Prior to the invention of the Model 4800 Industrial Battery De-Sulfation System, the battery service industry used aggressive charging and discharging techniques, over days or weeks, to de-sulfate batteries in a service operation.
The Model 4800 was revolutionary because by the simple connection of the machine to the battery and the application of a specific "Peak Amplitude," the operator was able to de-sulfate a "normally sulfated" battery in about 10 to 20 minutes.
The Model 4800 was developed and marketed beginning in 2009, and it soon became the standard for many battery service providers in the Forklift, Golf Cart, Automotive and Telecom Industries. The Model 4800 was a "First Generation" breakthrough in technology allowing for the first time, a commercially viable method to remove sulfate buildup on the inside of a battery’s lead plates. BZI Laboratories previous mastery of “Pulse Width Modulation” (PWM) in the aircraft motion simulation business, is the basis of this exciting product line. The Model 4800 is a "First Generation Device" that introduced the idea of an applied symmetrical, high amplitude - low frequency electrical wave to the battery plates to gently re-ionize the lead-sulfate molecule back into the electrolyte.
Unless the battery has internal damage, the BattRecon process applies a precise Peak Amplitude
electrical charge to the lead-sulfate molecule, causing the lead molecule Pb to repel from the
SO4 molecule, chemically referred to as "re-ionization." The BattRecon re-ionization process
quickly de-sulfates and restores most batteries, to their optimum condition. It is important to
note that while many companies claim their products make the batteries like new again,
the truth is that a battery can only be restored to an "optimum condition," or one that
considers other factors such as the battery cycles, the battery operating environment
temperature, and the normal decrease in capacity due to simple corrosive effects of the
electrolyte and many other factors.
The Model 4800 is popular because it is a rugged design, it is lightweight and portable, uses a standard 120 VAC - 20 amp household outlet, (or a 220 VAC - 10 amp household outlet), it de-sulfates a typical battery in about 10 minutes, and is was adjustable by the operator for different battery internal resistances. The system is used in more than 45 countries around the world, in every conceivable climate and environment. The system is used in the Warehousing industry on forklifts, in the Golf Industry as a battery restoration device, in the auto/marine/aviation industries, and in the remote repair and optimization of batteries in many different cell tower locations around the world. The rugged and robust design means that the Model 4800 is very dependable in the field. In the unlikely event the device needs repair, it is typically the replacement of a simple fuse or power output transistor, costing about between $10 and $45 on the world market.
This machine features two Patented instrument designs, 1) the Peak Meter, and 2) the "I" Meter (Impedance), later known as the BHI Meter (Battery Health Indicator). The Peak Meter indicates the height of the pulse used to re-ionize the lead sulfate molecule back into solution. The proper Applied Pulse Peak is critical to the time required to de-sulfate a battery. If the peak is too low, the battery will not reach it's maximum capacity, too much Peak Amplitude simply wastes energy and increases lead particle shedding.
Both the I-Meter and the BHI-Meter can be used as a quick diagnostic tool because it measures the internal battery resistance using a special pulse algorithm developed within the Model 4800. The higher the I Meter or BHI Meter reading, for a specific power or voltage input to the battery, then the higher the internal resistance and the lower the battery output. As an example, a new 12V car battery will have an impedance of about 6 milli-ohms, and when you apply 100 Peak amps, it will show about 25 on the BHI meter. A used 12v car battery with much higher resistance, such as 18 milli-ohms at the same applied 100 Amps Peak, would take greater voltage (more knob rotation) to create this Peak and the BHI meter might read 45, as an example. The higher the internal resistance of the battery, the higher the impedance and the lower the power output from the battery, all other factors remaining constant.
The required Applied Peak depends on the degree of resistance within the battery, referred to as Impedance, which is typically measured in Milli-ohms. Each battery has a different internal resistance caused by: 1) the battery design and construction, 2) the amount of sulfation on the plates, 3) the degree of natural corrosion of the battery caused by the acidic electrolyte, and 4) the amount of lead particle "shedding" caused by normal charging or aggressive charge and discharge cycles. Therefore, each battery has a unique internal resistance and would require the operator to increase or decrease the applied power to the battery to create the desired Peak Amplitude.
As an example, if you have two batteries "A" and "B," that are identical is size, construction and operating history, you might expect different characteristics as follows:
Battery A: 16 milli-ohms of impedance might require 16.0 volts to create 100 Peak Amps.
Battery B: 22 milli-ohms of impedance might require 16.5 volts to create 100 Peak Amps.
The BattRecon Patented Process allows the operator to control the size or amplitude of the peak applied to the battery by simply increasing the output power using the large black knob on the front of the machine. The operator determines the correct amount of output power by referring to the "Peak" of "BHI" Meter. Turing the knob clockwise increases the power output, which should also increase the Peak Amplitude. If the Peak is higher than desired, the operator simply rotates the knob counter-clockwise, which lowers the output power and the indicated Peak Amplitude. This power changing ability compensates for slight impedance differences within each battery, allowing the batteries to be de-sulfated in minutes, rather than hours or days using other branded equipment.
The Model 4800 is a “Universal Machine” allowing it to work on most lead-acid types of batteries. Because of it’s “Variable Power Pulse Technology” and “Multi-Channel” design, this machine has the power to de-sulfate and restore a large 3,000 pound forklift battery, or the delicate finesse to de-sulfate and restore a small automotive battery, either in about 10 minutes! Even Motive batteries that have been sent to the “Graveyard” can be restored to a serviceable condition, but they may require successive BattRecon treatments followed by battery charging.
The BatRecon systems work best on batteries that have Level 1 and Level 2 sulfation, Level 3 sulfation may take repetitive applications of the BattRecon process. Level 1 sulfation, often referred to as the "Good" or necessary sulfation, occurs as a natural process of discharging a battery during normal use. Discharging requires the electrolyte solution H2SO4 molecule to separate into free Hydrogen molecules and sulfate radicals. The sulfate radical (SO4) is then in an ionic manner drawn to the lead plate molecule PB, which combine outer shells releasing excess electrons as a flow of current out of the battery. These excess electrons are then used as energy to power external devices such as a headlight on a car.
During the recharging process, not all SO4 molecules are re-ionized (forced) back into the acid solution; those that remain on the lead plates are called Level 2 sulfation. As this charging and discharging process continues over time and many cycles, the Level 2 sulfates accumulate and eventually develop into a crystalline form, referred to as Level 3 sulfation. As the battery sulfates increase, they reduce the battery’s performance until you notice the battery no longer has the strength it needs to start your car, for example. In addition, the life of the battery is shortened significantly requiring expensive replacement.
As the battery increases in internal sulfation, the time to re-charge your battery keeps getting longer, wasting electricity. As the batteries age and Level 2 and 3 sulfation increases, most batteries will not reach a high enough cell voltage to allow the charger to shut off or progress into the “top-charge” processing rate. As this happens, you are literally throwing electricity away and are costing your company’s operation thousands of dollars. In fact, over the life of the battery, most companies can save between 10 and 25% of the electricity used to charge their motive batteries by simply keeping them tuned up with the BATTRECON system!
BattRecon Model 4800
The World's First Generation of Industrial Battery De-Sulfation Systems
U.S. Patent # 8,330,428 B2
Model 4800 Features:
Low Purchase and Ownership Cost
Portable and Light Weight
Uses Standard Household Electrical Outlets
10 Minutes to De-Sulfate Most Batteries
Rugged Design - Easy to Field Repair
Worldwide Customer Support and Training
Universal Battery Voltage from 2 to 80 VDC
Operator Adjusts the Machine to the Battery
BattRecon Servicing and Restoration Devices for Forklift, Golf Cart, Auto, Marine and Telecom Batteries