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Transcript of 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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
• 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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Marketing Approach – Solar
• Implemented direct ship model (USA)–Considered a marketing cost– Accelerated demand– Congruent with production– Grew with our customers
SURRETTE BATTERY CO LTD
Marketing Approach – Solar • 2002 -BP exits BOS -USA
–10 “Partners”•Kept 4
• 2004 – Distribution (USA & EU)• Supported Integrators• Reduced lead times• Highly successful
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Marketing Approach – Railroad• Full product line
• Custom design opportunities
• OEM • EMD & GE
• Short Line • Opportunity (ALCO)
• Displace GNB / Enersys • local repair / service• short line
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
• 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
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
Features & Benefits – Solar Series 4000
• Competitive Price• Well Recognized• Plate Thickness• High Capacity / Cycle Life• Large Liquid Reserve• Great Warranty
SURRETTE BATTERY CO LTD
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.
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Features & Benefits – Marine Series 4000
• Premium price• Well recognized• Modular design• Numerous sizes• Large Liquid Reserve• Great Warranty
SURRETTE BATTERY CO LTD
Features & Benefits – Marine Series 4000
Limitations:•Too many models•Not maintenance free•Higher cost than average•Not for every client
SURRETTE BATTERY CO LTD
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).
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
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).
SURRETTE BATTERY CO LTD
Features & Benefits - Series 5000
•Limitations:–Higher upfront cost–Larger size–Unfamiliar sizes
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Series 5000 – New Model
•2-YS-31PS–Modular 2-volt–2,430AH (20 hr)–3,435AH (100 hr)–285 lb (wet)–200 lb (dry)
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Series 4000 – Being Tested•FC-420
–Flooded Calcium L-16
–Designed for FLOAT SERVICE
–320AH (20 hr)–420AH (100 hr)–SHIPPING Early 09
SURRETTE BATTERY CO LTD
New Level Indicators
SURRETTE BATTERY CO LTD
New R+ Recombi Caps
SURRETTE BATTERY CO LTD
New Terminal Boots
SURRETTE BATTERY CO LTD
Flooded Lead-Acid Battery PresentationDiagnosis & Trouble Shooting
SURRETTE BATTERY CO LTD
Agenda• Background • Construction & Battery Basics• Jargon Clarification• Installation Procedures• Optimizing Inverter Charging / Settings• Sulfation & Prevention• Diagnosing a Bad Cell • Product Line Review• Questions
SURRETTE BATTERY CO LTD
Off-Grid / Battery Back-Up System
HomePower Issue 104
SURRETTE BATTERY CO LTD
Battery Basics How they work;
Discharge - 2e Pb + PbO2 + 2 H2SO4 2 PbSO4 + 2 H2O
Charge +2e
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
Positive Plate Construction
Active Material Glass Mat
Poly Envelope
SURRETTE BATTERY CO LTD
Group Construction – CS-21
Strap / BarPost
Positive Ear
SURRETTE BATTERY CO LTD
Strap
Pos EarNeg Ear
PostMoss Guard
Group Construction – CS-21
SURRETTE BATTERY CO LTD
Group Construction – CS-21
Post
Pos Strap
Neg Strap
Moss Guard
SURRETTE BATTERY CO LTD
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)
SURRETTE BATTERY CO LTD
SURRETTE BATTERY CO LTD
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.
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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.
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
D&T Correct Acid Level
SURRETTE BATTERY CO LTD
Charging “3-Step” Algorithm
SURRETTE BATTERY CO LTD
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)
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
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)
SURRETTE BATTERY CO LTD
Sulfation Preventative Measures
• Keep SG records–Observe trends
• Extend “Absorb time”• Get bank to 100%, once per month
–May require frequent equalization
SURRETTE BATTERY CO LTD
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)
SURRETTE BATTERY CO LTD
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
SURRETTE BATTERY CO LTD
Thank YouThis presentation is available online at
www.rollsbattery.com/alco