REPLUS Battery regenerator

Operating manual

ENVIRONMENTAL CONDITIONS
Operation Condition Indoor use only
Temperature Min 0°C to max 45°C
Humidity 20% to 85% RH
Altitude 0 to 6,562 ft. (2000 m) above sea level installation
Category III and pollution degree 2

This device may cause harmonic disturbance.

Design and specifications of products may change without notice for the improvement of function and quality.
The pictures in this manual may look different from the actual colour depending on the light and monitor settings.

IN CHARGE OF YOUR BATTERIES

www.energicplus.com
CONTENTS • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Safety manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Installation and environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4. REPLUS operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5. Battery management system option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6. PC Integrated monitoring program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7. Checkout and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8. Drawings/Data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9. Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

© December 2018. Energic Plus is a trademark of TVH Group NV, Brabantstraat 15, B-8790 Waregem. Photographs and illustrations are included for reference purposes only.

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1. INTRODUCTION • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
GENERAL

The greater the age of a battery, the more the capacity of the lead-acid battery decreases through a repeated charge and
discharge cycle. This is primarily caused by formation of crystallized lead sulphate and deactivation during the discharge
cycle. This may result in an increase in internal resistance, a decrease in sulphate gravity and a decline in battery life. REPLUS is
a battery regenerator that increases battery capacity and life span by dissolving and activating lead sulphate using electrical
methods, not chemical or battery dissolution methods.

The Energic Plus REPLUS battery regenerator is classified into several models according to the purpose and capacity of the
battery and REPLUS has models for capacities up to 3500 Ah.

The REPLUS has the advantage of being able to restore several batteries simultaneously. Using the REPLUS results in
minimum cost for maintenance management and efficient battery management.

Model Setting max voltage Setting max ampere

MCS M-1001I 100 V 30 A
MCS M-1005G 120 V 50 A
MCS M-1007F 125 V 100 A
MCS M-1009A 75 V 350 A

! In case you need technical support please make a picture of the technical label on the replus, write a short discription of
the problem and send it to: support@energicplus.com.

CHARACTERISTICS AND SPECIFICATIONS

Characteristics

• High Power Control Technology

• Charging of high-efficiency IUI (constant ampere, constant voltage, constant current).
• Discharging with Smart control ampere and inverter technology.
• All-in-one system with discharger and discharging feature.
• Rapid restoration time and efficient restoration capacity.
• Digital Control
• 6-program mode support according to the deterioration of battery.
• Reliable and easy checking of battery condition using Graphic UI.
• Accumulation of driving data and easy software upgrade by means of an SD card.
• Adapted for 8-inch LCD and touch screen.
• Built-in record-issuing feature.
• Simultaneous restoration of several large lead-acid batteries
• The number of batteries to be connected depends on the REPLUS model and battery capacity. Contact the agency
before use.
• When selecting a BMS device, the charge/discharge condition can be checked per battery (cell). (BMS: Battery
Monitoring System)
• IT Technology Fusion
• Using the integrated receiver and integrated monitoring program enables the REPLUS operation and data condition to
be checked using an office PC.
• A wireless environment with the application of Bluetooth and Zigbee communication.
• Certification
• TUV CE-certificate
• UL

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REPLUS Specifications

Model M-1001I
Input power AC 1P2W + PE 220 V
50/60 Hz , 35 A Max
Output DC 1.2 V ~ 100 V, 0~30 A
Battery capacity 300 Ah
Transformer 7.5 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13”.
Certification CE / UL

Model M-1005G
Input power AC 3P3W + PE 380/400 V~
50/60 Hz , 20 A Max
Output DC 1.2 V ~ 120V, 0~50 A
Battery capacity 500 Ah
Transformer 10 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13“.
Certification CE

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 Model M-1007F
Input power AC 3P3W + PE 380/400 V~
50/60 Hz , 35 A Max
Output DC 1.2V ~ 125V, 0~100A
Battery capacity 1,000 Ah
Transformer 20 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13”.
Certification CE / UL

Model M-1009A
Input power AC 3P3W + PE 380/400 V~
50/60 Hz , 125 A Max
Output DC 1.2 V ~ 75 V, 0~350 A
Battery capacity 3,500 Ah
Transformer 70 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13”.
Certification CE

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 REPLUS DRAWINGS

REPLUS Model external features

Digital monitor Emergency switch

Antenna
with touch screen
SD card &
Power LED
serial port

Key switch

Input AC 3-ph Output DC

Ventilation
circuit breaker circuit breaker

Temp sensor

REPLUS function description

SD card Serial port Antenna Display Input Output Temp Vent

monitor AC 3-PH DC Circuit sensor
breaker
Memory & PC cable PC BT Setup Input power DC output Battery Internal
upgrade connection communication control supply battery temp cooling
connection sensor

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2. SAFETY MANUAL • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
IMPORTANT SAFETY INSTRUCTIONS

1. Save these instructions:

This manual contains important safety and operating instructions for REPLUS battery charger models.
Exception: if the instructions are exactly the same for all models, specific model numbers are not required to be specified.

2. Do not expose charger to rain or snow.

Exception: a battery charger complying with the outdoor enclosure requirements of 7.8 and a cart-type battery charger
that complies with the requirements for corrosion-protection in 10.4 – 10.7 and the outdoor enclosure requirements of 7.8,
doesn’t need to include this instruction.

3. Use of an attachment not recommended or sold by the battery charger manufacturer, may result in a risk of fire, electric
shock or injury to persons.

4. To reduce the risk of damage to the electric plug and cord, disconnect the charger by pulling the plug rather than the cord.

5. An extension cord should not be used unless absolutely necessary. Use of an improper extension cord could result in a risk
of fire and electric shock. If an extension cord must be used, make sure:
a) That pins on plug of extension cord are the same number, size and shape as those of plug on charger;
b) That the extension cord is properly wired and in good electrical condition; and
c) That the wire size is large enough for AC current rating of charger as specified in Table 52.1. Exception: The portion of
the chart not applicable to a specific charger may be omitted.

6. Do not operate a charger with a damaged cord or plug – replace the cord or plug immediately.

7. Do not operate a charger that has received a sharp blow, been dropped or otherwise damaged in any way; take it to a
qualified serviceman.

8. Do not disassemble the charger; take it to a qualified serviceman when service or repair is required. Incorrect reassembly
may result in a risk of electric shock or fire.

9. To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. Turning off
controls will not reduce this risk.

10. WARNING – RISK OF EXPLOSIVE GASES.

a) WORKING IN VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES GENERATE EXPLOSIVE GASES DURING
NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT YOU FOLLOW THE
INSTRUCTIONS EACH TIME YOU USE THE CHARGER.
b) To reduce the risk of battery explosion, follow these instructions and those published by the battery manufacturer
and manufacturer of any equipment you intend to use in vicinity of the battery. Review cautionary markings on these
products and on the motor.

11. PERSONAL PRECAUTIONS

a) Consider having someone sufficiently close by to come to your aid when you work near a lead-acid battery.
b) Have plenty of fresh water and soap nearby in case battery acid comes in contact with skin, clothing or eyes.
c) Wear complete eye protection and clothing protection. Avoid touching eyes while working near batteries.
d) If battery acid comes in contact with skin or clothing, wash immediately with soap and water. If acid enters eyes,
immediately flood eyes with running cold water for at least 10 minutes and get medical attention immediately.
e) NEVER smoke or allow a spark or flame in the vicinity of the battery or motor.
f ) Prevent metal tools from dropping onto a battery. This may cause a spark or short circuit the battery or other electrical
parts and cause an explosion.
g) Remove personal metal items such as rings, bracelets, necklaces and watches when working with a lead-acid battery.
A lead-acid battery can produce a short-circuit current high enough to weld a ring or the like to metal, causing a
severe burn.
h) Use the charger for charging a LEAD-ACID battery only. It is not intended to supply power to a low voltage electrical
system other than in a starter motor application. Do not use the battery charger for charging dry-cell batteries
that are commonly used with home appliances. These batteries may burst and cause injury to persons and damage to
property.

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 i) NEVER charge a frozen battery.

12. PREPARING TO CHARGE

a) If necessary to remove battery from the vehicle to charge, always remove grounded terminal from battery first. Make
sure all accessories in the vehicle are switched off, so as not to cause an arc.
b) Be sure that area around battery is well-ventilated while battery is being charged.
c) Clean battery terminals. Be careful to keep corrosion from coming into contact with eyes.
d) Add distilled water to each cell until battery acid reaches level specified by battery manufacturer. Do not overfill
For a battery without removable cell caps, such as valve-regulated lead-acid batteries, carefully follow manufacturer’s
recharging instructions.
e) Study all battery manufacturer’s specific precautions while charging, as well as the recommended rates of charge.
f ) Determine voltage of the battery by referring to truck owner’s manual and make sure that output voltage selector
switch is set to the correct voltage. If charger has adjustable charge rate, charge battery initially at lowest rate.
Exception: For a charger that doesn’t have an output voltage selector switch, determine voltage of battery by referring
to truck owner’s manual and make sure it matches output rating of battery charger.

13. CHARGER LOCATION

a) Locate charger as far away from battery as DC cables permit.
b) Never place charger directly above battery being charged; gases from battery will corrode and damage charger.
c) Never allow battery acid to drip onto charger when reading electrolyte specific gravity or filling battery.
d) Do not operate charger in a closed-in area or restrict ventilation in any way.
e) Do not place a battery on top of charger.

14. DC CONNECTION PRECAUTIONS

a) Connect and disconnect DC output clips only after setting any charger switches to “off” position and removing AC
cord from electrical outlet. Never allow clips to touch each other.
b) Attach clips to battery and chassis as indicated in 15(e), 15(f ) and 16(b) through 16(d).

15. FOLLOW THESE STEPS WHEN BATTERY IS INSTALLED IN VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR THE BATTERY:
a) Position AC and DC cords to reduce risk of damage by hood, door or moving engine parts.
b) Stay clear of fan blades, belts, pulleys and other parts that can cause injury to persons.
c) Check polarity of battery terminals. POSITIVE (POS, P, +) battery terminal usually has larger diameter than NEGATIVE
(NEG, N,–) terminal.
d) Determine which terminal of battery is grounded (connected) to the chassis. If negative terminal is grounded to
chassis (as in most vehicles), see (e). If positive terminal is grounded to the chassis, see (f ).
e) For negative-grounded vehicle, connect POSITIVE (RED) clip from battery charger to POSITIVE (POS, P, +) ungrounded
terminal of battery. Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery. Do not
connect clip to carburetor, fuel lines or sheet-metal body parts. Connect to a heavy gauge metal part of the frame or
engine block. f ) For positive-grounded vehicle, connect NEGATIVE (BLACK) clip from battery charger to NEGATIVE
(NEG, N, –) ungrounded terminal of battery. Connect POSITIVE (RED) clip to vehicle chassis or engine block away from
battery. Do not connect clip to carburetor, fuel lines or sheet metal body parts. Connect to a heavy gauge metal part
of the frame or engine block.
g) When disconnecting charger, turn switches to off, disconnect AC cord, remove clip from vehicle chassis and then
remove clip from battery terminal.
h) See operating instructions for length of charge information.
Exception: the instruction manual for a battery charger, marked in accordance with exception n° 2 to 49.3 and
constructed to prevent current flow in excess of 0.1 ampere until the battery is connected (with correct polarity)
followed by the activation of a manually-operated control, is not required to include the following statements located
in 52.4 items: 15(e), “ Connect NEGATIVE (BLACK) clip to vehicle chassis or engine block away from battery.” , “Connect
to a heavy gauge metal part of the frame or engine block.” ; 15(f ), “Connect POSITIVE (RED) clip to vehicle chassis
or engine block away from battery.” , “Connect to a heavy gauge metal part of the frame or engine block.” ; and 15(g), “
...remove clip from vehicle chassis...”

16. FOLLOW THESE STEPS WHEN BATTERY IS OUTSIDE THE VEHICLE. A SPARK NEAR THE BATTERY MAY CAUSE BATTERY
EXPLOSION. TO REDUCE RISK OF A SPARK NEAR THE BATTERY:
a) Check polarity of battery terminals. POSITIVE (POS, P, +) battery terminal usually has a larger diameter than NEGATIVE
(NEG, N, –) terminal.
b) Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N, –) battery terminal.
c) Connect POSITIVE (RED) charger clip to POSITIVE (POS, P, +) terminal of battery.
d) Position yourself and free end of cable as far away from battery as possible – then connect NEGATIVE (BLACK) charger

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 clip to free end of cable.
e) Do not face battery when making final connection.
f ) When disconnecting charger, always do so in reverse sequence of connecting procedure and break first connection
while as far away from battery as practical.
g) A marine (boat) battery must be removed and charged on shore. Charging it on board requires equipment specially
designed for marine use.
Exception: the instruction manual for a battery charger, marked in accordance with exception n° 2 to 49.3 and
constructed to prevent current flow in excess of 0.1 ampere until the battery is connected (with correct polarity)
followed by the activation of a manually-operated control, is not required to have the following statements contained
in 52.4 items: 16(b),” Attach at least a 24-inch-long 6-gauge (AWG) insulated battery cable to NEGATIVE (NEG, N,–)
battery terminal.” ; 16(d), “Position yourself and free end of cable as far away from battery as possible – then connect
NEGATIVE (BLACK) charger clip to free end of cable.” ; and 16(f ),” ... and break first connection while as far away from
battery as practical.”

Never disassemble the product without reason. Unless otherwise specified in the manual, never disassemble, modify
or repair the product on your own. Risk of accidents such as electric shock and abnormal operation may cause
charged A/S. Damage to the sticker of the equipment housing may negatively impact A/S and is not covered by
warranty.

Use the product only for intended purposes.

Avoid use in high temperatures or in dusty and damp environments.

Avoid use outdoors in a site that is subject to direct sunlight.

Avoid damage to the product including scratches or impacts.

Make sure that the connector follows all applicable local and safety rules.

Shut off all power before moving the equipment.

Connect only lead-acid batteries to this device.

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DEFINITION OF DANGER, WARNING AND CAUTION

Before using the REPLUS, it is necessary to read and understand the following completely. We assume no
responsibility for any damage caused by mishandling that is beyond normal usage defined in these manuals. Always
carefully read and understand this manual before using this system to ensure safety.

This symbol indicates an imminent hazardous situation that, if not avoided, will result in death or serious injury.

This symbol indicates information that, if neglected, could possibly result in serious personal injury or even death due to
incorrect handling.

This symbol indicates information that, if not avoided, could result in minor or moderate injury or property damage.

1. Always use a power source with the specified power and voltage. Check electrical wires for normal conditions before
connecting the power to the equipment. Always use the power specified.
2. Make sure to ground the equipment as instructed in this manual before using.
3. Always ensure that no power is present before connecting an electrical connector.
4. The REPLUS produces a very high voltage. To protect against shock, always shut off all power and wear personal protective
equipment before service or maintenance of the equipment.
5. Do not reach inside the REPLUS while the equipment is operating or the power is on. Avoid using flammable materials, gas,
etc., in the vicinity of this device.
6. Battery acid is very corrosive and will cause severe burns. Never drink the electrolyte.
7. Install the equipment in a well-ventilated area.
8. Avoid impacts to the battery while charging and discharging.

1. The high voltage of the REPLUS can be deadly. The REPLUS can cause injury or death. Never reach inside the REPLUS while
the power is connected.
2. Always wear appropriate, intact eye and body protection. Always wear safety gear and check for damage daily.
3. Do not modify or disassemble this REPLUS without reason. Abnormal operation due to random modifications may cause
severe bodily injury or fatal damage to the equipment.
4. The REPLUS generates a high voltage. Always shut off all power before maintenance of the REPLUS.
5. Keep the cooler outlet of the REPLUS more than 20 cm from the wall or other appliances. Failure to do so may cause
decreased cooling capacity and damage to the equipment.

1. Install the REPLUS on a level surface. Apply the brakes on the castor wheels.
2. Voltage that is either too high or too low may cause mis-operation or malfunctioning of the REPLUS.
3. When using the regenerator, use the specified voltage and current according to the battery capacity to charge and
discharge the batteries.
4. Keep the equipment clean. Dirt and/or dust can adversely effect cooling capacity and cause deterioration.
5. Do not restore or discharge a frozen battery.
6. Restoration or charging must be done in a well-ventilated area.
7. It is possible that the machine can cause harmonic disturbance

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REPLUS SAFETY SWITCH AND USAGE

1. Key switch: used to turn the REPLUS on/off

2. Emergency switch: emergency stop button if an emergency occurs during REPLUS operation. (If the emergency button is
pressed, the system power turns off. Refer to page 18.)
3. Circuit breaker: used to turn off the main power of the REPLUS. (Used in emergencies and also available during
misoperation of the emergency switch).
4. Output breaker: DC output breaker (DC breakers between the REPLUS and the battery, automatic cut-off when the standard
current is exceeded or manual cut-off ).
5. Input breaker: AC input breaker (all power cut off to the housing)

CAUTION: When moving the REPLUS, turn OFF the power breaker in advance (5)

N° Name Function Result Operating method

1 Key switch REPLUS ON/OFF Magnetic power cut-off Key ON/OFF
2 Emergency switch System power cut-off in case of Magnetic power cut-off Button ON/OFF
an emergency
3 Main switch REPLUS ON/OFF Magnetic power cut-off Switch ON/OFF
4 DC breaker DC output cut-off Power cut-off between REPLUS Switch ON/OFF
and BATT
5 Input breaker AC input cut-off All power cut off to the Switch ON/OFF
housing

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Safety switch and dimension drawings

1 2 3 4 5 6
Key switch Emergency switch LED lamp Circuit breaker DC circuit breaker AC circuit breaker
Height 1120 mm 1220 mm 1150 mm 880 mm 150 mm 150 mm
Description MCS ON/OFF Emergency shut Power ON/OFF Main power down Output disable Input disable
down indicator

SAFETY LABEL AND DESCRIPTION

Safety label and replacement of memory battery

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REPLUS EMERGENCY STOP

When to operate the emergency stop switch?

If any problem occurs in the cable, battery etc. related to the REPLUS operation or REPLUS, press the emergency stop button
to stop the equipment. Set the key switch and circuit breaker to OFF and then the main circuit breaker to OFF.

• Increased volt and ampere exceeding the REPLUS setting

• Damage, smoke or sparking occurring in the input/output cable sheath
• Rapid increase in temperature at input/output cable and jumper cable
• Key switch failed to switch to OFF
• REPLUS monitor touch screen failed to operate
• Burning smell, smoke or sparking visible in the REPLUS
• Rapid increase in temperature or sparking at the battery
• Broken or deformed battery
• As determined by the individual

Emergency stop procedures

1 2 3 4
Emergency stop Key switch OFF Circuit breaker Main circuit
button OFF OFF breaker OFF

M-1007F EMERGENCY STOP

How to reset the REPLUS after emergency stop?

• In case of an emergency, contact the supplier or manufacturer for any questions or required actions.
• Find and resolve the probable cause of emergency (replace the cable, repair the battery, etc.)
• If A/S is required due to inoperable REPLUS, always contact the supplier or manufacturer (the equipment generates a high
voltage, so it is very dangerous to disassemble and modify yourself. Self-repair will void the warranty.)
1. Set the emergency switch to ON.
2. Set the circuit breaker to ON.
3. Set the main circuit breaker to ON.
4. Set the key switch to ON.
5. Check the setting of the REPLUS monitor.

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 6. Restart the REPLUS according to the desired purpose.
7. Check if it starts according to the default setting.

REPLUS reset procedures after emergency stop

1 2 3 4
Emergency stop Circuit breaker ON Main circuit Key switch ON
switch ON breaker ON

REPLUS EMERGENCY STOP

How to operate the emergency switch?

1. To activate the emergency switch, press the RED button at the top right of the device. This button remains as set before
re-operation.

2. Resolve the situation that caused the use of the emergency switch.
3. To reset the emergency switch, turn it CW to return it to its original position. The system then restarts.

PRECAUTIONS DURING BATTERY RESTORATION

• Do not restore and discharge a battery if it is frozen or if there is any problem, including cracks or damage, in the exterior
of the battery.
• Wear protective goggles: batteries generate an explosive gas, as a result of which there is a risk of explosion. Always wear
protective goggles or a face shield when handling this product.
• Fire prevention: heating the battery or using it near open flames may cause an explosion. Always keep sparks, flames,
burning cigarettes and other sources of ignition away from the handling area.
• Sulphuric acid prevention: batteries contain very corrosive sulphuric acid. This can cause severe burns or loss of eyesight
if it comes into contact with eyes, skin, etc. Always wear protective goggles and rubber gloves to avoid and prevent these
dangers.
• Keep children away from work area: lack of familiarity with battery handling and the risks involved may cause severe burns
or loss of eyesight in case of an explosion or when sulphuric acid comes into contact with eyes or skin. Keep children away
from work area. Children must never touch the battery or be involved in the handling of the battery.
• Keep vinyl or objects that produce static electricity away from the battery. Batteries generate hydrogen gas that becomes
explosive in certain concentrations in the air. Do not use vinyl or metal as a battery cover. This may cause sparking or short
circuits due to heating or an explosion due to static electricity.
• Always use the battery as specified in this manual. If specifications are exceeded, it may cause damage or an explosion to
the battery or leakage of sulphuric acid, resulting in damage to the REPLUS or bodily harm such as severe burns or loss of
eyesight.
• Do not use the battery in a wet environment. Moisture may cause damage to the battery or fire due to electrical short
circuits.
• Avoid impacts to the battery; the battery must remain upright. Failure to do so may result in severe problems due to

14
 leakage of electrolyte.
• When charging or discharging the battery, care must be taken to prevent missing clamps, battery short circuits, shortage
of electrolyte, etc. Failure to do so may result in an explosion.
• Immediate action during restoration of battery: accidents involving electrolyte may cause severe injury. In case of
electrolyte in the eyes, flush thoroughly with clean water and seek professional medical attention immediately. In case of
electrolyte in the mouth, gargle and rinse mouth several times. If swallowed, drink plenty of water and seek professional
medical attention immediately. In case of contact with skin or clothes, rinse with plenty of water and if any symptoms or
signs are present on the skin, including burns, seek professional medical attention immediately.

While restoring and charging the battery, care must be taken to prevent sulphuric acid gas from entering the
ventilator.
Always be familiar with the precautions during battery restoration to prevent any accidents from occurring.

CLASSIFICATION BETWEEN GREEN AND RED AREAS

Green area Red area

• In case of contact with diluted sulphuric acid, rinse affected limb under running water and seek professional medical
attention immediately.
• During the restoration of a BATTERY, it may generate harmful gases. A ventilation system should always be installed to
provide an adequate amount of fresh air.
• Keep away from the red area during work if possible. When entering the red area, always wear proper protective gear and
equipment.
• Remaining in the red area for long periods may cause dizziness, nausea and vomiting. In this case, find fresh air
immediately and seek professional medical attention right away.

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3. INSTALLATION AND ENVIRONMENT • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
GENERAL REQUIREMENTS FOR SAFE INSTALLATION

• Installation site must meet the basic requirements for proper operation of the REPLUS.
• Installation site must have adequate and effective fire protection equipment.
• Installation site must be equipped with sufficient capacity in terms of power supply.
• Avoid storage of any flammable and explosive materials.
• Ground the equipment before installation.
• The REPLUS grounding has to be connected to the spot indicated on the picture as a permanent wiring system.

Grounding

Grounding

• Risk of electric shock. Do not connect a circuit operating at more than 150 volts to ground.
• Avoid use of equipment on an uneven floor.
• Ensure space between the equipment and the wall or other devices to prevent interference with the operation of the
cooling fan inside the equipment.
• This machine is a fixed type of product, so please secure bottom of the machine to the floor using locknuts after
installation.

* Set anchor construction method

Bolt size M12
Total length (l) 100 mm
Screw length (S) 60 mm
Degree (A) * 17 mm
Pipe length (B) 30 mm

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ENVIRONMENTAL CONDITIONS

Environmental conditions
• Ambient temperature: min 0°C ~ max +45°C
• Relative humidity: 20%RH ~ 80%RH
• Altitude: height above sea level 0 ~ 6,562ft (2,000m) - installation category III and pollution degree 2
• Verticality: avoid impacts and grade must not exceed 5º
• Installation location: indoors
• Proper ventilation system should be provided in the work area

Power requirements

M-1001I specifications

Model M-1001I
Input power AC 1P2 W + PE 220 V
50/60 Hz , 35A Max
Output DC 1.2 V ~ 100V, 0~30A
Battery capacity 300 Ah
Transformer 7.5 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13”.
Input breaker 35 A~40 A
Input electric energy 5 kW max

Input breaker and electrical capacity according to output

Input voltage Input breaker Minimum Output in use Input amount of Recommended
thickness of electricity used capacity (P)
input cable (P)
DC 100 V / 30 A 4.3 kW
DC 100 V / 20 A 2.5 kW
DC 100 V / 10 A 1.1 kW
AC 220 V 35~40 A 4m 5 kW
DC 60 V / 30A 3.5 kW
DC 60 V / 20A 1.8 kW
DC 60 V / 10A 0.7 kW

17
M-1005G specifications

Model M-1005G
Input power AC 3P3 W + PE 400 V 50/60 Hz , 20 A Max
Output DC 1.2 V ~ 120 V, 0~50 A
Battery capacity ~ 500 Ah
Transformer 10 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13“.
Input breaker 20 A ~30 A (400 V)
Input electric energy 8 kW Max

Input breaker and electrical capacity according to output

Input voltage Input breaker Minimum Output in use Input amount of Recommended
thickness of electricity used capacity (P)
input cable (P)
DC 120 V / 50 A 7.9 kW
DC 120 V / 25 A 3.3 kW
DC 120 V / 10 A 1.3 kW
AC 380~400 V 20~30 A 4 mm 8 kW
DC 60 V / 50 A 5.8 kW
DC 60 V/ 25 A 2.0 kW
DC 60 V / 10 A 0.7 kW

18
M-1007F specifications

Model M-1007F
Input power AC 3P3 W + PE 400 V 50 / 60 Hz , 35 A max
Output DC 1.2 V ~ 150 V, 0~100 A
Battery capacity ~ 1000 Ah
Transformer 20 kW
“Suitable for nonsinusoidal current load with
K-factor not to exceed 13“.
Input breaker 40 A ~50 A (400 V)
Input electric energy 19 kW Max

Input breaker and electrical capacity according to output

Input voltage Input breaker Minimum Output in use Input amount of Recommended
thickness of electricity used capacity (P)
input cable (P)
DC 150 V / 100 A 18 KW
DC 150 V / 50 A 7.9 KW
DC 150 V / 10 A 1.5 KW
AC 380~400 V 35~45 A 6~10 m 20 kW
DC 60 V / 100 A 11 KW
DC 60 V / 50 A 3.9 KW
DC 60 V / 10 A 0.6KW

19
 UNPACKING AND MOVEMENT

Unpacking and movement

• Use a forklift to unload (weight: 310 kg)
• After receiving this equipment, check the contents (refer to pages 28 to 30)
• This equipment is firmly packed but accidents or damage could occur during shipment
• If damaged, notify the transport company or the supplier of said damage
• Unpack the equipment and release the castor to move the equipment. Move slowly to a level area

Moving and storage instructions

• Set the REPLUS key switch to OFF
• Remove the BATTERY while operating
• Set the main power shut-off to OFF
• Remove the power CABLE at the rear of the REPLUS
• Release the castor and move it slowly to a level area

For long-distance movement or movement of packaging products, contact the supplier or manufacturer for advice.

CHECKLISTS BEFORE POWER INPUT

• Check if connected properly according to the input and output.

• Check if the main circuit breaker and DC breaker are set to ON.
• Check if the emergency switch and circuit breaker are set to ON.
• Check if the input voltage is within the rating.
• Check if BATTERY capacity is within the capacity of the REPLUS.
• Check the input/output cable for deformations, stripped sheath, proper terminal connection and BATTERY polarity.
• Never disconnect output cable connectors and jumper cables during operation.
• Do not work around flammable or harmful materials.
• Always wear protective gear and equipment.

POWER INPUT PROCEDURES

1. Set the input main circuit breaker to ON to power on the REPLUS.

2. Check if the circuit breaker and emergency button are ON. Then set the KEY to ON to power on the REPLUS.
3. Check if REPLUS is set to ON and then connect the BATTERY (check the BATTERY polarity).
4. Set the REPLUS according to the intended use.
5. Check if operated as specified in the default setting.
6. After completion of work, set the KEY switch to OFF, main circuit breaker to OFF and then disconnect the BATTERY.

1 2 3 4
Main circuit breaker is ON Emergency switch and circuit Key switch ON Setting according to the intended
breaker ON check use

20
REPLUS CABLE INTERCONNECTION METHOD

1. INPUT: Power input of REPLUS / AC 3-ph 400V / 50Hz / L1, L2 ,L3 3Wire (1001I 220V 1-ph)
2. TEMP SENSOR: Temperature sensor connecting terminal block / Use the connected temperature sensor
3. DC output breaker: If ampere exceeded the standard current, the breaker will operate. Be careful not to inverse battery
polarity
4. GROUNDING: Always ground before power input for safety

Connect the cable to the correct position when connecting to terminal block at the rear of REPLUS.

REPLUS CABLE INTERCONNECTION

Take care to avoid incorrect connection of cables or reverse polarity of output cable when connecting OUTPUT DC
cable.

21
REPLUS ACCESSORIES
Output cable
N° Photo Description Qty REPLUS Model
1 Output cable 1 1 M-1001I
(1,5 m) M-1005G
2 Output cable 2 1 M-1007F
(1,5 m(UL) or 2,5
m(CE))
3 Output cable 3 1 M-1007F
(1.5 m)
4 Output cable 4 1 M-1007F
5 Output cable 5 1 M-1007F
6 Output cable 6 1 M-1009A
(4 m)

Accessories provided are subject to change without prior notice for safety or inventory.

REPLUS server and others

N° Photo Part Spec Qty REPLUS Model
7 Temperature PT100/ 1 COMMON
sensor 4m
8 Serial cable REPLUS to receiver 1 COMMON
9 REPLUS receiver 1 COMMON
10 USB cable Receiver to PC 1 COMMON
11 Receiver antenna 1 COMMON
12 REPLUS antenna 1 COMMON
13 SD card 2G 1 COMMON
14 SD card reader 1 COMMON
15 Key 1 COMMON

Accessories provided are subject to change without prior notice for safety or inventory.

Safety gear
N° Photo Part Spec Qty REPLUS Model
16 Gloves PT100/ 1 COMMON
4m
17 Apron REPLUS to receiver 1 COMMON
18 Arm covers 1 COMMON
19 USB cable Safety glasses 1 COMMON

22
4. REPLUS OPERATION • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
BASIC OPERATING METHOD
The operation of the M-1007F is enabled through the display monitor at the top of the device and by installing the
integrated monitoring program if an extra PC is available. Chapter 4 describes how to use the display monitor. The
integrated monitoring program can be used more effectively with the Battery Management System. For detailed
information, refer to chapters 5 and 6.

Start of the system

Boot screen

1. Set the REPLUS key from OFF to ON.

2. System boot sequence and logo screen appear and boot sequence starts.

- In the main screen, the applicable equipment model is displayed.

- MCS-1001I
- MCS-1005G
- MCS-1007F
- MCS-1009A
Main screen

3. After completion of boot sequence, the main screen is displayed as shown in the above figure.
4. Select one of two modes to enter the mode.
- OPERATION: Mode to operate restoration, charge, discharge function.
- SETTING: Mode to set system time and various settings, software upgrade.

Setting screen

Main screen Setting screen

1. In the main screen, touch SETTING to enter.

2. Go to the settings screen.
1. Date: set Year / Month / Day.
2. Time: set time.
3. Touch: set touch screen parameters.
4. Screen LOCK: to prevent other users from accessing the screen.
5. Bluetooth: to exchange info using Bluetooth communication.
6. Backlight off: backlight turns off automatically after preset time has elapsed.
7. Language: to set the language of the system. (Korean, English, Japanese, Spanish/to be upgraded)
8. S/W upgrade: to upgrade the REPLUS to the latest firmware.
9. HW and SW version information of REPLUS.
10. Set REPLUS display: current time, communication state.

When operating (charging, discharging) the REPLUS, its settings and work file will be saved on the SD card based on
the operating time. The date and time must be set correctly according to local time. The date and time have been reset
to factory default settings according to the intended use.

23
Setting screen - touch calibration

This option is used for calibration of the touch screen. Choose Touch Cal. Run in the settings screen.

1. When activating Touch Cal, the icon “+” will appear as shown on below picture.
2. Keep pressing the icon with finger or touch pen, it will move and calculate location of coordinate.

Setting screen details - screen lock setting

The screen lock of the REPLUS prevents other users from accessing it. All touch input is disabled without the password.

1. Select ‘Setting’ of Screen Lock

2. Select 6 letters to set a password

24
3. After setting the password, select YES

4. How to activate screen lock:

In the Settings screen, set Screen Lock to ON

After 10 minutes have elapsed, screen lock will activate.

In the top menu of the operating screen, select ScrLock to activate screen lock immediately.

Setting screen - release screen lock

Activate screen lock

When you select “Screen Lock” on the screen, you can release screen lock by entering your password

When you lost your password or need urgent operation, you can perform a compulsory power-off and resume
power-on to cancel screen lock. Compulsory power-off during operation could damage the units & cause problems in
batteries.

Setting screen details - Bluetooth

Displays Bluetooth connection between the REPLUS and integrated receiver.

Connected: Bluetooth connected.

25
Disconnected: Bluetooth disconnected.

Screen details – Backlight off

Used to protect LCD screens. The LCD will automatically switch OFF after the set time. While the equipment is in operation, the
equipment continues to operate normally but only the LCD turns OFF. If you want to turn the LCD on, touch anywhere on LCD
screen to turn it back on.
Always On: Always ON.
After 30 min: OFF after 30 minutes
After 1 hour: OFF after 1 hour

Setting screen details - Language

Used to set the language for REPLUS users. Korean, English, Japanese and Spanish are available.

Setting screen - S/W upgrade

Download the latest software to SD card from the website. You can then upgrade REPLUS via the SD card.
Details of upgrade will be explained in chapter 7.
You are requested to use officially supplied files for the Energic Plus REPLUS only.

26
 OPERATION (RESTORATION & DISCHARGE)

Operation screen - Menu

1 2

Main screen

1. Touch “OPERATION”
2. Operation screen will be shown as above.

All measured data during REPLUS operation will be displayed on the operation screen. When touching area 2 of the screen, all
running data will be displayed on the graph.

Operation screen - Description

1
• Set voltage
1 2 3 4 5 6
• Start voltage
• Min/Max voltage
• Set ampere
• Amp/Hour: total charge/discharge capacity
• Temp: present temperature
• Freq: input frequency

2
• Set: set value
• Active: active value
• Current voltage
• Current ampere
• Charge/discharge time
• Other time information
1 2 3 4 5 6
Operation screen - Menus
Top menu
1. Exit: return to main screen
2. Manual: enter manual mode
3. Program: enter program mode
4. Filter: enter filter mode for graph
5. Log file: open the saved log file
6. ScrLock: screen lock ON/OFF
Indicator for serial communication
Bottom menu
1. Restoration: start restoration in manual mode Indicator for Bluetooth communication
2. Discharge: start discharge in manual mode
3. Program: start program mode
4. Pause: temporary stop
5. Stop complete stop
27
6. Zoom : zoom in/out in graph mode

Top menu of Operation screen is related to all REPLUS settings.

Bottom menu of Operation screen is related to the REPLUS operation.

Manual mode - Setting

• Touch “Manual” in the top menu.
• Exit: return to operation screen
• Calc: calculator
Calculate total voltage easily when charging or discharging battery
Calc only works for entering voltage
• Touch “Voltage”
• Touch “Calc”. Calculator will be shown as picture
• Calculate the voltage
• Touch Ins. , the data will be put in.

If “OK” is selected, the set data will be saved and you return to the
Operation screen. If “Cancel” is selected, no data will be saved and
you return to the Operation screen.

Start of manual mode - Setup

1
• Voltage: charge, discharge voltage setting.
• Ampere: charge, discharge ampere setting
• Time: charge, discharge time setting. Max 99 hours 59 minutes
• Pressing the -(Dec), +(Inc) button once: 2
• Increases/decreases voltage by 0.1V between 2V and 120V
• Increases/decreases ampere by 0.1A between 0.1A and 100A
• Increases/decreases time by 1 min

2 1
To enter voltage/ampere/time, click the letter of voltage/ampere/time
to activate the number box in white. Then use N° 3 keypad for entry.
Press ‘Enter’ key.

E.g. to enter 15A

1. Click 1 ‘Ampere’ in Setting window 1
2. Click ‘1’ and ‘5’ on Keypad 2
3. Click ‘Enter’ on Keypad 2
4. ‘15’ is entered in the setting window 1
2
E.g. to enter 10 hours
1. Click ‘Time’ in Setting window 1.
2. Click ‘1’ ‘0’, ‘0’, ‘0’ on Keypad 2.
3. Click ‘Enter’ on Keypad 2
4. ‘10:00’ is entered in the setting window 1

Before setting the voltage, ampere and current, always check the specifications of battery to be charged or
discharged. Improper setting of REPLUS can cause deterioration and damage to the battery.

Manual mode - Operation

1
• Confirm all set values on Operation screen

2
• Restoration: start charging The time will start counting when restoration or discharge starts
• Discharge: start discharging and total Ah (ampere-hour) will be shown on the screen.

28
REPLUS operation - Screen switch

 CHANGE DISPLAY
TO GRAPH

SCREEN TOUCH

During the operation of the REPLUS or when viewing the saved log file, you can change the display to graph as shown
above. Touch the screen to return to the previous screen. This will be applicable to both Manual mode and Program
mode.

Restoration process in manual mode

Constant current/voltage restoration method is used in manual
mode.
The diagram shows the restoration graph of the REPLUS.

Charge graph description:

1. If the charge starts as in [Section 1], the charge continues with the
set current until it reaches the set voltage.
2. If the battery voltage reaches the set voltage, the battery voltage
adjusts the charging level according to the set time to maintain it
in the set voltage as in [Section 2]. Identical to Pulse2 in Program
Mode.

• Check the temperature of the battery every 5 minutes. If it exceeds 50°C, adjust the charge current by 10%.
• Install the temperature sensor at the back of the REPLUS on top of the battery or in a suitable spot to measure the
heating of the battery.
• Corrosion tends to occur on temperature sensors when they
come in contact with an electrolyte. Therefore, do not install it
near electrolyte or never use it in electrolyte.

Discharge process in manual mode

In manual mode, a constant current discharge method is used.
The above figure shows the discharge graph of the REPLUS.

Discharge graph description:

1. Discharge the set current to the set voltage.
2. If the battery voltage reaches the set voltage, the discharge
is terminated regardless of the set time. Identical to Pulse 1 in
program mode.
3. Although the battery voltage did not reach the set voltage, the
discharge is terminated at the set time.

• Do not discharge the battery beyond the discharge final voltage as specified by the battery manufacturer.
• This can cause severe damage to the battery.

29
Start of program mode - Setup
Select Program in the upper section of Operation screen.
• The REPLUS is programmed to be operated automatically
according to the determined MODE sequence.
• Total of 5 MODES are available and time can be set for a total of
99 hours and 59 minutes.
• Pulse is operated in 6 restoration and 2 discharge scenario modes.

Program mode setting

• If you want to charge immediately after discharging the battery.
• Or if you want to discharge immediately after charging.
• If battery fails to restore while charging the battery.
• If the battery reaches the set voltage rapidly.
• If the battery has been neglected for too long.
• Charging/discharging the battery in several program modes
including manual discharge charge mode enables more effective
restoration.

• MODE : Restoration, Discharge, Pulse Scenario setting, Voltage,

Current, Time setting in each MODE.
• Select MODE ON / OFF to skip the mode if applicable.
• For example the above [Program Setting Screen], In MODE 1, Restoration Pulse2 continues for set time and if MODE is
terminated, goes to Discharge Pulse1 of MODE2. If the applicable mode is terminated, MODE3 to MODE6 continue for the
set time. That is, the operator can control the restoration and discharge in several scenario modes.

Voltage, current and time must be set correctly according to the specificationss and condition of the battery to be
restored. Improper setting can cause damage to battery due to
overcharging of battery.

• Select MODE1
• Set screen of each mode
• Use same method with manual mode to set voltage, current, time

Program mode only

• Method : choose restoration or discharge
• Pulse: Restoration – Enter 1 ~ 6 on keypad
• Pulse: Discharge – Enter 1 ~ 2 on keypad

• Restoration  Charge
• Discharge  Discharge

Voltage, current and time must be set correctly according to the

specifications and condition of the battery to be restored. Improper
setting can cause damage to battery due to overcharging of battery.

Program mode – Pulse scenario details

Pulse scenario in restoration method

Restoration Pulse1 scenario is as follows:

1. If the battery voltage reaches the set voltage, the mode is terminated regardless of the set time.
2. If the set time has elapsed before the battery voltage reaches the set voltage, the mode is terminated.

Constant current mode charging is used.

30
Restoration Pulse2 scenario is as follows:
1. Battery set current is applied to the set voltage (constant current).
2. If the battery voltage reaches the set voltage, adjust the battery current to maintain the set
Pulse 1
voltage (constant voltage).
3. If the set time has elapsed, the mode is terminated.

Voltage, current and time must be set correctly according to the specifications and condition
of battery to be restored.
Improper setting can cause damage to the battery due to overcharging of the battery.

Restoration Pulse3 scenario is as follows:

1. If the battery voltage reaches the set voltage, maintain 0A for 1 minute (stop charging for 1
minute).
2. Discharge the battery with a third of the set current (e.g. 10A if set current is 30A) for 5
Pulse 2
minutes and maintain 0A for 1 minute.
3. Repeat step 1 and 2 until the set time has elapsed.
4. If the set time has elapsed, the mode is terminated.

Restoration Pulse4 scenario is as follows:

1. Regardless of set voltage, apply set current for 5 minutes and maintain 0A for 1 minute.
2. Discharge the battery with a third of set current for 5 minutes and maintain 0A for 1 minute.
3. Repeat step 1 and 2 until the set time has elapsed.
4. If the set time has elapsed, the mode is terminated.
Pulse 3
For program mode Pulse3 and Pulse4, it is recommended to increase the charge time in
consideration of the battery charging level, because of the ongoing discharge.

Restoration Pulse5 scenario is as follows.

1. Apply set current for 10 minutes and maintain 0A for 5 minutes (stop charging for 5 minutes).
2. Repeat step 1 until the set time is reached.
3. However, if the battery voltage reaches the set voltage, adjust the current to maintain the
voltage in constant current mode.
Pulse 4
Restoration Pulse6 scenario is as follows.
1. Apply set current so that the battery voltage can reach the set voltage.
2. If 0.2V drop occurs while battery voltage increases, the mode is terminated regardless of set
time.
3. If there is no voltage drop of 0.2V, the mode is terminated upon reaching the set time.

Voltage, current and time must be set correctly according to the specifications and condition of
battery to be restored. Improper setting can cause damage to battery due to overcharging of
Pulse 5
battery.

Pulse 6

31
 Pulse 1

Pulse scenario in discharge method

Discharge Pulse1 scenario is as follows:
1. Battery starts discharging with the set current.
2. If the battery voltage reaches the set voltage, the mode is terminated regardless of the set
time.
3. If the set time has elapsed before the battery voltage reaches the set voltage, the mode is
terminated.

Discharge Pulse2 scenario is as follows:

1. Battery starts discharging with the set current. Pulse 2
2. If the battery voltage reaches the set voltage, adjust the discharge current to maintain the set
voltage.
3. If the set time has elapsed, the mode is terminated.

Voltage, current and time must be set correctly according to the specifications and condition of
battery to be restored. Improper setting can cause damage to battery due to overcharging of
battery.

Useful additional functions

Filter description
• Click “Filter” in the top menu
• Set items to display on graph to ON/OFF.
• Set Voltage: display set voltage on graph
• Set Ampere: display set ampere on graph
• Voltage: display active voltage on graph
• Ampere: display active ampere on graph
• Temperature: display temperature on graph

Active ampere, set ampere

Active voltage
Set voltage
Temperature

Example if all (5) items were set to ON.

Filter function simply displays the progress and status of battery

during operation of the REPLUS (restoration or discharge) on the
graph.

Log file description

• Click “Log file “ in the top menu
• Check REPLUS operation history by loading log file saved on SD
card.
• Active log files are created according to the operating time
of REPLUS and saved with as title the starting date & time of
operation.
• R: Restoration (charge)
D: Discharge
P: Program mode
• Output and easy check of the result of operation.

If you have problems during the operation of the REPLUS, please

32
send your log files to the Head office for a quick solution.
Log file : all operation data will be saved as a log file onto an SD card.
It shows the REPLUS operation history clearly on a graph.
Zoom In/Out
• When calling up the log file during the REPLUS operation, the graph shows the operating result through a zoom function
about every 30/60/120 minutes or total hours.

Zoom function will be provide a more efficient method to check the trend of battery change.

33
5. BATTERY MANAGEMENT SYSTEM OPTION • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
SYSTEM DIAGRAM
Through a Battery Management System (BMS), the progress of the battery restoration or discharge can be monitored. This
system consists of a BMS device, integrated receiver and integrated monitoring program. This chapter will give more info
about the BMS device and integrated receiver. The next chapter will provide info about the integrated monitoring program.

34
BMS DEVICE (OPTION)
BMS device is connected to each battery cell and used to easily check the progress when restoring more than 2 batteries. All
data of the BMS device will be collected through the integrated receiver.

Battery terminal clamp

Status LED

Set ID & Cell No

Part of BMS Description

SET ID & Number of Cell Battery Identity
LED Communication indicator with Integrated Receiver
Green LED on – success / Red LED on – Fail
Battery Terminal Clamp Red Terminal Clamp – Positive (+) terminal
Black Terminal Clamp – Negative (-) terminal

BMS device installation

1. Connect BMS device to battery terminals
2. Make sure that terminals ( + & -) are connected correctly as shown on below picture
3. Green LED will be ON if connected correctly (starting with red blinking)
4. The BMS can be connected to a maximum of 50 cells

Inverse connection of (+) & (-) will cause damage or failure. Make sure that the device is
connected to the correct battery voltage.
When starting the BMS via the application program, radio frequency interference may cause
operating errors or data omission.
In that case, change the frequency channel.

Precautions when using the BMS system

1. The BMS device for 2 V is used exclusively for 2 V batteries. Do not connect to a battery rated at more than 2 V. Voltage
exceeding 5 V may cause failure of the battery. The BMS device for 12 V is used for 8 V and 12 V batteries. Do not connect
to a battery rated at less than 6 V or more than 18 V. Voltage exceeding 18 V may result in failure of the battery.
2. When connecting the BMS device to the battery, observe proper polarity (+) and (–). Improper connection can cause
failure due to inverse voltage.
3. The BMS device is connected to the integrated receiver, linked to the computer using 2,4 GHz Zigbee wireless
communication. Do not use near a wall or in enclosed areas as this may result in abnormal communication.
4. After using the BMS, clean the terminal before storage. If exposed to the electrolyte of a forklift battery, corrosion is likely
to occur. This may cause measurement errors.

35
INTEGRATED RECEIVER
The integrated receiver has 2 functions (see below).
1. Send BMS data to PC via Zigbee communication
2. REPLUS control via Bluetooth or serial communication

MCS LED LED is on when connected to REPLUS

BMS LED LED is on when connected to BMS devices
Serial Port 1 PC connection
Power & Serial Port 2 Communication with PC and power supply for receiver operation
Serial Port 3 Not available
DC 5V Reserve power supply when serial Port 2 provides insufficient power

SPECIFICATIONS

BMS device and integrated receiver

ITEM BMS device Integrated receiver

2V 1.6~5V
Input (V DC) 5V
12 7~18V
Current consumption (mA) Max 150 Max 250
CPU MG2470 (18 Bit ADC, 12 Bit DAC) CANTUS
Communication Zigbee MG2470 MG2470
Interface 2.4GHz Zigbee RF USB, UART
Antenna 1 dBi dipole antenna 3 dBi dipole antenna
Connector Banana jack, clamp-cable ass’y USB, 6mm DC jack, DB9
Inverse voltage General diode in a row N/A
Dimension (W, D, H) 80 X 57 X 15 mm
OS Windows XP, Win7
PC SW RAM 1 GB ~
Requirement .net framework 4.0 ~
Operation temperature(°C) -20 ~ +60 °C

36
6. PC INTEGRATED MONITORING PROGRAM • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
INTEGRATED MONITORING PROGRAM
The integrated monitoring program on PC is used in combination with the integrated receiver.
• REPLUS control
• Simple data management
• Checking data progress of each battery (option: when using BMS device)

Use the integrated monitoring program to control REPLUS and/or BMS device
1. Control REPLUS only
2. Control BMS device only
3. Control REPLUS and BMS device together during discharge

Through the PC monitoring program it is possible to control the REPLUS efficiently and save log file onto the PC.

PROGRAM INSTALLATION AND START-UP

Installation
• Execute installation file on the SD card of the REPLUS.

• The icon “Integrated Monitor” is created on the desktop.

• List: show list of connected integrated receivers
• Log: show log file of REPLUS & BMS saved on PC
• Share: display operation process on another PC or smartphone (Beta Function)
• Option: change the temperature display values and the path where you want to the save log file
• Check error log
• Support: send question by e-mail, check for update of integrated monitor, visit website
• Exit: terminate program
• No: number of opened windows
• Kind: window attribute
• Memo: window memo
• Window title: name of window

37
Main window
1. Select serial number by clicking ‘List’ button after connecting the receiver to the PC via USB
2. Left panel: REPLUS, right panel : BMS
3. Select the connection method to control the REPLUS panel.

The integrated server and the REPLUS unit are connected one by one. (1 to 1)

Setting
• Common
• Folder: place where battery log file is saved
• Tag: title of battery log file
• File: path of saved log file
• REPLUS (Restore, Discharge tab)
• Voltage: value of voltage limit to finish charging or discharging
• Current: value of constant current for charging or discharging
• Duration: value of time to finish charging or discharging
• BMS
• SetID: BMS set ID to operate
• The number of devices: the number of BMS connected to batteries
• Duration: value of time to finish monitoring
• Channel: frequency channel for Zigbee communication
• T type: 0~7, B type : Auto
• Full Voltage: final charging voltage
• Alarm Voltage: final discharging voltage
• Synchronise control of REPLUS and BMS
• Check REPLUS and BMS at once after selecting the synchronise button.

HOW TO CONTROL
Operate REPLUS only
• REPLUS (Program tab)
• Save: save set values of program mode (up to 5)
• NO: number of program mode
• Method: select restoration or discharge
• V: value of voltage limit to finish charging or discharging
• A: value of constant current for charging or discharging
• Hour: value of time to finish charging or discharging
• Min: value of time to finish charging or discharging
• Pulse: please refer to 4-2.
• Setting: during the process, the set values can be changed without pause
• Stop: stop the entire process
• Pause: pause the current process
• Alarm: turn on/off alarm
• Extending panel: zoom in on right- or left-hand panel
• Turn on/off each alarm: turn on/off alarm of each battery
• Memo: write a memo during the process
• Process: show total operation duration
• Voltage, Ampere, Temperature graph: total voltage of battery, amperage,
temperature are recorded as a graph every second.
• Battery voltage per every three minutes: battery voltage is recorded every three
minutes,
• Alarm sounds if battery voltage drops below set voltage
Information of current condition

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• MCS
• TAG: Tag memo to distinguish log files
• MODEL: REPLUS model name
• SERIAL: REPLUS serial number
• CONNECTION: REPLUS connection method
• METHOD :
• SET V: set voltage
• SET A: set ampere
• START V: voltage at the start of the process
• AH: amount of amps during the process
• MAX / MIN V: max/min voltage during process
• ACTIVE: voltage, ampere, temperature at that moment
• TIME: running time of process

• BMS
• TAG : tag memo to distinguish log files
• SET ID : identification number
• CHANNEL : channel number to communicate with device
• DEVICES : number of connected devices
• FULL V : voltage of fully charged condition
• ALARM V : warning voltage
• MAX V : max voltage during process
• MIN V : min voltage during process
• TIME : running time of process

Log browser
• Start Time : the first time that log file is recorded
• Operation : restoration, discharge, program
• Sync : did synchronisation between REPLUS and BMS occur?
• Tag : title to easily distinguish different log files
• Run Time : total time
• File Name : log file name
• Size: log file size

• Analyses charts
• 3 chart types about status of batteries

• Print
• PRINT & EXPORT: print log information or save in another format.

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40
7. CHECKOUT AND MAINTENANCE • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
GENERAL
Read and understand this manual thoroughly before use. If you have any questions, contact the supplier or manufacturer.
• The REPLUS uses a very high voltage. Before maintenance and storage, always shut OFF the mains and main circuit breaker
and disconnect the battery.
• Do not disassemble or modify without the authorisation of the supplier or manufacturer. Removal without authorisation or
damage to the sticker may cause issues to A/S as this is not covered by the warranty.
• If the cover is removed without authorisation or the sticker is damaged, warranty will not cover repairs. (Except for the
removal of the monitor back cover to replace the battery of monitor memory.)
• Remove the back cover of monitor to replace the AA-TYPE BATTERY (refer to Page 15) if time is incorrect during use.
• The REPLUS is an electrical appliance. Do not expose it to water or moisture. Do not use it in the presence of flammable
gas. It should be stored in a clean place.
• Periodically check the cooling fan in the REPLUS for normal operation. Keep sufficient distance between other equipment
or from the wall to prevent interference with the operation of the cooling fan. If any problem occurs, contact the supplier
or manufacturer for corrective actions. (How to check the fan: if the temperature raises to a certain level during the
operation of REPLUS, check the fan through ventilation slots.)
• Periodically check for input voltage and input/output cable and replace if necessary.
• If any problem occurs during the operation of the REPLUS, shut off the main power circuit breaker and contact the supplier
or manufacturer.

REPLUS CHECKOUT PERIOD

Main circuit Emergency Cooling fan Input power Input/output Bolt Compensation Battery (AA)
breaker switch cable engagement
Month       
Year 
Actions Replace Contact A/S Contact A/S Replace Replace Retighten Contact A/S Replace

REPLUS : ERROR MESSAGE

• Set voltage has exceeded the range of REPLUS specifications.

• Voltage specifications of REPLUS.

Model Set voltage

MCS M-1001I 1.2 V ~ 100 V
MCS M-1005G 1.2 V ~ 120 V
MCS M-1007F 1.2 V ~ 150 V
MCS M-1009A 1.2 V ~ 75 V

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• Set Current has exceeded the range of REPLUS specifications
• Current specifications of REPLUS
Model Set current
MCS M-1001I 0A ~ 30A
MCS M-1005G 0A ~ 50A
MCS M-1007F 0A ~ 100A
MCS M-1009A 0V ~ 350A

• Bad connection between battery and REPLUS or failure (short circuit, open or low voltage)

When any error message shows up on screen during operation, please take appropriate actions. If you need
assistance, please contact your local dealer or head office.

• When active voltage has exceeded the set (max) voltage during operation.
• Max voltage of REPLUS

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 Model Set voltage
MCS M-1001I 130V
MCS M-1005G 130V
MCS M-1007F 130V
MCS M-1009A 95V

• When active current has exceeded the set (max) current during operation.
• Max current of REPLUS
Model Set current
MCS M-1001I 40A
MCS M-1005G 80A
MCS M-1007F 120A
MCS M-1009A 370A

• When starting restoration of REPLUS after set voltage, active voltage is higher than set voltage.

• When starting discharge of REPLUS after set voltage, active voltage is lower than set voltage.

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• In program mode, active time has exceeded max set time.

• Active frequency differs from set frequency on REPLUS

• You are requested to confirm your local frequency before REPLUS operation

• SD card is not present in SD slot.

• Non-existing program mode set (no program mode is selected for activation). This occurs in program mode.

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• Control error in internal REPLUS devices

• No files found on SD memory Card for REPLUS S/W upgrade.

• The operating file on the SD card doesn’t exist.

• Non-recognized SD card.

When any error message shows up on screen during operation, please take appropriate actions. If you need
assistance, please contact your local dealer or head office.

• There is a problem with the electric fan inside the REPLUS.

45
• Inner temperature of the REPLUS exceeds the set temperature.  The REPLUS operation will stop.

REPLUS : ALARM MESSAGE

• Program mode is completed.

• Discharge has finished in Manual mode.

• Restoration has finished in Manual mode.

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TROUBLESHOOTING
When you are faced with problems, please refer to following actions first.

Situation How to act

Booting is not completed on LCD monitor.
Active voltage or current is not shown.
Temperature is not confirmed.
1. Check connection of electricity of REPLUS unit
2. Check key switch to be sure electric power is ON
3. Make sure that the emergency switch is OFF
1. Make sure that the DC circuit breaker of REPLUS is ON
2. Check connection of the battery
1. Check the connection between the temperature cable and terminal of the
REPLUS

UPGRADE
Software update

• Visit the website of Energic Plus REPLUS (http://www.energicplus.com)

• Select Firmware update on the main screen
• Download the latest version of the released software
• Download MCS2FWDATA.FWD to your PC
• For firmware updates contact support@energicplus.com and provide a picture of the technical label on your machine. The
support team will provide you a download link to the latest Firmware version
• Before copying the downloaded file onto the SD card via your PC, check if the file needs to be unpacked.

• Insert the SD card into the REPLUS and turn the power on
• Select APP & MCU in the Setting screen and click S/W upgrade
• APP & MCU will be updated
• The program will reboot automatically after the update

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• If you select ‘Yes’ to upgrade, REPLUS will search the file on the SD card
• After checking the device, the upgrade will be performed

Upgrading the REPLUS with unofficial files can cause serious problems. Always make sure to use authorised software
provided by the head office.

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8. DRAWINGS / DATA SHEET • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
MCS-1001I DIMENSIONS (L X W X H), WEIGHT

Dimensions (L*W*H) Height of the wheels Weight

610 x 400 x 1330 mm 80 mm 123.5 kg

49
MCS-1005G DIMENSIONS (L X W X H), WEIGHT

Dimensions (L*W*H) Height of the wheels Weight

610 x 500 x 1330 mm 80 mm 184 kg

50
MCS-1007F DIMENSIONS (L X W X H), WEIGHT

Dimensions (L*W*H) Height of the wheels Weight

610 x 500 x 1330 mm 80 mm 251 kg

51
MCS-1009A DIMENSIONS (L X W X H), WEIGHT

Dimensions (L*W*H) Height of the wheels Weight

1000 x 800 x 1430 mm 80 mm 500 kg

52
MCS-1009A DIMENSIONS (L X W X H), WEIGHT
Circuit diagram

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9. CERTIFICATES • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
CE-certification (MCS M-1001I)

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CE-certification (MCS M-1005G)

55
CE-certification (MCS M-1007F)

56
CE-certification (MCS M-1009A)

57
CE-certification

58
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info@energicplus.com • www.energicplus.com
TVH Parts NV • Brabantstraat 15 • 8790 Waregem • Belgium
For technical support, please contact us via support@energicplus.com
December 2018. Energic Plus® is a registered trademark. TVH Group NV, Brabantstraat 15, B-8790 Waregem. TVH is a supplier of after-market spare parts and accessories that
are suitable for the maintenance of OEM-equipment.
© April 2017. Energic Plus is a trademark of TVH and
Group
repairNV, BrabantstraatREF
15,38016540
B-8790-Waregem.
12-2018 - JS Photographs and illustrations are included for referencepurposes only. • REF 00000000 • 03-2017 • JR