The Current Production Model 6048, with WEBB Based Operating System
Bravo Zulu International Ltd., and the BattRecon Story
In 1999, Bravo Zulu International Ltd., (BZI) entered into the Flight Simulation Market by designing
a full motion based, helicopter flight simulator. The Helitrainer was unique in the world of flight
simulation because it has a full motion base with continuous rotation in either a clockwise or
counterclockwise rotation. This was a tremendous advantage in flight simulation because it was
the first time you could actually simulate with motion, the effects of a complete tail rotor system
failure in a helicopter or a flat spin in a fixed wing aircraft. The hydraulic motion based system
invented and manufactured by BZI, was controlled very precisely by the use of Pulse Width
Thus, BZI engineers became masters of PWM in order to provide accurate resolution of the
motion-based hydraulics, when referenced to the flight simulation software and visuals. This
expertise was used to develop the BattRecon Pulse Width Modulated Battery De-Sulfating
In late 2002, BZI entered into a contract with Pakistan Air Force, the fifth largest Air Force in the world, to design and develop flight simulators for their Air Force Academy. In 2004, BZI was awarded a multi-million dollar contract to design and develop 13 different types of flight simulators.
Also in 2004, BZI began work on a large helicopter simulator project for the Egyptian Air Force
in Cairo, Egypt, the MI-17 Simulator Project. BZI began with a wrecked Russian MI-17 Helicopter hull,
completely re-wired the aircraft instrument panel and integrated complex software and computerized
systems to the flight controls. BZI designed and implemented a multi-projector display to project
visual scenery in front of the pilots of the helicopter, while contained in the simulator theater
enclosure. Once the projection system was finished, BZI fabricated a large theater enclosure to
house the entire simulator and encapsulate the large forward projection screen in total darkness.
The advent of the BZI/EAF MI-17 Helicopter Flight Simulator enabled the Egyptian Air Force to train
their helicopter pilots without actually using expensive aircraft flight time.
In 2005, BZI began research and development on a project to determine if Pulse Width
Modulation (PWM) could be utilized to re-ionize lead sulfate deposits from the internal
plates of a lead acid battery. After conducting thousands of tests on various sizes of
batteries, we discovered the optimal manner to de-sulfate a lead acid battery.
We recognized that the basic battery operation requires a daily sulfation chemical reaction
we refer to as “Level 1” sulfation. This “good” sulfation is the basic operating feature of a
battery, without it the battery will not store and discharge electricity. Daily sulfation that is not
re-ionized into solution by the battery charger is referred to as Level 2 sulfation, or as “excess
As Level 2 sulfation continues to accumulate on the battery’s internal plates, the measureable
plate resistance increases. With this increase comes a proportional loss of conductivity, or
battery runtime capacity. Eventually Level 2 sulfation molecules join with adjacent Level 2
molecules and form a Level 3 crystalline form of sulfation. Ideally, the battery should be
returned to a Level 1 sulfation status during each re-charging process of the battery.
Battery chargers do not have the capability to fully re-ionize Level 2 sulfation back into solution on a daily basis. They rely on a weekly “Equalization Charge” to try and compensate for the lack of sulfation elimination during the normal charging process. Even when an equalization charge is applied, the battery is still left with remaining sulfation accumulation. After hundreds of field tests and comparisons, in virtually all cases the BattRecon system was able to improve the battery’s performance, even after a battery was equalize charged.
In 2008, BZI engineers ultimately developed a system, the Model 4800, creating a market for commercial
battery de-sulfation. BZI began building and selling the Model 4800 to the commercial market in
mid 2009. We continue to build the 4800 series, the latest version is now identified as the
In 2010 - 2011, BZI research and development teams worked on a new system to precisely measure
battery and battery cell impedance in real time. This development created a new way to monitor
and automate battery service, which we named, the Zulu One, SCAN – COMMAND and CONTROL
system. We discovered a difficulty in measuring impedance conducted over several feet of wiring,
so it was determined that a new process had to be developed to measure real time battery impedance.
In 2012, we changed the design of the BattRecon PWM system to allow the automation of commercial battery de-sulfation. Automation allowed us to develop a daily, weekly or other periodic application of the BattRecon process, which we refer to as, “Battery Optimization.” The benefit of Automated Battery Optimization to the battery operator is, 1) a reduction in service labor and costs, 2) a reduction of the charging electrical consumption, and 3) the extension of the battery’s life expectancy.
Automated Battery Optimization allows the BattRecon system to be applied for a brief time after each
charge, or delayed for several charge cycles at the owner’s discretion. This brief 5 minute daily or
weekly application, removes all possible Level 2 sulfation buildup and restores the battery to Level 1,
optimum performance. Automation required the capability of the PWM system to be controlled by a
computer and software, therefore, a new PWM process had to be developed.
In 2013 this new control system, which was recently awarded a US Patent, was named Eco-Pulse, because
it dramatically reduced the amount of electrical energy required to de-sulfate the battery. The Eco-Pulse
system is our next generation of battery de-sulfating processes, setting a new world standard for battery
restoration efficiency, low cost and the reduction of service labor.
Eco-Pulse creates and applies an individually controlled, variable amplitude pulse current to a battery. Eco-Pulse then measures the affect of those individual pulses upon the battery. Once the affect of the previous pulse is compared to the desired effect, Eco-Pulse will then adjust the subsequent pulse(s) always striving for the desired battery affect. This rapid and exacting pulse adjustment process continues until the battery is fully optimized, which in most normally sulfated batteries is about 5 minutes.
In 2014, with the successful computerization of the Eco-Pulse system, we were able to develop a
sophisticated software management system to monitor and control the BattRecon machines anywhere
in the world. Using an internet connection and a WIFI capable computer, the BattRecon Model 5000 and
6000 series of devices are now completely capable of remote viewing and control by the operator, or
they can simply operate with pre-programmed instructions as a stand-alone device. Initial prototype
systems were windows based, requiring an operator have a computer with the Microsoft Windows*
operating system installed.
The current development designated a "-W" model (such as Model 6048-W),
was converted to a WEB Based system. The operator may use any internet capable
device, and a web browser, to operate the system either locally in the operator's shop
facility, or remotely anywhere in the WORLD! In September of 2015, the new Industrial
Battery Optimization System was made commercially available as a Patented product and process we call "Fleet-Tune." Fleet-Tune is based upon the idea of an automatic
and applied, Eco-Pulse de-sulfation process, that maintains the battery in an optimum
operating condition. Used in conjunction with the client's external charge, or the internal BattRecon Charger module, Fleet-Tune first allows the battery to connect to ... and be charged by ... the desired charger. After the charge is complete, Fleet-Tune interrupts the charger to battery connection,
followed by the application of an approximate 5-minute Eco-Pulse application. The result, .... a Fleet Battery that is fine Tuned for maximum performance, minimum electrical consumption per charge, and will have a longer life!
An additional product offering soon to be released is the Patented Digital Specific Gravity Probe recently displayed
at the 2015 Promat Show. The Specific Gravity Probe measures in real time, a temperature compensated, electrolyte
specific gravity that may be used to control a battery charger. Fleet-Tune allows the client's battery charger to be
turned off basedupon the real time measurement of electrolyte specific gravity, controlling the charger based in
whole or in part, upon specific gravity. This means that the clients may instantly save 10 to 40% off thier electrical
bill by eliminating the daily excess charging design to ensure that the acid in the electrolyte is mixed. With the
advent of Fleet-Tune and digitized specific gravity, ANYconnected charger may now be turned off when the acid
within the battery is properly mixed, without the guess work of daily overcharging.
Today the world has a new and powerful tool to significantly change the way industrial batteries are maintained and operated. The advent of the Eco-Pulse Automated Battery Optimization System, will dramatically improve battery performance, lower operational cost and conserve considerable energy.
Eco-Pulse Technology: Save a Battery, Save Electricity, … Save the Planet!
*Microsoft Windows is a product owned by Microsoft Corporation
The current production version
of the Model 4800F/CX
The Patented Digital Specific Gravity Probe
The ECO-PULSE WEBB Based operating system released in October of 2015
Mr. Bruce Zeier and the BZI Flight Simulator delivered to the Pakistan Air Force in 2003
Egyptian Air Force Mi-17 Flight Simulator Theater Enclosure completed in 2004
Egyptian Air Force Mi-17 Helicopter Flight Simulator Cockpit completed in 2004
The Initial Eco-Pulse, Windows Based Operating System