte leakage and spillage 8.2 Provision shall be made to prevent the spillage of electrolyte on equipment/components or the ground 8.3 tray to underlying It shall be made possible to remove any accumulation of spilled electrolyte or water from the battery NOTE Waste electrolyte from maintenance work on batteries shall be disposed of in accordance with local regulations - 13 - Accommodation for charging / maintenance 9.1 Charging areas shall be clearly defined by permanent marking of the floor area EN 50272-3:2002 (Not required for electric equipment for domestic use, e.g wheel chairs, lawn movers, etc.) 9.2 The charging area shall be adequately spaced from materials which may constitute a hazard such as inflammable or explosive goods 9.3 Except during essential battery maintenance/repair, the charging area shall not be subjected to any sources of ignition such as sparks or sources of high temperature The exception is where high temperature equipment is required for work on the battery and this shall be in the control of trained and authorized personnel who shall take all necessary precautions 9.4 Prevention of electrostatic discharges when working with batteries: care shall be taken not to wear clothes and footwear which may build up electrostatic charge Absorbent cloth for battery cleaning shall be antistatic and used moistened only with water without cleaning agents 9.5 When the battery is being charged or serviced, a space 0,8 m wide shall be provided on those sides required for access 9.6 When charging batteries on or off the vehicle the ventilation requirements of Clause shall be met 9.7 The charger shall be mounted, such that it is not vulnerable to damage by movement of the vehicle The charging area shall not be vulnerable to falling objects, drip water or liquids that could leak from fractured pipes 9.8 10 Battery peripheral equipment/accessories 0.1 Battery monitoring system When applying battery monitoring the recommendations of Technical Report IEC/TR3 61 431 should be observed A battery monitoring system shall be designed and installed in such a way, that no hazard will occur during use and operation, for example - measuring cables installed on top of the battery shall be protected against short circuit by use of fuses, double insulation or high impedance, - cable installation shall follow the potential of the series connected cells to avoid leakage currents, e.g by means of accumulated dirt or electrolyte contamination, - shunt cables or other measuring equipment shall be carefully fixed to the battery 0.2 Central water filling system 0.2.1 General During service of vented type traction batteries, water is lost mainly due to its electrolysis occurring towards the end of charge which generates hydrogen and oxygen This water must be periodically replaced in the battery cells to restore the electrolyte level and specific gravity This can be done by the use of a "central" or "single point" topping up installation EN 50272-3:2002 - 14 - The plugs of each cell are connected in series or series/parallel through a piping system Water is fed to the cells from a central reservoir either by gravity, vacuum or under pressure according to the plug design Once the electrolyte level in the cell achieves the prescribed level water is prevented from further entering into the cell This is accomplished in different ways according to the plug design “Float” design The plug is fitted with a float which closes a water inlet valve once the electrolyte achieves the required level The gases are vented from each cell through an opening in the plug “Air-lock” design The plug has no float or other moving parts; once the electrolyte achieves the prescribed level an overpressure is generated in the cell space above the electrolyte or within the plug itself sufficient to prevent the water from further entering into the cell The gases are vented from the cell through the same piping used for the water topping-up 0.2.2 Safety aspects In any battery where the cells are interconnected by pipes, this may be a gas mono-venting system or a water filling system, precautions should be taken to minimize any risk of electrical tracking or the propagation of battery explosions between cells The following precautions shall be followed: - the risk of electrical tracking is reduced if the piping system follows the potential of the electrical circuit; - the risks of both electrical tracking and the propagation of explosions is reduced if the number of cells connected in a piped series circuit is reduced; - the maximum number of cells which is to be connected in a series piped branch, is to be specified by the manufacturer based on the system design NOTE In order to prevent an explosion occurring within an individual cell from propagating into the contiguous ones, the plugs may be fitted with a built-in safety feature such as a water trap that prevents hydrogen from entering into the water piping circuit 0.3 Central degassing systems Central degassing systems are used to vent the battery gases outside the battery compartment In many cases they are associated with central water filling systems In the case of central water filling of the float type plug (see 0.2) the cell plugs have a double piping system one for watering and the other for venting the gases The safety requirements in this case are the same as in 0.2.2 With central degassing systems the gas venting outlets shall be located outside the battery compartment and protected with flame arrestors against the risk of explosions caused by sources of ignition close to the gas outlets Where during charging individual degassing circuits are coupled to a forced ventilation system which exhausts the entire gas evolved to the outside of the charging area, the ventilation requirements of the system shall be in accordance with 6.2 and 6.4 Provided that all batteries being charged have a central degassing system that exhausts to the outside, the room will have no special ventilation requirements 0.4 Thermal management systems Where thermal management systems are installed, care must be taken that no hazard is caused by sources of ignition, leakage currents, electrolyte flooding, etc 0.5 Electrolyte agitation system Lead-acid traction batteries may be equipped with an electrolyte agitation system to eliminate stratification and reduce charging factor Mixing of the electrolyte is achieved by means of a continuous or intermittent air stream released near the bottom, inside of the cell containers The air is fed through flexible tubes by an air pump to an air inlet on each cell - 15 - EN 50272-3:2002 Provision shall be made to avoid confusion between air and water filling pipe systems The piping system shall follow the potential of the electrical circuit The maximum number of cells with peripheral accessories connected in series in a section shall be specified by the battery manufacturer based on experience on his design 0.6 Catalyst vent plugs For the reduction of water consumption and the extension of topping up intervals catalyst vent plugs may be used Catalyst vent pugs recombine hydrogen and oxygen generated mainly during the recharge process, forming water which drops back into the cell The following hazards must be considered: - due to the exothermal recombination reaction heat is generated and must be dissipated into the ambient air (hot surface areas); the recombination reaction takes place only with certain efficiency depending on the relationship of catalyst size to charge current and ageing of catalyst Surplus charging gasses, which are not recombined, will be released from the catalyst vent plugs The ventilation requirements according to 6.2 shall be observed, despite the use of catalyst vent plugs To avoid drying out of the battery, regular checks of the function of the catalyst and of the electrolyte level are required 0.7 Connectors (plugs/sockets) Plugs and sockets for use with traction batteries shall be in accordance with the requirements of EN 1 75-1 , Annex A For voltages higher than 240 V d.c refer to manufacturers information 11 Identification labels, warning notices and instructions for use, installation and maintenance 1 Safety labels The following safety labels shall be used to inform and warn of risks associated with batteries and battery installations At the minimum the standardized IEC symbols shall be indicated at the battery - follow the instructions (iInformation sign), - use protective cloths and goggles (command sign), - dangerous voltage (when 60 V d.c is exceeded) (warning sign), - prohibition of naked flame (warning sign), - warning sign - battery hazard (warning sign), - electrolyte is highly corrosive (warning sign), - explosion hazard (warning sign) 1 Identification label The following information shall be indelibly marked on each battery assembly unit: - name of battery manufacturer or supplier; - battery type reference; - battery serial number; - nominal battery voltage (within one battery unit); - battery capacity with time rating; - service mass 2), including ballast if used 2) Not required for individual monobloc batteries EN 50272-3:2002 1 - 16 - Other labels According to the European battery directives EC 93/86 and EC 91 /1 57 traction batteries shall be marked with the crossed-through roll-out container In addition marking with the recycling symbol ISO 7000-1 35 with reference to the chemical system of the battery according to EN 61 429 is required Traction batteries exceeding a nominal voltage of 75 V d.c shall be marked with the CE mark according to the European low voltage directives EC 73/23 and EC 93/68 12 Transportation, storage, disposal and environmental aspects 2.1 Packing and transport The packing and transport of secondary batteries is covered in various national and international regulations The following international regulations for transport, safe packing and carriage of dangerous goods apply: Road: European Agreement for the International Carriage of Dangerous Goods by Road (ADR) Rail (international): International Convention concerning the carriage of Goods by Rail (CIM), Annex A: International regulations concerning the carriage of dangerous goods by rail (RID) Sea: International Maritime Organisation, Dangerous Goods Code IMDG Code Class corrosive Air: International Air Transport Association (IATA), Dangerous Goods Regulations 2.2 Disassembly, disposal, and recycling of batteries Only competent personnel shall undertake disassembly and disposal of batteries The following EC-directives must be followed: − 91 /1 57 (EEC, council directive) ”Batteries and accumulators containing certain dangerous substances” − 93/86 (EEC, commission directive) ”Adapting to technical progress Council Directive 91 /1 57/EEC on batteries and accumulators containing certain dangerous substances” 13 Inspection and monitoring To secure the safe operation of a traction battery regular inspection is required Any signs of deterioration shall be noted and be subject to repair, specifically in the case of electrolyte leakage and insulation failures The inspection of the battery can be incorporated into the regular maintenance routine of the battery, such as during the topping-up procedure Inspection and monitoring of batteries in service shall be in accordance with battery manufacturer's instructions blank BS EN 50272-3:2002 BSI — British Standards Institution BSI is the independent national body 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