GAZ SOL G Series Bedienungsanleitung

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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:

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

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

ItA=

• 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.

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

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

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

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.: +49 375 86 0

Mob.: +49 173 95 117 93, +420 602 174 634

Fax: +49 375 86 440

e-mail: [email protected], [email protected]

[email protected]m

www.gaz-gmbh.com

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