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Service manual BRT 20-3 de aout 2010

1. to electrolyte measurement after refilling the cell with distilled water Values would be false Check liquid level in each cell Complete in cells where the level 15 very low Check quantity on the battery manufacturers instruction datasheet In most cases the best level is I cm above the electrode plaques A Do not connect a dry battery to the BRT Explosion risks are then greater Dry cells are filled with distilled water Water may have evaporated and sulphuric acid turned into lead sulphate However all the active materials remain in the battery Do not add acid unless there is no more density at all and the cell has suffered over flooding while being charge at the owners place Mo BRT 20 3 14 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Sometime no electric or short circuit can be found during the check up however the regeneration process may have not effect on so called disable cells It may occur in situation such as When cells leak and operator keep on refilling it Corrosion marks on the rack can be noticed Over refilled cell even though it was not required Cell gets washed up In both situation sulphuric acid needed to generate current is spilled away and cell density is weakening In such a situation the operator may proceed to complete the cell in adding acid for density
2. Thyristors gt HE LE Transformation de tension Thyristors Switch board Processors Temperature gauge Scheme S Current sensor 4 2 Installation The BRT is simple to set up There is anyhow some minimum requirements Power supply shall be on three phases 380 to 400 V disruptor 40 A or 50A on a D curve The BRT requires a lot of energy during very short moment and disruptor shall be strong enough to keep current flow during those peak period To keep things moving without any trouble we recommend to increase disrupter capacity to 60 Amps Mo BRT 20 5 44 Version 1 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 To get the BRT operational connection to the main PSU shall respect the phase order R S T and the main cable shall also be well connected As already done for the main connection European types plug with 3 phases and neutral shall be used Manufacturer shall supply plug with the phase in the right order Check the phase order after installation Upon the impedance of the electric network it may be required to change the order of the phases If phases are not in the correct sequences the BRT will not work correctly One can notice misfunctionning as follows Immediate disruption Disruption at the first pulse 1e about 2 minutes after connection Pul
3. 38 3 3 2 HIGH VOLTAGE diss 39 3 3 3 END OF REGENERATION LOOPBS 5 e coena enean e aoa npo na pe ee aea peso pannos 40 3 3 4 CONTROL ON THE DISCHARGER ANALYZER FOR ACKNOWLEDGMENT csccsecsssescesscesceseues 40 3 3 5 REGENERATION CONTROL ON ELECTROLYTE AND VOLTAGE 4 3 3 6 DISCONNECTING THE BATTERY 42 Mo BRT 20 3 1 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 AVRIL 2010 Prog V2 3 TECHNICALAPPENDICES ss 44 4 1 EQUIPMENT SCHEME DESCRIPTION cccccssccssccscccccsccscccccsccccccsccccccccccccsccccecccsccccccccsccccsccccccceees 44 BZ INS TALIA TION RTT 44 4 3 MAINTENANCE AND EQUIPMENT CHECK LIST cccccsscccsscccccccccccsccccccccccccsccccccccsccccccccscccccccceces 45 4 4 CHECKING THE TEMPERATURE GAUGE CONNECTION ccccccsssccsscccccccccccccccccsccsccccccccscccccccoeees 46 4 5 BREAKDOWN ANALYSIS ssossecsesssossessesosossessecssossossessesseossosseossoosesseossoosesseossossesseossossessesssssses 47 TNT NN 47 45 2 REGENERATOR GETS OVERHBA TED wec vscssacsantonsasuecnatadassuadedaveacasdontenaaousanebbbesautdebuseecasbenhseanowencs 47 KEENE NEP 47 4 5 4 OUTPUT DISPLAYS
4. the AC frequency Updating software fet Dre Kors gu 53 Bod 00 7 Vernes cok G Ti ETAPA 87 Fire 71 OG 04 993 Pici Girard Fn AE Frame Serial number of the processor appears in the about window Mo BRT 20 3 9 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 2 6 Airvent in the workshop Smoking is prohibited Sparks are banned welding grinding etc During regeneration and normal charging oxy hydrogen gas is generated However during the BRT process the explosive gas formation is reduced as constant current applies only during 5 of the total cycle Anyhow flame and spark should be avoided Air vent or air cooling is required according to the Norma in force 2 7 Required equipment Caution 1 Beware it is dangerous to work close to lead acid batteries When in tension some explosive gases are produced by the battery Reading the service manual and referring to it all the time 15 then mandatory 2 Toreduce explosive risks one must refer to the present manual but also to the instruction manual from the battery manufacturer or any other manual referring to equipments used closed to battery Make sure you ve red the caution stickers and warnings 3 Do not use the BRT if connecting cables are dama
5. gue 123 dia Ww In the traction or starting program select then enter the Once named proceed to the parameters setting starting from name of the new program minimum 3 letters the set number of loops phase 1 Modify a program In the Traction or starting menu select the program to be modified pressing the display the following display will show up ur gt LI Modifier un programme Press to go back to the former program selection screen Press to delete the selected program Press to place the name of program at Press to modify the parameters of the the dedicated place in the list selected program Mo BRT 20 3 36 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 6 Normal charge The BRT can also be used as normal charger 3 phases maximum can be programmed Usually one should check the battery capacity in Ah stamped on the battery A first phase will be set in order to reach the stabilization or equalization of the cell tension at 2 4 Volt the so called gas tension In the second phase the BRT will chose freely the current In phase 2 the amperage will slowly decrease automatically every 10 A till reaching 10 which 15 the minimum maintenance charge level Charge will then be completed Check the following set up table below Charge mode with ca
6. All measurement shall be conducted or converts at the standard temperature 30 C Mo BRT 20 3 4 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Above 30 operator should decrease voltage by 0 005 Volt every degree exceeding 30 The greater the temperature the higher voltage 15 showed on ammeter Ex Voltage red at 42 C gt V 2 18V After correction to adjust at 30 C gt V 2 12V Above 30 operator should increase density by 0 0007 every degree exceeding 30 C The ereater the temperature the lower the density 1s showed on densitometer Ex Density at 45 C gt 1 175 Density after correction adjusted to 30 C 1 185 At a usual continental temperature 20 C battery regeneration 1s over when the electrolyte density is between 1 27 and 1 3 per cell and when tension is between 2 1 et 2 3 volts per cell Those values are reached almost everytime To check whether the battery 15 completed those values are important but not enough and the 5 hours discharge test shall be conducted As a statement because we are working on used batteries test shall be conducted aver 5 hours at 80 of the nominal capacity of the battery If battery capacity is 850 Ah the discharge shall be conducted as follows 850x80 5 136A Battery shall deliver 136A during 5 hours After 5 hours of discharge the cut off voltage on
7. PMonoblac CE gt D Ah Battery parameters Set imurmber of Lines 7 C8 gt 70 Ah Battery parameters Line voltage 2 Select global voltage of the line Select battery capacity Set the number of parallel lines It is mandatory that all lines have the same global current Press start when ready to proceed Pre settings for the stationary batteries are as follows duration current Mo BRT 20 3 34 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 During the process amperage of the pulse highs can be adjusted One shall simultaneously press on I or I buttons and on the upper right button The new order will smoothly be executed over the two minutes onwards After being regenerated those batteries have to go on floating charge Stabilization will be at 2 35V per cell up to 0 5A residual flow Regeneration 15 adjusted in order to avoid quick increase of tension that means that at the end of the process the battery charge may not be completed TREATMENT PROCESS Reception of the battery and analysis Shape of rack and connectors voltage over or at the nominal value Check and fill the cells with distilled water for lead batteries Set up series line to discharge the batteries on the BDX discharger analyzer If already discharged battery can go on BR
8. sof gt plomb r g n r Once the lead sulphate is solid the classic chargers can not so reload electrodes and electrolyte Activ agents turn to crystal and will be off the normal path r g n r weakening the battery capacity H O 2H 802 12 Circulation des porteurs de charge et r actions lectrochimiques 7 lors de la recharge d un accumula teur au plomb Mo BRT 20 3 4 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Regeneration process removes the lead crystal sulphate for total battery capacity recovery Regeneration can by be conducted on curative way every 4 5 years preventive way once a year Prevention allows to keep the total battery capacity during the full life of the forklift preventing some electric failure to occur due to crystals growth and plaque distorsion Preventive regeneration process is conducted over short cycles 24h whereas curative regeneration may take up to 96 hours 100 I 60 NORMAL 40 BRT 20 1 20 o 2 3 4 5 6 I 8 10 11 12 Ann es Curative regeneration on traction batteries NORMAL BRT 20 1 Ann es Preventive regeneration once year Mo BRT 20 3 5 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90
9. 100 48 4 5 5 REGENERAION DOESN START esunvvnnvvnnnnnnvnnnvnnnvnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneenn 48 2 545 INO PEEC ERIC BLOW NTN EE T E 48 4 5 7 WORKSHEET REGENERATION TEST vessvessennvnnnsennennnenennsnnnenennsennennnnsennsnnnnnennsennenennsenenennneen 48 Mo BRT 20 3 2 Version 2 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 This comprehensive operator s manual 15 dedicated to the users of lead acid gel battery regenerator BRT 20 It shall be used as the operation as well as reference manual It is based on manufacturer s technical documents issued by him and he shall be the only liable person regarding its contents It describes all the functions of the equipment and explains how the operator shall proceed at each stage of the regeneration process in order to preserve the user s safety as well as the normal use of the equipment Caution one shall read carefully this manual before starting up the equipment Specific attention shall be drawn on the safety requirements during the regeneration process as well as for the batteries manipulation This product has been manufactured in accordance wi
10. 33 0 4 90 81 08 05 Hereafter exemples of regeneration test worksheets for traction stationnary and starting batteries Mo BRT 20 3 49 Version 2 AVRIL 2010 Prog V2 3 E F 2 Q E lt 2 5 Description Carrier Age operator Description Battery brand VOLT DENSITY Cell 1 I 10 12 13 14 15 16 17 18 19 20 23 24 25 26 27 28 29 21 22 30 31 32 33 34 39 36 37 38 39 40 Cells are recorded starting from the battery positive connector Dates Global tension Operator Comments 2 gt i m I D o 48 Version 1 Prog V2 3 Mo BRT 20 5 AVRIL 2010 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 REGENERATION TEST Description User Description Carrier EU Battery Brand Age Type VOLT STATIONNARY BATTERIES 2 PARALLEL LINES Discharger Analyzer LINE A BATTERY 1 2 2 EE ee 2 ae a LINEB 1S o 7 ELE A E __ Dates Global Tension Cells are recorded starting fro
11. AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 batteries with the same background and sulphating state I e same tension on connectors The main switch of the BRT shall always be on ZERO Then plug in the cable between the battery and the BRT Check and secure the connections If not tight you may get sparks which may be dangerous 3 1 5 Temperature gauge connection and positionning The connector for the temperature gauge 18 on the top right side of the regenerator As a basic statement remove the cover of the middle cell of the battery and insert the temperature gage in it Insert as deep as you can in order to get at least 1 3 of the gauge below the electrolyte level The gauge can touch the lead plaque it will not get any distortions effect on the temperature records When regenerating several batteries at once the gauge shall be placed in the cell of the weakest battery 1e the one with the highest sulphating level Connect the temperature gauge to the BRT As a global statement temperature gauge shall always be placed in the most sulphated cell 1 e lowest voltage or acid density and also in the cell that will be the less air cooled 1 e the one on the middle of the battery Anyhow during the first stage of the regeneration process a quick voltage test shall be conducted during the pulsation process which may he
12. to initiate the process per cell During the regeneration process the operator shall control every day the water in the cells and adjust to the appropriate level Mo BRT 20 3 22 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 a Charge by pulse Regeneration by pulsation screen display Animated signal showing the pulse Shows type of program selected and Shows type of loop selected with pulse gauge for the remaining battery type pulse time Display pulse and pause set up Manual program 2 V 200 Ah Phase in process Total number of phases Pulses charge 1 1 x Ex Loop Loop in process Total number gt 12 Out SB Uh Battery current gauge Total elapsed time and total Number of H Total time left 55 45 Lenght af pulse 4 21 55 45 EE al pause 5 Thyristors opening stage Re remaining time 235 33 45 Time Tor pulse charge flashing screen appear if sequence Current parameters taking into account the T default if any Loop time 5 55 45 current of pulse reaching 10096 Time for const charge Total high T 0 00 00 Current flrst cycle Loop high 0 00 00 Eie TR Info on the phase in process If you press on the di
13. 2 Clean up the main contacts of the battery as explained here after Beware that corrosion dust doesn t get in contact with your eyes or skin 3 Make a visual check of the battery If cracks rack or top damages mechanical damages do not use the BRT Mo BRT 20 3 10 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 2 7 1 Regeneration equipment The operator must always have the following equipment at his disposal Acid tester ammeter temperature gauge for batteries connectors and discharger analyzer equipment Tools shall all be electric proofed The acid tester 15 standard device The ammeter shall read up to 500 Volts and below One can use normal glass temperature gauge with scale up to 65 C Specific device dedicated to the batteries can be found on the market An infra red temp gauge can also be used In order to ease the connection of different battery types one can use intermediary cables with the most commonly used connectors you can find on forklift Discharger shall be able to unload battery under constant current for 5 hours One should be able to set the resistance in order to get the required current 2 1 2 Staff safety equipment The premises shall restricted area where only authorized and qualified staff 15 allowed All Norma concerning electric acid and fire risk shall be respected a
14. BRT top cover where operator can read Failure code Failure FF Phase failure no tension in one phase LU Tension between R and S to low Main power supply problem LI Current limitation Ir Internal Inhibition activated Ot High temperature in the thermo transistors Normal use 00 Thyristors are working correctly 4 5 2 Regenerator gets overheated If high temperature of the BRT 15 noticed check that the air vent system of the thyristors 15 working If not working the BRT shall not be used and operator should contact the nearest distributor 4 5 3 Temperature gauge Sometime sulphuric acid attacks the temperature gauge If there 15 doubt about it refer to chapter 4 4 to test the gauge Gauge shall be connected to the BRT If BRT stops and high temperature 15 on the screen display the gauge 15 working If nothing happens then the temperature gauge should be replaced If the gage 15 not connected then high temperature message appears on the screen display Mo BRT 20 3 47 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 4 5 4 Qutput displays 100 This failure may occur while the BRT 15 in pulsation mode If power 15 100 it means the circuit is not closed for the following reasons Main BRT fuse 125 A is dead No battery connected to the BRT The battery or one of the battery line is in short circuit
15. V 2 18V After correction to adjust at 30 C gt V 2 12V Mo BRT 20 3 13 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 b Cells acid density At an average temperature between 22 and 34 electrolyte density should be between 1 10 et 1 28 The highest acceptable level in a new battery 15 1 32 Check the electrolyte density in each cell with the densitometer Remove the covers and dip the densitometer in the cell Only pick up the liquid which is in the cell Close the cover of the cell after each measurement Proceed according to the same sequence you did to record the cell voltage Record the collected values in the Density section of the Regeneration Test worksheet Report the exact value collected on the worksheet All measures shall be recorded at a standard temperature of 30 C Above 30 operator should increase density by 0 0007 every degree exceeding 30 C The greater the temperature the lower the density 1s showed on densitometer Au dessus de 30 on devra augmenter la densit lue de 40 0007 par degr s au dessus de 30 C Density at 45 C gt 1 175 Density after correction adjusted to 30 C 1 185 3 1 3 Electrolyte level control Once electric and density test completed it is sometime necessary to refill the level of water in the cells I cm above the grid Never
16. check the battery and upon result 1t should be decided whether a new phase 1s needed or not During constant charge Regeneration will stop if the BRT notice that the battery global tension doesn t need more charge STOP High voltage appears on the screen report to previous chapter Operator will give a quick check on the battery 3 3 4 Control on the discharger analyzer for acknowledgment Mainly for traction batteries the discharging test is mandatory to validate the C5 Shours test This 1s part of the final quality control of the whole process For other batteries operator shall refer to manufacturers charts Stationary batteries are usually tested in the table charts Mo BRT 20 3 40 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Discharging test shall also b adapted to the use of the battery the owner is suppose to do For Traction batteries The five hours test shall be conducted This 15 an international chart requesting that battery should hold discharge during 5 hours with discharged down limit of 1 7 Volt per cell As a statement because we are working on used batteries test shall be conducted aver 5 hours at 80 of the nominal capacity of the battery If battery capacity is 850 Ah the discharge shall be conducted as follows 850x80 5 2 136A Battery shall deliver 13
17. on which oxide and lead sulphate appear on the electrodes may get overheated Electrodes may then weaken and some micro parts of those may drop on the bottom of the battery rack The BRT process is removing lead sulphate crystals on the electrodes During regeneration process lead parts return on the electrode dedicated surface Electrodes get then covered with micro lead balls enlarging the electrode surface and then easing the charge Not only extending the battery life span the regeneration process has also positive impact on the battery lift carrier with direct impact on its productivity Mo BRT 20 3 3 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 circuit ext rieur BATTERY DISCHARGE lectrodes de plomb During normal discharge process electrodes generate on both side lead sulphating process White liquid Along cycles this liquid will slowly turn to solid crystal form This emerging crystal will spread over the cycles and generate capacity decrease of the battery solution d acide de dioxyde sulfurique de plomb 9 Circulation des porteurs de charge et r actions lectrochimiques lors du fonctionnement d un accu mulateur au plomb CHARGING BATTERIES chargeur When charging the lead sulphation white liquid will split and reload electrodes and electolyte 2
18. recovery Report to regeneration help diagram hereafter Greatest care shall be taken to avoid acid contact with eyes and skin If this shall happen clean with still water and contact immediately the nearest medical care centre 3 1 4 Battery ies connection to the BRT Main switch should be on 0 zero First connect the cables to the battery and second to the regenerator Tight the cables with an isolated wrench at the manufacturers usually recommended torque 25Nm or use quick matching connectors Contacts should be clean to avoid overheating or sparks that may involve contact melting fire and explosion occurrence First connect the blue minus cable to the minus contact of the battery Make sure the cable 18 not in contact with the ground Second connect the red plus cable to the plus contact of the battery If one needs to connect several batteries at the same time they must be in series as mentioned above Only difference is that the contact of the first battery is connected with the contact of the second one If more than two batteries the same connection will be done with the others If several batteries are connected at once special care shall be given to the total voltage which shall not exceed 96 Volt Batteries connected together shall have the same voltage and the same amperage In order to get the best results it would be great to connect Mo BRT 20 3 15 Version 2
19. remain between 50 and 98 If you read 100 it is a failure alarm report to chapter 4 5 4 hereafter After few minutes of pulsation once nominal amperage 15 stabilized it is recommended to check voltage of each cell or of the battery if it is a sealed item Tension may reach 3 Volts or I volt PER CELL during pulsation which is normal If tension reach 5 or 6 volts per cell during pulsation you may be facing the following problems v Cellis more sulphated than the others v Cell might have been short in water during its operation v Cell is not the same quality as the other ones v There is a possible short circuit In this situation the temperature gauge shall be placed in this cell as it may be more sensitive to high temperature This will help to protect the battery and secure the process b Constant charge Constant charge screen display Type of cycle in process and gauge for the Animated sional showing the remaining constant charge time constant charge sequence anm tft Total time elapsed 0 01 2 8 bison Humber of loops Total time left 2 58 18 Lenght of pulse Phase time left 2 58 18 l ime Sica Eua If fixed current or AH has been Current of pulse 300 selected for the first cycle screen Loop time left J3 3 38 04 OA Time for const charge displays the intensity in process Total high T 0 00 00 Loop high T 0 00 00 00 Current first cy
20. whether the weakness 15 on one cell several or all of them c Automatic program Automatic program Select automatic program from the main menu ov Three programs are displayed gt Automatic Program Traction battery program Traction batte f Start battery Starting battery program Stationary battery program Mo BRT 20 3 23 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 2 Automatic program for traction batteries To ease the operators procedure the BRT has already some pre set programs ready to use You can access to those programs in the menu at the set application page Operator can work on three main treatments regeneration 241 be applied when you have annual maintenance contract with the battery owner It keeps the battery at its greatest capacity as new on the long run Loops are short and scheduled to treat and deliver charged battery in 24 hours in order to keep the forlfts production pace Curative regeneration 72 h This mode is for 4 to 6 years batteries Treatment last for 72 hours It aims at removing sulphation and increase current Full curative regeneration 96 h This mode 15 for batteries over 6 years old This 15 a deep treatment to remove all the sulphation from the plaques and give the battery
21. 0 07 Fax 33 0 4 90 81 08 05 Control the air vent grill on the right hand side of the BRT is dust free Once switch off and disconnected from the main psu check all cables connection mainly if the BRT is often move place to place Check the temperature gauge and test if 1t works when reaching temperature over 45 C Double check with a classic thermometer that will be placed temporarily in a cell next to the original gauge Another way could also by heating water up to 50 degrees and place the temperature gauge in order to see if the BRT stop processing displaying High temperature 4 4 Checking the temperature gauge connection Checking this device is quite simple as it 1s a closed circuit With a ammeter check position 1 and 3 without touching the ground which 15 in the metallic frame Current should flow between I and 3 Pin position as below Mo BRT 20 3 46 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 4 5 Breakdown analysis No problem shall disturb the BRT operation However here are some advices to cope with potential failures 4 5 1 Electric interruption If there 15 an electric disruption when BRT 15 started operator should check the phases order If disruption occurs from time to time check that the BRT is working correctly First thing to do check the card which is right below the
22. 6A during 5 hours After 5 hours of discharge the cut off voltage on each cell shall be over 1 7 V For a 48 V battery it means 24 x 1 7 2 40 8 V A well regenerated battery would be qualified if it can hold 4 5 hours on the discharger Indeed once in operation again the battery will gain value after several charge cycles Operator shall take into account how the battery 1s operated by the client 3 3 5 Regeneration control on electrolyte and voltage In order to get correct values measurements shall be conducted when the battery 1s disconnected at least 30 minutes after the regeneration process IS over Tension on connectors can be check during the pause along the regeneration process At the end of the regeneration process it is recommended to check tension and electrolyte density in each cell Sometime it may be necessary to change some parameters of the BRT as the battery sulphating is reducing With the electrolyte if the density fell below the standard level it is required to add some distilled water in the cell Measure shall be conducted before adding the water otherwise the density value will be false as dissolution of acid will occur when adding water If operator misses this part it would then be recommended to do a quick constant charge in order to mix electrolyte A battery which is not in a good shape will often loose steam during regeneration process So it 1s important to check electrolyte level after the process
23. 87 00 07 Fax 33 0 4 90 81 08 05 II Safety requirements 2 1 Removing the BRT from the crate The BRT is delivered strapped and wedged on a EUROPE type pallet with side extension Remove the top then the side extensions and the bottom chock between the wheels Cut the straps Push the BRT on the pallet edge Slip a thin strap under the BRT With two operators lift up the top of the BRT with the strap and let it stand on the edge of the pallet Remove the side chock CAUTION Leave the BRT rear frame on the pallet as shown F Take top of the crate and slide it under the wheels Move it till the second rim as shown Once lift up the BRT makes automatically a soft landing on its wheels Upon height of the pallet it may be required to use the top of the crate or any other support to ease the contact of the wheels when lifting up the machine Mo BRT 20 3 6 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 2 2 Equipment installation and environment The regenerator shall be used indoor in dry and clean place If used outdoor the BRT should be covered and in dry place No liquid shall stand close to the regenerator and the batteries After refilling a battery with distilled water make sure no water spilled on the floor if so remove it The regener
24. MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Lead acid gel Battery Regeneration SERVICE MANUAL Equipment BRT 20 3 Mo BRT 20 3 0 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 CONTENT L FORPNORDSG LE 3 EL SAFETY REOUREMENIS saksen 6 2 1 REMOVING THE BRT FROM THE CRATE ccccscccsscccscccccccccccccsccsccccccccsccccccccsccccccccscccsccscccsccees 6 2 2 EQUIPMENT INSTALLATION AND ENVIRONMENT ccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccccees 7 TONN 7 2 4 CONNECTING THE EQUIPMENT sene 8 2 5 CHOSE YOUR LANGUAGE AND SELECT THE ALTERNATE CURRENT FREQUENCY 9 2 6 AIRVENT IN THE WORKSHOP ss nn 10 2 7 REQUIRED EQUIPMENT Lune SAG 10 2 7 1 REGENERATION EQUIPMENT eroennvnnvnnennennennennennennennennennennennennennennennennennennennennennennennennennennennene 11 2 7 2 STAFF SAFETY EQUIPMENT eooeonvnnvnnennennennvnnennennennennennennennennennennennennennennennennennennennennennennennennene 11 IL REGENERA HON PROCESS wivsscsscssacsscaisassewatsacsiveisnssvecssacetvetvasssactsacsiseisssssedssavesveswesseuess 12 3 1 GETTING READY AND START UP esevessvensevnsevnnsennsnnnssnnnsnnnnsnnn
25. T directly Several parallel lines can be treated simultaneously Check the current balance on each line setting up short constant charge loop at 10 Report to starting battery chapter Set the requested standard loops CAUTION IF YOU HAVE TWO LINES OF 96V IN PARALLEL AND YOU WANT TO TREAT THOSE AT 50A IN PULSATION YOUR PROGRAM SHOULD BE ON 50 50 100A Same calculation apply for constant charge to be set at twice the value of the requested treatment Set up the floating charge stabilized at 0 5A and 2 34V per cell Check on the BDX discharger the results under Cs as per the battery criteria Caution When batteries are set in series tension will be added Maximum tension shall not exceed 120v ie 10 batteries of 12v each Over 120 volts there is physical risk for the oprerator When connecting the batteries in series take care not to close the pattern which may involve short circuits thus explosion and fire risk may occur ISOLATED TOOLS SHALL BE USED BY THE OPERATOR AS PER STAFF SAFETY REGULATION Mo BRT 20 3 35 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 5 MODIFYING OR SETTING UP A NEW PROGRAM Operator can set up and or modify programs Add new traction or starting battery program Manual program Program New Enter Program Name Set number of loops
26. There 15 phase problem The main reason would be the fuse of the BRT Its resistance should be checked For safety reason regarding short circuit occurrence in the battery the BRT will stop after one minute operation if the output remains steady at 100 CAUTION NEVER OPERATE MAINTENANCE ON THE BRT IF IT IS NOT DISCONNECTED FROM MAIN PSU ELECTRIC HAZARD MAY OCCUR If needed the fuse shall be replaced Once the fuse change check up the connection line and the battery 1n process looking for short circuits Indeed when output is 100 it is possible that a battery cell might be in short circuit To check this set a constant charge loop without pulsation If after a few minutes amperage doesn t increase and voltage of the battery is over nominal values operator will have to cope with a battery short circuit 4 5 5 Regeneraion doesn t start The BRT doesn t start even though the menu appears on the screen display Check if the temperature gauge is well connected 4 5 6 No electric flow on screen 1 no electric flow on screen 2 the BRT accumulate a lot of energy till the main fuse burns out Regenerator will have strange sound showing it is not under control Stop the BRT immediately and check if the current sensor 15 still working 4 5 7 Worksheet regeneration test Mo BRT 20 3 48 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax
27. an not bear any retrofit or modification Mo BRT 20 3 7 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 2 4 Connecting the equipment For the set up please refer to chapter 4 2 The regenerator shall only be connected to an approved dedicated plug in accordance with required voltage with appropriate phases Equipment requirements 360 400 V Three phases Ground Differential electrical device 300mA or 500mA 4010 50 A disruptor D curve This machine is equipped with a CEM filter requiring earth connection of 5 mA It is not required to connect this machine on a disruptor equipped with 300 mA differential fire protection or 500mA machine protection on a dedicated connection A 30mA disruptor complying with the human body protection in the working place is sufficient Draw specific attention to the phase ranking If phases are inverted the BRT will show malfunctioning such as Global electric disruption Disruption after the first pulse I 2 minutes after starting up Pulse with very high amp volatility Big or discontinued noise during pulse Output indicator 10090 If the above occurs phases shall be set in order Report to chapter 4 2 hereafter Do not connect a dry battery Any metallic item is banned within the battery environment Cables to the main PSU should be checked and secured wi
28. arning appears when tension exceeds the maximum eligible tension 2 4 Volts per cell involving then gas production This signal 15 notice showing that regeneration process may be finished Machine will then stop automatically for 10 minutes to get voltage decreased BRT will set the requested parameters automatically in order to reduce voltage in the battery Parameters will be as follows During pulse session pulse length reduced by 20 automatically down to 80ms if needed Below this figure then the pause length will be increased by I second In imposed constant charge phase Current will be decreased by 30 down to 10 minimum During free charge As self regulation in current will apply only stops of the charge shall occur during the process AFTER 4 STOP THE MACHINE WILL NOT RESUME PROCESS That can also mean that a cell may be damaged Some lead particles may then be floating in the cell generating short circuits If so operator will notice an excess of tension in the other cells and current will increase Sometime the damage cell may produce gas and some noise will come out from this cell To cure this check that all other cells are in good state taking tension measures during constant charge and looking for high voltage It is recommended to regularly check cell tension during the regeneration process 3 3 3 End of regeneration loops When regeneration 15 over finished appears on the screen Operator should
29. ator shall be placed in a air vent room in accordance with the EN NFC15 100 Norma and any other local rules regarding safety Regenerator shall be placed on a flat floor Keep all electricity input and battery connectors accessible Main switch has to be accessible in case of quick disconnection requirement Battery shall be placed as far as cables allow from regenerator Contact between battery acid and the regenerator has to be strictly avoided 2 3 Caution No operation shall be started on the equipment without understanding how to handle it For individual and equipment safety concern the following instructions shall be in force It is mandatory that the operator s manual shall be red entirely and fully understood before using the equipment Note The equipment is under high voltage 380V Contact with those components may be lethal Maintenance and repair procedure which are note described herein shall only be performed by the manufacturers qualified staff Light maintenance described hereafter can be performed by a qualified electrician The operator shall only perform tasks as described in this manual Do not perform operations for which you haven t received the required training Do not use the regenerator if repairs are required on it Regenerator shall only be used for lead acid gel batteries regeneration When performing maintenance spare parts shall be ordered upon manufacturers specifications The equipment c
30. cle if 2 4V imposed has been Phase Time selected Max targeted charging intensity will be displayed Mo BRT 20 3 24 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 When regeneration phase includes several loops the constant charge 15 as follows At first amperage is locked at 9 of Ah current or at a preset value see display 10 and 11 previous pages and this will last during period of 30 of the number of total loops set This value shall be between 10 and 15 of the battery capacity in order to keep pressure on the current value pulsed in the battery Then the amperage is set automatically by the BRT to reach 2 4 V per cell Charge is then so called free charge Constant charge is applied to the battery in order to proceed to equalization in each cell to reach 2 4 V per cell Amperage is automatically set by the BRT upon the intra resistance of the battery at the end of the pulse loops to reach 2 4 V No manual setting can be done It is then very important to check that the number of set loops is sufficient to make sure that when the BRT switches to free charge imposed current shall not be too high For specific situation when voltage 15 below 1 7 volts per cell you should report to the specific procedures described later on in this service manual Procedure shall be adapted
31. constant charge 91 heures 11 21 31 41 51 71 81 Phase 1 Phase 2 Phase 3 Manual program Mo BRT 20 3 20 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Li Manual program Manual program i Battery parameters Battery parameters Set Voltage Set battery Alt vow 9s Set battery voltage Set battery AH Enter 0 if not mentionned press Select application Go to Manual program Puke parameters Set number of hours for pulse 5 Pulse parameters Set lenglit of pulse Set number of loop 1 to 50 One loop Set pulse duration 0 to 24 hours Set pulse lenght in milliseconds includes pulse and constant charge period 80 to 500 ms Puke parameters Set pulse current 3 meters Sot oe b Set pause lenght 1 to 7 seconds Set pulse current in Amp 0 to 400 A Set constant charge duration 0 to 24 hours Note Standard current used for traction batteries is 300A Processing with a lower current 250 A allows to decrease the electric consumption of the BRT to reduce the temperature picks risks but it will required a greater number of loops Beware that for starting batteries current setting shall be limited to 45 A for car batteries and 90 A for Lorries and buses If puls
32. each cell shall be over 1 7 V A well regenerated battery will be noticed when during the first two hours of discharge both tension and electrolyte density values are not changing Every hour operator shall check global tension and cell tension Doing this allow the operator to see if one cell is weaker than the other and can proceed to its removal and replacement If new regeneration is needed then disconnect the cable from the discharge and connect it to the BRT for a new adapted regeneration process Record in the regeneration test worksheet the final value for the electrolyte density and the battery tension 3 3 6 Disconnecting the battery Before disconnecting the battery the process shall be terminated and the BRT switch off on zero position If regeneration process is finished main BRT switch will be on zero Remove the main cable connector from the BRT Main PSU cable Disconnect the battery cable plug purple plug Disconnect the red battery cable Disconnect the blue battery cable Mo BRT 20 3 42 Version 2 AVRIL 2010 Prog V2 3 TECHNICAL APPENDICES SECTION 4 Mo BRT 20 5 43 Version I AVRIL 2010 Prog V2 3 4 Technical appendices 4 1 Equipment scheme description Below here is the wiring diagram of the BRT However it 15 simplified diagram as some components are intentionally missing Main switch Ground disruptor Transformer 220 24 V Transformateur fet setje
33. es are too long cells may reach temperature highs A good setting of pauses between the pulses will help mastering temperatures and current Mo BRT 20 3 2l Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 If battery Ah has been set previously adjustment can be done either in of capacity or current fixed limit program Manuel program Constant Charg EE Constant Charge 4 Set Se Ah or Current Only first odos 4 J Set So of Ah E 96 Ah Phase 1 If is selected constant charge current limit will be adjusted between 590 and 25 of the battery capacity Constant Charge M nc OUR Set Fixed current Constant Charge Set AN or Current Ont est cycles Press Start to Start the program Press Add bo Addition Phase anal If Courant is selected constant charge id nl Constant Charg current shall be manually adjusted between 0 d Set Fixed pinnene and 120 A or 2 4V imposed 5 If 2 4V imposed is selected charge will Vi be done via equalisation of charge at 2 4 V 2 4V impos One or several phases can be added Select add If selected setting will start again from the set number of loops 5 section 1 Phase 1 to 3 phases can be input If no phases to be added simply press start
34. ess the stop button Dispatch the batteries in new order to reach the greatest balance After 10 minutes the program will start During the process amperage of the pulse highs can be adjusted One shall simultaneously press on I or I buttons and on the upper right button The new order will smoothly be executed over the two minutes onwards Qualification of the battery The real capacity of the batteries is measures with an analogical starting tester The electrolyte density is considered as good from 1 26 1 e a little lower than the traction batteries Dismantling the lines After regeneration is over lines should be dismantled This operation shall be conducted with the greatest care to avoid short circuits as the batteries are now fully charged General rules Regeneration parameters for truck batteries Pulsation 90A 4 loops for 6h 5h pulsations Ih constant charge Maximum capacity of the BRT 40 batteries within 24h Regeneration parameters for car batteries Pulsation 45A 4 loops for 6h 5h pulsations Ih constant charge Maximum capacity of the BRT 80 to 100 batteries within 24h Mo BRT 20 3 32 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 4 STATIONARY BATTERIES Stationary batteries are constantly kept in floating charge Thus there are often always fully charged and m
35. ged Replace the cables before using the machine again 4 If BRT is damaged for any reason do not use it Call the manufacturer ask him for advises or for repair Global safety care 1 Make sure someone is not too far away from you when working on a lead acid battery This person could assist you in case of problem In general avoid being alone when working on lead acid battery 2 Make sure you have a eye cleaning kit water and soap close to you in case your skin clothes or eyes get in contact with acid 3 Make sure to wear glasses and appropriate clothes to work on batteries Do not touch your eyes while working on batteries 4 If your skin or clothes get in contact with acid make sure to clean immediately with clear water and soap If acid get into your eyes rinse them with clean water for about 10 minutes and contact your closest medical care centre 5 Do not smoke generate sparks or flames closed to batteries and BRT 6 Be very careful not to drop any metallic tools on a battery A spark short circuit or any other electric hazard on a battery may involve an explosion 7 Remove your rings chains bracelets watch or any other metallic jewel or equipment you may wear when you are working on a lead acid battery A short circuit on a battery may generate high temperature involving metal melting and severe burns Before starting regeneration 1 Make sure you are operating the equipment in a place where air is circulating
36. ing for starting batteries To ease the operator s task 2 programs are already set for starting batteries regeneration Press Ok and access to the Press to go back to main menu Press down or up to access to selected program process dedicated program 1 Battery parameters set number of Lines Cars 24h 50A Battery parameters Set number of Batteries 12V Start zu Set number of battery per line This setting will determine the Set the number of parallel lines It is mandatory that all lines current to be processed which is not the total number of have the same global current Press start when ready to batteries proceed Pre settings for the 12 V starting batteries are as follows Lorries 24 h Cars 24h Mo BRT 20 3 31 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Batteries shall be gathered and regenerated within the same scope of capacity current and age Do not mix car and Lorrie batteries lines shall be balanced and with the same total voltage Check the current balance at the beginning of the regeneration phase Constant charge session starts and last for 10 minutes This time frame shall be used to control the current balance on each line The current balance shall be balanced with frame tolerance of 10 If balance is not reached pr
37. ing the batteries special attention shall be drawn not to make full connection ring otherwise shortcircuits will occur and the risk for fire and explosion will be high In order to avoid mistakes it is recommended to follow the procedure below Connecting procedure Positionning and lining up the batteries on a trolley Connect batteries in opposition line in order to keep clearance between two main connectors Connect both to the main distribution line Connect all the batteries in series Start the BRT Amps control on each line Starting batteries regeneration process Starting batteries requires well organized set up in the workshop to ease the work and ensure safety Indeed as the starting battery cost 15 far lower than the traction and or stationary ones starting batteries regeneration process requires to work on high volume Select the batteries Operator should test the capacity of the batteries Look for short circuits tension below 10 Look for failures Drop on the starting test bench Check the global aspect of the batteries To proceed to those tests it is recommended to use Mechanical tester with needle more efficient than the Analogical ones Mo BRT 20 3 29 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Testing The operator should avoid to many manip
38. ing the temperature height Monitoring the voltage increase When the High Voltage alarm appears 2 4v during pulsation and density over 1 28 that means the regeneration 1s almost over and the battery shall be tested on the discharger analyzer BDX At a first step turn the main switch of the BRT on the start position The menu of the regenerator is divided in 3 main applications Manual Manual program Automatic Pre set program for traction batteries Parameters To access to parameters of the program in use To select an application press OK Then you can select any values or choices pressing the arrows selectors To validate your choice once on the display screen press OK and to the next parameter Mo BRT 20 3 19 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 1 MANUAL set up In this chapter we introduce the Manual set up which 15 the largest scope in terms of program possibilities Later on the Pre set section will be described too Definition One loop 15 full period of time including pulsation period followed by constant charge period Loop description Time of Pulse Time of constant charge 1 23450678939 10111413 14 15 16 17 18 19 20 21 22 23 24 heures 1 cycle A phase is a number of loops Several phases description Time of Pulse E Time of
39. lp to identify a weak cell needing special care Then the temperature gauge will be place in this cell Check Pulse charge caper 3 2 1 Mo BRT 20 3 16 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 1 6 Plug to the main power supply Check first that the BRT main switch 15 on Zero Then plug in the main red plug on the mid right side of the BRT Lift the safety cover and connect the plug For details about general connection please report to chapter 2 3 connecting the equipment 3 2 Starting up the regeneration process Main purpose of the regeneration 15 to make sure that the active agents of the battery which turned into chrystal will return to their original liquid status To reach this point the BRT will proceed to pulsation sequences up to 300 amps at the specific vibrating lead sulphate chrystal frequency Chrystal will resound and vibration will erode it and turn it into liquid as it used to be Along the process the plaques surface sulphation free will have ereater chemical reaction withe the surounding elctrolyte accelerating then the process Pulsation scheme 300 amps Vibration la fr quence de raisonnance du cristal de sulfate de plomb longueur de La pulsation The pulsation cycles below are set to 200ms every 3 seconds in order to avoid temperatur of the cells
40. m the battery positive connector Comments Op rator Battery qualification Signature Mo BRT 20 3 49 Version 2 AVRIL 2010 Prog V2 3
41. nd implemented The operator shall comply with the domestic risk management involved in the regeneration arena as well as in terms of health and care in case several activities are processed in the same premises or in the immediate surrounding The staff involved in battery regeneration shall have and wear the relevant protection and equipment to proceed Necklace bracelets watches metallic glasses shall be banned from the regeneration workshop has they may get in contact with any electric devices and generate risk for the persons and the environment Recommended equipments are Acid resistant gloves Acid resistant talveg Safety face cover or safety glasses Eyes cleansing extinguisher absorption equipment etc Any specific safety operation rules within the premises where the regenerator is used shall be set up by the operator s management according to his own risk management Mo BRT 20 3 11 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Regeneration process 3 1 Getting ready and start up Main safety switch shall be set on 0 position Cables shall be disconnected from the main PSU and battery line shall also be disconnected 3 1 1 Battery preparation All work on the battery shall be done while it is disconnected While working one should always wear safety clothes gloves and glasses o
42. pacity lt 700 Ah Pulse intensity Amp J Pulse lenght Pause Seco J Je Constant charge Hours 5h 5h current imp Charge mode with capacity gt 700 Ah Pulse intensity J Pulselenght J Pause J Je current imp Caution As 2 4 V impose has been chosen during the 2 phase constant charge current will determined by the machine during the process to reach 2 4 V per cell If duration or amperage of 1 phase are too low set up current may by very high involving high temperature and even disruption of the main fuse in the machine Special care is mandatory in the choice of the battery capacity input Mo BRT 20 3 37 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 3 Control and regeneration acknowledgment 3 3 1 High temperature High temperature warning Warning signal with red flashing report Manual program 24 V 200 Shows number of warning detected during the cycle in process 0 time elapsed 0 07 22 ide e al Total time left i 11 52 27 Lenght of pulse 120 ms Lenght of pause 5 11 52 27 lime for pulse charge 1h Phase time left Current of pulse 20004 E ae time lef
43. r face shield Battery should be cleaned and dried Dust and liquid shall be removed from the upper part of the battery to avoid 5 or any hazardous electricity flow This 15 mandatory before proceeding to the regeneration With hard non metallic brush operator shall clean both and contacts Proceed to battery visual inspection looking carefully for any mechanical or electrical failures such as cell leak short circuited cells or battery while cells are not isolated from the battery rack If the battery is equipped with hard bridges between the cells attachment to the cells shall be checked Sometime those connection can be loose check with an isolated screwdriver and cracks can appear avoiding the normal contact between the cells On copper bridges blue dots and tracks can appear showing that corrosion 15 already in place and contact between the cells may be faulty Those should be cleaned or replaced upon corrosion status In case of cell short circuit operator will notice big difference on voltage compare to the other cells During pulsation process with the BRT voltage can be checked on each cell the weakest one will then be identified easily see later Mo BRT 20 3 12 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 If any of the above mentioned 15 noticed the breakdowns shall be solved befo
44. ram process jCure 96h Battery parameters Set battery Ah Start Battery parameters Set Voltage Set voltage of the battery Set charge capacity of the battery then press strat to proceed Mo BRT 20 3 27 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 3 2 3 START mode dedicated to 12 V starting batteries Starting batteries shall be treated at lower intensity than the traction or stationary ones as the plaques are thinner and the starting batteries globally weaker than the biggest ones As the BRT can proceed with intensity up to 400 it is recommended to set up several battery parallel lines taking care of the intensity dispatch on each line Starting batteries regeneration Getting connected Control depressiostat vAy mE gt Air ventilation P V Q Relay 380V 132 D curve Main distribution line Plugs Trolley 1 Trolley 3 10 batteries of 12V 10 batteries of 12V Mo BRT 20 3 28 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Caution When bateries are in series you have to add the tension Maximum tension shall not exceed 120v ie 10 batteries of 12v Over 120 volts it is consider as risky for the operator health When connect
45. re starting the regeneration process On battery showing short circuit failure to proceed to regeneration may endanger the operator as high risk of explosion may occur 3 1 2 Control and battery cells measurement An initial test on each cell shall be conducted All measures are collected on the Regeneration Test record sheet see appendices As global rule cells will be counted from I to starting from the connector From time to time operator should clean the cells with compressed air to ease air circulation on top of the battery Battery 15 always producing small quantity of hydrogen gas when mixed to air generate oxy hydrogen very ignitable gas with explosion risks a Cell voltage With an ammeter check each cell voltage starting from the connector moving to the one following the connections Always proceed according to the same pattern Ammeter sticks shall be strongly applied on the connectors under the cell covers Usually some holes are on the top of the cover to ease the measurements Report all figures on the work sheet Regeneration Test Voltage shall be recorded in the Volt section Report the exact value red on the ammeter All measures shall be recorded at standard temperature of 30 C Above 30 operator should decrease voltage by 0 005 Volt every degree exceeding 30 C The greater the temperature the higher voltage is showed on ammeter Ex Voltage red at 42 C gt
46. second life frame To be efficient this process requires 96h of treatment which means 8 loops of 12h Standard settings are as follows Preventive regeneration 24 h Curative regeneration 72 h Curative regeneration 96 h Number of cycles Number 8 Mo BRT 20 3 26 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Note that in those programms pulsation amperage is set at 300A However for the small sealed traction batteries golf carts cleaneing machines it is recommended to set a limit at 200 A in order to get a better control over temperature and voltage During the process amperage of the pulse highs can be adjusted One shall simultaneously press on I or I buttons and on the upper right button The new order will smoothly be executed over the two minutes onwards Traction battery program Allow the operator to add a new program for traction battery Cure regeneration Z2h Program listing for traction batteries To ease the operator s task 3 programs are already set for regeneration and 1 for battery charge Touch here and access to the program modification display Note that already pre set program cannot be modified Ok Press to go back to main menu Press down or up to access to Press Ok and access to the dedicated program selected prog
47. sennnnnnnsennnnnnnsennsennssnnnsennssnnnsennsennneen 12 SLIBATTERY TN Ne 12 3 1 2 CONTROL AND BATTERY CELLS MEASUREMENT cscccsccsccssccsccsccsccsccsscescessesscscescessesscesceuss 13 Ge 13 DCR ere ee EDEN NET 14 3 1 3 ELECTROLYTE LEVEL CONTROL ccicicsacsvnteczantavainisanionntenduenssanbdddonsedduobandeden dtu ks i o 14 3 1 4 BATTERY IES CONNECTION TO THE 15 3 1 5 TEMPERATURE GAUGE CONNECTION AND POSITIONNING 16 3 1 6 PLUG TO THE MAIN POWER SUPPLY 17 3 2 STARTING UP THE REGENERATION PROCESG ccscccsscccsccccccccccccscccsccccccccsccccccccsccccscccscccccscoeees 17 D qu roli 1 c 23 D COR ee 24 3 2 2 AUTOMATIC PROGRAM FOR TRACTION BATTERIES eosrornevnnvnnevnnsnnennnvnnsnnennnnnnnnnennnennunnennnennnnnee 26 3 2 3 START MODE DEDICATED TO 12 V STARTING BATTERIES csccseccsccssccsccsccscescesccscesseseuss 28 32ASTATONARY BATTERIE NE 33 3 2 5 MODIFYING OR SETTING UP A NEW PROGRAM 36 ONE uum 37 3 3 CONTROL AND REGENERATION ACKNOWLEDGMENT 38 3 3 1 HIGH TEMPERATURE viwesncvccescnsacundhevsvasddebavenanenconncdes ies
48. ses with strong amperage gaps Noise at random or chocks during pulse Output 100 Then proceed to set up phases in the right order This shall be done at the main electric switch board or in the plug One shall avoid changing the phases in the BRT Next step is to control the installation 1s equipped with differential disruptors such as 300mA one This machine is equipped with a CEM filter requiring earth connection of 5 mA It is not required to connect this machine on a disruptor equipped with 300 mA differential fire protection or 500mA machine protection on a dedicated connection A disruptor complying with the human body protection in the working place is sufficient The machine is equipped itself with a 30mA disruptor complying with the human body protection If the regenerator has been in a long transport please check that all screws are sufficient turned especially those around the transformer Wood shocks are placed in the machine to sustain the transformer during shipping while the BRT lies down Operator shall remove those before using the BRT Use those shocks again if transport of the machine 1s needed 4 3 Maintenance and equipment check list The BRT is almost maintenance free equipment Nevertheless a special care 1s recommended on the following components Mo BRT 20 3 45 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 0
49. splay you see for a short period information on the remaining phases and if temperature or voltage alarm occurred Stop display if pressed you ll have to Pause Play display If pressed regeneration Displays I and I Can set the amperage of the confirm your command before the stop process will be on pause mode Operator can pulse highs New set up will smoothly be in place Operator can keep control order will be executed work safely on the battery Pulse are set to increase intensity smoothly over 2 minutes to reach set level in order not to damage the battery 1 to 3 minutes may elapsed till pulses get stabilized sometime One may notice some difference between pulses that may go from 10 to 20 Those variations are normal and may be even greater at the beginning of the regeneration process during the first loop Those variations disappear smoothly to reach the set value During the process amperage of the pulse highs can be adjusted One shall simultaneously press on I or I buttons and on the upper right button The new order will smoothly be executed over the two minutes onwards Caution The modification will only apply to the phase on course and will resume the initial settings at the following phase Mo BRT 20 3 23 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 This thyristors value shall
50. t E 35227 rud Tine for core changes E r Total high a oth Pa Cur rend first 5 nt 287 Phase Time 6 h p t Ls ET Total time high temp and time elapsed during the cycle on red font as a warning signal If battery temperature is getting to high over 45 C The BRT will stop automatically for 30 minutes to allow the battery to cool down High temperature will appear on screen Once the temperature recovers normal level the BRT will resume the process BRT will set the requested parameters automatically in order to reduce high temperature pics again Parameters will be as follows During pulse session pulse length reduced by 20 automatically down to 80ms if needed Below this figure then the pause length will be increased by 1 second n imposed constant charge phase Current will be decreased by 30 down to 10 minimum During free charge As self regulation in current will apply only stops of the charge shall occur during the process AFTER 4 STOP THE MACHINE WILL NOT RESUME PROCESS Mo BRT 20 3 38 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 It is very important not to stop the process of the BRT operator shall leave the machine to run the full program Values will automatically be set as initially requested for the following loops Temperature may also be reduced by set
51. th high quality norms and comply with the CE European standards BRT 20 regenerator 15 based on high tech process allowing the recovery of the original traction lead acid battery capacities after enduring an electrochemical treatment s a result battery will get an extended life span a greater efficiency and de facto their operating cost will drop The process mainly applies to traction lead acid or gel batteries which are usually used in the electric forklifts electric elevators cleaning machines golf cart type vehicles and other electric tractor and equipment Process concerns Stationary and starting lead batteries as well This equipment is not suitable for other type of batteries namely the ones using other material than lead As everyone knows battery capacity 15 decreasing yearly and after a few years it almost remains only 25 of the original characteristics During normal discharge of the battery one can observe that oxides lead sulphate crystals and water emerge Usually those components are recovering their original stage 1 e lead and sulphuric acid once the battery is charged again From the very first battery charge lead sulphate crystal are emerging slowly and growing constantly Those crystals are the main cause of the battery failure All active agents within the battery are then solid and the electrochemical reaction can not work properly thus reducing the electricity generation During charging process battery
52. th no default If not this could be life threatening as high voltage 1s provided If any doubt on cable integrity replace those by new ones Before connecting units to the BRT make sure the regenerator is not plugged in Screen display should show no indication Following sub units shall be connected as follows e Connect the battery first e Then the temperature gauge shall be connected At last the cable is connected to the main PSU Do not start up the BRT if the red and blue cables are not connected to the battery Do not connect battery cables to the regenerator unless they are already connected to the battery Mo BRT 20 3 8 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Air vents on the side of the BRT shall never be covered Unplug the battery cables from the regenerator s side first before switching to another device or disconnecting the cables from the battery To disconnect the batteries remove the connecting plug on the regenerator 2 5 Chose vour language and select the alternate current frequenc Once connected wait few seconds gt before the main screen appears In the parameters menu you have access to Total running time of the BRT Change the language of the menu Ttek Set the alternating current 50 60 Hz pres e Update the software with via USB port Parameters
53. ting up manually parameters reduce length of pulsation increase the pause lap To keep temperature cool air vent or cooling system shall be implemented When a temperature failure occurs a temp gauge will be displayed on the screen Caution Exceeding temperature may cause severe damages to the battery that may destroy it It is important to check as follows that the temperature gauge is working well Once operator notice there is a rotten egg smell in the workshop it means temperature reach 60 C At this stage battery produces Sulphuric hydrogen H2S This gas is toxic and explodes 3 3 2 High voltage High voltage warning Warning signal with red flashing report Shows number of warning detected during the cycle in Ah process I 1 g ri Ex rl li je e oh i U 15 1 V Out 0 Total time elapsed 0 00 05 ae 5 Number of loops 3 Total time left 26 59 55 Lenght of pulse 130 ms pe ETES Lenght of pause 35 Phase time left 14 59 55 lime pulse charge 1h Loop time left 4 59 55 pulsa coUe rer Time for const charge 1 h r Total high T 0 00 00 Current first cycle 5 Phase Time 6 H Loop high T 0 00 00 ali Mo BRT 20 3 39 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 This w
54. to raise to rapidly Mo BRT 20 3 17 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Standard set up 200 ms pulse 3 s pause pulse pulse pulse During the regeneration process density is getting greater smoothly at the beginning and and increase dramatically when reaching the end of the process Indeed at the end of the process the remains of the lead chrystal sulphate are changed to their original active element status The BRT has safety device that will stop the process if some parameters are getting to high Paro Tension Cellule 2 50 2 40 235 Tension de GAZ 2 30 COURBE DE 2 20 2 10 2 00 1 90 Densit 1 80 numm CHARGE 2 3 p T di P ad 7 A oa Batterie SURCHARGEE A stop 7 D 3 7 F Batterie SULFATEE M jM d densit 1 30 1 28 1 20 1 10 Temp gt 45 C e Voltage gt 2 4V per cell Mo BRT 20 3 AVRIL 2010 18 Version 2 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 The operators knowhow will then consist of reaching the best sulphation dissolution 1e no chrystal remains e Monitoring and master
55. ulation so that the workshop shall be well organized He would have first to clean and identify with stickers all batteries Then he will measure tension and density of the electrolyte With trolleys and baring tables such operation will be faster and safety will be preserved Positioning on trolleys Connecting the batteries Regeneration in progress Caution the above procedure shall be followed in order to avoid short circuits in respect with operators safety All connectors shall be adapted 100A pliers lead connectors or jump lines in parallel must all have the same tension voltage The temperature gauge will be placed in the electrolyte of the weakest battery or in the centre cells of one of the batteries When connecting the batteries it is important Not mixing type of batteries truck and cars do not mix e For each battery type mix the lines to get an average capacity about the same per line Do not set up parallel lines with good and very weak batteries otherwise the treatment will benefit to the weakest one but not to the other Mo BRT 20 3 30 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 12 V starting batteries program iE Start battery Lorries 24h 90 Cars 2th 1505 Allow the operator to add a new 1 program for starting batteries Program list
56. ust go on the discharger before being regenerated on the BRT Stationary batteries with tubular plaques and liquid electrolyte will be treated the same way we do for traction batteries Report to previous chapter Stationary batteries sealed AGM shall be treated in series such as we do with the starting batteries in order to get a better profitability as those batteries may need high volumes for good ROI Those batteries are subject to tension memory so that it 1s requested to discharge the battery prior to any regeneration Then it is recommended to set up battery line which maximum voltage will suit the discharger analyzer used by the workshop Usually most discharger have cap at 96v The temperature gauge shall be placed between two batteries close to each other if they are gel or AGM Mo BRT 20 3 33 Version 2 AVRIL 2010 Prog V2 3 MIN 135 av Pierre SEMARD 84 000 AVIGNON cedex FRANCE Tel 33 0 4 90 87 00 07 Fax 33 0 4 90 81 08 05 Stationary batteries program se Stationary battery Monobloc 70 Ah Allow the operator to add new CE gt 70 program for stationary batteries Tubular 2300 Ah Program listing for starting batteries To ease the operator s task 2 programs are already set for strating batteries regeneration Press Ok and access to Press to go back to main menu the selected program process

Service manual BRT 20-3 de aout 2010

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