P 5.

1 E
May 2020

Solar Range Ni-Cd

Batteries
Installation and
operating
instructions

Important recommendations
WARNING: Risk of fire, explosion, or burns. Do not disassemble, heat above 70°C, or incinerate .
Never smoke while performing any operation on the battery.
For protection, wear rubber gloves, long sleeves, and appropriate splash goggles or face shield.
The electrolyte is harmful to skin and eyes. In the event of contact with skin or eyes, wash immediately with plenty
of water. If eyes are affected, flush with water, and obtain immediate medical attention.
Remove all rings, watches and other items with metal parts before working on the battery.
Use insulated tools.
Avoid static electricity and take measures for protection against electric shocks.
Discharge any possible static electricity from clothing and/or tools by touching an earth-connected part “ground”
before working on the battery.
Ventilation, in accordance with the IEC 62485-2 standard, is mandatory during commissioning and operation.

1. Receiving the shipment If a central water filling system is used as an option, refer
to the corresponding installation and operating
Commissioning at ambient temperature between
+10°C to +30°C (+50°F to +86°F)
Check the packages and cells for transport damage. instructions sheet.
The battery is shipped filled and charged, and is ready • Constant current charge
for immediate use. 3.3. Ventilation 30 h at 0.1 C5 A recommended (see Table A).
During the last part of charging, the battery is emitting Note: At the end of the charge, the cell voltage will
gases (oxygen and hydrogen mixture). reach the level of 1.75 V/cell, thus the charger shall
2. Storage Ventilation inside the battery room must be adequately be able to supply such voltage.
The battery must be stored in a dry indoor location, managed, comply with IEC 62485-2 and local When the charger maximum voltage setting is too
on open, well ventilated shelves away from direct sunlight regulations. low to supply constant current charging, divide
between 0°C and +30°C (+32°F and 86°F). the battery in two parts to be charged individually.
Solar Range batteries are supplied filled with electrolyte 3.4. Electrolyte
and charged. They can be stored in this condition for When checking the electrolyte levels, a fluctuation in level • Constant potential charge
maximum 24 months from date of shipment in accordance between cells is not abnormal and is due to the different 1.55 V/cell for a minimum of 24 hours with current
with the recommendations set forth in this I&O. amounts of gas held in the separators of each cell. limited to 0.1 C5 A (see the current in Table A).
Storage of a filled battery at temperatures above +30°C The level should be at least 15 mm above the minimum
(+86°F) can result in permanent change and loss level mark and there is normally no need to adjust it.
of product performance, depending on the duration Do not top-up prior to initial charge. After commissioning, Commissioning at ambient temperature above
of the storage above the maximum recommended when the level is stabilized, it should be not less than +30°C (+86°F)
temperature. 5 mm below the maximum level mark.
Never drain the electrolyte from the cells. • Only Constant current charge
To ensure maximum protection of the cells always store 20 h at 0.1 C5 recommended.
the product in its original packaging. 4. Commissioning The battery container temperature is to be
Verify that ventilation, in accordance with the IEC monitored during charge. If the temperature
62485-2 standard, is provided during this operation. exceeds +45°C (+113°F) during charging, then it
3. Installation A good commissioning charge is important. must be stopped to reduce the temperature. The
charging can be resumed when battery container
Charge at constant current is preferable. If the current
3.1. Location limit is lower than indicated in Table A, charge for temperature drops below +40°C (+104°F).
Install the battery in a dry and clean room. Avoid direct a proportionally longer time.
sunlight and heat. The battery will give the best After commissioning, the battery shall be charged In the case of remote areas, where the only charger
performance and maximum service life when the ambient permanently according to section 5. available is the photovoltaic array, the battery should be
temperature is between +10°C to +30°C / +50°F to +86°F. Prior and during commissioning charge, record all connected to the system with no connected load and
data requested in the commissioning report available on no voltage limit. The battery should then be charged in
3.2. Mounting www.alcad.com good sunshine conditions.
Verify that cells are correctly interconnected with the During this operation, the Ah charged shall be in
appropriate polarity and with the connectors are correctly 4.1. Cells stored up to 6 months the magnitude of 1.6 times the rated capacity, and, in
torque. The battery connection to load should be with order to limit the risk of electrolyte overflow, it is
Charge at constant current is preferable. recommended not to exceed the charge current value
nickel plated cable lugs. A commissioning charge is normally not required and specified in Table A.
the cells are ready for immediate use. If full performances
Recommended torques for terminal bolts are: are necessary immediately, a commissioning charge 4.3. Cell electrolyte after prolonged float charge
• M6 = 11 ± 1.1 N.m (97.4 ± 9.8 lbf.in) as mentioned in section 4.2. is recommended. Check the electrolyte level and adjust it to the upper level
• M8 = 20 ± 2 N.m (177.0 ± 17.7 lbf.in) mark by adding distilled or deionized water.
• M10 = 30 ± 3 N.m (265.0 ± 26.6 lbf.in) 4.2. Cells stored more than 6 months and up to Note: When full battery performance is required for
2 years capacity test purposes, the battery has to be
The connectors and terminals should be corrosion A commissioning charge is necessary. charged in accordance with IEC 62259
protected by coating with a thin layer of anti-corrosion oil.
section 7 (7.1 & 7.2).

Reliability inside
 Table A
Cell Type Rated Nominal Capacity Charging Current Max. quantity Cell
Capacity 120 h - 1.00 V 0.1 C5 A of water Terminal
5 h - 1.00 V C120 Ah to be added
C5 Ah Ah A cc
PV 100 95 100 9.5 280 M8
PV 150 140 150 14 380 M10
PV 200 185 200 19 500 M10
PV 250 235 250 24 590 M10
PV 305 280 305 28 700 M10
Data in this document are subject to change without notice and become contractual only after written confirmation by Alcad.

PV 355 325 355 33 880 2xM10

PV 405 375 405 38 1000 2xM10
PV 455 420 455 42 1100 2xM10
PV 505 470 505 47 1200 2xM10
PV 555 515 555 52 1300 2xM10
PV 610 560 610 56 1400 2xM10
PV 660 610 660 61 1600 3xM10
PV 710 650 710 65 1700 3xM10
PV 760 700 760 70 1800 3xM10
PV 810 750 810 75 1900 3xM10
PV 860 800 860 80 2000 3xM10
PV 910 840 910 84 2100 3xM10
PV 960 890 960 89 2300 4xM10
PV 1015 940 1015 94 2400 4xM10
PV 1065 980 1065 98 2500 4xM10
PV 1115 1030 1115 103 2600 4xM10
PV 1170 1080 1170 108 2700 4xM10
P 5.1 E - Edition: May 2020 - Finedesign

PV 1215 1120 1215 112 2800 4xM10

PV 1270 1170 1270 117 3000 5xM10
PV 1320 1220 1320 122 3100 5xM10
PV 1370 1260 1370 126 3200 5xM10
PV 1420 1300 1420 130 3300 5xM10
PV 1470 1350 1470 135 3400 5xM10
PV 1520 1400 1520 140 3500 5xM10
PV 1570 1450 1570 145 3700 5xM10
PV 1620 1500 1620 150 3800 6xM10
PV 1670 1550 1670 155 3900 6xM10
PV 1720 1600 1720 160 4000 6xM10
PV 1775 1650 1775 165 4100 6xM10
PV 1830 1700 1830 170 4200 6xM10

5. Charging in service Case of regulators based on the switching

When this system service is carried out, it is recommended
that the following actions should be taken:
The photovoltaic array converts solar irradiance into principle
DC electrical power at a pre-determined range of • Boost threshold (not mandatory): 1.65 V/cell The batteries should also be checked for external
voltages whenever sufficient solar radiation is available. cleanliness, and if necessary cleaned with a damp brush
• Float threshold: 1.55 V/cell
Unlike a main connected system, the output from a using water. Do not use a wire brush or solvents of any
photovoltaic array is variable and, to obtain the best • Battery reconnect threshold: 1.45 V/cell kind. Vent plugs can be rinsed in clean water if necessary.
efficiency from the system, it is quite normal to have
some form of charge control. For lower back-up time, the values have to be Cell electrolyte levels should be checked visually to ensure
increased depending on the load requirement. that the level is above the minimum and if necessary
Two main techniques for charging the batteries are Consult the manufacturer. the cells should be topped-up. Use only distilled or
generally used in photovoltaic systems. deionized water (see Table A for the quantity of water per
For use in warm areas, a temperature compensation cell). Topping-up of Alcad Solar battery shall be carried out
These are those which have a constant voltage limitation on the charge voltage is not recommended. when battery is fully charged. Experience will tell the time
based on the PWM techniques and those with several For use in cold areas, a temperature compensation interval between topping-up.
voltage steps charging where the battery, by switching is recommended to increase the charge acceptance.
means, is charging up to a high pre-set voltage (boost The recommended value is: – 3.0 mV/°C/cell The connectors and terminal bolts should be
or float threshold), then drops to a lower voltage level (–1.68 mV/°F/cell) starting from +20°C (+68°F). corrosion-protected by coating with a thin layer of
(battery reconnect threshold) and then back to the high anti-corrosion oil.
pre-set voltage and so on.

Recommended charging voltages for a typical

6. Preventive Maintenance High water consumption is usually caused by improper
voltage setting of the charger.
photovoltaic application sized for 5 days or more In a correctly designed standby application, Alcad Solar
back-up time. Range batteries require the minimum of attention.
However, it is good practice with any system to carry
Case of constant voltage limitation (PWM out an inspection of the system once per year or at 7. Environment
regulator system or similar): the recommended topping-up interval period to ensure To protect the environment all used batteries must be
that the charging system, the battery and the ancillary recycled.
• Float: 1.50 V/cell
electronics are all functioning correctly. Contact your local Alcad representative for further information.
• Boost (not mandatory): 1.65 V/cell

Alcad Limited Alcad Sales Offices

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