January 16, 2018

Eliminating sulphation from battery management


By applying a continuous stream of pulses to lead-acid batteries, Megapulse is able to prevent sulphation, whose knock-on effects include – but are not isolated to – downtime costs and vehicle starter replacement.

Megapulse is a purpose-designed, self-powered, electronic device that connects directly across lead-acid batteries, with the latter providing the power to the device. It applies a continuous stream of pulses to the batteries it is connected to, fine-tuned to prevent or reverse sulphation.

The power requirement is so minimal (± 8mA) that no special procedures are required other than the regular charging that the batteries receive during normal operation.

Because no external power is required, it works 24 x 7 in all environments, particularly where no external power is available.

Industry endorsement

Various European truck manufacturers – Volvo and Scania in particular – are well aware of the problems caused by sulphation. After an extensive period of testing lasting around 6 years, they separately found that if Megapulse was connected to the truck batteries, there was no significant deterioration in battery performance over a much longer lifetime. Scania compared 70 identical trucks with Megapulse to 70 without, and concluded that the cost saving in terms of lower running costs was 35%.

As a result, both Volvo and Scania sell a rebadged version of Megapulse for use on all their trucks. Mercedes has also approved Megapulse for use on its vehicles.


Megapulse can be applied to all types of lead-acid battery, including gel, AGM and sealed batteries. The batteries used on fork-lifts and electric vehicles are no different to truck batteries, and will benefit from Megapulse in the same way. One Megapulse unit can be connected to multiple batteries up to a total of 2000Ah, ranging in voltage from 6v to 48v.

Virtually no maintenance

Megapulse requires no maintenance: once fitted – just leave it in place. As a result, there are no running costs. Fully encapsulated and with an IP67 rating, it can withstand use in harsh environments. Every 24 hours, a simple load test is performed: this provides early warning of both impending battery failure at end of life, and also cabling and terminal corrosion problems affecting battery performance.

It has been found that Megapulse not only prevents sulphation, but in many instances will reverse it.

Not applicable to physically damaged batteries

However, the effects of the previous sulphation – such as warped plates, damaged separators and shorting cells – will remain, so physically damaged batteries will not benefit.

New and older mid-life batteries

Ideally, Megapulse should be attached to new batteries. Typically what happens in practice is that Megapulse is applied to older mid-life batteries where the problem of sulphation is first noticed.

When they are eventually replaced, the same Megapulse unit is easily transferred to the new batteries.


With a warranty period of 7 years and a much longer MTBF, Megapulse should be seen as cost-effective and long-term solution to the problem of sulphation.

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