BATTERY imary and secondary. h are not rechargeable when they are discharged and are #€ used in wall clocks, radios, torches, wrist watches est. ‘There are two types of batteries namely the Pri ‘The primary batteries are those batteries whict discarded. Examples of such batteries are thost ‘TYPES OF SECONDARY BATTERY ‘There are a number of secondan from the plates and also the ty © Lead Acid © Maintenance Free Batteries © Nickel Alkaline ¥ batteries in use today these are classified by the materials used to 'ype of electrolyte used into which the plates are immersed, These are: \ Lead acid batteries and maintenance free batteries are widely used on motor vehicles today due to that they are: > Cheep > Easy to maintain ~ Durable (perform well if maintained /charging system is okay) > Lighter in weight Smaller in size ‘Nickel alkaline type of batteries which are termed as dry batteries which only uses nickel as plate materials, This type is slowly being phased out of use due to that they are: Expensive > very big in size Heavy in weight Needs to be maintained periodically This is an electrochemical device which converts chemical energy to electrical energy, The main functions of a lead acid battery are: © To provide a source of current for starting and operating the engine, Qo stabilize the voltage in the electrical system, to supply curent tothe electrical systems when the demand exceeds the output of the alternator Although other functions are to: Store energy Allow the dynamic memory/ alarm systems to be active when the vehicle is left idle for @ long period. To allow other components to operate even when the vehicle is not running, e.g. parking lights, hazard, and radio e.t.c. a te rea eeconstruc ‘The battery consists of the following components: Casing/housing Separators Ge Battery posts / free ends / terminals. Vent plugs Top cover Cells plates Compartments leadcennecng Sediment chamber ceoewe shirt pecan Cell connector “= Straps Ea Ribs 7 Electrolyte sane Filler holes. cve materi inegatve ste) sediment a9 Lead-acid battery; 12 V ‘THE CASING ‘The casing is a container which accommodates all the parts of the battery. Its said to be acid and water proof. It has as many compartments as there are cells in a battery. The casing is made out of Milam, hard rubber, polyprothelene, treated plastic which is mixed with carbon black. ‘These casings are treated and tested by the manufacturers if there’s no leakage of current from the battery and across the battery casing, ‘The Milam casing Is a composition of pitch and asbestos. ‘THE SEGIMENT CHAMBER SEGIMEN TS ‘Sectoned portion of container showing GEC. MENTS ‘This is the space below where the segments are trapped during the operation of the battery. Thé active materials wean away stowly and these are trapped and rest at the segment chamber to protect the cells from short circuiting. There are some baffles or ridges which restricts them from rising up. a 2_ BATTERY TERMINALS/ POSTS These are sometimes known as posts, free ends or terminals which protrude through the upper cover. These are tapered posts where the battery lugs are connected in order to transmit current to the circuits in order to transmit current to the circuits. ‘These can be identified by: Size — the positive is bigger than negative. Symbol ~ the positive has the ' + sign and negative '- Color - the positive red the negative is blue/ black. SEPARATORS ‘The separators ‘There are insulators which insulate the positive and negative plates to prevent them from short circuiting, The separators are made of porus materials which are grooved vertically to permit the free circulation of electrolyte during the chemical reaction. These materials are: Rubber, Fiber glass, Alas mat, treated plastic and are acid resistant. VENT PLUGS. B— vem ca /PLUc, The opening on the cell cover is sealed with the vent plugs. These are lids or cups that close up the opening on the upper cover. These lids have vents to allow the escape of gases that are generated while the battery is working, On some batteries the vent plugs are friction fitted so that they are closed or clogged this can even burst due to the fact that there's no outlet for the escape of gases. The vent plugs if kept dirty can also lead to battery sulphation.THE GRIDS ry plate eid ‘The grids are termed as a screen or mesh that forms the frame work of the plates. The active materials of the positive and negative plates are built or moulded on the grids. ‘The grids are made out of an alloy of lead ancl antimony. Pure lead isto soft and lacks strength. The functions of the grids are: They conduct electricity to and from the active materials. ‘They save to support the active materials and hold it in place. UPPER COVER Terminal Yent plug Cover ‘opening Terminal ‘Most batteries have one piece cover that is bonded to the battery casing. The cover provides a seal over each compartment of the cell. ‘The opening on the cover provides access to the cell for filling of battery acid and topping up of battery water when required. “The skirt is also moulded onto the cover to determine the correct level of the electrolyte in the battery. | This also provides an opening where the inspection of the condition of the battery is done,Battery plete with ead-oxide paste The positive plates are built by filling all the opening of the grid with the active material which is lead oxide. This lead oxide is then converted to hard porous brown lead peroxide (Pbo.) by giving the plate a forming charge when the grids are filed with the active material, they are placed in a weak acid solution (HS0,) and an electric current is passed through them ‘The lead oxide is then hardened and converted to lead peroxide and changes its color to chocolate brown. After drying they are then assembled as plates in parallel and separated by separators from the negative plates and assembled in the battery to other cells in series. ‘The positive plates are bigger in size than the negative plates due to that the materials used on them are easily corroded, and there's more reaction on the positive plate since current flows from the positive terminals, NEGATIVE TERMINAL Negative Plate Unlike the positive plates, the negative plates are also filled up by molding and with the active material known as the spongy lead which is an inert expander that keeps them porous. ‘The same procedure which is done on the positive plates is also done on the negative plates. The negative plates are more in number than the positive plates. This isso in order to maintain the potential difference and have polarity. The number and size of the plates are also increased in order to increase the capacity of the battery and also the amount of current flowing out of the battery. The standard size of the positive plates ina light duty battery is 0.08 inches (2.03) and 0.07 inches (178mm). Heavy duty batteries go up to 0.25 inches (6.35mm) positive and 6.10mm negatives.BATTERY ELECTROLYTE Battery electrolyte isa liquid which comprises a mixture of sulphuric acid and distilled water mixed to the right proportion. This electrolyte comprises 34% of S, acid and 66% of water with the ratio 1:3. The charge specific gravity of electrolyte is between 1.260 ~ 1.300, The specific gravity of the electrolyte is measured by an instrument known as a hydrometer which ‘measures/ compares the mass volume of sulphuric acid and that of water. The electrolyte is filled in the battery before put into use. MEASURES TO FOLLOW WHEN MIXING ELECTROLYTE ‘When mixing the electrolyte the following measures are to be observe Proper protective clothing Should be done in a highly ventilated place Health should be observed Add acid to water ‘Add 1 part of S. acid to 3 part of water. Use acid proof utensils e.g. glass/ plastic HOW TO MIX THE ELECTROLYTE Concentrated sulphuric acid has an S.G of 1.835, which is supposed to be reduced to between 1.260— 1.300, which is suitable for the battery To reduce the following must he done: ‘Mixin a plastic container and use a stirring rod made of glass to stir the mixture. 1 part of acid is to be added to 3 part of water. Never add water to acid, the heat might be produced due to use in temp which can cause the mix to spill out and injure the person mixing it. Measure the S.G of the mixture to the right proportion by using a hydrometer. Check the temperature of the electrolyte by using the thermometer if not incorporated in the hydrometer. Then let the mixture cool and carry out the measurements again. BATTERY OPERATION The battery operates on the principal of electrolysis. It operates by chemical reaction between the active materials of the plates and the sulphuric acid in the electrolyte. The charging and discharging process forms a cycle. The chemical reaction which forms a cycle is divided into two parts which are; the chemical reaction during charging and discharge. ‘The medium in which the charging and discharging is the electrolyte. The charging in the battery start a chain reaction of the electrolyte. In the charged start of the battery, the active materials on the positive plates are lead peroxide which denotes the chemical symbol of PbO2 whilst that of the negative is ‘spongy lead with the chemical symbol Pb. The sulphuric acid in the electrolyte has the chemical formula symbol as H,50s, as below. $n rene er ir rr ern 6Qo }—~ | AL Hs 0, poo.” be PAH, so: Positive plate Negaive plate ‘Chemical action berneen plates and acl battery is being discharged BATTERY CHEMICAL RE ON DURING DISCHARGE . ie] pes rosa] Xie fo A Positive plate Chemical ston beeen pts ad aid we battery is being charged. an When the battery is being discharged, the chemical reaction starts. The active materials lead peroxide the positive plates and spongy lead on the negative plates will react with the sulphate on both plates and water. The sulphuric acid molecule splits into H. and SOs. One part will unite with Pb of the positive plates and the other with the negative plates, and forms lead sulphate. This reaction sets free the atoms of oxygen from the lead peroxide of the positive plates which will later reunite with the hydrogen left behind in the electrolyte to form water. Itis during this time when the battery is said to be discharged when it is put on charge the reverse reaction will take place. The lead sulphate of the positive plates is reconverted to lead peroxide and the lead sulphate on the negative is also reconverted to spongy lead. This then release sulphuric acid to the solution 2s electrolyte. Hydrogen and oxygen, the two gases which form water are released during this reaction, following which they escape to the atmosphere through the vents on the vent plugs. This then reduces the amount of water in the electrolyte. That's the reason why distilled water or battery water is topped up in the battery when the level is low. ‘When the lead sulphate in both plates has been reconverted to its original form, the battery is said to be charged.WHAT HAPPENS TO THE BATTERY WHEN IT DISCHARGES, Pos. plates + (Neg. plates >) becomes (pos.+neg. plates.) + { water ) Lead peroxide Spongy lead lead sulphate PbO: +Pb+2H:SO, === 2PbSO, + 2H20 Fully charged battery completely discharged battery SPECIFIC GRAVITY A specific gravity is the thickness of liquid, water is assigned 1. Any liquid that is thicker than water will be given a higher number and any liquid lower than water will be glven a lower number. In short the specific gravity of a substance is the ratio between the mass of a certain volume of a substance fsthe Hatin between the-mass-ofecertaingelome-sta-substanmt® and the mass of the same volume of water. The specific gravity of the electrolyte varies with temperature. Note that the liquid expands and becomes thinner when heated and it loses its specific gravity. Its therefore, then essential to take into account the specific gravity to known the state of charge of the battery. SPECIFIC GRAVITY BATTERY CONDITION (5.6) 1.260- 1.290 Tully charged 1.250~1.260 | Three quarters charged 1.251.225 One half charged 1.200~ 1.225 One quarter charged 1.175 - 1.200 (or below) Discharged 4.100-1.175 | Fully discharged | oem neeoeneeemeenevenescaeee |eELECTROLYTE DENSITY The electrolyte density is measured by the use of the hydrometer. This is an instrument which compares ‘the mass of a given volume of electrolyte with the mass of an equal volume of pure water. Pure water is assigned a gravity of 1.000, So the electrolyte which is heavier than water will be assigned a higher S.G. lass tube {—avobor ube The hydrometer consists of the following: = Rubber bulb ~ Glass tube Or Glass barrel - Float ~ Rubber tube The float inside the clear glass barrel is graduated from 1.100 at the bottom to 1.300 at the top. Some floats are colour coded. le. Green for the charged and Red for discherged. The rubber tube on the bottom of the hydrometer is used to draw the electrolyte into the barrel. The electrolyte is caused to enter in the barrel by the bulb which is squeezable. Some hydrometers are incorporated with a thermometer, temperature is very important as the specific gravity will change with temperature Battery hydrometer FECT OF TEMPERATURE ON ELECTROLYTE DENSITY — When the electrolyte temperature is increased, the electrolyte will expand. It must be taken into account if accuracy is required, since it loses its specific gravity. The electrolyte's specific gravity will be higher ifthe temperature of the liquid is lower so the S.G needs to be converted to actual state of charge through temperature compensation. Electrolyte gravities should be measured at standard temperatures of 80"f or 60°F and 15°c or 20°C. In Fahrenheit (*f) for every 10°f below 80°F (60°f) subtract 0.004 from the observed reading, For every 10°F above 80°F (60°f) add 0.004 points. eer ENDL 9& * i of s38 welts wo HSS ott 38 ee ae Sites col § rE olftE mites oH oft 8 Temperature compensation chart from a battery hydrometer In Celsius (°c) for every 3°c above the STD temperature of 15*c (20°c) 0.002 points are added the S.G. Reading and every 2°c drop is subtracted from the S.G reading, Example If the specific gravity reading of an electrolyte temperature at the STD temp. Of 80"fis 1.240. Calculate the equivalent 5. at the 40°F S.G = 1.240 ~ (4 x 0.004) S.G = 1.240 -0.016 S.G = 1.224 ans. The battery electrolyte state is sometimes stated in percentage. Below is the formula and calculation on how the state of charge of electrolyte is derived at State of charge = measured S.G ~ when fully discharged. In% fully charged ~ when fully discharged. eg. = 1160-1,100x 100 1.260 ~1.100 =0.050 x 100 0.260 =375 38% ans. 10‘THE EFFECT OF TEMPERATURE ON BATTERY PERFORMANCE The battery on the vehicle is less active when cold than at normal air temperature. However, when a battery is being discharged, the voltage of the battery is influenced not only by its capacity and state of charge or discharge, but also by the temperature of the electrolyte. As the electrolyte temperature increases, the chemical reactions between the electrolyte and the plate’s takes place more readily. n cold weather when the temperature decreases, the electrolyte becomes Thicker, concentrated, slewing down the diffusion of (acid) electrolyte into the pores of the plates and separators. This retards the rate of chemical reaction, lowers cell voltage and while drawing a large amount of current required for cold starting and limits the output of the battery. Besides the fact that the battery efficiency is decreased, the starting load during cold weather is. burdened by the viscosity of the engine oil. Itis important then to note that the battery is kept in a fully charged state in the cold weather. NB. Never keep or put the battery direct on the floor or metal plate, but on wood and rubber so as to prevent the electrolyte from freezing and being more concentrated. ‘SELF DISCHARGE OF THE BATTERY Storage batteries gradually lose their strength when left ide. This is brought by the slow internal chemical reactions between the battery materials, which result in slow internal discharge. The other factor is if the upper cover (top of the battery) is subjected to moisture or water which will act as @ conductor and lead to self discharge of the battery. The self discharge rate increase as the battery temperature increases, such slow discharge causes a hard sulphate to form reducing the plate surface area and plate porosity. A battery which is badly self discharged or sulphated may be ruined since itis difficult to recharge the battery since itis difficult to recharge the battery under these conditions. Batteries which are to remain idle for some time should lve well taken of. They should be stored in a cool place and be recharged at fixed intervals to replace loss due to self discharge, of the electrolyte be drained and stored dry in a cool place and a wooden shelf, BATTERY RATING __ Battery rating is the measure of the energy stored in it. This rating is mostly expressed in terms of the Period during which the battery will give the rated current before it gets discharged (its final voltage reaches about 1.8¥) NoTE, The quantity of electric current a battery can deliver depends on: 2. The total area and volume of the active materials. 2. The internal resistance of the battery. 3. The strength of the battery electrolyte 4 The temperature also governs the amount of current, When the temperature decreases the capacity also decreases and vice — versa, ner PST w« Most manufacturers rate their batteries in several ways, but the most important or the widely used rating are: 1. A/H rating ( Ampere Hour) 2. C.CA( Cold Cranking Ampere) 3. Reserve Capacity Rating. Some manufacturers term the A/H rating and the Reserve capacity to be one and the same thing and this has enabled the BATTERY COUNCIL INTERNATIONAL to rate their batteries according to the reserve capacity and cold cranking power only. The BCI also emphasis’s that when replacing a battery on a vehicle options such as air conditioning and a number of electrical accessories may indicate the need for an optional heavy duty battery with a higher rating than before. A/HRATING ~ The ampere hour rating is the ability of the battery to deliver current or the amount of current a battery can deliver ina period of time ie. 10 ~20 hours while holding a cell vltage of 1.75V or 1.8V at 27°C. Ifa battery delivers a steady current of 5A for a period of 20 hours (vehi is commonly used when 100 as the rating). It will be rated as a 10CAH kattery. This is calculated finding the product of 5 X 20 ‘AH using the formula AX H = AH If another battery is discharged for 20 hours at a rete of 2.5A. It will be rated at 50 AH ie, AXH=AH 2.520 50 AH. This rating is also used when one needs to change the battery either slow or fast charge u: source charge (the battery charger) using the formula: Ya AH (fast charge) and Yi0 x AH (slow charge). This i the ability of the battery to supply current when cold to crank the vehicle, It denotes the amount of amperes a battery can deliver for 30 seconds when itis at - 18°C (O°F) without the cell voltage falling below 1.2 volts This rating allows cranking capability to be related to such significant variables as temperature, compression ratio, condition of engine, electricals, ol viscosity to name a few. The three standards which are commonly used are the 8S ( British Standards), the DIN (German. Standards) and the SAE (Society of Automobile Engineers). Since the C.C.A is denoted as the current in amperes delivered at - 18°C until the battery voltage falls to 1.7V or more per cell ( 7.2.V for a 12V/} the above standards rate the battery for the C.C.A. Testing as follows. ne rm 2End Voltage 84V 9.0V 7.2V NB. It is important to compare batteries using the same standards; through the commonly used is the DIN. Same batteries are stamped with a 5 digit manufactures number followed by the terminal voltage, terminal ampere hour capacity and cold starting voltage as below. The ampere hour and C.C A are always indicated on the battery to help the customer to choose the right battery. This is because during cranking the starter motor will need more current for it to turn the engine when cold and this ranges from 150A to 850A for heavy and light vehicles. ‘The reserve capacity indicates the time in minutes for the battery voltage to fall to 10.5V with a constant load of 25A at 25°C for a period of 20 hours. Itdenotes the time in minutes a battery can deliver a current of 25A at 25°C before the cell voltage drops to 1.7V when the charging system is faulty The standard current of 25 represents the everage discharge on a vehicle if the charging system should fail, t indicates the time that a battery will keep the vehicle in operation assuming the electrical load is normal ‘The rate at which the discharge is measured was 10 or 20 hours, but now only the 20 hours rate is used. Eg. A SOAH battery can be expected to deliver 7.58 fer 20 hours before the terminal voltage falls to 10.8v. LOW MAINTENANCE BATTERY ~ Pecaie eee trough the partion interetl connector intareat) partion postive plate negative pate eatwoides letconraner seal deparator polyprcoylene container 13In the Lead Acid Battery we realize that the charging produces Hydrogen and Oxygen in gas form. The amount of electrolyte also decreases in time as the battery is charged and discharged as itis in service. Its capacity also due to self discharge even when it is not even used for this reason the hydrogen and oxygen has to be replaced with H,0 (distilled water). The batteries must be periodically checked. Because of this the manufacturers started to develop the low MAINTENANCE BATTERIES to minimize the electrolyte consumption rate, the rate of self discharge and the frequent checks maintenance of the battery, The low maintenance battery is more or less in construction like the lead acid battery. Most of the features of the low maintenance battery are the same in construction. The main difference is that the low maintenance batteries have grids made out of antimony which reduced gas during charging. By SO doing the usage of water was reduced and if under normal working conditions i.e. if the charging system of the vehicle isin perfect condition the battery would not even require the addition of water in each cell during its life time. butt testhycremeter burt ame seater ent > 7 es aug separator : mmoulsea symbol on cersty pase serproovene leao-eicum ged Me terse mount separator envelopes heapauite ites Maintenance-free battery ‘These batteries are those that do not need topping up of battery water during the battery life and do not need frequent care an exception of keeping it clean. All batteries in the class have same form of vent to allow gases to escape. Some maintenance free batteries have a fully sealed top so that no topping up is done. Only a small vent is applied. Some have vent plugs through which topping up is done in the event of accidental overcharge. This type of a battery differs in some ways from the lead acid battery or conversional battery. In construction the maintenance free batteries have envelope type of separators so that when paste (active material) becomes dislodged from the plates. It rests at the bottom of the envelopes and short Circuits cannot occur between plates.‘An improvement in the maintenance free batteries in construction is that it has its grids made out of antimony of calcium to eliminate gassing during battery use. The other improvement is that the use of multi grids in which thin machine filled plates are closely packed in a cell to increase the capacity which gives a stating power of 30% than that of a starting power of 30% than that ofa LEAD ACID BATTERY. Same designs even incorporate a built in hydrometer or indicator which is known as the DELCO EYE to determine the density and the electrolyte level. This has various coloured balls to show the state of charge. These coloured balls are in Green, Black, and Light Yellow, When the Green shows on the prism, this is an indication that it is charged and serviceable and in good condition. When the black ball shows ‘on the prism, this is an indication that the battery needs to be charged or recharged. Ifit isa light yellow ball showing on the prism, then the indication is that the battery has an internal fault and needs immediate replacement. 1 does not need any test or any charge. ifthe battery has an internal fault, the engine should not be jump started thus using jumper cables for thus will buckle the plates in case of an internal short, check the alternator and check the output of alternator for correct operation. ADVANTAGES OF MAINTENANCE FREE BATTERY OVER THE LEAD ACID BATTERY ~ This type of battery requires no service, It offers better cranking power even during coir weather, Ithas improved resistance to heat and vibration. Itcan also deliver a current to 420 for C.C Ampere. It is light in weight and low maintenance costs. veene During charging and discharging of a Lead Acid Battery, electrolyte evaporates in from of gases which are a decomposition of water and electro ~ chemical reaction electrolysis, which changes water into two ‘elements of oxygen and hydrogen. This then causes the level of the electrolyte to go down and the distilled water is required to be tonnes. In the maintenance free battery an elimination of L2ad Antimony in the grids has over comed the issue of topping up distilled water. This has also aver comed other causes like early battery failure, overcharging, water usage, sof discharge and thermal runavay which is a condition which occurs in a lead acid battery when faulty regulation of the charging system is combined with the using in electrolyte temperature or when the battery temperature is higher than normal. The operation of the M.F.B depends much on the design of the battery, the Valve Regulated Lead Acid battery (V.R.L.A) which i @ recent innovation use of the recombination principal to reduce the formation of oxygen and hydrogen when the battery is being charged. In this type cf the battery, the separators are made of micro ~fiber glass which absorbs the entire liquids electrolyte in its pores. These separators wrap the plates and make it impossible for free acid or electrolyte to be above or sides of the plates. The combination of these features ic. Micro — fiber separators, no free electrolyte, plate groups compressed and elevated pressure allow electrolytic water loss to be suppressed by the following ‘mechanism. During the fully charged state, the oxygen liberated at the positive plates passes through the separator pores saturated with the electrolyte to the negative plate. In the presence of sulphuric acid at the separators and at the negative plate, the oxygen reacts with the lead of the negative plate to ferm lead sulphate because of this reaction the negative plate never reaches the full potential for hydrogen to be released, so no water is formed or lost. After initially reacting to lead oxide, the plate quickly changes to lead after further changing done for short period and the oxygen is recombined to the positive plate and the cycle continues. ante nr tt RE 152Pb + O2 + 2H,SO2 > 2PbSO, + 2H20 CHARGE DISCHARGE The Other design is the FREEDOM BATTERY. This type of battery has separators in form of an envelope. It also incorporates the liquid ~ gas separator cooling reservoir for the condensation mechanism to be done. In this type of the battery during charge, the os sprayed electrolyte is given off which then is trapped in the liquid gas separator cooling volume under the top cover and returned to the electrolyte and there’s no loss of water hence no topping is done. NB This type of the battery is easily damaged by overcharging. Bear in mind that it should operate under ormal charging rate at 14.5V. Any rate above 15.8V may damage the battery. Ifa bench charger or Outer sources not exceed 14.4V. To prevent the plates from being buckled never: 1. Boost charge the battery 2. Never continue to charge the hattery or use it on the vehicle ifit has started gassing. 3. Never charge the battery from an excessive rate of 15.8V BATTERY CAPACITY ‘This is the amount of current that a battery can deliver for @ certain length of time at certain temperature. HIGH DISCHARGE CAPACITY. ‘The amount of power that can be taken from the battery st each time.HOW TO USE A HIGH DISCHARGE TESTER ON A BATTERY 1. Check battery terminal voltage (open circuit test by using a voltmeter). Ifthe battery terminal voltage is less than 12V do not use the High Discharge Tester but if more than 12V you can use the High Discharge Tester 3. Remove the vent pl Connect the High Discharge Tester Negative to the battery Negative and HDT pointer to positive whilst observing time and gauge on the instrument. 5. The High Discharge Tester should not be used for more than § seconds. 6. While observing the gauge on the tester it will how the following. RED For bac. fad don't tse the battery. Yellow For recharged / slow charge Green --—---For good condition (use the Battery). ‘THE SPECIFIC GRAVITY Fig. 3 Reading the hydrometer | Measuring specific gravity * samen Specific gravity of a substance is the ratio between the mass of a certain volume of a substance and that of water. The specific gravity of the electrolyte is the density of sulphuric acid compared to that of water. Anything (liquid) which is thicker than water will be given a higher number since water is, assigned with 1.000, ‘The specific gravity of the electrolyte states the strength of the electrolyte anc hydrometer. 5 measured by the ‘The table below states the state of charge of the electrolyte when you use the figures. ‘SPECIFIC GRAVITY "BATTERY CONDITION "1300-1260 Fully Charged 1.260-1.250 % Charged 1.225 1.250 % Charged 1.200- 1.225 | % Charged 1.175-1.200 | Discharged 1.100 1.175 | Fully dischargedEEE The specific gravity of the electrolyte varies with temperature of the electrolyte. When the electrolyte expands. This will lead to the electrolyte becoming thinner and lose its specific gravity and the level will go down, The electrolytes gravity will be higher if the temperature of the liquid is lower. This will lead toa concentrated electrolyte which will et it to difficult to diffuse to and from the active materials which will retard the battery current output. ‘The freezing of the electrolyte depends on the state of charged of the electrolyte. When the density of the electrolyte decreases, the acid strength falls. The freezing point rises as the electrolyte composition moves towards a pure water state. ‘The electrolyte of a discharged battery will freeze at a higher temperature than a fully charged battery. Electrolyte of an S.G. of about 1.260 will nat freeze until its temperature goes down to 80°f(15%c) or below to zero, but the electrolyte at an S.G. of 1.100 will be frozen at 15% oF above zero. BATTERY SELECTION ‘When choosing a suitable battery for a particular vehicle one should consider the relationship to starter current, the oil viscosity though there are other factors Ike type of fuel used e.t.c, but the first two are important The battery for a vehicle is normally selected in relation to the requirements of the starter motor. In order to start the engine, the cranking speed must be at $0 to 100 rev/min in temperate climates and the starting system must be capable of operating at temperatures as low as -30°c (in some countries - 40°C). ‘ For the starter motor to operate, the required starting current must be supplied at the appropriate voltage. When the starter motor is turning the engine, the battery terminal voltage will fall due to the internal voltage drop, but must not fall helow (9v) far a satisfactory operation. The minimurn voltage at the starter switch (sw) should be 8.5y, allowing a 0.5v drop along the battery main lead and battery terminals. If the difference is more than 0.5v then there's a high resistance in the cables causing excessive voltage drop. Low temperatures also have an effect on the engine. This also increases an oil resistance, resulting in harder starting conditions, therefore, the correct oil should he used as directed by the S.A.E or EP ‘companies increased torque is therefore required at low temperetures. 18BATTERY MAINTENANCE SERVICE PROCEDURES 1. Clean the battery with carbonate soda. 2. Clean the battery terminals also with the remely cloth. 3. Carry out the visual inspection, Cheek for: ‘a. The date when the battery was put into service. This is stamped on the casing or on a tag; this will help you when charging the battery since old tatteries have a better chance of being worn out. 'b. Check the battery top (even before cleaning) for acid and dirt accumulation. For this can allow the battery to discharge across the top by making a connection through dirt from the positive to the negative Check for crack on the casing d. Check the vent plugs for the vents if they blocked, fe. Remove the caps (vent plugs} and check or inspect the colour of the electrolyte. Discolored electrolyte indicates cell problem note the odor (smell) of the electrolyte, a toxic odor indicates the cellis sulphated and wil not take 2 charge. {Check electrolyte level. The level is importart ifthe batt=ry is going to function normally, since cell capacity is reduced greatly when itis low on water. If ow top up and charge the battery. Check battery posts for looseness anid signs of abuse. Such as partially melted posts cause by arcing from terminals to terminal, starting vehiclo with loose connections, and fitting wrong size of battery clamps (lags) 4, Carry cut the ‘open circvit test’ (or light load test or terminal voltage test) with the multimeter or voltmeter record the reading 5. Carry out the ‘charge test’ with the hydrometer, as follows: a. Remove the vent plugs and squeeze the bulb of the hydrameter. Expelling the air init b. Insert the hydrorneter sucking tube in the cell of electrolyte and release slowly, drawing electrolyte into the glass barrel Draw in only encugh electrolyte to cause the float to float. a. Read the number directly at the electrolyte level o- observe the coloured paper on float. fe. Correct the reading for the temp. Depending on the type of hydrometer you have. f. Squeeze the bulb to force the electrolyte back into the cell and then flush the hydrometer wit water. After determining what the cell's $.G. is making your decision about the battery? ifthe battery needs charge then charge it 6. Carry out the “battery load test”. This testis done on a fully charged battery 12v and above. You can use eithor the high rate discharge tester or the ampere ~ Volts Resistor (A.V.R) a. High rate discharge tester b. Remove the battery caps (vent plugs) from the battery. Connect the tester to the battery with response to polarity ¢. Maintain the lead for approximately 5 seconds, e. If the battery is in good condition, the battery voltage should stay above 4.8v for 6v battery, 9.6v for a 12v battery. a eneneenm renner entrsn AOA LUPE AE YE 19Ifthe battery voltage meets the recommendation voltage after discharge tests. The battery is good the charge was satisfactory. When using the AVR, the connections are as above but obtain the lead for 15 seconds. 7. Change the batteries / battery. If more than two batteries use either constant voltage charge or constant current charge and observe the batteries frequently when on charge. 8, Clean the testers and working place. BATTERY TESTS Battery testing is important if carried correctly, you will be able to predict the failure of it to perform well. Abattery is tested in order to: 1. Isolate a problem to a component. 2. For preventive maintenance. 3, Predicting failure 41. Isolating a problem to @ component cr elimina*ing a faulty component in any system is ideal when you are testing a battery. Batteries mask other problem of other components that may need repair or replacement ‘The stating system, ignition kay and sulphaced cables are a great examples of problems that can be masked by the hettery. When starting the above mentioned problems can drain a lot of ‘current. Isolating a battery and caring out tne battery bench test will lead you to know the cause and solve the problem. 2. Preventive maintenance on an automobile battery is very important, when the battery is free from sulphation, moisture and dirty resistance is eradicated. This enables the current to have @ ow resistance path and flows where work is to be done. When preventive maintenance is regularly done on a battery this ensures that the vehicle will be able to start even during cold season where more current is needed 3, Predicting failures of a battery on a vehicle can be done after caring out the preventive maintenance on 2 bettery. You can be able to advice your client if the battery will be ideal to crank the vehicle during cold weather hy caring out the cold cranking test/ 3 minutes test. By carrying out the charge test you can predict the state of the charge ofthe electrolyte and condition of the battery and advice to replace it if need arises. You can also predict the failure of a battery if it’s a wrong size, duration and itis a transit battery. een ct RE RE CEE 20 — : |BATTERY TESTS 1. Charge test (by using a hydrometer) 2, Terminal voltage test (by using a voltmeter) 3, Load test (by using a high discharge tester) 4. Cadmium test (by using a call tester) 5, Cold cranking test/ 3 minute test. BATTERY CHARGING normally there are two common methods of external battery charging which are used nowadays which TAGE CHARGE though there are other method ‘are CONSTANT CURRENT CHARGE and CONSTANT VOI like fast or boost charge and tuckle charge £ (quick charge! CONSTANT VOLTAGE CHE PROALLEL CONNECTION method of charging a battery with a large currentin a short period of ime. *he aa ener components wil be adversely affected, hence this type of xeperais not desablet can damage the baer quick charge cannot charge Te battery fully, char pater wl be fully charge by the alternator on the vehicle, Normal quick charge lasts yor 30 minutes to 2 hour, With a current equivalent to haf the capacity of he battery eg. 30A for GOAH battery (% AH) Ail batteries maybe safely ch: ‘without overheating. However reading is more than 25 points apar increasing current and constant voltage. The batteries if m the charger. During this charge the battery with a smaller the measure when connecting, Quick charge is the temperature will nose so high that t arged on a fast charger ata high rate, provided they accept the charge patterias with badly suiphated plates, discoloured electrolyte. Or S.G. 1, or is old should not be quick charged. During C.V.C there's nore are connected in parallel connection to ‘AH capacity can be easily damaged so observeCONSTANT CURRENT CHARGE ORDINARY (slow charge! -] BATTERY [+ CHanced MACHINE + OAK a0nH SERIES CONNECTION stow charge is the most recommend end way of fully charging the batteries. This charges the batteries Since using this method is the best, its possible to with a small current for a long, period of time. Completely charge the battery. The battery can be charged for along time even more than an hour. catteries ef dfferent amp/ hour (minutes} without any damage to the batteries. The recommended formula when charging batteres using this method is 1/10 x AH e.g. 6A for a 60AH battery. Diccolored electrolyte batteries, discharged or sulphated batteries old, est. can be charged using this method. Batteries using this method are connected in series. And there's an increase in voltage and Steady constant in current. When the batteries ae connected to the charger of various sizes. The horging rate is determined by the smallest battery group. The arrangements ofthe battery to the charger are as follows. Ne ‘The batteries maybe safely charged at a higher rate, providied the battery temperature is not high and is in good condition, During the first few hours of charging, The battery should be checked regularly to make sure that its temperature does not rise, or is not gassing so much that the electrolyte bubbles over, Otherwise lower the charging rate temporarily. 2emave the battery from the charging machine and let the temperature of the battery be low to let the battery cool, 22STORING OF WET AND ORY BATTERIES = — Genanal EC>| FE =EC = Fc 1 E| >: F=f |---| | “Method of string batteries. in a cool place, with the temperature free from moisture and be place in the fe. The period of storing the Since batteries are sensitive to temp, they must be stored recommended by the manufacturers. The place should be wooden casing without electrolyte. The period of stored without electrolyt batteries in such a way should not exceed 3 years. Storage battery ifstored with electrolyte gradually loses their strength if left idle. This is due to that there's a slow internal chemical reactions between the battery materials. Which result in a slow internal discharge? Such slow discharge causes a hard sulphate to from, reducing the plate porosity. A badly self w Gischarge or sulphated battery maybe ruined since its difficult to recharge the battery under such Conditions, Batteries which are to be stored need to be flashed with warm water and dried complete and stored in a cool place. Dry charge batteries also shipped forsale should also be stored in 2 cool place, free from moisture and dry and bestrode in a wooded box or put on the wooded shelves, These can only be topped up with electrolyte and charged wihen to be used. NB Remember to charge the wet batteries every after week or 20 days, to avoid self discharge.