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

Modulation (PWM).

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

daily sulfation.” 

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

Model 4800F/CX.

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