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CHAPTER 1 : BATTERIES
Take your time and read these over until you understand the concept fully:
Electron: The basic unit of electricity. Think of these little guys as "bullets",
traveling down the wire. It's the movement of electrons which runs the
devices which make our lives - and our cars - so comfortable and convenient.
Voltage: This is the force (or pressure, if you like) of electricity in the wire. If
you think of your garden hose as the wire, the water pressure would be
equivalent to the voltage. Older cars run on six volt systems and newer (most
1956 and later) utilize twelve volt systems. All vehicles' manuals specify the
system voltage.
Watts: The unit of power in electricity and the product of Amps x Volts.
Why is this important? Because designers of circuits need to know the
amount of current required for a given device (such as a fan, horn, light, etc.)
in order to figure out which diameter wire to use. Example: a 50-watt brake
light, operating on 12 volts, will draw 4.1 amps (4.1 amps x 12 volts = 50
watts). The wire diameter must be large enough to carry the current without
heating up and melting off its insulation.
IMPORTANT FACT! This is the only formula you will ever really need to
understand basic electricity, be it in your car or in your house.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
Ground: All electrical devices must be part of a circuit. That is, electrons
must flow from the power source through the device to a ground. In cars, the
metal chassis is the ground (that's why the battery's negative lead is bolted
to the engine or frame) and the power source is the positive lead on the
battery. Without a ground there is only a POTENTIAL circuit. No electrons will
flow - and therefore nothing will work - unless the circuit ends in a ground.
Note: Some cars and trucks utilized "positive ground" electrical systems,
where the positive lead from the battery connects to the frame and the
negative lead goes to the electrical wiring harness. This in no way makes it
more difficult to wire or troubleshoot; all that's required is to remember that
the system is the reverse of normal systems.
Ready to go on? Okay, let's start with the fact that all cars run on Direct
Current (DC) electrical systems, as opposed to alternating current (AC) which
runs your home. DC is a "single wire" system. That is, the flow of electricity
always runs from the source of current through the device and then to
ground. It may do this through any number of connections and through other
devices, but tracing the path is straightforward if you always ask the
question:
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
Battery
Battery Construction:
Lead acid batteries usually consist of two 6-volt batteries in series, or a single
12-volt battery. These batteries are constructed of several single cells
connected in series each cell produces approximately 2.1 volts. A six-volt
battery has three single cells, which when fully charged produce an output
voltage of 6.3 volts. A twelve-volt battery has six single cells in series
producing a fully charged output voltage of 12.6 volts.
A battery cell consists of two lead plates a positive plate covered with a paste
of lead dioxide and a negative made of sponge lead, with an insulating
material (separator) in between.
The plates are enclosed in a plastic battery case and then submersed in an
electrolyte consisting of water and sulfuric acid (see figure # 1). Each cell is
capable of storing 2.1 volts.
In order for lead acid cell to produce a voltage, it must first receive a
(forming) charge voltage of at least 2.1-volts/cell from a charger. Lead acid
batteries do not generate voltage on their own; they only store a charge from
another source. This is the reason lead acid batteries are called storage
batteries, because they only store a charge.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
The size of the battery plates and amount of electrolyte determines the
amount of charge lead acid batteries can store. The size of this storage
capacity is described as the amp hour (AH) rating of a battery. A typical 12-
volt battery has a rating 125 AH, which means it can supply 10 amps of
current for 12.5 hours or 20-amps of current for a period of 6.25 hours. Lead
acid batteries can be connected in parallel to increase the total AH capacity.
In figure # 2 below, six single 2.1-volt cells have been connected in series to
make the typical 12-volt battery, which when fully charged will produce a
In figure # 3, above a fully charged battery is connected to a load (light bulb) and
the chemical reaction between sulfuric acid and the lead plates produces the
electricity to light the bulb. This chemical reaction also begins to coat both positive
and negative plates with a substance called lead sulfate also known
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
In figure # 5 the battery is now fully discharged, the plates are almost completely
covered with lead sulfate (sulfation) and voltage has dropped to 10.5-volts.
NOTE: Discharging a lead acid battery below 10.5 volts will severely damage it!
Lead sulfate (sulfation) now coats most of the battery plates. Lead
sulfate is a soft material, which can is reconverted back into lead and sulfuric
acid, provided the discharged battery is immediately connected to a battery
charger. If a lead acid battery is not immediately recharged, the lead
sulfate will begin to form hard crystals, which can not be reconverted by a
standard fixed voltage (13.6 volts) battery converter/charger.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
During the recharging process as electricity flows through the water portion
of the electrolyte and water, (H2O) is converted into its original elements,
hydrogen and oxygen. These gasses are very flammable and the reason your
batteries must be vented outside. Gassing causes water loss and therefore
lead acid batteries need to have water added periodically. Sealed lead acid
batteries contain most of these gasses allowing them to recombine into the
electrolyte. If the battery is overcharged pressure from these gasses will
cause relief caps to open and vent, resulting in some water loss. Most sealed
batteries have extra electrolyte added during the manufacturing process to
compensate for some water loss.
The battery shown in figure # 7 above has been fully recharged using a fixed
charging voltage of 13.6-volts. Notice that some lead sulfate
(sulfation) still remains on the plates. This build-up will continue after each
recharging cycle and gradually the battery will begin to loose capacity to
store a full charge and eventually must be replaced. Lead sulphate build up
is reduced if battery is given an Equalizing Charge once every 10 discharge
cycles or at least once a month. An Equalizing Charge increases charging
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
voltage to 14.4 volts or higher for a short period. This higher voltage causes
gassing that equalizes (re-mixes) the electrolyte solution.
The optional Charge Wizard automatically senses when a battery has a very
low state of charge and automatically selects its BOOST MODE of
operation. BOOST MODE increases the voltage of converter/charger to 14.4
volts. When the battery reaches the 90% charge level, the Charge
Wizard automatically reduces the charge voltage down to 13.6 volts to
complete the charge.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
1. The electrolyte and plates "wear out". The life of a battery (36 months, 48
months, etc.) is determined by the thickness and number of plates and you
get what you pay for in that regard. Eventually the battery wears out and
can't hold a charge. To test for this, have a service station test the cells with
a hygrometer (a device which measures specific gravity ) .If the hygrometer
says the battery is shot and it won't hold a charge, replace it.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
Mechanical Testing
Typical tests are included in the safety standards below. They include simple tests for
dimensional accuracy to dynamic testing to verify that the product can survive any
static and dynamic mechanical stresses to which it may be subject.
Environmental Testing
Typical tests are included in the safety standards below. They are designed to
exercise the product through all the environmental conditions likely to be encountered
by the product during its lifetime.
Visual inspection A visual inspection locates cracks, leaks, and corrosion. You can find
these problems before they become catastrophic failures; however, visual inspection says
nothing about the strings state of charge (SOC), capacity, or state of health (SOH).
Voltage testing A low float voltage shows a cell that is not fully charging and cannot
supply full capacity, which may be an indication of plate sulfation. A high float voltage is
an indication of overcharging. This can lead to premature grid corrosion and higher
temperatures in the battery. High temperatures may lead to valve-regulated lead-acid
(VRLA) batteries drying out or even thermal runaway. Incorrect float voltage shows
something is wrong. However, if the float voltage is correct, it says nothing about SOC,
capacity, or SOH.
Float current A high float current could be a precursor to thermal runaway. It could
also indicate a short circuit/ground fault or be a sign of a high float voltage. Incorrect
float current, once again, shows that something is wrong. But if the float current is
correct, it says nothing about capacity or SOH.
Ripple current Excessive ripple will cause internal heating of batteries. Ideally, ripple
current should be less than 5A for every 100Ah. However, ripple current says more about
the state of the charger than the battery. Ripple current does not provide any information
about SOC, capacity, or SOH.
Specific gravity measurement A specific gravity measurement reads the ratio of the
density of a liquid to the density of water. Specific gravity measurements in batteries
indicate how much sulfate is in the electrolyte, providing information about the SOC, but
not capacity or SOH.
Impedance testing An impedance test does not measure the capacity of the battery, but
it is an indicator of the SOH of the battery.
Discharge testing Discharge testing is the only form of test that will determine the
actual capacity of the string, but not necessarily the SOH.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
Fully charged automotive batteries should measure at 12.6 volts or above. When the engine is
running, this measurement should be 13.7 to 14.7 volts.
Set the multimeter dial to 20 DC Volts. Connect the red probe to the positive terminal and the
black probe to the negative terminal. The reading should be above 9.6 Volts for a good battery,
but a value between 11-12.7 signals a great battery. It's a good idea to test the battery several
times for consistency.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
Lead peroxide.
Sulfuric acid.
Lead sulfate.
75%
50%
25%
10%.
Correct, a spicific gravity of 1.190 is 50% charged, 1.270 is 100% charged, and 1.100 is 0%.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
1.75 volts
4.2 volts
1.2 volts
2.1 volts
Correct, each cell produces 2.1 volts. 6 cells @ 2.1v = 12.6 volts
number of plates.
size of plates.
both a and b.
neither a nor.
Correct, both the number and size of plates determine the surface area.
water.
kerosene.
Correct, a solution of baking soda and water will neutralize the battery corrosion.
9. To check for a battery drain, you would connect an ammeter between the:
Correct, placing an ammeter in series. Most cars will draw less than 35mA.
10. In order to properly and accurately perform Heavy Load tests on batteries, the
battery must be at least:
50% charged.
25% charged.
100% charged.
75% charged.
Correct, a battery less than 75% charge cannot be acurately tested and must be recharged.
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
11. When performing a battery capacity (heavy-load) test on a 12-volt battery, the
voltage should not fall below
12.0 volts.
10.6 volts.
9.6 volts.
8.6 volts.
Correct, replace battery if voltage drops below 9.6v.
5 seconds.
10 seconds.
15 seconds.
20 seconds.
Correct, load test for no more than 15 seconds due to the heat.
13. The state of charge of a sealed battery is to be estimated based on its open-
circuit voltage. A full-charged battery that has been standing for a few hours will
have an open-circuit voltage of at least:
12.6 volts.
12.2 volts.
11.5 volts.
9.6 volts.
Correct, 12.6v = 100% charged, 12.4v = 75% charged, 12.2v = 50%, 12.0v = 25%,and 11.9 or less
0%
14. A 400-CCA battery is being load tested. The correct load will be:
1200 amps.
400 amps.
200 amps.
330 amps.
Correct, load test battery at 1/2 the CCA rating, or 3X the amp-hour rating
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DR. S.R.MAHAJAN
Automotive Electrical and electronic Systems
CHAPTER 1 : BATTERIES
15. What is the reading on the DVOM when performing an open circuit voltage test
on battery with a 50% charge:
12.0 volts.
12.2 volts.
12.4 volts.
12.6 volts
Correct, with a digital DVOM, 12.2v = 50%. 12.6v=100%, 12.4v=75%, 12.2v=50, &
12.0v=25%.
16. A battery that is undercharged for a long period of time will become:
cycled.
overheated.
sulfated.
hydrometer.
ammeter.
load tester.
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DR. S.R.MAHAJAN