MEGAPULSE INSTALLATION
- Index:
- Quick installation in one step
- Megapulse specification
- Connecting to a battery
- Securely fixing Megapulse to a battery
- Maximum lead length
- Example configurations
- Installing the Megapulse filter
- Simple AM radio test to see if Megapulse is operating
- Installing on golf cars & carts
- Installing on fork-lifts
- Installing on petrol/diesel engine vehicles
- Installing on solar and wind powered systems
- Installing on aircraft
- Installing on marine craft
- Installing on UPS battery banks
- Installing on caravans
- Smart chargers may require the Megapulse filter
- Comparison of Megapulse to other desulphation methods
Quick installation in one step (choose the most appropriate below):
- One battery: Attach the Megapulse directly across the battery terminals.
- Series battery bank: Attach the Megapulse directly across the battery bank. Connect to the -ve terminal at one end and the +ve terminal at the other end of the bank. Ensure the Megapulse voltage is the same as the voltage across the points of connection.
- Large series battery banks: Use multiple Megapulse units to span large battery banks in sections: max physical length of batteries in series per Megapulse unit: 4.0 metres. (This includes 80cm Megapulse lead length.)
- Parallel battery bank (best): Attach the Megapulse directly across the battery bank. Connect to the -ve terminal at one end and the +ve terminal at the other end of the bank.
- Parallel battery bank (good): Attach the Megapulse directly across the battery bank. Connect across the terminals of as many batteries as possible physically situated at the centre of the battery bank.
- Parallel battery bank (fair): Attach the Megapulse directly across the battery bank. Connect across the terminals of the battery physically situated at the centre of the battery bank.
- Magnet: Not required for most applications. (Keep for possible future special purpose configurations).
- Caution: Connect directly to battery terminals, not to wiring loom. If possible, do not lengthen the wires on the Megapulse. If required, the negative (black) lead can be lengthened by up to 70cm to a length of 150cm.
- Warning: Do not connect Megapulse in quick succession to one or more batteries. Allow at least 30 secs between removing it and re-attaching it.
- Here is a document summarizing the above, with examples of various battery banks
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Connecting to a battery
- Always connect Megapulse directly across the battery terminals.
The spade or ring lug is designed to fit to the securing bolt on most battery terminal clamps (see picture left).
Alternatively, the spade/ring lug will also fit the screw thread on most deep-cycle batteries (see picture right).
For maximum effectiveness, Megapulse must be fitted physically close to the batteries being desulphated - see below for more details on lead length.
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Maximum lead length
- The standard lead length on a Megapulse unit is 40 cm. This means when separated, the maximum span of a Megapulse unit is 80 cm.
If absolutely necessary, the span may be increased to 1.5m by lengthening the black (negative) lead by a further 70 cm.
Greater lead lengths will result in excessive dissipation of the pulse, and therefore less energy being available to desulphate the battery, severely degrading the performance of Megapulse.
Megapulse must be connected directly across the battery terminals. When fitted across a battery bank, the batteries should be arranged so that Megapulse can be stretched across the bank. This document shows some examples.
Please refer any issues you have with installation design to us here
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Securely fixing Megapulse to a battery
- Choose a spot close to the battery / battery bank where the leads can reach both +ve and -ve terminals.
The more protected the spot from weather and hosing down cleaning operations the better.
5 ways to fix Megapulse to a vehicle or other surface. In order of bond strength:- 1. Use 4 bolts through the fixing holes to attach to a solid surface.
- 2. Use 3M Dual Lock™ tape (Type SJ355D 70mm x 25mm width tape) - recommended
- 3. Use cable ties (Hellermann Tyton Insulock T50L 392mm x 4.7mm)
- 4. Use Velcro tape
- 5. Double-sided mirror tape
Bolts with locknuts and Dual Lock™ 400 is suitable for all high vibration and ruggedized applications.
Cable ties are not recommended in a high vibration environment as they tend to break after a time.
Velcro and mirror tape should only be used in static situations such as immovable battery banks.
The Dual Lock™, Velcro and mirror tape have self-adhesive backing. They require completely grease-free and clean surfaces. (Note that fibreglass surfaces are often covered with a slightly oily residue left over from the moulding process.)
Recommended cleaning method:
Really oily/greasy environment:- Stage 1. Wash and brush off loose mud and dirt
- Stage 2. Use water-soluble engine cleaner to remove oil and grease, then continue with stages 3 and 4 below
All other situations:- Stage 3. Use methylated spirits to clean off any remaining oily residue
- Stage 4. Use isopropyl alcohol on a clean cloth to remove all residues from previous cleaners
Dual Lock™ tape usage example:
Cut two strips each 70mm long
Carefully clean the back surface of Megapulse, and the position on the vehicle where the Megapulse is to be stuck.Peel off backing tape . . . . . . and stick one strip onto the back of Megapulse.
Stick the other strip to a bulkhead or a flat surface on the battery. Mounting can be either horizontal or vertical, whichever is easier and more appropriate. Press the two strips together ensuring complete overlap to stick the Megapulse firmly in place. Done correctly, there will be a distinct crackle as the strips are joined.
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Installing on fork-lifts
Table of fork-lifts | ||
|---|---|---|
| Make / model | Voltage | Installation method |
| Hyster | 48v | Directly across battery pack - 45mm extension to negative lead |
| Taillift flexi | 48v | Directly across battery pack |
| Manhand | 48v | Directly across battery pack |
| TCM Reach truck 2001 | 48v | Directly across battery pack |
| Dawewoo 1996 | 48v | Directly across battery pack |
- Installation notes:
In essence, one Megapulse unit of the correct voltage is fitted across the supply terminals of each fork-lift battery pack.
If the distance between the - and + supply terminals is greater than the maximum stretch of the Megapulse leads, the -ve lead can be increased up to 50 cm.
Megapulse installation guide for electric fork-lifts (PDF)
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Installing on golf cars & carts
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Golf cars | 36v, 48v | Check the table below for golf car installation guides Megapulse configuration guide for golf cars (PDF) |
| Walk-behind golf carts | 12v, 24v | Megapulse installation guide for golf carts and trolleys (PDF) |
Golf car installation guides (by make and model) | ||||
|---|---|---|---|---|
| Make | Model(s) | Charger type | Filter required? | Installation guide |
| EZgo | TXT 1996- 36v Marathon 36v 1975-1993 Medalist 36v 1993-1999 ST 36v 1999- MPT 800 36v MPT 1000 48v 2004- |  Lester | No | Details |
| EZgo | TXT 1996- 36v Marathon 36v 1975-1993 Medalist 36v 1993-1999 ST 36v 1999- MPT 800 36v MPT 1000 48v 2004- |  Delta-Q | Yes | Details |
| EZgo | RXV 2008- 48v | All types | No | Details |
| Club Car | V-glide 36v | All types | No | Details |
| Club Car | PowerDrive System 48v PowerDrive Plus 48v Villager 4,6,8 48v Transporter 4,6 48v | All types | Yes | Details |
| Club Car | Precedent 48v | All types | No | Details |
| Melex | 36v | - | No | Details |
| Melex | 48v | - | No | Details |
| OTM | 48v | - | No | Details |
| Yamaha | G-3 Sun Classic 48v 1986- G-5 Fleet Classic 48v 1990- G-19 Ultima 48v 1996- G-20 Concierge 48v G-22 G-Max 48v YDR DRIVE 48v |  Yamaha | No | Details |
| Yamaha | G-3 Sun Classic 48v 1986- G-5 Fleet Classic 48v 1990- G-19 Ultima 48v 1996- G-20 Concierge 48v G-22 G-Max 48v YDR DRIVE 48v |  Lester | No | Details |
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- Installation notes:
The following notes are for electric vehicles that do not require a filter.
Please refer to the table above to check whether the golf car in question requires the filter.
Most fork-lifts do not require the filter. Walk-behind golf carts do not need the filter, as Megapulse is connected to the battery only when it is on charge.
First check the voltage of the battery bank. The easiest way to work out the voltage is as follows:
Count the number of round caps (sometimes hidden under a cover spanning the battery) - 2v per cap
Count the number of batteries - multiply the above answer by this number
E.g. 4 caps per battery = 4 x 2 = 8v
6 batteries = 6 x 8v = 48v
The 36v / 48v Megapulse Mk.4 units default to HI mode, unlike the 12v / 24v units.
Defaulting to HI mode means Megapulse will operate during charging, but not during vehicle operation. In this way, there will be no interference between Megapulse and the vehicle's electronic controller.
When connected across the charger, a 12v / 24v Megapulse Mk.4 unit can be left in LO mode, since it is not attached to the vehicle or walk-behind cart when it is in use.
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Installing on petrol/diesel engine vehicles
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Vehicle starter battery | 12v | Connect Megapulse directly across battery |
| Truck battery | 24v | Connect one 24v Megapulse directly across both batteries |
| 4x4 auxiliary battery | 12v | Connect Megapulse directly across battery |
| Engine & deep-cycle | 12v / 24v | Megapulse installation guide for vehicles (PDF) |
- Installation notes:
The installation is very straightforward: Simply connect the Megapulse unit directly across the battery or battery bank.
Typical small vehicle example:
Typical fitment to a battery in the engine compartment
A 12v Megapulse fitted in minutes to a bakkie, cable-tied to the battery clamp in the engine compartment
Scania truck example:
One 24v Megapulse serves the two 12v batteries connected in series
Mercedes Sprinter example:
Here, thick double-sided 'mirror' tape has been used to fix the 12v Megapulse to the battery, which is an alternative to using cable ties.
However a more robust solution is to use one 70mm length of 3m Dual Lock™ SJ355D to fix the Megapulse to any suitable flat surface in the battery compartment. -
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Installing on solar and wind powered systems
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Solar battery bank | 12v - 48v | Connect Megapulse directly across battery bank If required, connect 30A filter between battery bank and regulator |
| Solar battery bank | > 48v | Classify battery bank into 48v segments Connect one 48v Megapulse directly across each segment Depending on the total bank voltage, the last segment may be < 48v Connect appropriate Megapulse directly across the last segment If required, connect 30A filter between battery bank and regulator Megapulse installation guide for solar systems (PDF) |
- Installation notes:
Not all charger/regulators need a filter. Generally, only those charger/regulators controlled by microprocessors which sample the battery voltage with no averaging function, require a filter.
The following table shows the results for regulators which have been tested:
NO FILTER REQUIRED REQUIRES FILTER Steca - PRnnnn, Solsum, Solarix, Outback MX60 [none identified to date]
Where a filter is required, it should be fitted as shown in this diagram. Note the filter between the charger/regulator and the battery. The load is connected directly to the battery. The filter prevents the pulse output affecting the charger electronics.
Megapulse filter unit short specification here. Megapulse filter unit installation leaflet here.
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Installing on UPS battery banks
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| UPS | 12v - 48v | Connect Megapulse directly across battery bank |
| UPS | > 48v | Classify battery bank into 48v segments Connect one 48v Megapulse directly across each segment Depending on the total bank voltage, the last segment may be < 48v Connect appropriate Megapulse directly across the last segment Megapulse installation guide for UPS systems (PDF) |
- Installation notes:
Use the Megapulse unit rated for the same voltage as the battery bank, as in this example:
Higher-voltage battery banks can be served with multiple Megapulse units. In the example below, the battery bank is broken down into 48v sections, and one 48v Megapulse is used across each section.
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Installing on caravan and vehicle batteries
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Caravan, vehicle | 12v | Connect Megapulse directly across battery bank |
- Installation notes:
For caravans that are parked over long periods, consider using a trickle charger or solar panel to keep the battery fully charged. Alternatively consider the Megapulse solar charger:
Megapulse 8w solar panel battery charger. The ideal companion for Megapulse, keeping the battery charged while not in use
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Installing on aircraft
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Aircraft battery (fixed) (minor modification) | 12v, 24v | To be done by a suitably qualified AMO only Connect Megapulse directly across battery terminals Switch to WW mode, with the magnet (red LED on) Mount securely on fuselage according to best aviation practices Record minor modification as an entry in the logbook Megapulse installation guide for aircraft (PDF) |
| Aircraft battery (charger socket) (minor modification) | 12v, 24v | To be done by a suitably qualified AMO only Install a charger socket within 1m of the battery Record minor modification as an entry in the logbook Attach appropriate plug to Megapulse (shorten leads to ±7cm) Connect Megapulse to charger socket Remove Megapulse before flight Megapulse charger socket installation guide for aircraft (PDF) |
| Aircraft battery (external power socket) | 12v, 24v |  Attach appropriate plug to Megapulse(shorten leads to ±15cm) Connect Megapulse to power socket Remove Megapulse before flight Photo: AN2552 power receptacle - requires AN2551 type plug |
- Installation notes (fixed installation):
The installation of Megapulse on aircraft is governed by CAA regulations, specifically explained in AIC 61.6 dated 12 Feb 2009
- This AIC applies to maintenance carried out under Part 43 of the Civil Aviation Regulations, which includes the fitment of Megapulse.
This AIC does not apply to any aircraft for which an experimental airworthiness certificate has been issued, unless a different kind of airworthiness certificate had previously been issued for the aircraft in question.
The essence of AIC 61.6 is that Megapulse must be installed by a suitably approved maintenance organization (AMO), in accordance with accepted practices. The log book must include an entry to show that Megapulse has been installed.
After installation and connection to the aircraft battery, the Megapulse unit must be set into Window mode which will prevent it operating during flight. While our tests in a light single-engine aircraft have shown that operation during flight does not affect the avionics or electrical system in any way, Window mode provides an additional margin of safety.
Megapulse must be set into Window mode after the battery is reconnected (for example, after the regular annual maintenance)
Rarely used aircraft which are not flown for periods greater than 25 consecutive days should be attached to a low-current trickle charger while in the hangar to prevent the battery running flat. Should this happen inadvertently, as soon as the aircraft engine is started, the battery will quickly reach full charge at a high charge rate, due to the lack of sulphation in the battery resulting from the use of Megapulse.
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Installing on marine craft
Quick installation guide Megapulse Mk.4 | ||
|---|---|---|
| Application | Voltage | Installation method |
| Marine engine battery | 12v - 24v | Connect Megapulse directly across the battery |
| Marine house battery bank | 12v - 24v | Connect Megapulse directly across the ends of the battery bank One Megapulse unit serves all the batteries in the bank If the house batteries comprise two or more separate banks situated more than 1m apart, one Megapulse must be connected across each separate bank. |
- Installation notes:
Megapulse must be connected directly across a battery or battery bank. The reason for this is that the high frequency pulsing rapidly loses energy over longer lengths of wire.
For this reason, if the house battery bank is split into two separate groups, each group requires its own Megapulse unit
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