Here I have moved 'Saint Julian' back to KLATTAU, which is 5 hexes from the Operations Centre at PILSEN, the 'Add Replacements' button lit up and I was able to restore the unit to full strength (24/24). The distance from the Operations Centre to be able to add replacements might vary, but I have seen up to 7 hexes.
The 'Add Replacements' button has gone grey again, as this unit is no longer eligible for replacements as it is now at full strength. There are now 4 replacements available as, although 1 has been used, more replacements have arrived this turn.
This shows how important it is to select the right town as your Operations Centre, it needs to be close to your area of operations, but not so close that it is endangered. Be prepared to move your Operations Centre and Hospital as the fighting moves, or the strategy changes.
You can see which town has been designated at the Operations Centre and change to another town in the Army Commander info box, when you select the Army Commander (e.g. Napoleon).
Before you allocate replacements, look how many stragglers there are, 'Saint Julian' shows 1 straggler point and could have come back into full strength, by itself, when the stragglers return and the replacements might be better used in other units.
The stock game unit counters show stragglers in a red box and sometimes uses red text to show the number of stragglers in a unit, which is 'red on red', e.g. invisible. You need to use
Chemkid's counter mod, shown in these images, to always be able to see the stragglers. [:)]