Financial Impacts of Battery Charging, Maintenance, and Operational Problems

1. Financial Impacts ofBattery Charging, Maintenance, and Operational Problems Potential Solutions & Benefits to Consider

2. Today’s Agenda • What does a Battery Do? • Battery Operations and Expectations • Battery Ownership & Maintenance • Battery Ownership Costs • Quantify the costs • How to address these costs • Benefits of implementation

3. What Does a Battery do? • The battery provides two basic functions: • Power for the forklift • Counterweight

4. PbO2 Pb ++ How a Battery Works • Fully charged • POS = PbO2 • NEG = Pb • Electrolyte = 2H2SO4 • Two unlike metals in sulfuric acid H2SO4

5. Battery Design • Forklift batteries are “Deep Cycle” batteries • One discharge and one recharge is a “cycle” • Our batteries are designed to exceed 1,800 cycles • Today’s batteries’ lives are measured in AH throughput, too • When the battery fails to deliver 80% of its rated capacity it is at the end of its life cycle (BCI standard)

6. Battery Design • A battery consists of: • Two or more cells, connected in series • Each cell is two (2) volts (nominally) • 18 Cell Battery = 36 Volts • A cell consists of: • Alternating positive & negative plates • Always 1 more negative than positive • Plates are separated by microporous separators for electrical insulation

7. Plate Design • The structure of a plate is the grid • The grid is pasted, then cured in ovens • After curing, the plates are “Formed” in our exclusive open tank formation process • Fully formed plates • Each one individually inspected The Deka Difference!

8. Battery Basics Summary • Batteries consist of: • Cells • plates • Steel tray • Cables • Life is measured in cycles & AH throughput • Proper use, charging, and care will deliver long life and value to the customer

9. Battery Operating Specifications • The battery is to be discharged to 80% depth of discharge daily • The battery is to be fully recharged daily (to nameplate SpG) • The battery requires maintenance • Equalize charging weekly • Water when it is fully charged (~weekly) • Washing about once a quarter • Periodic testing and repairs

10. The Expectations of a Properly Operated Battery • Long life of the battery • High day-to-day capacity • High reliability • Minimal, if any downtime • Low operating temperatures • Lowest lifecycle cost to power the forklift The Deka Difference!

11. The Expectations of an Improperly Operated Battery • Shorter life of the battery • Reduced day to day capacity • Reduced reliability • Increased downtime • Higher operating temperatures • Higher lifecycle cost to power the forklift

12. Operational & Maintenance Areas of Concern • Over-Discharging • Improper Charging • Lack of Equalize Charges • Watering • Over or under watering • Cleaning • Physical Damage • Cut cables • Dented and/or damaged battery

13. Overdischarging • Causes the battery to work “harder” • Increases heat • Stresses the cells • Requires the battery charger to charge at higher rates for a longer time • Increases heat • Increases gassing • Accelerates “aging” and shortens life • Can lead to thermal runaway where the battery heat goes up and up and up...

14. Overdischarging (Cont’d) • Causes the forklift to operate at lower voltages • Shortens life of contacts/contactors • Shortens life of motors • Increases “down time” of forklift trucks • Increases costs associated with operating the forklift truck

15. Improper Charging • Under or over-charging are detrimental • Overcharging heats the batteries (>120°F) • Undercharging creates: • Lead sulfates • Stratification (strong acid in the bottom) • Heat shortens battery life • For every 18°F >77 °F, life is halved • Undercharging requires more frequent changing and charging and reduces overall life

16. Lack of Equalize Charges • The required weekly Equalize charge is simply a three (3) hour extension of the normal recharge. • Raises each cell SpG & Volts to their maximum potential • Reverses lead sulfates formed during discharge • If not provided, battery capacity will diminish resulting in more frequent battery changes and shorter life

17. Potential Causes of Over or Undercharging • Improper AH Matched Batteries & Chargers • Charger too high, overcharges & overheats • Charger too small, undercharges… • Lack of Weekly Equalize Charging • Can lead to sulfation not being removed, reduced capacity, reduced life • Both lead to shortened battery life, capacity, and increase lifecycle costs

18. Under-Watering Concerns • If a portion of the plate “dry’s out” • That portion cannot be resurrected • Battery capacity is diminished • The remaining SpG electrolyte increases • Higher SpG accelerates grid corrosion • Battery life is reduced significantly • Battery failure is immanent • Results in increased costs to operate

19. Over-Watering Concerns • Electrolyte leaves the battery, spilling into the truck compartment and onto the floor. The result: • Corrosion on the battery and/or cables • Streaks on the battery sides • Floor deterioration • Reduced electrolyte SpG = less capacity • “Overcharging” of the battery occurs… • Heating results • Reduced capacity, life, & performance result

20. Over-Watering Corrections • What can we do? • Send the battery to the shop for acid adjustment and evaluation: • Remove weaker and add stronger acid • Battery capacity and recharge testing is performed • Train battery people to properly water • Initiate watering equipment & PM of the batteries & chargers • Result: Battery capacity is returned

21. Cleaning • When properly watered and maintained, batteries should be slightly dusty on their cell tops • Ideally, the batteries should be clean & dry • Quarterly washing seems to be adequate and optimal • Less frequent washing causes voltage “tracking” on battery tops • Can cause truck “faults” • Corrosion is probable

22. Physical Damage Concerns • Cut battery cables • Potential for short circuit (safety) • Battery is out of service • Dented tray - damaged cell • Battery is not functional • Battery is out of service

23. Approximate Costs Incurred • Sometimes the cost of repairs is material, other times, costs are lost production. • Production costs may be greatest... • Improper charging, heat, & short life $2,000 • Overdischarging and truck component failures. Motors & contactors $1,000 to $3,000

24. Approximate Costs Incurred (Cont’d) • Lack of equalize charging - short life $1,000 • Acid adjustment & evaluation-$300 to $500 • Cleanliness - causes warm batteries, corrosion, rotted cables, holes in operators’ clothing $100 to $500 • Damaged batteries $300 to $800

25. Recommendations • Match the Battery AH to the Charger • Replace if necessary • Color code connectors • Equalize Charge Weekly • Set up chargers for auto equalize by: • Day of week or Number of cycles • Establish Maintenance Schedules • Watering, washing, periodic testing • Extend battery life • Lower lifecycle costs, increase reliability, and value The Deka Difference!

26. Summary • Battery maintenance is known and affordable • Battery maintenance can be done by your adequately trained technicians, or, by the local Deka Representative • Costs associated with improper battery operations and maintenance programs can be substantial in terms of repair costs and lost productivity. Corrective action saves money. • Proper maintenance will yield lowest costs to power the forklift trucks

27. Thank You! For letting us present costs associated with improper operating and maintenance as well as potential solutions. How can we help you achieve, The Deka Difference?