Chapter 1
Batteries
Introduction
• An automotive battery is
an electrochemical device
• It produces and stores
direct current electricity
Basic Battery Cell
• Contents:
– negative plate
– positive plate
– container
– electrolyte (battery acid)
• When a load is connected to the cell, current
will flow through the load
3
Lead-Acid Battery Cell
Electrolyte causes a
chemical reaction
between the plates,
producing 2.1 volts
4
Discharging Charging
• Changes chemical • Electrical energy is
energy into converted to
electrical energy chemical energy
• Stored energy is • Energy is stored until
released needed
Cell Action
(Charging)
• Alternator causes free electrons to be
deposited on the negative (–) plate
• This causes the plates to have a difference
in potential (voltage)
6
Cell Action
(Discharging)
• Load is connected across the terminals
• Current flows through the load to equalize the
difference in charges on the plates
• Excess electrons (current) move from the
negative plate through the load to the positive
plate
7
Battery Functions
• Operate the starter, ignition, and fuel
injection during cranking
• Supply electrical power when the engine is
not running
• Supply electrical power when current
demands exceed alternator output
• Act as a capacitor (stabilize voltage)
• Store energy for extended periods
Battery Construction
• Batteries must be built to withstand severe
conditions:
– severe vibration
– extreme temperatures
– corrosive chemicals
– high current discharge
– prolonged periods without use
Battery Element
• Battery plates
– grid coated with porous lead
– several in each cell
• Lead strap
– one connects several negative plates
– another connects several positive plates
• Separators
– insulating material between plates that keep
them from touching each other
Cont.…
Most automotive
batteries have
six elements
Case, Cover, and Caps
• Battery case
– high-quality plastic, holds elements and
electrolyte
• Battery cover
– bonded to the top of the case
– seals the top
• Battery caps
– keep electrolyte from splashing out
– serve as spark arrestors
Cont.…
Electrolyte
• Mixture of sulfuric acid and distilled water
• Poured into each cell until plates and are covered
Battery Terminals
• Means of connecting the
battery to the vehicle’s
electrical system
Battery Voltage
• Open circuit cell voltage is 2.1 volts
• Cells are connected in series
• Battery voltage depends on the number of
cells
• A 12-volt battery has 6 cells and an open
circuit voltage 12.6 volts
• A 6-volt battery has 3 cells and an open
circuit voltage 6.3 volts
15
Battery Ratings
• Cold cranking rating
• Reserve capacity rating
• Amp-hour rating
16
Cold Cranking Rating
• Determines the current that the battery can
deliver for 30 seconds at 0 ºF (-18 ºC) while
maintaining terminal voltage of 7.2 volts (1.2
volts per cell)
• Expressed as cold cranking amps (CCA)
• Indicates ability to crank the engine at cold
temperatures
• Typical applications:
– 305 CCA for small 4-cylinder engine
– 450 CCA for 8-cylinder engine
17
Reserve Capacity Rating
• Time needed to lower battery terminal
voltage below 10.2 volts (1.7 volts per cell)
at a discharge rate of 25 amperes at 80 ºF
(27 ºC)
• Expressed in minutes
– example: If a battery is rated at 90 minutes and
the charging system fails, the driver has
approximately 90 minutes of driving time with
a current use of 25 amperes before the battery
voltage drops below 10.2 volts
18
Amp-Hour Rating
• Once used to indicate battery power
• Measures current that the battery could
produce for 20 hours at 80 ºF (27 ºC) with
the battery voltage above 10.5 volts
19
Battery Temperature and
Efficiency
• As battery temperature drops, output is
reduced
– chemical process is slowed
– battery cannot produce as much current
20
Cont.…
Temperature versus Efficiency
21
Battery Terminal Test
• Check for poor connections between the battery
cables and terminals
• Connect the negative voltmeter lead to the cable
end
• Connect the positive lead to the battery terminal
• Disable the injection or ignition
• Crank the engine while watching the voltmeter
readings
• Clean the connections if the voltage is above 0.5
volts
22
Battery Terminal Test
23
Checking Electrolyte Level
• Remove vent caps
• Electrolyte should just cover the top of the
battery plates
• Fill ring may be used inside the filler
opening
• Fill until even with the fill ring
• Overcharging from a faulty charging system
may cause loss of electrolyte!
24
Checking Battery Charge
• Common methods of determining state of charge
– hydrometer check
– battery voltage test
25
Hydrometer Check
• Measures specific gravity (SG)
• Compares the weight of electrolyte to the
weight of water
• Water has a SG of 1.0
• Electrolyte in a fully charged battery is
more dense than water and has a SG of
1.265 to 1.299
• As a battery becomes discharged, the
electrolyte has a higher percentage of water
and a lower SG
26
Hydrometer Check
Do not drip electrolyte
27
Battery Voltage Test
• Used on maintenance-free batteries
• Connect a voltmeter across the battery
terminals
• Turn on headlights for a light load
• Read the meter
• A fully charged battery under a 5 amp load
should have a voltage of 12.5 volts
Cont.…
This battery is about 100% charged with a 5
amp load
Cell Voltage Test
• Insert special cadmium (acid resistant) tips
of a low voltage meter into each cell
• Test all cells
• Maximum variation between cells should
not be more than 0.2 volts
Battery Drain Test
• Tests for abnormal current draw with the
ignition off
• Remove the battery cable and connect an
ammeter in series in the circuit
• Disable all the lights and the clock circuit
• Compare the ammeter reading to
specifications
• If the reading is high, isolate the problem by
pulling one fuse at a time
Cont.…
Typically maximum 10 milliamps (mA)
Battery Chargers
• Force current back into the battery to restore the charge
on the plates
• Change 120 volts AC to 14–15 volts DC
Slow Charger
• Often called a trickle charger
• Feeds a small amount of current into
battery
• Charging time is relatively long (about 12
hours at 10 amperes)
• Active materials are plated back on the
battery plates better than they are during
fast charging
Cont.…
Several batteries
may be connected
Fast Charger
• Forces high current into the battery
• Allows an engine with a low battery to start
in a few minutes
Thank You!
