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BattRecon Model 6048/6080
The World's First "CLOUD BASED" Battery ServiceSystem for Motive  Batteries

U.S. Patent # 8,330,428 B2  and   9,166,435 B2

Model 6048/6080 Automated Service  System Features:

"Permanently" Connect your Charger to the Model 6048/6080, thereafter, Connect Your Service Batteries to the 6048/6080.  Our Patented "Auto Sequence Mode" Automatically Cycles Between your Charger, the BattRecon De-Sulfation Process, and the BattRecon Integral Discharge Tester.   The Result, .... Perfectly Serviced Batteries - Minimum Labor. 

Use as a Stand-A-Lone System, or Connect to the "The Web Based BattRecon Cloud" and Remotely Control the System - from Anywhere in the WORLD !

One "Super Technician"  Could Monitor Hundreds of Remote Battery Service Processes Per Day, Virtually Eliminating Service Labor and Training.

Pre-Position the System at a Client's Remote Location and Service Batteries from the Comfort of your Local Shop.   The Client Adds Water and  Connects the Battery to the 6048/6080.  Your Centralized  Battery Technician takes over the Process Remotely, Monitoring and Controlling the System from any Web Based device, such as  Smart Phone, Laptop, Tablet or other Computer.

Model 6048 Designed for 12/24/36/48V  Forklift Batteries

Model 6080 Designed for 12/24/36/48/80V Forklift Batteries

Optional Build in Load Testing System 0-225 Amps Discharge Rate

Low Cost Rental, Lease or Purchase, Low Operating Cost

Portable using Standard Electrical Outlets -  Rugged Design

BattRecon Servicing and Restoration Devices for Forklift, Golf Cart, Auto, Marine and Telecom Batteries

Prior to the invention of "A Remote COMMAND and CONTROL Battery Servicing System," the battery service industry incurred  technician labor and training costs, paid for a battery service facility,  incurred battery transportation costs and paid large monthly electrical bills; ... to service Motive/Industrial Batteries.   The majority of the Gross Profits earned by Battery Service Companies are allocated to these costs, while the costs to the battery end-user are correspondingly increased. 

With the new "BattRecon Cloud Based Service Systems," the Battery Service Company could position the system at a client's location, then remotely "COMMAND and CONTROL" the battery servicing process.  The result would be a high quality service, while eliminating the marginal costs related to Technicians, Transportation and Facilities.  The service operator would make higher marginal profits, while lowering the cost to the client.  

 With the release of the Model 5000/6000 series of Automatic Battery Service Systems, the next generation of “Cloud Based” battery service capabilities are now available. 

The Model 6048/6080 Service Systems allow the service operator to pre-program the

operational parameters for the devices that they would normally, manually connect to the

battery.  Once those [parameters are set, then the operator selects what sequence the

devices should be connected to the battery, and how often, during the servicing sequence. 

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 decreasein 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 6048/6080 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 6048/6080, which we refer to as a “Charger By-Pass” relationship, or they may use an internal charger within the Model 6048/6080, 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 6048/6080

If you select Auto Start Mode, then after the Model 6048/6080 senses a battery pack is connected and after a brief delay, the Model 6048/6080 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 6048/6080 is placed at a warehouse with forklift batteries, as an example, the forklift driver or battery attendant, simply drives up to the Service/Optimization Station and plugs the forklift into the Model 6048/6080.  If setup for Auto Start, then the Model 6048/6080 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.  The operator may elect to use a Battery Discharge test to verify the capacity of the battery, followed by another charging process. Once this forklift battery is serviced/optimized it may be placed back into service, then the operator may connect a different forklift to the Model 6048/6080.  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 Series feature 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 run-time before and after, could determine your energy savings. 

Some variants of the Model 6000 Series 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 series 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!