To:Working Group Members

Date:March 2, 2000

From:Stanley Kwa, WG 10 Chair
Re:Meeting Minutes # 5

held at Exide Corporation, Reading, PA

The Working Group Meeting # 5 was held on February 25, 2000 at Exide Corporation in Reading, PA. I want to thank Richard Niederberger of Friwo for hosting the meeting. The agenda of the meeting is to continue review/discuss the remaining sections of the standard. We completed review of the following sections:

6.0 Electrical Requirement

7.0 Battery Compartment

Ten participated with one new member, John Gmelch, STV consultant.

This is the first time that a complete draft standard was reviewed line by line by the working group and prepared for a full RTVIS committee review.

Attached is a draft standard dated March 1, 2000.

DRAFT

March 1,2000

P1536

Standard for Rail Transit Vehicle Battery Physical Interface

Prepared by the Transit Vehicle Battery Standardization Working Group of the VTS Rail Vehicle Interface Standards Committee.

345 East 47th Street

New York, NY 100 17, USA

This is an unapproved draft of a proposed IEEE Standard, subject to change. Permission is hereby granted for IEEE Standards committee participants to reproduce this document for purposes of IEEE standardization activities. If this document is to be submitted to ISO or IEC, notification shall be given to the IEEE Copyright Administrator. Permission is also granted for member bodies and technical committees of ISO or IEC to reproduce this document for purposes of developing a national position. Other entities seeking permission to reproduce portions of this document for these or other uses must contact the IEEE Standards Department for the appropriate license. Use of information contained in the unapproved draft is at your own risk.

IEEE Standards Department

445 Hoes Lane, P.O. Box 1331

Piscataway, NJ 08855133 1, USA

Participants

At the time this standard was being drafted, the Transit Vehicle Battery Working Group had the following membership:

Bruce Alexander

Bob Cerra

John Gmelch

Nathan Grief

Seyed Hosseini

David Jacobs

Sachit Kakkar

Ted Mavronicolas

Larry Meisner

Lawrence Mirecki

Chris Morris

Richard Niederberger

John Pesuit

John Shea

Alex Sinyak

Ron Walter

Stanley Kwa, Chair

The following persons were on the balloting committee: (to be supplied by IEEE)

TABLE OF CONTENTS

1.Overview

1.1. Scope

1.2. Purpose

2.References

3. Abbreviations, acronyms and definitions

3. 1. Abbreviations and acronyms

3.2. Definitions

4.Physical Requirement

4.1 Cells

4.1.1 Cell Markings

4.2 Battery Tray Envelope

4.2.1. Battery Tray Arrangement

4.3 Hardware

5. Environmental Requirement

5.1 Disposal

6. Electrical Requirement

6.1 Load Profile

6.2 Sizing Parameters

6.3 Rating

7. Battery Compartment

7.1 Safety

7.2 Ventilation

7.3 Spacer

7.4 Clamping Forces

P 1536

Standard for Rail Transit Vehicle Battery Physical Interface

1.0Overview

This standard applies to new procurements or major rehabilitation of rail transit vehicles occurring on or after the effective date of this standard. Existing rail transit vehicles and those vehicles currently being procured need not comply except when specifically required by the authority having jurisdiction. Where a need exists to maintain compatibility with existing rail transit vehicles, those portions of this standard in conflict with compatibility requirement need not be applied.

1.1Scope

This standard prescribes the maximum dimensional requirements of each battery tray for a specific numbers of cells and battery capacity or performancerating. The battery hardware requirement and battery compartment are also prescribed in this standard.

1.2Purpose

The purpose is to standardize the physical dimensional requirement of a battery tray. Currently, there are no overall dimensional standards for a battery tray. The same rating batteries are being produced in different cell sizes by different manufacturers to suit customer battery compartment requirements. This standard will provide an optimal battery compartment with interchangeability of batteries supplied by various manufacturers. Thus, it will facilitate joint multi- userspurchasing.

2.0References

This standard shall be used in conjunction with the following publications. If the following publications are superseded by an approved revision, the revision shall apply. In case of a conflict between this standard and the referenced document, this standard takes precedence. Those provisions of the referenced documents that are not in conflict with this standard shall apply as referenced.

IEC 623: Vented NickelCadmium Prismatic Rechargeable Single Cell, 3rd edition 1990 including amendments 1& 2

IEEE Std. 1001996: The IEEE Standard Dictionary of Electrical and Electronics Terms, Sixth Edition

IEEE Std. P1476 (Draft): Standard for Passenger Train Auxiliary Power Systems Interfaces

APTA RP–E-007-98R1: Recommended Practice For Storage Batteries and Battery Compartments

IEC 77: Call Ted for title

IEEE Std. P1478 (Draft): Environmental Standards for Rail Transit Equipment

3.0Abbreviations, acronyms and definitions

3.1Abbreviations and acronyms

AhAmpere hours

ANSI American National Standards Institute

DOT United States Department of Transportation

EMC Electro Magnetic Compatibility

FRA Federal Railroad Administration (of the DOT)

FTA Federal Transit Administration(of the DOT)

IEC International Electrotechnical Committee

IEEE Institute of Electrical and Electronics Engineers

LVPS Low Voltage Power Supply

NEC National Electrical Code (also known as NFPA 70)

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

ULUnderwriter Laboratory

ASTMAmerican Society for Testing and Materials

APTAAmerican Public transit Association

TRBTransportation Research Board

3.2Definitions

For the purposes of this standard, the following terms and definitions apply. IEEE std 1001996, The IEEE Standard Dictionary of Electrical and Electronics Terms 1, should be referenced for terms not defined in this clause. Because the rapid transit industry is possessed of significant unique terminology, the use of the TRB Glossary [B I] shall be normative for this standard. Websters; New Collegiate Dictionary [B2] shall otherwise apply.

3.2.1 authority: A geographical or political division created specifically for the purpose of providing transportation service.

3.2.2 authority having jurisdiction: that entity that defines the contractual (including specification) requirements for the procurement.

3.2.3 battery tray: one or more cells configured as one block or in a steel, stainless steel or polymeric crate

3.2.4 builder: The entity manufacturing the product

3.2.5 car: see vehicle

3.2.6 car builder: The entity manufacturing the car.

3.2.7 manufacturer: see: builder

3.2.8 Multi-cell block: see battery tray

3.2.9 rate, low discharged (L): “typically for discharges up to 0.5C5A per IEC 623”

3.2.10 rate, medium discharged (M): “typically for discharges above 0.5C5A and up to 3.5C5A per IEC 623”

3.2.11 rate, high discharged (H): “typically for discharges above 3.5C5A and up to 7C5A per IEC 623”

3.2.12 reliability: the probability that a system will perform its intended functions without failure, within design parameters, under specific operating conditions, and for a specific period of time. The ambient environment, conditions for operation are specified by the purchaser, or, in the absence of such specifications, by IEEE Std P1476.

3.2.13 supplier: the entity which contractually acts as the source of a product.

NOTE The supplier may or may not be the actual builder

3.2.14 vehicle: A land conveyance assembly for carrying or transporting people or objects, capable of traversing a guideway, having structural integrity and general mechanical completeness but not necessarily designed for independent operation.

4. Physical Requirement

4.1 Cells:

Battery manufacturers shall produce the individual multiplecells according to their own design and available technology. However, the overall dimensions shall fit within the standard tray envelopeas shown in Table 1.

4.1.1 Cell Markings

Each cell/multi-cell block shall be marked

a) per IEC 623 requirements

b) Date Manufactured (uncoded)

c) Additional markings requirements by the authority

The positive terminal of a cell shall be identified by either a red washer or an indented or raised “+” symbol as per IEC 623.

The negative terminal of a cell shall be identified by either a blue or black washer or an indented or raised “-” symbol.

4.2 Battery Tray Envelope

Battery manufacturers shall produce the battery trays according to their own design. The maximum length shall include the battery tray handles. The maximum height shall be to the highest point of the assembly with vent cap closed. The weight shall include electrolyte filled at the maximum level. The battery tray shall be constructed in such way to support the weight of the cells it carries. Table 1 is compilation of existing battery trays’ and cells’ largest individual dimensions. New battery cell container shall not exceed these dimension.

Note: It is prudent to select the next tray dimension in designing a battery box to allow for a future expension.

Table 1: (0 entery means insufficient information. In general Table 1 is incomplete!!!!!)

A: For Low Discharged Rate Battery (Low rate data is incomplete. Waiting for additional information!!!!!!)

(i) The maximum battery tray envelope and mass (kg.)for Polymeric Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity.AhWHLWt.LWt.LWt.L Wt. LWt.

 801403252191229416.937221.74502752731.9

 81  10014032521912.729417.93722345028.752733.9

 101  12017033026114.635620.94552755433.665339.8

 121  14017032526115.536022.947030.258037.669044.9

 141  16017032530318.441926.553934.56594377951

 161  1801703253031941927.553935.865944.677953

 181  20021132536021.951032.56704383053.699064.1

 201  22021132526122.635632.745542.655453.465363.6

 221  24017032536022.551033.467044.283055.199065.9

 241  26017442336027.45104067052.583065.599078.1

 261  28017032536023.551034.967046.283057.699068.9

 281  30017442336028.551041.767054.783068.399081.4

(ii) The maximum battery tray envelope and mass (kg.)for Stainless Steel Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity. AhWHLWt.LWt.LWt.L Wt. LWt.

 8016033023011.129516.63602242527.453032.8

 81  10019033027013.135519.64302651532.460038.8

 101  12019033027014.935522.343029.651536.960044.2

 121  14019033027015.335522.943030.451537.960045.4

 141  16019033029017.139025.64903459542.470050.8

 161  18019033032519.343528.755038.466047.977557.4

 181  20019033037022.551033.769044.883055.997067

 201  220000000000000

 221  240000000000000

 241  26019033037023.151038.66904683057.497068.8

 261  280000000000000

 281  30019033042526.560039.776052.892565.9109079

Table 1:

B: For Medium Discharged Rate Battery

(i) The maximum battery tray envelope and mass (kg.)for Polymeric Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity. AhWHLWt.LWt.LWt.L Wt. LWt.

 801703252191229417372224502752732

 81  10017032521912.729418.137223.845029.852735.5

 101  1201703252611636023.54703158038.669048.1

 121  1401783252611736025470335804069047.3

 141  16017832530319.741929.553938.265948.977958.6

 161  1801783253031941927.553935.865944.677953

 181  20021132536022.9510346704583056.199067.1

 201  22021134736023.551034.967046.283057.699068.9

 221  24017032036023.951035.56704783058.699070.1

 241  26017442336027.45104067052.583065.599076.1

 261  28017041536024.9510376704983061.199073.1

 281  30017442340628.560241.767054.783068.399081.4

(ii) The maximum battery tray envelope and mass (kg.)for Stainless Steel Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity. AhWHLWt.LWt.LWt.L Wt. LWt.

 801904242301530022370304503752534.6

 81  1001904242651735025445345404263040.6

 101  1201904242901839027490365954570047.8

 121  1401904242902139031490415955170052.8

 141  16019034532516.9440255803368541.180549.1

 161  1801904243252644038560516856380559.8

 181  2001904243702851042660568057095070

 201  22019042442533590497656594081111080.2

 221  24019034542527.159040.67655394067.4111080.2

 241  26019042442538590567655594069.9111083.8

 261  280000000000000

 281  30019044037043510646605980574.995089.8

Table 1:

C: For High Discharged Rate Battery

(i) The maximum battery tray envelope and mass (kg.)for Polymeric Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity. AhWHLWt.LWt.LWt.L Wt. LWt.

 8017033021913.132418.742824.853430.663836.5

 81  10017134726117.336025.647033.858042.169050.3

 101  12017134730318.841927.153935.865944.677953.3

 121  14021134726122.336032.447042.458052.969062.9

 141  16021134736025.951038.667051.683064.499077.2

 161  18021134736024.751036.767048.683060.699072.5

 181  20021132530727.44254054752.566965.579176.1

 201  22021134736028.15104167053.883067.299080.1

 221  2402113473433050344663588237179184

 241  260000000000000

 261  280000000000000

 281  3001803203903658752000000

(ii) The maximum battery tray envelope and mass (kg.)for Stainless Steel Cells in a crate

Dimension for W, H, L in (mm) and Wt. in (kg.).

Required2 Cell Tray3 Cell Tray4 Cell Tray5 Cell Tray6 Cell Tray

Capacity. AhWHLWt.LWt.LWt.L Wt. LWt.

 801913882901839027490365954470041.2

 81  1001913882902139031490415955170055

 101  1201913882902539038490505956370058

 121  1401913883702951043660578057195059.8

 141  16019136237024.751036.766048.680560.695072.5

 161  1801913883703751055660738059195078.4

 181  2001883883203946259000000

 201  2201913624252859041.876555.694069.4111083.2

 221  2401913883594753470000000

 241  260000000000000

 261  2801883884065160178000000

 281  3001913884685869087000000

4.2.1: Battery Tray Arrangement

Figure 1

Battery trayarrangement shall be in accordance with Figure 1.

4.3 Hardware

The hardware shall be corrosion resistant material. When a battery is replaced with a different terminal post, it is the responsibility of the battery manufacture to specify additional hardware to insure a proper physical connection and electrical conductivity without replacing the existing car body wiring or fastener. The overall cell dimensions with additional hardware shall fit the standard battery tray envelope as shown in Table 1:

5.0 Environmental Requirements

The battery cell container or battery tray material shall meet or exceed the environmental requirements of flammability, toxic gas emission, smoke emission and shock & vibration specified by the authority/users.

5.1 Disposal

Battery manufacturers shall conform to the requirements of the local, state/provincial and federal when disposing the unused battery.

6. Electrical Requirement

6.1 Load Profile

The battery Load Profile shall be provided to Battery Manufacturers. The load profile shall be developed as in IEEE P1476. The authority shall maintain and update the load profile information. The authority shall insure that the existing battery can provide sufficient electrical requirements with each change of the load profile. The updated load profile shall be readily available for the future procurement / replacement of the battery of the vehicle/consist.

6.2 Sizing Parameters

The authority and battery manufacturers shall select the size (in Ampere hour & performance rating) using the load profile and the requirements of IEC 623. The authority shall maintain the documentation and additional parameters used in selection of the size and the rating. The reason is the same load profile can produce a number of battery choices with different ampere hours and ratings. In order to maintain the interchangeability, it is critical to keep the size selection method and parameters available for future procurement/replacement of the battery. When this information is not available, the authority shall develop a new load profile. The authority may allow the replacement of the existing battery which shall meet the load profile with a physically different battery. It shall be the responsibility of the battery manufacturers to submit all necessary information for installation.

6.3 Rating

IEC623 latest revision shall be used in determining the capacity and performance rating (Low, Medium,High) of a battery. The same capacity and performance rating (i.e 80Ah, 100Ah, for L, M, H) from any battery manufacture shall provide a minimum discharge performance of IEC 623.

7.0 Battery Compartment

Note: It is the intend of this standard not only to establish a limited number of agreed-upon standardized battery box sizes, but to enhance the awareness and ability for operating entities to provide for future expansion to increased battery size, without having to replace the battery boxes, and/or re-arranged existing installed equipment.

The battery compartment shall be designed to accommodate battery size and tray arrangement provided by the operating authority/battery manufacturers. It shall be designed to utilize the available space efficiently. The battery tray arrangement shall be developed using table 1 to minimize the battery compartment dimension. The battery compartment shall be of adequate size to accommodate a crated battery from Table 1. The compartment shall be designed so that any water entered shall gravity drain out. The drain holes shall have baffling such that rain, snow and dirt shall not be blown in by car motion.

The battery compartment shall be designed and constructed of non-combustible, non hygroscopic, corrosion-resistant materials and to withstand the loads and forces of the interactions of the railcar and the battery. It shall either be electrically isolated from, or grounded to the car body, depending on the design criteria of the operating authority, and in accordance with applicable standards and specification.

The battery compartment shall be provided with full-size covers or doors, and locking roll-out tray racks, to allow for ease of battery periodic inspection and maintenance in accordance with operating authority’s requirements. The door or cover shall be removable and water tight. A safety catch shall be designed to prevent and retain the cover from accidental opening at all operating speeds. Door or cover mounting and latching hardware shall also be of non-corroding materials.

7.1 Safety

No aluminum shall be used within battery compartment . Means shall be provided within the compartment to prevent lateral and longitudinal movements of the battery using fire resistant material.

7.2 Ventilation

Battery compartment shall be adequately ventedto the exterior of the car body. Fiberglass or other approved fire resistant easily replaceable filtering media shall be applied to ventilation openings to prevent dust ingress due to car motion.

7.3 Spacer

If the battery trays do not fully occupy the length and/or with of the battery compartment, battery manufacturers shall provide spacers to restrain the battery trays from moving. The spacer shall be made of metal (not aluminum), plastic, or wood (treated for fire retardency). The spacers shall be removable to allow use of trays of varying dimensions.

7.4 Clamping Devices

Suitable clamping devices shall be provided by the car manufacturer as an alternative to or in conjuction with the spacers referenced in 7.5. Such clamping devices shall spread the clamping force over a large enough area of the tray to not damage the tray. To prevent excessive force, the clamping device shall be designed for hand tightening without use of tools.