BATTERY REGENERATION WORK PROCEDURE

As agreed, you will find here simple working procedures regarding battery regeneration.
However, let me point out the course that would be preferable according to your battery fleet:
Treatment of the park by circular permutation of the 48 volts batteries: that means that I
have to dismount a set of batteries, in order to regenerate it, and put back together one that
has already been regenerated, all in the same gesture!
A treatment with 48v will be set up at first in order to make things easy:
o Two parallel lines for 48v sealed batteries
o One 48v line for cell batteries
Eventually, the treatment will be done on 96v according to the same principle, allowing you
to double your yield.

1. Approach through the manufacturers information :

This approach allows to validate the real capabilities of a battery according to the data provided
by the battery manufacturer.
Removing the pack from floating charge
Discharge in C3 using the corresponding amperage that was given by the manufacturer,
with end voltage of 1.8v per cell. This discharge will allow you to measure the initial state
of the battery capacities.
Output of the discharge curve on the PC.
Launch a second discharge in C10, with end voltage of 1.7v per cell. This second phase
aims at breaking the voltage memory of batteries that are subject to floating.
Launch battery regeneration in automatic mode. According to the behavior of the
batteries, you will have to adjust the settings and set up your own programs. For
instance, if the loops cannot be completed, because the BRT stops (high tension), you
may have to lower the initial constant charge values.
Launch a final discharge in C3, using the corresponding amperage that was given by the
manufacturer, with end voltage of 1.8v per cell.
Caution! The manufacturers capacity data is reached when the battery was used merely a few times
following its manufacture. After that, battery capabilities naturally degrade. You should be able to
restore 80% of the initial capacity. See the spreadsheet attached: it includes these calculations.
2. Specific approach
This approach allows getting closer to the real usage conditions of a battery during backup
installation.
A specific, thorough analysis of your set-ups needs to be done beforehand.
Indeed, according to the fact that new equipments were added on site without modifying the
installations, the true capabilities are underestimated.

This diagnosis should cover :

The actual amperage needs for each installation during peak time (caution : this
amperage will be produced on 2 parallel lines concerning 120v sealed batteries). This
value shall be named Is .
The exact cutoff value of the regulator (1.80/1.85/1.80v per cell). This value shall be
named U stop .
The real needs in emergency backup time (2, 3 or 4h). This value shall be named Ts .
The definition of a security allowance (either in terms of consumption, or in terms of
duration, but never both at the same time!). Beware: the impact of the increase in
consumption is higher than the one concerning duration (logarithmic ratio see
Peukerts law). Concerning the consumption during peak time, you should check whether
it sees itself in extended time or in peak time. If it sees itself in peak time, you will have
to check that the application of the peak amperage over 3 or 4 hours already constitutes
in itself a security allowance. We advise you to take either 10% on the amperage or 25%
on duration.
The qualification procedure then becomes :
o Removing the pack from the floating charge
o Initial discharge in ls , with end voltage of U stop per cell.
o Output of the discharge curve on the PC.
o Launch a second discharge in C10, with end voltage of 1.7v per cell. This second
discharge aims at breaking the voltage memory of batteries that are subject to
floating.
o Launch battery regeneration in automatic mode.
o Launch a final discharge using ls, with end voltage of U stop per cell. The
reached time will be compared to our security allowance Ts.
Following the calculations, you may notice that batteries are undersized. The regeneration
will simply allow you to get back the best capabilities possible, but not to increase the initial
capabilities of the battery.
Feel free to get in touch with me if you have any further questions.