A visual operating guide for using the Dynapulse 248

1. BATTERY RECOVERY SYSTEMS Operating the Unit is easy! A Division of Power Products Inc. 1 (951) 392-2101

2. Common Causes of Battery Failure A common cause of battery failure is acid stratification. The electrolyte on a stratified battery concentrates on the top or the bottom of a battery cell, causing either half of the cell to become acid poor having low SG readings. Acid stratifies when operated with a low charge (below 80%) or by not receiving a complete or full charge, or with infrequent use of the battery. These high acid concentrations cause grid corrosion and promote quicker sulfation. This decreases conductivity even further. If left stratified, the battery will prematurely fail.

3. Acid stratification reduces the overall performance of a battery and induces sulfation to occur more rapidly. Regular conditioning and maintenance using the Dynapulse248™ will reverse the process ofsulfation and eliminate the acid stratification. This is a healthy battery with equally distributed acid levels at an 80% charge or higher. Regular maintenance with the Dynapulse248™ will keep your batteries healthy, operating at optimum capacities and able to reach their full cycles of life. Next is a stratified battery that has induced sulfation on the lower sections of the batteryplates. Forklift batteries stratify in the opposite manner. Even though open circuit voltage might read within range, it will not pass a load test. The capacity tests will show high resistance and low capacity. The CCA readings for auto and deep cycle batteries will also read very low. The Dynapulse248™restores batteries back to their service life fast, easy, and safely!

4. Introduction These instructions are for the commercial Dynapulse248™ battery recovery unit. Operation is easy when utilizing the 8 independent voltage settings built into the Dynapulse 248™. These independent voltage settings cover all common industrial batteries. More information about the history of this product line and its technology can be found at our Dynapulse™ division website, www.dynapulse-power.com.

5. The Dynapulse248™ uses the standard 12 gauge 3 wire (2 wire input plus ground) 115 volt or 230 volt 50/60 Hz and converts this to the selected appropriate DC voltages. Solid state devices are used, capable of generating sharp, very fast rising pulses. These pulses are controlled by Power Products’ US patent pending technology and circuitry, using the battery’s voltage and internal resistance as feedback information.

6. The selected automatic control allows the high input pulses to break-up crystallized sulfation which has formed on the lead plates of an “out of-service” or “Scrap” battery. This allows the battery to desulfate and accept a charge quickly and automatically without causing the damaging excessive heat and battery gassing produced by today’s conventional charging methods.

7. In most cases, and depending on the history of the battery, the high input pulses will restore and enhance battery performance to a like-new condition. The Dynapulse248™ has an automatic operation that requires the operator to select the battery rated voltage with the voltage selector switch, regardless of the batteries actual voltage prior to start-up of the Dynapulse™.

8. In cases of very heavy sulfation (Stage 3), where the battery is completely non-conductive and close to, or at zero volts across the terminals when measured before start-up, the breaking through the heavy sulfation may require several additional hours. To accelerate this, there is a manual override setting titled the ‘Power Boost’, which may be used as often as needed during the recovery process to break through the heavy sulfation. The sharpness of the pulse energy, the amplitude, the US Patent pending technology, the versatility and controllability of the system and its portability are only a few of the many features that set the Dynapulse 248™ above all of the other battery recovery methods available today.

9. The Dynapulse248™ dramatically increases the efficiency of your battery operated vehicles by reversing the process of sulfation. In addition to increasing the efficiency and productivity of your batteries, the Dynapulse248™ decreases the impact on our environment from the needless premature disposal of batteries throughout the world. Almost 100 million batteries are prematurely recycled each year in North America alone. An estimated 75% of those batteries are sent through the recycling process due to sulfation related issues. The Dynapulse248™ solves the issue of sulfation.

10. Safety Instructions Always wear protective hand, clothing and eyewear when working near motive batteries. Always have an eye cleaning station available. Hydrogen gas can be present, so always operate in a well ventilated area. Have baking soda and water available to absorb any of the electrolyte solution. Before you use your Dynapulse248™, be sure to read all instructions and cautions printed on the Dynapulse™, the battery, and the vehicle or unit using the battery. Use only attachments recommended or sold by Power Products, use of non-recommended attachments may result in fire, electric shock, or injury. All tools used in or around a battery should be insulated.

11. Do not service or repair battery connections on a charged battery or when the circuit is energized. Do not operate with a damaged cord or plug. Have cord replaced immediately. Do not disassemble the Dynapulse™. Contact the manufacturer for any repairs or inspections. Improper reassembly may result in electric shock or fire or void your warranty. Do not use an extension cord unless absolutely necessary and ensure that extension cord meets safety requirements. Ensure that the wire gauge is large enough for AC ampere rating. Locate Dynapulse™ as far away from battery as cables safely allow. Do not expose Dynapulse™ to rain or snow.

12. Never charge a frozen battery. If battery fluid (electrolyte) is frozen, bring it into a warm area and allow complete thawing before charging. Do not allow alligator clamps to touch each other when Dynapulse™ is on. Remove all personal metal items (necklaces, rings, watches, bracelets etc.) when working with lead-acid batteries. Batteries can produce a short circuit current high enough to weld a ring (or similar) to metal, causing a severe burn. Take precaution to not drop a metal tool or other metal onto the battery. Metal may cause sparking or short circuit the battery or other electrical devices. Never smoke or allow a spark or flame in the vicinity of the battery or engine.

13. Pre- Operation Batteries and electrical equipment can be hazardous. Therefore the operator of the Dynapulse248™ should have knowledge of the potential hazards and heed all safety instructions. He/She should also have a working knowledge of how to handle, charge, and test motive batteries using conventional battery chargers and load testers. If the operator is not experienced with conventional means, he/she should gain this experience before operating the Dynapulse 248™. Review safety instructions in the beginning of this instructional presentation.

14. Note: Set voltmeter scale switch to low to view 2-12 volt range.Set voltmeter scale switch to high to view 24, 36 and 48 volts.

15. The following chart is the end charging voltage limits as automatically set by the Dynapulse248™. The actual voltages are within these safe “non-high gassing” limits set by agencies such as Battery Council, Society of Automotive Engineers, and the United States Military. Setting Reading 2V 2.5V 4V 5V 6V 7.5V 8V 10V 12V 15V 24V 30V 36V 45V 48V 60V

16. The Dynapulse™ unit is used to allow sulfated lead acid batteries which will not accept normal recharging with a conventional charger to again accept a conventional charge. After the battery is subjected to the very high impact pulsing of the Dynapulse™, the Dynapulse™ has accurate analog meters that will indicate that the battery is accepting a normal charge. This is seen on the DC ammeter, which should read a maximum of 30 amperes (if the battery is discharged). The battery can then be disconnected from the Dynapulse™ and connected to a conventional charger, or it can remain connected to the Dynapulse™ until completion of charge and readiness for service, or both can be hooked up together at the same time.

17. Use the Dynapulse 248™ alone or at the same time with your conventional chargers (Picture is blurred on purpose)

18. Pre-Operation KEEP LID OPEN WHILE THE UNIT IS IN OPERATION

19. A. Check the nameplate or other printed voltage rating of the battery you are servicing. Set the Dynapulse “Volt Set” selector switch to the battery rating.

20. B. Make sure AC toggle switch is ‘OFF’

21. C. ‘Set the amp adjustment fully counter-clockwise, which is zero amps output before the unit is put into operation.

22. D. Voltmeter scale to ‘Low’ for 2-12 V batteries, ‘High’ for 24-48 volt batteries

23. Properly setting the operation time is a very important safety feature. A battery which is sulfated and has a defective cell, from positive grid corrosion or a short in the cell may draw current and overheat. Setting the timer will limit the operating time and prevent excess venting and overheating of the damaged cell. The cell should be changed out before continuing the recovery process.

24. Setting the timer

25. CONNECTING THE BATTERY A. Red clamp to (+) positive, black clamp to (-) negative, or use an appropriate battery connector adapter such as shown in the next slide.

26. Battery Adapter Connector

27. B. Observe voltmeter for battery’s open circuit voltage (OCV). Low OCV signals a highly sulfated battery or possible cell damage

28. Ready to Start the Dynapulse248™ Operation A. Flip AC toggle switch to ‘ON’ position

29. B. Press ‘Start’ button

30. C. Adjust charge amperes knob CW (clockwise) toward MAX DC amps. Keep AC within your input line amp limit (AC breaker line for receptacle).

31. D. If Battery accepts little or no DC amps, set ‘Power Boost’ to desired setting. Repeat until substantial DC amps are maintained without the help of the “Power Booster” or “Cell Booster”

32. E. Dynapulse may be used to complete the charging and desulfation all by itself, or after max amps are maintained without power boost, and battery is finally desulfated, it may then be fully charged with a conventional charger.

33. F. The Dynapulse 248™ can be safely hooked up in simultaneous conjunction to a conventional forklift battery charger to accomplish desulfation and amp hour input back into the forklift battery at the same time. Dynapulse 248™ customers have claimed faster battery recovery times and results when using this method on batteries as part of their regular battery maintenance programs. Use the alligator clamps for the Dynapulse 248™ and the battery cable connector going into the charger.

34. 1. Battery should be charged 100% 2. Take initial baseline voltage and SG readings 3. Hook up the Dynapulse248™ to battery and set timer for 3-4 hours. 4. Take voltage and SG readings 5. Allow battery to cool 6. Discharge battery to 80% (1.7 volts per cell) 7. Adjust acid as needed during recharge 8. Take final readings 9. Repeat as needed The General Recovery Process

35. The Battery on Dynapulse and Charger at the same time (Picture blurred on purpose)

36. Contact us today by calling: 951-392-2101 Dynapulse Factory Sales 415-883-6300 Power Products Factory Fax: 415-883-6302 E-mail: sales@dynapulse-products.com Visit our Web Site Download a data sheet Now you are ready to restore your batteries