BATTERY REJUVENATION PROCESS (E&F)

INTIAL STEPS TO FOLLOW

SCREENING TEST:-

Step1:-

1. First check for the physical damage of battery i.e. bulging, leakage of acid, terminal connections and alo four
sides and bottom of battery for any physical damage. Check if any plate’s damage and its colour.

2. If any of above defects found in physical test battery will be rejected. If not move to the step 2

Step2:- After physical test we want check some electrical parameters like

i) OCV ii) IR iii) CCA iv) LCV & v) Gravity

OCV= Open circuit voltage

IR = Internal Resistance

LCV = Load Circuit Voltage

CCA= Cold Cranking Ampere

i) Use Battery Analyzer for checking OCV, IR&CCA of battery.

ii) Electrolyte colour, D.M water level also should be as per our parameters, I.e colour of electrolyte should be
transparent and D.M water level should be above to conducting plates.

iii) Load test:- Battery must have capable to take load, when we apply load by using load tester. These is for
knowing LCV of battery.

Battery Analyzer Working:-

The One important parameter we consider is “IR” for all batteries .CCA is for
automotive batteries which should be high.

i) After physical test ,connect battery analyzer to battery terminals.(Red +ve terminal & Black -ve
terminal)
ii) Then analyzer is ON, It shows OCV, IR, & CCA.

Note:- OCV should be above 11.76V

IR should be <30mohms

iii) The battery is pass from above conditions we will go for Load test if battery will fail above test is
reject.

Note:- If battery analyzer not working after connecting battery terminals battery may be deep discharge ,Then
we want boost charge battery , after charging do same as above process then it passes test continue or not
rejected.

Load Test:- We have two types of Load testers

i) 100Ah Load tester(Automatic)

ii) 500Ah Carbon Pile Load Tester

100Ah Load Tester:- This Load tester used for (65Ah-<100Ah)

500Ah Load Tester:- This Load tester used for (0-500Ah)

Conditions for load tester pass: - By applying load on battery voltage should be 10v or above 10v i.e. LCV
How to apply Load:-

Step1:- Connect Load test terminals to battery terminals

Step2:- Before applying load first take “Clamp Ammeter” for measuring apply load in Amperes

Step3:- Then slowly rotate knob load tester load will varies observe smoke &bubbles in any cell of battery

[ If Smoke is coming for any of the cell battery goes reject &Bubbles in any one cell also battery reject 2 or more
battery ok for rejuvenation]

Gravity Test:- This is also an Important parameter in the screening test of battery (flooded batteries like
Inverters & Automotive ) Gravity level should be 1.120.(we will change gravity by adding acid).

i) Sometimes some batteries are dry then the battery should be hydrated by adding DM water
(DEMINERALIZED WATER) Its TDS is “6”.
ii) After hydration of battery wait for 2-3 hours for voltage build up ,then follow same as above process

Now battery passed above tests then we take battery for Diagnosis.

Diagnosis:- These is done by “X-CHARGER” Machine.

This machine will give battery internal conditions i.e. CFP, SOC & Sul.

CFP=Condition for process

SOC= State of Charging

Sul= Sulphating level

i) X-charger diagnosis only one battery at a time it’s take time minimum 15sec.
ii) X-charger will give position of battery rejuvenation process.

By finishing above process note down all parameters in “12v battery Initial check up sheet”

Backup test:- Here after diagnosis test we want check battery initial backup, Because after rejuvenation how
much backup is improved we will know.

Note:-

i) Before going to charge battery, it should be discharged first.

ii) If we do directly without discharging battery put 24 hours for charge battery it may be damaged r not
rejuvenated.

Charging and Adding Elixir:-

Charging:-

1. Now battery is passed screening test then go for charging battery by using X-charger in Resonance Mode,
these is first cycle of battery charging.

Note: - current calculations (I) Charging Time of battery (T)

I=AH/C-20
T=AH/A

AH= Rating of battery AH= Rating of battery

C-20= Charging rating of battery A= Current of battery

(Some batteries have C-10) (Here AH= battery Ah*20%+Battery Ah)

For boost charging current is = Battery AH*0.03 with 24hours.

X-Charger:-

i) X-charger is charge at a time 16nos 12V batteries

ii) 12V batteries connect only in series for proper charging
iii) Carful to connect batteries to X-Charger in proper way ,if not it damages machine. Charging should be
in Resonance Mode.

Conditions (Observations):-

i) After connecting X- charger observe any Smoke ,Bubble and Chit chat sound
ii) Smoke and bubbles will happen in any cell remove those batteries.
iii) Chit-chat sound occurring means terminals are not proper connected or cleaning not proper.so remove
connectors clean properly then start again the charging.
2. After two hours take readings of battery like voltage, charging current, gravity and temperature of each
cell.
3. These parameters are note down in every 2 hrs in sheet i.e. “In-process check sheet”
4. Temperature is varies based on area temperature voltage must be lesser than 22v.
5. If any abnormal condition observed stop machine solve it, if major problem disconnect those batteries.

Adding “Elixir Additives”:- Along with x-charger machine this liquid is second main component of Rejuvenation.

Elixir:- It is non-harmful liquid .It mainly used for reducing sulphation level of battery. It dissolves the crystal
formation of H2S04 into liquid form.

Advantages:-

i) Improves battery life

ii) Increases backup
iii) De-sulphation
iv) Reduces Temperature

In charging process after completing of 2 hours add Elixir in each cell of battery according to our “Solution Quantity
Table”

Note:-

i) Use Elixir judiciously because it’s cost high

ii) Don’t kept Elixir in outside environment @ high temperature as will effect liquid and crystallization
Initiates.
iii) After completion of 24hours charging keep batteries idle for decreasing its temperature.

De-sulphation:- These is checked by x-charger machine by doing diagnosis. It (removes) shows sulphation level.
Now it gets to due to added elixir.

Recovery of battery parameters:-Here check battery OCV, IR & CCA. After 24 hrs charging, those are changed ocv
increases, IR decreases, and CCA increases. Now also do load test same as screen test.

Performance after REJUVENATION:-

Battery backup check:-Here we have to discharge the battery for arriving at how much backup has improved.
That should be noted down in” Discharge format sheet”.

NOTE: - Now after all parameters & performance of battery has improved, we gain have to charge the battery.

Battery recharging: - Here same AMP & Time to charge battery to hand it to customers.

This is called final cycle.

NOTE:-Observe batteries & x-charger working during charging process.

Battery equalization:- Here we check battery previous & present data parameters tabulated. Voltage also
improved, it should be more than 12.8V. If not charge some more time, then puts ideal for reducing temperature
after 2nd cycle.
Final Quality Test:-These test same as screening test like OCV, IR & CCA and LOAD TEST.

When Battery passes this entire test go for finishing.

Battery finishing &cleaning:-

i) Clean battery alike a new one.

ii) Put vent plugs of battery and sealed it.
iii) If batteries are ups then remove D.M water from then de-hydrate and charge for 2-3 hours.
iv) Paint batteries and put the franchise logo or stickers.
v) Place a sticker for rejuvenation date, warranty time & its parameters.

Delivery batteries:-

i) Before giving batteries to customer take its complete data save in computer or in record tabulation.
ii) The data is useful for future Rejuvenation and if customer has done any improper maintenance on
battery , these data will be proof for us on the warranty of battery
iii) While handing batteries to customer convey them how much back up for how much load and warranty
of battery.

Note:-

i) Back up: Decide on how much Ah & load applied on battery as mentioned by E&F Back UP chart.
ii) For Automotive batteries no necessity to go for second cycle, after first cycle apply 3 times load its
capacity and hand it to customer.

Energy And Fire Tech India Pvt Ltd in collaboration with Battery Services International, L.L.C., USA uses
a very unique technology that brings great benefits to all sorts of lead acid batteries in the market. This
technology allows the recovery of the lost potential of any lead acid battery of any brand, make, and
application, and state-of-charge, level of sulfation, age, size, and price. Our technology for battery
improvement can do this in a very quick, safe, and effective manner following scientific method and
procedures regarding the maintenance, handling, recharging, and electrochemistry of lead acid
batteries. Our technology helps in:
a. Restoration of any lead acid battery at the end of its useful life

b. Recovery of almost full potential of batteries by de-sulfation

c. Routine maintenance to get optimum performance of batteries

d. Prevention of the loss of back up time of any lead acid battery

If you have a battery Bank that is made up of individual VRLA, AGM, Gel, or flooded batteries then you
can do a huge cost saving for your organization and be a valuable part in saving the environment by using
our Electro-Chemical Battery Enhancement Process (EBEP) to increase the serviceable life of all your
batteries. The objective of the EBEP process for your batteries is to sustain and prolong continuous
performance, secure reliability, extend life span, and maximize return on investment. The EBEP
rejuvenation process will bring back to life the so called dead batteries which are actually sulphated and
will also yield the following benefits:

a. It will enhance the useful life of your batteries by one year (minimum).

b. Guaranteed to cut expenditure in replacement batteries.

c. Will recover lost capacity or back up time.

d. Recover low internal resistance of each cell.

e. Reduces the amount of charge current required to keep them at full capacity.
f. Reduces the rate of water loss per cell.
g. Restores plate potentials and voltage.
h. Protects grid plate and paste from passivation due to hard sulphation & corrosion.

i. Recovers the soft porosity of sulphated plates.

j. Reduces the risk of thermal runaway.

k. Helps the environment by extending battery life.

Procedure:-

Our power recovery technology for secondary batteries is based on an ELECTRO-CHEMICAL procedure
that we call the Genesis Battery Power Recovery Process. This methodology was designed to follow strict
scientific principles of electrochemistry of lead acid batteries. The overall purpose of the methodology is
to recover the lost potentials of any lead acid battery in any state of health, including those considered
to be scrap , or spent, and out of service in any state of charge. Batteries can be flooded or sealed,
AGM, GEL and VRLA of any brand, size, voltage, amperage and any manufacturing age. The main
characteristic required for success is that the batteries should be mechanically intact inside.

We use EBEP (Electrochemical battery enhancement process) technology, power plus additive / XTR
additive which are imported from USA , to sustain healthy, soft , moisture and porous lead sulphate
(Pbso4) particles. X-charger rejuvenates these batteries over a process time of 12-18 hours by charging
them with patented wave-form current.

This Genesis method includes the following steps:-

Screening:- This step is for identifying batteries not good for reconditioning covers visual checkup and
health checkup of batteries.

Hydration: - Hydration refers to pour distilled water into batteries and ensure plates not in dry
condition.

Regen Diagnostic: - This step is done to conduct various tests to access the battery condition for
rejuvenation. This diagnose test does various level of tests which helps in identifying these batteries as
qualified or not for rejuvenation even after they have passed in screening test

Recovery and Charging: - This function is designed to de-sulphate and recover the lost capacity of all
types of lead acid batteries. The combination of charger and solution restores five potency in the battery
and make it healthy. These potency are - Voltage, Internal Resistance, Capacity, SOC and CCA.
 Final Quality Control Test: - This step is done to conduct various test to check technical parameters,
required for battery at final stage before the battery is put to service use and ensures that the battery is
capable to give the service life on its application.

Thus, because of the EBEP one can gain a great benefit from not spending unnecessary Money on battery
replacements. This environment friendly process will extend the useful life of any new, weak or
discarded UPS bank battery at a fraction of the cost of new batteries.

Our re-energizing process starts with selecting batteries which still have sound plates (ageing of 1 yr to 6
yrs) and removing the excess sulphation. Energy and Firetech technology dissolves the hard crystallized
sulphate from the plates and returns it into the electrolyte thus re-establishing the normal battery
voltage and amperage. The Energy and Firetech Re-energizing station activates the Energy and Firetech
solution to recondition the plates and then recharges the batteries to finish the process

Main Causes of Battery Failures and Hazards to environment

Aging, Incorrect charging, Poor maintenance, Excess heat, over charging are causes. Did you know 80% of
Lead acid batteries die prematurely due to sulphation, which we can treat and revive. Rejuvenate your
old batteries, save environment, save cost. We need to rejuvenate batteries because when they are
disposed off the harmful substances present in the batteries permeate into the soil, groundwater and
surface water through landfills and also release toxins into the air when they are burnt in municipal
waste combustors. In addition smelting lead, disposing plastic waste and Landfills also generate methane
gas leading to the ‘greenhouse effect’ and global climatic changes.
Through our rejuvenation technology we enhance the battery life and delay the scraping which helps the
environment.