AAR Manual of Standards and Recommended Practices

04/2008
Locomotives and Locomotive Interchange Equipment
RP-590 PART 3

Part 3

LEAD-ACID BATTERIES AND COMPARTMENTS

Recommended Practice
RP-590

Adopted: 1960; Revised: 1973, 1984, 1994, 2001

1.0 SCOPE
The purpose of this recommended practice is to set up uniform practices for battery use in service.
It will make available to the railroads comparable information as to the capacity to be expected
from batteries of various types and sizes offered for use under conditions of low and high tempera-
ture and discharge rates. By consideration of the information furnished under this method, deter-
mination of the proper battery for a given connection, load, discharge rate, and required hours of
discharge, both at initial rating and at 80% final rating, will be greatly facilitated and service
requirements will be satisfied.
2.0 CLASSIFICATIONS
2.1 On diesel-electric locomotives using engines larger than 600 hp in switching, passenger, and
freight service, a nominal 74 V system using 32 cells of lead-acid storage battery or equivalent
shall be standard for engine starting, auxiliary power, and lighting.
2.2 Batteries having a minimum capacity of 450 A·h at the 8-hour rate are required for road loco-
motives equal to or larger than 1500 hp. Batteries having a minimum capacity of 280 A·h at the
8-hour rate are required for switcher locomotives of less than 1500 hp. Capacities in ampere-hours
at other hourly rates must be specified when other than 8-hour rates are used.
2.3 All connections for lighting circuits are to be across the entire battery (no midpoint or other
intermediate tap from the battery is to be used).
3.0 LOCOMOTIVE STORAGE BATTERIES
A storage battery of suitable capacity and characteristics for engine starting and for operation of
controls, lights, and auxiliary apparatus shall be provided on each road and switcher locomotive
unit.
4.0 RATINGS
4.1 Locomotive batteries shall be rated on the number of start cycles they will deliver at initial
electrolyte temperatures listed below:
°F ± 4 °C ± 2
32 0
0 –18
–20 –29
4.2 The tests in paragraph 4.1 may be performed under laboratory conditions on a minimum of
four cells with standard intercell connectors and terminals. The start test cycle for batteries shall
consist of a 19.5-second discharge followed by a 60-second open circuit period. The number of suc-
cessive start test cycles that can be performed in accordance with Tables 4.1 through 4.3 shall be
recorded. The cell electrolyte temperature, which shall be at the specified test temperature at the
start of the first cycle, shall be recorded at the start of each successive cycle. The ambient battery
temperature shall be maintained at the specified test temperatures, ±4 °F, throughout the test
period.
4.3 No auxiliary heating devices shall be used for this test.

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PART 3 RP-590

4.4 The number of cycles is to be specified by the battery manufacturer for each of the tempera-
tures listed in Table 4.1.
Table 4.1 Start test cycle at 32 °F
Road Locomotives Switching Locomotives
1500 hp or Greater Less than 1500 hp
Breakaway current for 1.5 2000 A 1600 A
seconds
Rolling current for 18 seconds 1300 A 700 A
Minimum total voltage during 1.0 V × number of cells on test 1.0 V × number of cells on test
breakaway current (1.5 seconds)
Minimum total voltage during 1.1 V × number of cells on test 1.1 V × number of cells on test
rolling current (18 seconds)
Rest period in seconds after 19.5 60 seconds 60 seconds
seconds discharge

Table 4.2 Start test cycle at 0 °F

Road Locomotives Switching Locomotives
1500 hp or Greater Less than 1500 hp
Breakaway current for 1.5 2000 A 1600 A
seconds
Rolling current for 18 seconds 1300 A 700 A
Minimum total voltage during 1.0 V × number of cells on test 1.0 V × number of cells on test
breakaway current (1.5 seconds)
Minimum total voltage during 1.1 V × number of cells on test 1.1 V × number of cells on test
rolling current (18 seconds)
Rest period in seconds after 19.5 60 seconds 60 seconds
seconds discharge

Table 4.3 Start test cycle at –20 °F

Road Locomotives Switching Locomotives
1500 hp or Greater Less than 1500 hp
Breakaway current for 1.5 2000 A 1600 A
seconds
Rolling current for 18 seconds 1300 A 700 A
Minimum total voltage during 0.8 V × number of cells on test 1.0 V × number of cells on test
breakaway current (1.5 seconds)
Minimum total voltage during 1.1 V × number of cells on test 1.1 V × number of cells on test
rolling current (18 seconds)
Rest period in seconds after 19.5 60 seconds 60 seconds
seconds discharge

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Locomotives and Locomotive Interchange Equipment
RP-590 PART 3

5.0 CAPACITY
5.1 Storage batteries for use in railroad locomotive service shall be rated for capacity in accor-
dance with the following requirements:
5.1.1 The rated ampere-hour capacity of all cells for lead-acid batteries shall be based on the
S-hour discharge rate at a specified specific gravity of electrolyte. A 5-hour discharge rate shall be
included for maintenance purposes. Other discharge rates, including the 3-hour rate, may be spec-
ified to illustrate pertinent characteristics of the battery.
5.1.2 Values of not less than 100% of the rated capacity must be delivered after not more than 10
cycles of charge and discharge at the normal 8-hour/5-hour discharge rate. Values of not less than
90% capacity must be delivered after 5 cycles of charge and discharge.
5.1.3 If the railroad requires batteries to be delivered fully formed to 100% capacity, the railroad
shall so state when inquiries are made for the purchase of the batteries.
6.0 MINIMUM VOLTAGE LIMITS
The battery voltage on a minimum of four cells at the end of discharge shall conform to the values
given below. The rated capacity for the 5-hour or other rates stated by the manufacturer must be
delivered at the voltage values set forth for the respective batteries. All voltage readings shall be
taken at the cell terminals.
Table 6.1 Minimum battery voltage
3-Hour Rate 8-Hour Rate
Lead-acid type (no cell below 1.72 V) avg. 1.75 V avg. 1.75 V

7.0 TEMPERATURE
The rated capacity must be available with an electrolyte temperature of 77 °F (25 °C) at the start
of discharge. A time-temperature correction shall be made for other temperatures in accordance
with the following formula (NEMA IB-2-R1980):
actual capacity (measured)
capacity at 77 °F = ----------------------------------------------------------------
1 + 0.025 ( t – 77 )
where
t = temperature of discharge
Note: This factor is to be used only for initial electrolyte temperatures, 77 °F, ± 10 °F.

8.0 ELECTROLYTE
8.1 The specific gravity of the electrolyte at 77 °F (25 °C) with the cells fully charged and filled
to the normal height shall not exceed the limits given below for the various types:
Table 8.1 Specific gravity of electrolyte
Electrolyte SG
Nominal ± 0.010
Lead-acid antimony 1.250
Lead-acid calcium 1.275

8.1.1 Battery manufacturers may specify other specific gravities but must furnish ratings at
these gravities.
8.1.2 No lead-acid battery shall have a specific gravity less than 1.100 after delivering the rated
capacity.

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8.2 When comparing specific gravity readings in service, allowance must be made for variation
due to temperature of the electrolyte. The following rules are presented for this correction:
8.2.1 Lead-Acid Battery
For each 3 °F rise in temperature of the electrolyte above 77 °F, add 0.001 to the hydrometer read-
ing. For each 3 °F drop below 77 °F, subtract 0.001 from the hydrometer reading.
8.3 A CAUTION sign will be displayed at a conspicuous location on the battery to warn of the
dangers of handling electrolyte solution and the possible presence of explosive gases.
9.0 VOLTAGE AND CAPACITY DATA
The manufacturer shall furnish the following data that applies to the type of battery being pur-
chased for use on railroad locomotives:
• Number of starting cycles the battery is capable of delivering at 32 °F (0 °C), 0 °F (–18 °C),
and –20 °F (–29 °C)
• Ampere-hour capacity at the 8-hour/5-hour rate
• Ampere discharge rate at the 8-hour/5-hour rate
• Finish charging rate in amperes
• Maximum specific gravity value of the electrolyte when cells are fully charged and filled to
normal height
• Minimum specific gravity value after delivering the rated capacity at the normal
8-hour/5-hour discharge rate for lead-acid batteries
• Normal height of the electrolyte above the top of plates or splash cover when filled to nor-
mal level
• Voltage and capacity data at the 8-hour/5-hour and other discharge rates shall be fur-
nished by the manufacturer upon request in the form of a graph similar to Fig. 15.1, giving
the following information for the 8-, 5-, and 3-hour discharge rates to 1.75 volts per cell:
• Ampere hours per positive plate
• Amperes per positive plate on rates of discharge
• Number of plates per cell
• Initial, average, and final voltages for rates shown
• Specific gravity of electrolyte at start of discharge
• Temperature of electrolyte
• Type of cell
• Manufacturer’s name
• Date of manufacture, including month and year
10.0 NAMEPLATE
10.1 An electrolyte-resistant nameplate (4 3/4 in. × 2 3/4 in.) shall be applied to the positive end
of each tray of a set of batteries in accordance with Fig. 15.2.
10.2 Railroad set number and date new shall be stamped with approximately 3/16-in. stencil on
one lead intercell connector per tray on monoblock tray batteries or unitized battery unit, or at
another visible location specified by the railroad.

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Locomotives and Locomotive Interchange Equipment
RP-590 PART 3

11.0 CAPACITY TESTS—SUGGESTED TESTS FOR CONDITION OF AN ORDER

11.1 When capacity tests are to be made at the manufacturer’s plant before shipment in accor-
dance with a contractual agreement between the battery manufacturer and the purchaser, the
manufacturer shall supply the necessary apparatus, electrical energy, and labor for conducting the
tests and shall give due notice when the batteries will be ready for test.
11.2 If the tests are to be made at the manufacturer’s plant, the railroad shall state how many
sets of any lot ordered are to be tested.
11.3 Acceptance of the total number of batteries ordered as a result of testing a limited number
shall not affect the manufacturer’s responsibility as to individual set performance in meeting
capacity rating.
11.4 Two battery sets are to be picked at random from any lot ordered. The batteries shall give
100% of full rated capacity by the tenth discharge cycle, the manufacturer having previously given
all the batteries the necessary developing charge to meet this condition before they are tested. The
batteries selected are to be tested at the 8-hour/5-hour rate, followed by a test at such higher rates
as may be specified by the railroad if needed.
11.5 Before the first discharge, the cells shall be given a freshening charge at the finishing rate,
shown on the nameplate, until the cell voltage has remained constant for not less than 2 hours.
This charge shall be considered as the completion of the charging portion of the first test cycle.
Each successive charge should not exceed 125% of the previous discharge, should it be desired to
vary the rate of hours of charge, followed by a discharge at the 8-hour/5-hour rate to a final voltage
as given in paragraph 6.0 above.
11.6 Prior to the start of the first test cycle, the specific gravity shall be adjusted to within
±5 points of gravity specified by the manufacturer with the electrolyte at the correct level. Read-
ings to be taken after sufficient time of charge has elapsed to thoroughly mix the electrolyte.
11.7 The capacity of the battery shall be the number of ampere hours delivered during the final
test cycle, the cell temperature at the start of discharge to be 77 °F ± 5 °F. The interval between
the start of the test discharge and the end of the previous charge shall be not more than 24 hours.
11.8 In the case of batteries to be used in service where the discharge rate is to be higher than
the 8-hour/5-hour rate, the battery, after having successfully met the 5-hour test, shall then be
given a test at the higher rate specified by the railroad to determine its ability to meet the manu-
facturer’s rating for such high rate. This high-rate discharge is to be made after recharging the
battery at not more than 125% of the previous discharge for lead-acid batteries. The period
between the end of this charge and the start of the high-rate discharge must not exceed 24 hours.
Under this high-rate discharge test, the battery must meet the voltage, temperature, and
ampere-hour requirements specified. The capacity of the battery at this high discharge rate shall
be the number of ampere hours delivered during this discharge.
11.9 If an initial current output test is requested by the railroad, the following data should be
obtained:
• Minimum value of the maximum current output available for 1 1/2 minutes at 77 °F, dis-
charged to an average of 1 volt per cell
• Minimum value of the maximum current output available for 1 1/2 minutes at 32 °F, dis-
charged to an average of 1 volt per cell for lead acid
Only one tray from each set of batteries should be tested in order to obtain this data.

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Locomotives and Locomotive Interchange Equipment
PART 3 RP-590

12.0 ELECTROLYTE FOR LEAD-ACID STORAGE BATTERIES

Electrolyte for lead-acid storage batteries shall be in accordance with the manufacturer’s recom-
mendations.
13.0 BATTERY CONNECTORS—INTERCELL AND INTERTRAY
13.1 All intercell connectors shall be of a corrosion-resistant type with low joint resistance and
ample current carrying capacity to reduce losses to a minimum.
13.2 For intertray connectors, cables shall be in accordance with RP-586 or RP-588.
Table 13.1 Minimum cable requirements for inter-tray connectors
Ampere-Hour Capacity Cable Size
Up to 285 No. 00
286 and up No. 000

13.3 For lead-acid batteries, the terminals on intertray connectors shall be of the copper tube
type, heavily lead-covered or of a cast lead alloy with wire sealed into the terminal to prevent cor-
rosion due to acid entering the terminal.
13.4 For lead-acid batteries, stainless steel or lead-covered brass nuts and bolts shall be used to
connect intertray connector terminals to battery terminal posts. Two-bolt terminals shall be used
for all size batteries.
13.5 For lead-acid batteries, stainless steel or brass terminal bolts shall be 5/16-in. diameter with
18 threads to the inch. A bolt shall have no more than 1 3/16 in. of projecting thread. A nut shall
take not less than 13/16 in. of bolt thread length. The effect of this is to result in a distance of not
more than 3/8 in. between the clamping surface of the nut and the inside surface of the bolt head.
13.6 The manufacturer shall coat all battery terminal bolts and nuts with a nonoxidizing lubri-
cant.
14.0 CONTAINERS (TRAYS)
14.1 The containers shall be made of high impact, electrolyte- and heat-resistant, nonconductive
material.
14.2 Dimensions
To ensure interchangeability of different makes of storage batteries and to permit designing com-
partments of ample size for the desired arrangements of four-cell container assemblies, the dimen-
sions of nominal container units for road locomotives shall be as shown in Fig. 15.3.
14.3 Unitized Containers
14.3.1 Unitized plastic container batteries are to be 16-cell units with the configuration and
dimensions shown in Fig. 15.5.
14.3.2 Cells are to be contained in nonconductive jars or in high-impact, acid-resistant material.
14.3.3 Cells are to be covered with a dead-top construction of acid-resistant compound that will
effectively seal the unit but will enable easy removal of individual cells if required.
14.3.4 The interior and exterior of the container are to be nonconductive high-impact material.
Maximum leakage current allowable from positive and negative to ground is to be 5 µA from either
terminal to ground.

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RP-590 PART 3

14.3.5 Top and sides are to be orange for lead-calcium trays and another color for lead-antimony
trays.
14.3.6 Unitized batteries should be designed for loading by fork lift. The connections must be pro-
tected with a protruding bumper to prevent shorting during installation.
15.0 BATTERY BOXES AND COMPARTMENTS
15.1 All locomotives are to be provided with battery compartments capable of containing eight
monoblock trays as shown in Fig. 15.3 in the configuration shown in Fig. 15.4 or two 16-cell unit-
ized tray as shown in Fig. 15.5.
15.2 On road locomotives, the minimum unobstructed side or top opening (for installation)
dimensions for the battery compartment will be 46.75 in. wide, 22.50 in. high, and 28.75 in. deep.
15.3 For underframe-mounted battery boxes, side-serviced compartments should have at least
5 in. of clearance above the battery.
15.4 On switching locomotives, the preferred battery box size is 34.00 in. wide, 22.50 in. high, and
28.50 in. deep. Other configurations that are capable of containing eight monoblock trays and that
have an opening on top for loading purposes are also acceptable.
15.5 Top-serviced compartments should have an entrance opening large enough to permit free
access to all cells by means of automatic cell filters.
15.6 Boxes mounted beneath the underframe and serviced from the side shall in all cases meet
the requirements of the latest issue of the AAR Standard Clearance Diagram.
15.7 Compartments shall be painted with a suitable acid-resisting paint or cement such as neo-
prene or an asphalt base paint.

15.8 Compartments shall be ventilated, providing not less than 6 in.2 per four cells. Drainage
shall be provided so that leakage and wash water will drain clear of other locomotive parts. The
bottom of the battery box is to be designed to facilitate drainage.
15.9 When four monoblock trays are used, the connections will be made as shown in Fig. 15.4.
15.10 All hinged top opening covers must be secured by latches in the open position.
15.11 All covers must be provided with corrosion-resistant hinges.

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PART 3 RP-590

INITIAL VOLTS 2.0

AVERAGE VOLT 1.9

4.0 S
1.8
FINAL VOLTS
AMPERE-HOURS PER POSITIVE PLATE

1.7

1.6
UR
12 HO

VOLTS PER CELL

3.0
UR

R
8 HO

OU
5H

CAPA
CITY T
R

CAP O FINA
OU

O UR ACIT L VOLT
S
3H

2H Y TO 1
.7 5 V
2.0 OLT
S
UR
1 HO

2 4 6 8 10 12 14 16 18 20
AMPERES PER POSITIVE PLATE
NOTE:
1. SPECIFIC GRAVITY IS 1.250
2. TEMPERATURES IS 77 °F. OTHER CURVES MAY BE FURNISHED AT OTHER SPECIFIED TEMPERATURES.
3. CAPACITY FOR 1 ½ MIN. TO 1.0 VPC IS 158 AMPS PER POSITIVE PLATE.
Fig. 15.1 Typical discharge curve—diesel locomotive batteries

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Locomotives and Locomotive Interchange Equipment
RP-590 PART 3

EIGHT 3 32" DIA. HOLES, OPTIONAL

(NOT REQUIRED FOR LEAD-ACID BATTERIES,

OR ON MONOBLOC BATTERIES

4 ¾"
1
8 " 2 ¼" 2 ¼" 1
8 "
1
8 "

(SPACE FOR MANUFACTURER’S NAME, ETC.)

¼" 2 8"
1
2 8"
1
¼"
R.R SET NO. DATE NEW

2 ¾"
OWNER 8 HR. CAP. A.H.
1
8 " TYPE * HR. CAP. A.H.
NO. CELLS Ø
¼" TRAY WT. LBS. + AMPS.
MFR. NO. ELECT. HT. IN.
¼"

Ø WORDING FOR LEAD-ACID BATTERIES "FULL CHG. GR."

+ WORDING FOR LEAD-ACID BATTERIES "FINISH CHG."
COLOR: LIGHT BASE WITH CONSTRASTING LETTERING
MATERIAL: ELECTROLYTE RESISTANT
Fig. 15.2 Representative nameplate

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PART 3 RP-590

4"

4"

2 ½" 2 ¼"
A.C. FLEX CABLE
28 ¼" 11 1 8 "
26 5 16" 3
16" 9 ¼"
1 ¾" HOLES FOR 5 16" 1 ¾"
CONNECTOR STUD 5 29 32"

4 ¾"

3 ¼"
15 7 16"
14 7 16"
4 ½"
18 ¼"

9 3 16"
5 29 32"

4" 2 38 " 4" 1 13 32" 2" 5 18 " 2"

10 1 8 "
Fig. 15.3 Four-cell container unit for diesel road locomotive battery—typical dimensions

Fig. 15.4 16-cell, 4-monoblock unit in locomotive compartment

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Locomotives and Locomotive Interchange Equipment
RP-590 PART 3

0"
3.0

NE
G.

20.50" MAX.

S.
PO

.
AX
"M
27.00
44.
00"
MA
X.
1.47"
NOTE: 1.31"
INNER CELL CONTAINERS TO BE
POLYPROPYLENE OR EQUAL. 1.69"

3.00"
PRESENT MAXIMUM OVERALL DIMENSIONS – INCHES
2.00"
L W H
27.00" 44.00" 20.50" 0.34" DIA. (2 HOLES)
TERMINAL DETAIL
POS. OR NEG.
Fig. 15.5 16-cell unitized tray

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PART 3 RP-590

– +

4 25 32"

7 78 "
21 19 32" 15
16 "
7 ½"
28" 3
8 " DIA.

1 ¼"
1 18 "

18"
3 38 "
15 15 32"
10 5 8 "
NAME 1 18 "
5" PLATE

½" 2"
4" 1 9 16" 8 18 "

Description: Lead acid storage battery in a 4-cell, 13-plate, acid-resistant, hard rubber or plastic container.
Capacity: 280 A·h at 8-hour rate.
Fig. 15.6 Diesel switcher, monoblock battery—typical dimensions

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