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


Strap

Pos EarNeg Ear

PostMoss Guard




Post

Pos Strap

Neg Strap

Moss Guard


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

discharge rate

S-460

–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.


0

1000

2000

3000

4000

5000

6000

100 90 80 70 60 50 40 30 20

CYCLE LIFE VS. DEPTH OF DISCHARGE - SERIES 5000

NU

MB

ER O

F C

YCLE

S

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

http://www.rolls.com/alco

http://www.rolls.com/alco

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Rolls Surrette ALCO