Rolls Surrette ALCO

SURRETTE BATTERY CO LTDSURRETTE BATTERY CO LTD

December 8 & 9, 2008 by James Surrette

Product Line Introduction

SURRETTE BATTERY CO LTD

Company Background• Established 1939

– 1959: Springhill, NS, Canada

• Rolls / Surrette• Strictly flooded cell, deep-cycle

» Widest product range (80AH - 3,300AH)» BETA TESTING a line of Flooded Lead Calcium for GT Systems

• ISO 9001:2002 registered• Geothermal / Back-up system• RE represents >50% of production• Inventory in 10 countries, 4 continents• Over 30k installed off-grid systems

Background• Production allocation;

–RE: 55% – 12% EU, 8% CAN, 30% USA

–Marine: 8% – Regional distribution

–Railroad: 28% – GE, GM, Class 1 & Short Lines

–Motive Power: 4% – Mostly local

Production Capacity • Small / Medium manufacturer

• One shift (10 hr)• Two lines (Auto & Industrial)• ~300,000 units per annum (L-16 = 2.25 units)

• Significant CapX & PI spend (5 yrs)– Auto (L-16 – COS)

– Auto wrapper stacker– Auto welder (cell-cell)– Heat sealing upgrade– High rate tester

• Industrial• Robotic COS• Auto heat sealer• Computerized formation (Nov 08 install)• High rate discharge testing

• General Plant• Auto oxide process• Oxide storage upgrade• Pneumatic oxide transfer• Pasting oven• Robotic “tail end”• Mist elimination

Consumer Expectations• Capacity -Density of oxide & Strength of acid

• Life / Durability -Thickness of plates, matting, DOD, antimony etc.

• Low Maintenance -Liquid reserve, separator, antimony, Hydrocaps

• Reliability -Warranty (7 & 10 year) -Product access

Marketing Approach – Solar • Originally two distributors

– KSI & BP - USA

• Limited print advertising– Few options

• Limited tradeshow presence– Less options

• Significant training efforts– Built dealer loyalty / “brand equity”

• Supported “RE” distributors – Great help in building brand

Marketing Approach – Solar

• Implemented direct ship model (USA)–Considered a marketing cost– Accelerated demand– Congruent with production– Grew with our customers

Marketing Approach – Solar • 2002 -BP exits BOS -USA

–10 “Partners”•Kept 4

• 2004 – Distribution (USA & EU)• Supported Integrators• Reduced lead times• Highly successful

Marketing Approach – Marine • Mature market

– Experiencing minimal growth – Good margins

• Reputation

• Geographically assigned Distributors– Most 20+ years

• Inventory levels

• Support – National print ads– Numerous tradeshows

– Pulling back

Marketing Approach – Railroad• Full product line

• Custom design opportunities

• OEM • EMD & GE

• Short Line • Opportunity (ALCO)

• Displace GNB / Enersys • local repair / service• short line

SWOT - RE MarketStrengthsQuality / WarrantyBrand equityUnique designDistributor support (direct)L-16 & UpTechnical supportSystem knowledge

WeaknessNo sealedStocking distributorsScaleL-16 & Up

OpportunitiesImproved distributionGrow at market rateNPD (GTS, 2V)AGM

ThreatsLower cost providersPrice erosionDemand - too much

• Up to 12 years of operational life.

• 6, 8, 12 volt configurations.

• 1400 cycles (50% DOD)• 7-year warranty.• S-460 & S-530 most

popular models.• Max bank 1060AH, 48V.

Solar Series 4000

Features & Benefits – Solar Series 4000

• Competitive Price• Well Recognized• Plate Thickness• High Capacity / Cycle Life• Large Liquid Reserve• Great Warranty

Features & Benefits – Solar Series 4000

Limitations:•Easy to Cost Compare •Too many per bank.

Large amount of cells to maintain.Too many wire connections.Reduced charging efficiency.

Marine Series 4000• Up to 12 years of operational life.• 6, 8, 12 volt configurations.• 1400 cycles (50% DOD)• 7-year warranty.• 12-MD-325/375 & 12-

HHG-325/375 most popular models

• Max bank is 3 parallel strings – less is better

Features & Benefits – Marine Series 4000

• Premium price• Well recognized• Modular design• Numerous sizes• Large Liquid Reserve• Great Warranty

Features & Benefits – Marine Series 4000

Limitations:•Too many models•Not maintenance free•Higher cost than average•Not for every client

Series 5000 – Dual Container• Eliminates stray current &

stray voltage.

• Up to 20 years of operational life.

• 2, 4, 6, 8 & 12 volt configurations.

• 3300 cycles (50% DOD).

Features & Benefits - Series 5000• Durability• Advantages over steel trays / Ind. Cells• Bolt-together connections• Eliminates stray current & stray voltage.• Up to 20 years of operational life.• 2, 4, 6, 8 & 12 volt configurations.• 3300 cycles (50% DOD).

Features & Benefits - Series 5000

•Limitations:–Higher upfront cost–Larger size–Unfamiliar sizes

Product Differentiators• Broadest flooded product line• Best warranty• Best cycle life• Unique features of Dual-Container• Robotically welded groups (COS)• All wet product load tested• Series 5000 capacity tested (Dec 08)• We honour distribution agreements

Series 5000 – New Model

•2-YS-31PS–Modular 2-volt–2,430AH (20 hr)–3,435AH (100 hr)–285 lb (wet)–200 lb (dry)

Series 4000 – New Model• S-1380

–L-16 2-volt–1,050AH (20 hr)–1,380AH (100 hr)–117 lb (wet)–Series String

• Charge Efficiency

–Less Maintenance–Shipping Jan 09

Series 4000 – Being Tested•FC-420

–Flooded Calcium L-16

–Designed for FLOAT SERVICE

–320AH (20 hr)–420AH (100 hr)–SHIPPING Early 09

New Level Indicators

New R+ Recombi Caps

New Terminal Boots

Flooded Lead-Acid Battery PresentationDiagnosis & Trouble Shooting

Agenda• Background • Construction & Battery Basics• Jargon Clarification• Installation Procedures• Optimizing Inverter Charging / Settings• Sulfation & Prevention• Diagnosing a Bad Cell • Product Line Review• Questions

Off-Grid / Battery Back-Up System

HomePower Issue 104

Battery Basics How they work;

Discharge - 2e Pb + PbO2 + 2 H2SO4 2 PbSO4 + 2 H2O

Charge +2e

Positive Plate Construction

Active Material Glass Mat

Poly Envelope

Group Construction – CS-21

Strap / BarPost

Positive Ear

Pos EarNeg Ear

PostMoss Guard

Pos Strap

Neg Strap

Moss Guard

Performance JargonCapacity: Measured in Amp Hours (AH) but based on

discharge rate

–460AH @ 100 Hr-rate (460AH/100H = 4.6A)or 350AH @ 20 Hr-rate (350AH /20H = 17.5A)

Effected by: –Density of oxide–Temp (104% 40C, 75% -10C)–Strength of acid (+5% for 15 points)

Jargon…Cycle-life / Durability

–Thickness of plates, matting, oxide density

Effected by:–Depth of Discharge (DOD)

•Refers to amount of energy removed from the battery.

100 90 80 70 60 50 40 30 20

CYCLE LIFE VS. DEPTH OF DISCHARGE - SERIES 5000

PERCENT OF DISCASRGE

Jargon

State of Charge

SOC: Can be determined by measuring the weight of the acid (specific gravity) or voltage.

Concerns:SG will lag on recharging due to mixing.Voltage must be open circuit and rested.

SOC – Specific Gravity

% Charged Specific Gravity 100% 1.255 – 1.275 75% 1.215 – 1.235 50% 1.200 – 1.180 25% 1.165–1.155 0% 1.130-1.110

*Refer to Bulletin 606

SOC- Voltage

% Charged Single Cell 12V 24V 32V 48V

100% 2.10 12.60 25.20 33.60 50.40OPEN CELL

75% 2.01 12.06 24.12 32.16 48.24UNDER LOAD

50% 1.93 11.58 23.16 30.88 46.32UNDER LOAD

25% 1.84 11.04 22.08 29.44 44.16UNDER LOAD

0% 1.75 10.50 21.00 28.00 42.00UNDER LOAD

Initial Activation• Check polarity• Measure specific gravity & inspect level

• Don’t add water if plates are not exposed

• Initial charge; 2.50 – 2.60VPC• Min 2 hours • Until SG readings are stable

• Inspect liquid levels • Notice level rises while charging

D&T Correct Acid Level

Charging “3-Step” Algorithm

Optimizing Charging

Setting “Absorb” Time

1. Determine bank size (350AH)2. Assume 20% DOD when “Bulk” is reached.3. Calculate required AH (20% x 350AH = 70AH)4. Compensate for charge inefficiency (70AH x 115% =

80AH)5. Divide by charge rate* (80AH / 20A = 4 Hrs) *Charge rate: average current during “absorb” cycle

Or Use: t = 0.42 *C/I t = Absortion charge time, C= 20 hr rate, I = charge current

0.42 = (20%/50%) +5% (for loss)

D&T Voltage Settings

(Volts per cell) 12V 24V 48V Equalization 2.50 -2.67(max) 15.0-16.0 30.0-32.0 60.0-64.1 Bulk 2.37-2.45 (max) 14.2-14.7 28.4-29.4 56.9-58.8 Absorption 2.37-2.45 (max) 14.2-14.7 28.4-29.4 56.9-58.8 Float 2.20-2.23 (max) 13.2-13.4 26.4-26.8 52.8-53.5

Refer to Bulletin 614

Sulfation Determining

• Measure & record SG• Charge bank

– Note time to reach “Bulk Voltage”

• Measure & record SG – All low = sulfation problem

• Equalize – (2.50-2.67VPC)

Sulfation Preventative Measures

• Keep SG records–Observe trends

• Extend “Absorb time”• Get bank to 100%, once per month

–May require frequent equalization

Equalize Time How to calculate

1. Determine bank size (1000AH)2. Estimate DOD (20%)3. Calculate required AH (20% x 1000AH = 200AH)4. Compensate for charge inefficiency (200AH x 115%

= 230AH)5. Divide by charge rate (230AH / 50A = 4.6 Hrs)

Bad Cell How to determine • Measure & record V & SG• Charge bank• Measure & record V & SG again

•Excessive water loss in all but one•No activity in one cell•One low cell (>30 pnts) = CONCERN

• Replace cell / battery (if needed)•Charge bank

Thank YouThis presentation is available online at

www.rollsbattery.com/alco

Rolls Surrette ALCO

Documents

manual alco

Alco Aluminium Ladders – House of Aluminium Ladders Hyderabad · 2017-11-29 · ALCO Alco AN ISO 9001 :2008 Certified Company Material Handling Equipments HYDRAULIC HAND PALLET

Alco Locomotive Bogies - rskr.irimee.in

Alco locomotives

Alco Intelligent Solutions

Alco Century 628's

Alco Nothing Serious, You Know

Monthly Alco Package July 2010

Alco Designs 2009-2010

ALCO-SENSOR Alco-Sensor VXL...ALCO-SENSOR VXL 1-800-227-9890 Alco-Sensor VXL ALCOHOL TESTING INSTRUMENTS • Now with Two Year Factory Warranty • One-handed opera-tion leaves one

ALCO for a bank

Alco lite fire ladders catalog

Manual Etilômetro Alco-Sensor IV

DECEMBER 2012 ALCONOTES - ALCO NOTES NEWSLETTER...The Friends of the ALCO Locomotive is a loosely ... This operation has ... following articles about ALCO diesel locomotives: 1) In

ALCO ALPFA Student Symposium 2015

ALCO Process - Liquidity Risk Management

Edcon Power Tongs · 2012. 12. 3. · ALCO HYDRA OIL TOOL ALCO INDUSTRIAL EQUIPMENT ALCO FLOW CONTROL ALCO INDUSTRIAL 6925 - 104 Street Edmonton, Alberta Canada T6H 2L5 ENERGY INDUSTRIES

ALCO Online Academy Flyer

draft abc alco 08052013.xlsx.xls

Alco hawk Breathalyzers