GAZ SOL G Series User manual

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SOL G
Technical Manual SOL G Ni-Cd Batteries for renewable
energy applications
Made in Germany

1. Receiving the battery
Cells must not be stored in their packaging, therefore, unpack
the battery immediately upon receipt. Do not tilt the package or
turn it upside down. The battery cells are equipped with a blue
plastic transport plug. SOL...G batteries will be delivered filled and
charged. The battery is ready for installation. Replace the transport
plug with the yellow vent cap included in the accessories just
before use (see section 7).
The battery must not be charged with the transport plug installed
as this can damage the battery.
2. Storage
The rooms provided for storing the batteries must be clean, dry,
cool (+10°C to +30°C) and well ventilated. Cells must not be stored
in the transport packaging and must not be exposed to direct
sunlight or UV-radiation.
If the cells are delivered in plywood boxes, open the boxes before
storage and remove the packing material on the top of the cells. If
the cells are delivered on pallets, remove the packing material on
the top of the cells.
Filled SOL...G cells can be stored up to 12months from the day of
delivery.
Storage of filled cells at a temperature above +30°C will result in a
loss of capacity of approximately 5% per 10 degrees per year. It is
very important that the cells are sealed with the plastic transport
plugs tightly in place. This is to be checked after receiving the
goods. In case of electrolyte loss during transport, refill the cell up
to the “MAX” mark with genuine electrolyte before storage.
3. Installation
The installation should be carried out in accordance with the
requirements of IEC 62485-2:2010, Part 2 “Safety Requirements
for secondary batteries and battery installations – Part 2: Stationary
batteries”. For non-stationary installations, specific standards may
also apply.
3.1 Location
Install the battery in a dry and clean room. Avoid exposure to direct
sunlight and heat. The battery will give the optimal performance
and maximum service life if the ambient temperature range is
between +10°C and +30°C.
3.2 Ventilation
During the last phase of charging, battery gases are released
(a mixture of oxygen and hydrogen). Ventilation is necessary, even
if the generation of gas is very low during float charging.
Compliance with local regulations as to ventilation may be
necessary for certain applications. If there are no special
regulations, standard IEC 62485-2:2010, Part 2 must be met.
3.3 Setting up
Always follow the assembly drawings, circuit diagrams and other
separate instructions. In the case of parallel string connection
only use battery cells of the same capacity, design and age up to a
maximum of two parallel strings. For parallel connection of more
than two strings, please contact the manufacturer for technical
approval. Use nickel-plated cable lugs for cable connections.
The transport plugs have to be replaced by the yellow vent caps
included in the accessories.
Tighten the terminal screws with corresponding tightening torque
as per table 1.
It is recommended to use a calibrated torque wrench.
Table 1: Torque loadings for terminal screws:
2
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Warning!
The gases emitted during charging are explosive. The electrolyte (potassium hydroxide, KOH) is highly corrosive. Exposed metal parts of
the battery always conduct a voltage and are electrically active parts. Precautions in accordance with IEC 62485-2:2010 must be observed.
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Handling
DataSafe®XE batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
California Proposition 65 Warning - Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.
Care for your safety
Keep flames away
Discharge any possible static electricity from clothes
by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatch and articles of clothing
with metal parts that may come into contact with
the battery terminals.
No smoking, no naked flames, no
sparks
Shield eyes Read instructions
Electrical hazard Danger Re-cycle scrap batteries.
Contains lead
Electrolyte is corrosive
Clean all acid splash in eyes or on skin
with plenty of clean water.
Then seek medical help.
Acid on clothing is to be washed with
water
Warning: Risk of fire, explosion, or
burns. Do not disassemble, heat above
60ºC, or incinerate. Avoid any short
circuit. Metallic parts under voltage on
the battery, do not place tools or items
on top of the battery
Observe the instructions for use and place them
visibly close to the battery! Work only on batteries
after receiving instruction from qualified personnel!
When working on batteries wear safety glasses and
protective clothing. All metallic personal objects, such
as rings, watches, bracelets etc. shall be removed
before starting work on the battery! Only use insulated
tools! Comply strictly with the accident prevention
regulations and your national Health and Safety
standards as well as IEC 62485-1:2010
Electrolyte is harmful to skin and eyes. Therefore, after
an accidental contact with the electrolyte flood the
eyes immediately with large quantities of clean water
for an extended period of time of at least 15 minutes.
In all cases, consult a doctor immediately! Clothing
contaminated with electrolyte should be washed in
water immediately!
Warning: Risk of fire, explosion, or burns! Avoid any
short circuit! Metallic parts of the battery are always
under voltage on the battery, do not place tools or
items on top of the battery!
Electrolyte is highly corrosive!
Cells are heavy! Make sure they are safely installed!
Only use suitable transport equipment!
No smoking! Do not allow naked flames, embers or
sparks near the battery due to the risk of explosion
or fire!
The Installation, Operation and Maintenance Instructions
must be strictly observed.
Non-compliance with the Installation, Operation and
Maintenance Instructions, use of nongenuine spares and
the usage of other than by EnerSys/GAZ specified parts,
use of additives to the electrolyte and unauthorised
tampering will invalidate any entitlement to warranty.
Used batteries with this
symbol are recyclable products
and have to be put into
a recycling system. Used
batteries must be disposed of
as special waste in accordance
with all standards.
WARNING!
Never use sulphuric acid or
acidic water.
Acid will damage the battery!
M8 20-25 Nm
M10 25-30 Nm
Connectors and terminals should be protected by a thin layer
coating of anti corrosion grease.
Terminal Torque
Ni-Cd
Cd

3
3.4 Electrolyte
The electrolyte for SOL…G NiCd batteries consists of a diluted
potassium hydroxide (KOH) solution (specific gravity 1.22 kg/litre
+/-0.01 kg/litre) with a lithium hydroxide component, in accordance
with IEC 60993:1989. The potassium hydroxide solution is prepared
in accordance with factory regulations. The specific gravity of the
electrolyte does not indicate the state of charge of the battery.
The specific gravity changes very little during charging and
discharging, and has limited relationship to the temperature.
When checking the electrolyte levels, a variation in level between
cells is not unusual and is due to the different quantity of gas held
in the separators of each cell. Before the battery is put into service
for the first time, check that the electrolyte level is not lower
than 10mm below the “MAX” mark. There is usually no need to
adjust it.
If the electrolyte level is lower than the “MIN” level during
service, the battery should not be disconnected from the charger
for a time longer than 12 hours.
If visual inspection is not possible, due to restricted view, use
an electrolyte level testing tube to check the electrolyte level.
For further instructions, please contact your GAZ/EnerSys
representative.
3.5 Commissioning
3.5.1 Site Test
If a site test is requested, it must be carried out in accordance
with IEC 61427-1:2013 / IEC 62259:2003.
Charge and discharge currents for tests shall be based on the
value of the rated capacity (C5Ah). These currents are expressed
as:
Example: Cell type: SOL 1110 G
Rated capacity: C120 = 1110 Ah
Rated capacity: C5= 1056 Ah
Constant charging
current (14-16 h): 0.1 ItA = 105.6 A
Battery discharge
current (5 hours): 0.2 ItA = 1056 A x 0.1 = 211.2 A
3.5.2 SOL...G cells stored up to 6 months
A commissioning charge is normally not required and the cells are
ready for service. If full performance is necessary immediately, it is
recommended to charge the cell according to point 3.5.3.
3.5.3 Commissioning of SOL..G cells stored more than 6 months
and up to 12 months
3.5.3.1 Commissioning procedures for ambient temperatures of
+10°C up to +30°C
Mode of charging: Constant voltage
Charging voltage 1.65 V/cel
Current limitation 0.1 ItA
Duration: 30 hour
Mode of charging: Constant current
Current limitation 0.1 ItA
Duration: 15 hours
During the charge the temperature should be checked
(see point 3.5.3.3).
3.5.3.2 Commissioning procedures for ambient temperatures of
+30°C up to +40°C
Constant current charge mode is the only approved method
for charging under such conditions. The battery must be
connected directly with the PV-Installation (the consumer load
is disconnected). The battery capacity shall be measured for
the whole period of recharge during sunshine hours. 1.6 times
the 5 hour rate shall be used to recharge the battery during the
commissioning procedure.
Mode of charging Constant current
Minimum charging current: 0.05 ItA
Maximum charging current: 0.1 ItA
During the charge the temperature should be checked
(see point 3.5.3.3).
3.5.3.3 Electrolyte temperature
During the whole commissioning process, check the electrolyte
temperature. The temperature of the electrolyte should never
exceed +45°C, as higher temperatures have a detrimental effect on
the performance and lifetime of the cells. On exceeding +45°C the
charging should be temporarily interrupted until the electrolyte
temperature drops to +40°C.
4. Charging in operation
The supply of consumers and the charge of SOL…G batteries in
PV applications is challenging because of the sunshine hours and
the limited power supplies in such systems. It is necessary to use a
charge controller to maintain the battery in propper conditions.
There are two methods of charging established in the market for
PV-offgrid charge controllers:
• Constant voltage charge controller
• Pulse charge controller
The following table reperesents the system settings for a typical
PV-offgrid application with 5 days or more autonomy time. Note,
these limits are provided only as a guideline. It may be necessarry
to modify and to adjust the settings on the current operating
conditions.
Charge controller Charge controller
Constant voltage principle Pulse Charge principle
Single step charge:
Charging voltage: 1.50 V/cell Threshold values:
Switching threshold ON:
1.45 V/cell
Current limitation: 0.1 ItA Switching threshold: OFF:
1.55 up to 1.65 V/cell
Current limitation: 0.1 ItA
Two step charge:
Float mode: 1.42-1.50 V/cell
Boost mode: 1.55 up to 1.65 V/cell
Current limitation: 0.1 ItA
For temperatures lower than +10°C, the correction factor for
charge voltage is -3 mV/K per cell. It is not necessary to adjust the
charge voltage for higher temperatures.
5. Periodic maintenance
GAZ ®SOL…G provides good reliability with long maintenance
intervals in typical PV stand-by applications. In order to sustain a
permanent availabilty of the system, we recommend the following:
Standard service inspection
In a regular twelve months period, carry out a check-up under
normal operating conditions. Depending on site location, water
consumption, local regulations, or special application requests,
these check-ups can vary in frequency or period.
When performing the standard service inspections please be sure
to carry out the following:
• General appearance and cleanliness of all the batteries and the
battery room or shelter.
The battery must be kept clean using only water. Do not use a
wire brush or solvents/additives of any kind. Ventilation must
fulfill the requirements of section 3.2.
CnAh
1h
ItA=

4
• Electrolyte level
Visually check the electrolyte level. Refilling is recommended
when the electrolyte level reaches the “MIN“ mark. However it
must never drop below the “WARNING LEVEL” mark. Adjust
the electrolyte level only in fully charged conditions. Only use
distilled or deionized water to top-up the cells in accordance
with IEC 60993:1989. Because of the specifics of PV-Installation
the time intervall for topping up should be adjusted depending
on the water consumption.
NOTE: Once the battery has been filled with the correct electrolyte
at the factory, there is no need to regulary check the electrolyte
density. Interpretation of density measurements is difficult and
could lead to misunderstandings.
• Electrical parameters
Check the voltage measurements of every single cell and the
battery charging current.
It is important that the recommended charging voltage remains
unchanged. High water consumption of the battery is usually
caused by improper voltage settings of the charge controller. If a
battery is parallel connected the charging current in the strings
should also be checked to ensure equality.
• Electrolyte temperature
Check the electrolyte temperature from one of the cells in the
middle of the battery.
Extended service inspection
Regular check every 24 months
In addition to the standard service inspection the following
measures are required:
• Connector torque and corrosion protection
Check that all connectors, nuts and screws are correctly torqued.
All metal parts of the battery should be coated with a thin layer
of anti-corrosion grease supplied by GAZ. Do not coat any
plastic parts of the battery, for example cell cases.
Measurement readings - battery log book
It is recommended to utilize a battery log book. Within this log
book, one should record all significant events such as power cuts,
service activities, inspections, discharge tests, equalizing charges,
topping up dates. If needed, these battery log books can be
obtained from GAZ/EnerSys.
6. Additional warning notes
Lead-acid and NiCd batteries shall preferably be accommodated in
separate rooms. Where both battery types are located in the same
room, the charging gases from the lead-acid batteries must be kept
away from the NiCd batteries. Tools for lead-acid batteries must
not be used for NiCd batteries.
Risk of short circuit and fire:
Do not place electrically conductive objects such as tools etc. on
top of the battery!
Risk of injury:
No rings or metal bracelets should be worn during the assembly of
the battery.
Risk of explosion:
Open the doors of the battery cabinet during charging so that the
charging gases can escape.
The charging gases from batteries are explosive. Do not allow
naked flames, sparks or other sources of ignition in the vicinity of
the battery!
Caution – potassium hydroxide solution is corrosive!
A potassium hydroxide solution is used as electrolyte. It is a
highly corrosive liquid which can cause severe damage to health
if it comes into contact with eyes or skin (risk of blinding). Even
swallowing of small quantities may cause internal injuries.
When working with the electrolyte and on the cells or batteries,
rubber gloves, safety glasses with side guards, and protective
clothing must always be worn!
Contact with the eyes:
Flood eyes immediately with large quantities of water for 10 to 15
minutes. Consult a doctor immediately.
Contact with the skin:
Remove contaminated clothing immediately and wash the affected
skin areas with large quantities of water. In case of discomfort seek
medical advice.
Swallowing:
Rinse the mouth immediately with large quantities of water and
keep drinking large amounts of water. Do not provoke vomiting.
Call an emergency doctor immediately.
In the event of injuries:
Rinse thoroughly for a long time under running water. Consult a
doctor immediately.

5
7. Removal of the Transportation Plugs and Fitting of Vent Caps
SOL 140-485 G
Step 1 Step 1
Step 2
(before commissioning charge)
Step 2
Step 3
(before commissioning charge)
SOL 555-1680 G

1
1
2
2
3
3
4
4
5
5
6
6
A A
B B
C C
D D
Innengewinde / Female thread
1 Zellengefäß / Cell case
2 Zellenverbinder / Cell connector
3 Polverbinder /Terminal connector
4 Federscheibe / Washer
5 Schraube / Screw
6 Abdeckung / Cover
7 Winkelendpolableitung / Angle terminal connector
8 Endableitungsabdeckung / End terminal cover
6
5
4
3
2
1
8
7
6
8. Layout details: inter-cell connection
SOL 140-485 G
1 Cell
2 Cell connector
3 Spring washer
4 Screw
5 Connector cover
Note, typical layout only. Refer to section 9 for details
SOL 555-1680 G
1 Cell
2 Cell connector
3 Terminal connector
4 Spring washer
5 Screw
6 Connector cover
7 End terminal connector
8 Cover and terminal connector
1
5
4
3
2
6
8
1
5
4
3
2
7

7
KGL 1260 P - KGL 1570 P
(Female thread M10)
9. Cell Layout
SOL 140 G - SOL 310 G
(Female thread M8)
SOL 555 G - SOL 693 G
(Female thread M10)
SOL 345 G - SOL 485 G
(Female thread M10)
SOL 730 G - SOL 935 G
(Female thread M10)
SOL 1110 G - SOL 1525 G
(Female thread M10)
SOL 1680 G
(Female thread M10)
Cells assembled in a 2 row
configuration

All dimensions and weights stated are subject to usual manufacturing tolerances, electrical values are approximate. The right is reserved to make any
alterations without prior notice.
GAZ Geräte- und Akkumulatorenwerk Zwickau GmbH
Reichenbacher Str. 62-68 | 08056 Zwickau | Germany
Tel.: [phone]
Mob.: [phone]
Fax: [phone]
e-mail: [email protected], [email protected]
[email protected]m
www.gaz-gmbh.com