Chapter 2 - Battery

MEV 390

DESCRIPTION
The battery is an electrochemical device designed to supply electricity to the engines
starting system, ignition system, lights and other electrical equipment.
It stores electricity in the form of chemical energy, releases (discharges) it as needed and
supplies it to each electrical system or device as needed.
Since the battery loses its chemical energy in the process, more electricity is supplied to it
(that is the battery is charged) by the alternator, and the battery stores it in the form of
chemical energy. The cycle of discharging and charging is repeated continuously.

CONSTRUCTION OF THE BATTERY

An automobile battery contains a diluted
sulfuric acid electrolyte and positive and
negative electrodes, in the form of several
plates.
Since the plates are made of lead or
lead-derived materials, this type of battery
is often called a lead battery.
Internally, a battery is separated into several
cells (usually six in the case of automobile
batteries), and in each cell there are several
battery elements, all bathed in the electrolyte.

(1) Battery Element.

The positive plates and negative plates are each connected together by separate plate
straps. These group of positive and negative plates are then placed alternately, separated
by separators and fiberglass mats. Taken together, the plates, separators and mats are
called a battery element. Grouping the plates in this way serves to enlarge the contact area
between the active materials and the electrolyte, thus allowing a greater amount of
electricity to be supplied. In other words the battery capacity is increased.
The electromotive force (EMF) generated by one cell is approximately 2.1V, regardless of
the quantity or size of the plates.

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Since automobile batteries have six cells that are connected in series, their nominal
output EMF is about 12V.

(2) Electrolyte.
Battery electrolyte is a solution of sulfuric acid diluted with distilled water. Electrolytes that
are used in batteries today have a specific gravity of both 1.260 and 1.280 (at 20C. 68F)
when the battery is fully charged. This difference is due to the particular ratio of distilled
water to sulfuric acid in each type: the electrolyte having a specific gravity of 1.260 contains
65 percents of distilled water and 35 percents of sulfuric acid, while the electrolyte having a
specific gravity of 1.280 contains 63 percents of distilled water and 37 percents of sulfuric
acid.

REFERENCE

CAUTION

Specific gravity

Battery electrolyte is a strong acid. It can

burn skin and eyes, and damage clothing.
If you get acid on your skin or clothes,
flush the affected areas with a lot of
water, then neutralize the acids with a
mixture of baking soda (sodium
bicarbonate, NaHCO3) and water for
several minutes, and then consult a
physician immediately.

The ratio of the density of a substance to

that of water. Water has a specific gravity
of 1.0, so a substance with a specific
gravity of less than 1 is less dense than
water, and one with a specific gravity
greater than 1 is denser than water.

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(3) Battery Case.

The container which holds the electroylete and baterry elements is called baterry case. It is
divided into six comparments or cells. Upper and lower electrolyte level markers are
provided on the transparents or semi-transparent batttery case. The plates raised up the
bottom of the case with ribs tp prevent them from shorting out if any of the active materials
(lead, etc) should happen to fail from the plates.

(4) Vent Plugs.

Vent plugs are caps for the holes that are used for adding electroyte. They are also
designed to separate the hydrogen gas (formed when the battery changes) and sulphuric
acid mist that are present in the air inside the baterry by allowing the hydrogen to escape
through the vent holes and sulphuric acid mist to condense on the sides of the vents and
drop back into battery.

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Battery capacity
Battery capacity refers to that portion of the electricity stored in a battery that can be
released as a source of electricity. It is measured in ampere-hours (ah) as shown below:
Ah = A (ampere) x h (hour)
Battery capacity varies depending on discharging conditions. The JIS defines it as the
amount of electricity released to reach the final discharge voltage (10.5V) in five hours, as
calculated according to the above formula. The result is referred to as a 5-hour rate. For
example assume that a fully charged battery is discharged continuously at 5.6A and that is
look five hours before the final voltage is reached. The battery therefore has a capacity of
28Ah (5.6 x 5hr).

BATTERY CHECKING AND CHARGING

(1)Checking electrolyte level.
The electrolyte level must be checked occasionally, and the battery must be topped up with
distilled water to the specified level if necessary. Batteries encased in translucent
(transparent or semi-transparent) material have normal level ranges indicated on them. The
electrolyte level must be maintained within the range.
When distilled water is added during extremely cold weather, the battery must be charge
immediately until the electrolyte is agitated sufficiently to prevent freezing. On batteries with
black casings, the electrolyte level must be maintained 10 to 15 mm (0.39 to 0.59 ) above
the separators high enough to cover the plates in each cell.

(2) Checking Battery Charge.

To check the battery charge, the specific gravity of the electrolyte must be measured and a
load test to performed. The battery condition can be determined from the results of both.
i.

Testing Specific Gravity of Electrolyte.

Specific gravity is measured with hydrometer. To measure specific gravity, draw electrolyte
into the hydrometer, and read the indicator with the fluid level held at eye level. Hold the
tube straight so the float did not contact the tube.

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NOTE:
There are two types of hydrometer: one with the float level that is read at A(the topmost
edge of the meniscus), and the other that is read at B(the surface of the fluid). Therefore,
follow the operation procedure of the particular type of hydrometer that you will be using.
However, because the difference between A and B is small, your judgment of the condition
of the battery would not be affected by selecting one method or another.
Do not add distilled water prior to measurement unless the level is to low and sufficient
amounts of electrolyte cannot be taken into hydrometer. If this is done, however, charge the
battery immediately until enough gas is formed to agitate the electrolyte before the
measurement is taken.
The specific gravity of an electrolyte varies by 0.0007 per 1C (0.0004 per 1F). specific
gravities are normally specified at 20C. for this reason, specific gravities measured at
others temperatures must be converted according following formula:

Celsius measurement
S20(C) = St + 0.0007 (t 20)
Fahrenheit measurement
S68(F) = St + 0.0004 (t 68)
where:
S20: Specific gravity at 20C (68F)
St : Measured value of specific gravity
t

: Temperature of electrolyte when specific gravity was measured

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Take a battery, for example, whose electrolytes specific gravity is 1.260 when fully charged.
If the measured specific gravity was 1.260 and the electrolyte temperature was 0C (32F),
the batterys charge at the time can be determined as follows:
Celsius measurement
S20(C) = St + 0.0007 (t 20)
= 1.260 + 0.0007 (0 20)
= 1.260 0.014
= 1.246
Fahrenheit measurement
S68(F) = St + 0.0004 (t -68)
= 1.260 + 0.0004 (32 68)
= 1.260 0.014
= 1.246
The standard specific gravities at 20C (68F) when batteries are fully charged are as
follows:
1.250 1.270

(Batteries with nominal specific gravity of 1.260)

1.270 1.290

(Batteries with nominal specific gravity of 1.280)

(Difference between cells must be 0.040 or less)

The following remedies must be taken according the measured specific gravity:
Measurement
1.300 OR HIGHER

Remedy
Add distilled water to lower the specific gravity

1.290 1.220
1.210 OR LOWER

NONE (OKAY)
Fully charge battery, and measure specific gravity again. If
still below 1.210, replace battery

DIFFERENCE IN
SPECIFIC GRAVITIES
OF CELLS LESS THAN
0.040
DIFFERENCE IN
SPECIFIC GRAVITY OF
CELLS 0.040 OR
GREATER

NONE (OKAY)

Fully charged battery, and measure specific gravity again. If

difference between cells still exceeds 0.030, adjust specific
gravity. If this cannot be done, replace battery.

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ii.

Load (High-discharge) Test.

With the battery fully charged, let the battery discharge at a current four times greater than
its capacity (122 A if its five-hour rate capacity is 28 Ah), and measure the battery terminal
voltage after five seconds. The battery terminal voltage should be 9.6 V or higher. If it is not,
internal resistance of the battery is too much and should be replaced.

(3) Battery Charging.

Batteries may be charged either fast charging or slow charging. In either case, always
observe the following precautions:
i)

Precaution during charging.

Because the battery emits explosive hydrogen gas, be sure not to allow fire or sparks near
the battery.
Never disconnect the battery chargers cables from the battery terminals when the battery is
being charged: turn the main switch of the charger off before disconnecting them.
The battery fluid temperature must not exceed 45 C (113F). if it goes above this, reduce
the charging amperage or stop charging.

DANGER!!! Hydrogen gas is given off during charging.

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ii)

Quick charging.

A quick charging is used when it is necessary to charge a battery in a short period of time at
high amperage. However, this may impair battery life. If time allows, slow charging is
preferable.
(1) Clean dirt, dust, rust and corrosion off the battery. If necessary, clean the terminals with
sandpaper.
(2) Remove all vent plugs from the battery.
(3) Check the battery fluid level and add distilled water if insufficient.
(4) If the battery is to be charged while on the vehicle, be sure to disconnect both negative
and positive battery cables from the terminals to prevent damage to the alternator
rectifiers and/or other solid state devices.
(5) Determine the allowable charging amperage and time.

Most chargers have a test device for determining the charging amperage and required time,
so follow the instructors on the quick charger.
If the charger does not have a test device, use the following method:
Detemination of Charging Amperage.
Determine the state of discharge of the battery from the specific gravity, using the below
graph, then calculate the correct charging amperage using the following formula (the
charging time for quick charging is usually from to 1 hour):
Correct charging amperage (A)
=

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Calculation example:
Battery capacity: 40 Ah
Specific gravity measured at 20C
(68F): 1.18
This tells us that the battery is 40% discharged, so it needs a charge of 16 Ah (that is, 40%
of the batterys 40 Ah - capacity).
If the charging time is 30 minutes (0.5 hr), the correct charging amperage (A) would be:

10A

NOTE
We use the state of discharge here rather than the state of charge because it tells us how
empty the battery is. This allows us to calculate how long and at what amperage we will
have to charge the battery to bring it to its fully charge state.
NOTICE
To protect the battery, the maximum charging amperage must not exceed one-half of the
battery capacity figures. For example, the maximum charging amperage of a 40-Ah battery
should be 20 A or less.
(6) At the end of charging, measure the specific gravity of the electrolyte, and ensure that it
is within the standard range. If it falls outside of this range, take appropriate remedial action.
(7) Install the vent plugs and wash the battery case to clean of acid, etc.
iii)

Slow Charging.

High charging rates make it difficult to completely charge a battery. To completely charge a
battery or charge a completely discharge battery, slow charging with a low rate of charging
amperage is required. Slow charging procedures are the same as previously described
under the quick charging procedures and precautions except for the following:
(1) The maximum charging current should be less than 1/10th of the battery capacity figure.

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Example:
40 Ah battery capacity
40 + 10 = 4A or less
Slow charging time can be calculated by following formula:
Charging time (h)
= state of discharge capacity (Ah)
Charging current (A)

x (1.2 to 1.5)

Example:
Battery capacity : 40 Ah
Specific gravity : 1.16
The state of discharge is about 50% of the battery capacity according to the graph shown in
the previous page.
Therefore, the battery needs a charge of:
40 Ah x 50% = 20 Ah
Slow charging time is therefore,
20 Ah x (1.2 to 1.5) = 6 to 7.5 h
4A
(2) Set the charger switch to the slow position (if provided).
(3) Read just the current control switch whenever the charging becomes too low.
(4) As the battery gets near full charge, hydrogen gas is emitted vigorously. When there is
no further rise in specific gravity or battery voltage for more than one hour, the battery is
completely charged.