BattRecon Servicing and Restoration Devices for Forklift, Golf Cart, Auto, Marine and Telecom Batteries
BattRecon Model 6000
The World's First Dedicated Battery Optimization System for High Power Batteries
U.S. Patent # 8,330,428 B2 and 9,166,435 B2
Model 6000 Automatic Optimization System Features:
Compatible with the: "The BattRecon Cloud" - Remote Operation System
Connect the Model 6000 to your Charger, then Re-charge Batteries through the Model 6000 thereafter, automatically keeping your Fleet Tuned Up!
Low Cost Rental, Lease or Purchase, Low Operating Cost
When used Periodically, Saves about 25% of your Electricity - On Average, and Extends your Battery Life 25 to 50%
Reduce or Eliminate costly Service Labor and Training
Portable and Light Weight using Standard Electrical Outlets
Automatically Applies the BattRecon Process to Individual Batteries During the Normal Re-Charging, no separate actions required
Rugged Design - Easy Field Repair
Prior to the invention of Battery Optimization by Bravo Zulu International Ltd., the battery service industry used technician labor, incurred technician training costs, paid for battery service warehousing space and absorbed battery transportation costs; ... only to aggressively charge and discharge batteries during a service or restoration operation.
With the release of the Model 5000/6000 series of Automatic Battery Optimization Systems, the next generation of “Cloud Based” battery service or optimization process is here.
When the batteries are returned to service after “restoration” using a Conventional Battery Service, they immediately begin to accumulate “excess daily sulfation” slowing the battery performance day after day, until it is finally to a point where the battery has to be charged twice, ... for the same use that previously required only one charge.
Furthermore, since batteries are rated for a limited number of charge and recharge cycles, the increased excess charging to perform the same amount of work, reduces the battery’s expected useful life!
The Model 6000 will apply an Automatic Battery Optimization process, during the normal re-charging process, requiring no labor, training or transportation costs. If used periodically, such as every 14 to 30 days as an example, your forklift or other batteries, will maintain their optimum condition throughout the battery's normal life cycle. Battery Optimization will maximize the productivity of your batteries, while significantly reducing your operational and battery capitalization costs. In fact, most golf course operators will save enough money on electrical savings alone to easily pay for the system rental.
Unless the battery has internal damage, the BattRecon Battery Optimization Process automatically applies a precise Peak Amplitude electrical charge to the lead-sulfate molecule, causing the lead molecule (Pb) to repel from the sulfate (SO4) molecule, chemically referred to as "re-ionization." The BattRecon Battery Optimization process, in conjunction with your normal charger operation, automatically de-sulfates and restores most batteries, to their optimum condition during one re-charging cycle. It is important to note that while many companies claim their products make the batteries like new again, the truth is that a battery can only be restored to an "optimum condition," or one that considers other factors such as the battery cycles, the battery operating environment temperature, and the normal decrease in capacity due to simple corrosive effects of the electrolyte and many other factors.
The advantage of using a preventive process such as Battery Optimization, is that the battery should never accumulate harmful sulfate crystals, which we refer to as Level 3 sulfation. Sulfate crystals are formed after an extended period of excess daily sulfation, when Excess Daily Sulfate Molecules combine sharing a chemical bond. This crystal formation is very difficult to “dissolve,” or re-ionize, often simply forced off the battery plate by the use of aggressive Constant Current Charging methods, requiring days to complete and creating harmful heat and lead particle shedding within the battery.
As the sulfate crystal is forced from the lead plate, it tears the attaching lead molecules from the plate increasing the shorting material within the battery. This shorting material can accumulate on the sides of the battery plates as “Mossing Shorting,” or on the bottom of the cell where it builds up to eventually touch the lead plate causing “Sedimentary Shorting.” In any case, forceful removal of sulfate crystals reduces the battery’s life expectancy.
The Model 6000 system is placed near the battery charger, or in a dedicated Battery Optimization Station. The Client’s preferred external charger is connected to the Model 6000, which we refer to as a “Charger By-Pass” relationship, or they may use an internal charger within the Model 6000, if available.
On a one time basis for use on the same battery types, such as a fleet of 48 volt forklift batteries, the following parameters are set either at the factory before shipping, or by the client upon receiving the machine. (Note: if you change battery voltages that you want to optimize, then you will have to change the battery voltage parameters within the machine using the software or manual buttons and switches.) The machine parameters may be set using the BattRecon Cloud Based Software Program, or some versions may have manual buttons.
1) Set the battery voltage, such 48V in this example. (If you have 36 volt batteries, set the battery voltage window to 36, as another example)
2) Set the Charger By-Pass or Internal Charger Volts Per Cell (VPC) value to slightly lower than the recommended fully charged VPC, typically .1 VPC lower than recommended. This assures that the BattRecon process will take over near the end of the charge cycle. You can adjust this according to your field experiences and battery types or conditions. You could also set a maximum time at which point the charger would be disconnected and the BattRecon Process would begin.
3) Set desired maximum battery charging time, and a maximum charging amperage if desired.
4) Set the BattRecon Peak Amplitude, typically 225 Peak for forklift batteries.
5) Set the Battrecon operating time to 5 minutes.
6) Select “Auto Start Mode” or “Manual Mode” to start the Optimization Cycle.
For all continuing battery re-charging events the operator simply connects the battery/battery pack to the Model 6000.
If you select Auto Start Mode, then after the Model 6000 senses a battery pack is connected and after a brief delay, the Model 6000 will begin the Battery Optimization Process and stop when the pre-programmed optimization subroutines have been performed.
If you choose the Manual Mode, then the operator simply connects the battery and presses the START button, the system stops after completing the pre-programmed optimization subroutines.
If the Model 6000 is placed at a warehouse with forklift batteries, as an example, the forklift driver or battery attendant, simply drives up to the Optimization Station and plugs the forklift into the Model 6000. If setup for Auto Start, then the Model 6000 will sense the batteries are connected and begin the Auto Sequence Mode saved into the memory. This would typically be: 1) an applied Battrecon process for 5 minutes, followed by 2) a normal battery charge up to the saved VPC limit set by the operator, then 3) a finishing 5 minute BattRecon Applied Process. Once this forklift battery is optimized it may be placed back into service, then the operator may connect a different forklift to the Model 6000. This Optimization Cycle should be repeated once every 30 days, sooner if you have extreme temperatures or aggressive use of the vehicles.
The Model 6000 features advanced battery metric monitoring and processing. One metric that might be of interest, is the measurement of Kilo-Watt Hours (KWH). A likely use of this feature is to determine how much energy your battery packs consume during a typical charge. You could also measure the normal re-charging KWH consumption before using the Battery Optimization Process, then compare to the KWH per charge consumption after the battery optimization, … and when compared to the runtime before and after, could determine your energy savings.
Some variants of the Model 6000 will have an impedance measurement process, that provides a measurement of the battery’s combined resistance. This would be useful when you have battery cables that begin to corrode, as you could see a rise in measured impedance that is a result of either battery or cable connection issues, or sulfated batteries or internal battery damage.
The Model 6000 allows the operator to control the size or amplitude of the peak applied to the battery by simply changing the Peak Limit within the BattRecon Parameters settings. .
The BatRecon systems work best on batteries that have Level 1 and Level 2 sulfation, Level 3 sulfation may take repetitive applications of the BattRecon process and are best prevented using an optimization process. Level 1 sulfation, often referred to as the "Good" or necessary sulfation, occurs as a natural process of discharging a battery during normal use. Discharging requires the electrolyte solution H2SO4 molecule to separate into free Hydrogen molecules and sulfate radicals. The sulfate radical (SO4) is then in an ionic manner drawn to the lead plate molecule PB, which combine outer shells releasing excess electrons as a flow of current out of the battery. These excess electrons are then used as energy to power external devices such as a headlight on a car.
During the recharging process, not all SO4 molecules are re-ionized (forced) back into the acid solution; those that remain on the lead plates are called Level 2 sulfation. As this charging and discharging process continues over time and many cycles, the Level 2 sulfates accumulate and eventually develop into a crystalline form, referred to as Level 3 sulfation. As the battery sulfates increase, they reduce the battery’s performance until you notice the battery no longer has the strength it needs to power your forklift through an entire work shift, as an example. You may also have an operation that uses an “Opportunity Charging” process to rapidly re-charge the batteries. This process tends to aggravate your battery sulfation issues, in which case, the Battery Optimization system would be a tremendous benefit in controlling battery sulfation issues.
Additionally, the life of the battery is shortened significantly requiring expensive replacement. As the battery increases in internal sulfation, the time to re-charge your battery keeps getting longer, wasting electricity. As the batteries age and Level 2 and 3 sulfation increases, most batteries will not reach a high enough cell voltage to allow the charger to shut off or progress into the “top-charge” processing rate. As this happens, you are literally throwing electricity away and are costing your company’s operation thousands of dollars. In fact, over the life of the battery, most companies can save between 10 and 25% of the electricity used to charge their batteries by simply keeping them tuned up with the BATTRECON system!