Battery Maintenance Scan this code with your smartphone and view the Battery regeneration instruction movie. 1 Tvh parts nv PARTS & accessories DIVISION Brabantstraat 15 BE-8790 Waregem T +32 56 43 42 11 F +32 56 43 44 88 parts@tvh.com www.tvh.com
Problem If a battery is stored in a discharged condition the lead sulphate will form crystals, resulting in a higher electrical resistance. This is commonly known as a sulphated battery. The lead sulphate may become so hard that normal recharging will not break it down. Most charging sources, engine alternators and battery chargers, are voltageregulated. Their charging current is controlled by the battery s state of charge. During the charging process the battery voltage rises until it meets the charger s regulated voltage, lowering the current output along the way. When sulphate crystals are present, the battery shows a false voltage, higher than its actual voltage, fooling the voltage regulator into thinking that the battery is fully charged. This causes the charger to prematurely lower its current output, leaving the battery discharged. Sulphate crystals also form in a battery that constantly cycles around the middle of its capacity range (somewhere between 80% charged and 80% discharged), and is never recharged to 100%. Over time, a portion of the plate s active materials turns into sulphate crystals. If the battery is continually cycled in this manner, it will lose more and more of its capacity until it no longer has enough capacity to perform the task for which it was intended. Solution k REPLUS Battery Regenerator By using our REPLUS Battery Regenerator you will be able to dissolve the hardened sulphate and restore it to active material. It uses high-frequency wrinkle currents that are very effective in removing the hardened sulphate. The process is fully automatic (max 42 hours), temperature-controlled and consists of 5 steps. We start with a controlled discharge followed by 2 restoration cycles. After these 3 steps, the process is repeated once more by performing another discharge and a final restoration. This results in: Increased electrolyte gravity Reduced inner resistance Increased battery capacity The REPLUS Battery Regenerator comes with monitoring software. This software allows you to: Draw accurate facts/statistics from the regenerations. Create a full report on the regeneration. Monitor the battery s reaction when charging/discharging. Configure the REPLUS Battery Regenerator by means of a laptop. 2
Benefits: The lifespan of the treated batteries extends significantly. Discharged DC/AC energy is converted. This energy can be placed back onto the power grid and can be reused. Minimal maintenance costs. Quick regeneration Easy application: fully automatic regeneration program 24/7 use Note: Each customer purchasing a REPLUS Battery Regenerator can request a visit from our product responsible, who will provide a free on-site training on how to use the regenerator and give more technical info. Extremely user-friendly control panel The start-up screen of the REPLUS Battery Regenerator consists of 2 modes: Via Setting you can change the date and modify some screen settings. In Operation you can configure the final settings for the regeneration. In the operation mode you can set the REPLUS Battery Regenerator according to your battery s requirements. This curve displays a complete regeneration. 3
This curve shows a complete restoration: 1: controlled discharge 2: restoration 3: restoration 4: discharge 5: restoration When you compare 1 & 4, you see that the time needed to discharge the battery is much longer in step 4. This is a direct result of the restoration in mode 2 & 3. Comparing step 5 to step 2, you see that the set battery voltage is reached much later than in step 2. This means that your battery lasts longer and will be in good condition again. 2 ways to use the REPLUS Battery Regenerator: Reconditioning regeneration Reconditioning regeneration allows you to restore old (5, 6, 7 years), medium to well-maintained batteries that have silted up to a 90-100% productivity, as a result of natural sulphation. Maintenance regeneration Maintenance regeneration allows you to keep your battery in optimal, sulphate-free condition, by means of a yearly short regeneration. REF Application voltage Technical specifications 138TA6595 20-150 V up to 1000 A/H 139TA1917 0-120 V up to 500 A/H 139TA1918 0-100 V up to 300 A/H 139TA5237 0-75 V up to 3000 A/H 4
REPLUS regeneration liquid What to do with batteries in really bad condition: less than 50% capacity left. In some cases we see that batteries have less than 50% capacity left. Those batteries are in really bad condition and the sulphate has become very hard. We have created a liquid that helps the regenerator to remove the hardened sulphate from the plates inside. This to optimise the regeneration process and to assure a significant gain of capacity. Try now your free sample of REPLUS regeneration liquid (advised to be used together with the regenerator) REF 136TA3177 REF 138TA3949 1 l 20 l BDX battery discharger/analyzer The BDX is an automatic battery discharger/analyzer, designed to test the efficiency of industrial batteries of any type, voltage and capacity. This equipment can be programmed to discharge the battery with a precisely controlled constant current, adjustable from zero to the maximum rated value, while keeping the battery voltage under control. General information: High-frequency IGBT regulator, featuring constant current discharge of the battery. Rugged construction Compact and portable design Wide power range available battery voltages up to 600 VDC & discharge currents up to 600 A Intelligent electronic protection system Programmable digital board, controlled by microprocessor Can operate with batteries of any type Digital display (battery voltage and current, time, capacity discharged, programmed values) CE-certified USB-connection Free analyzing software provided (graphs of voltage, Ah & time) AC INPUT Standard Voltage Voltage range: 85-135 or 180-250 VAC Single-phase Maximum power: 250 W 50/60 Hz REF 124TA2652 Battery voltage: 12-48 V / Maximum discharge current: 100 A REF 124TA2653 Battery voltage: 12 96 V / Maximum discharge current: 200 A 5
Digital hydrometer This easy-to-use, compact digital hydrometer measures the acid content in your battery to know when the battery should be charged. Features: No-hassle measurement of hard-to-reach samples Large LCD-display with backlight Measuring cell with inspection window and backlight Possibility to export the measured data to excel (.xls or.csv) The value displayed on the hydrometer is directly temperature-compensated if the temperature is higher than 15 C. So the values displayed on the hydrometer are 100% correct and do not give a misrepresented idea due to a temperature that is too high or too low. Infrared receiver: REF 139TA5918 Protective case: REF 139TA5919 REF 138TA7531 6
Fluke Tis Thermal Imaging Scanner/camera With this thermal imaging scanner you can easily detect badly functioning battery cells. Aim the imaging scanner at the battery and you will immediately detect the warmer cells. These are the cells that need attending to. This is the most affordable thermal imager on the market that meets the proposed RESNET infrared inspection standard. Highest resolution (120 x 120) in its price class Only imager in its price class with versatile, manual focus Largest display size (3,7 ) in its price class, 30% larger than comparable imagers! Long battery life: lasts ~ 4 hours Weight: 1,2 kg REF 139TA1677 7
CBC High-frequency battery charger Before the regeneration, the battery must be fully charged. The CBC 2011 is the ultimate Energic Plus charger, and it is the result of 40 years of experience in design, production and customization of chargers for the material handling industry. Based on HF-IGBT technology with hybrid power conversion system, this charger offers a unique combination of performance, flexibility and electrical efficiency. The CBC has a multivoltage output, features automatic battery recognition and is completely programmable. Voltage: 12-80 VDC REF 139TA2732 REF 139TA2733 120 A - 1050 Ah 200 A - 1700 Ah Complete kit conversion SB175 REF 139TA3247 AQ-steam Cleans your traction batteries in an environment-friendly way without wasting water! The most important feature of the steam technique is the extremely low water consumption (approx 2 l/hour). This makes it the perfect option for cleaning traction batteries. A small quantity of cleaning product can be added to the steam, which will clean, degrease and neutralize excess battery acid. REF 115TA4701 Battery paint for box REF 106TA8932 REF 106TA8933 5 l 0,5 l Neutracid Neutracid absorbs liquid and neutralizes acids. When its colour turns yellow, the neutralization is completed. REF 106TA9020 5 kg Eyewashing liquid REF 134TA8689 TVH and Energic Plus are registered trademarks of TVH Parts NV. TVH is a supplier of after-market spare parts and accessories that are fitted maintenance and repair for OEM-equipment. Photographs and illustrations are included for reference purposes only. All sales are subject to the general terms & conditions of sale on www.tvh.com/avv 8 250 ml Receive a discount on all accessories in this leaflet when buying the REPLUS Battery Regenerator. REF 18424349 01-2012 MD