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Battery
 Operation
 Service
 Diagnosis
Battery
Electro Chemical Device
• 4 Functions - Source, Reserve & Stabilizer
• 1. Provides electrical energy to start car.
• 2. Provides electrical energy to ignition system
• 3. Provides electrical energy to accessories when
demands exceed alternators output
• 4. Voltage stabilizer absorbs abnormal voltages created by
electrical components
Converts chemical energy into
electrical energy
Top post
Side post
side and
top post
• A side and top post is becoming very common
today because it will fit so many cars.
Batteries a little history
• Up to 1955 most batteries were 6 volt
• General Motors started the move to 12 volts,
Volkswagen was the last in 1966 to switch over.
• Some day cars may have a 42V/14V System.
Several problems lie in wait such as cost of the
components. Life of batteries & arcing between
components.
Battery Construction
• Elements consist of two groups of plates
• One more negative plate than positive with
insulated separators in between
• Usually 9, 11, or 13 plates. 54, 66, or 78
total.
• Case is made of hard rubber (rough service)
or plastic (light service)
Battery Construction
• One element in each cell, connected to the
adjoining element, connected in series, each
cell produces about 2.1 volts
• Case is divided into 6 cells (12.6 volts)
• Case is divided into 4 cells (8.4 volts) Golf carts
• Case is divided into 3 cells (6.3 volts)
Electrolyte
64% water 36% Sulfuric acid
• H20-water 64% specific gravity 1.00
• H2S04-sulfuric acid 36% specific gravity 1.835 caution
• Electrolyte 100% specific gravity 1.270
• Specific gravity is the ratio of the density of a
substance to the density (mass of the same
unit volume) of a reference substance.
Water is the reference for specific gravity 1.00
Charged
• positive plate
negative plate
+
electrolyte
H2S04
Pb02
Pb
lead peroxide
Sponge lead
Discharge
• Oxygen and hydrogen form water, lead and sulfate form
lead sulfate. It is often seen in the plates/electrodes of car
batteries, as it is formed when the battery is discharged.
•
PbSO4
H20
PbSO4
• Charging sends electrons through in the
opposite way reversing the cycle
• Sulfated plates refer to plates harden with
lead sulfate
• Slow long charge to correct sulfated plates
sometimes it cannot reverse the affects.
• 2 amps 24 hours
Things to remember
• Little brown particles floating around can short
out battery (flakes off of the sulfated plates )
• Batteries can freeze if discharged H2O is water
• Charging battery emits oxygen and hydrogen gas can explode
• When you need to add fluid to a battery, use
distilled water (H2O it replaces the gas that is
released H & O2 during gassing.)
Battery Gassing
 During discharge
 During charge
 releases H & O2 during gassing
Batteries do blow up
Precautions
•
•
•
•
When jumping a battery
When using a charger
When disconnecting a cable
When using any flame source
Precautions
• Always remove ground terminal first
• Connect ground last
– Jumper cable/battery charger on block of engine
• Corrosive (Sulfuric acid)
Battery types
• WET CHARGE shipped with electrolyte must
charged during storage
• DRY CHARGE shipped empty with no
electrolyte. Manufacture gives forming charge
dries the cell elements and seals it. If you
keep moisture out it will remain fully charged
for long time. When needed just add
electrolyte.
Group size
• Batteries come in many different group sizes. A
battery's group size simply determines it's length,
width, height, and terminal configuration
• Will have a number like group 75,78 or 24 or 24F,
26, 34
Battery capacity
• 1) Plate size, the case is the same size, plates
are different size. Larger plates more amps
• 2) Number of plates
• 3) Amount of acid in electrolyte and battery
additives increase the sulfuric acid content
of battery.
Battery capacity rating
• Cold Cranking Amperes CCA most common
“Number of amperes load of battery will maintain
at 0 degrees Fahrenheit for 30 seconds without
battery voltage falling below 7.2 volts” (1.2 volts
per cell)
• Size of engine should be smaller than cold
cranking ampere rating.
• Do not be misled by CA that’s just Cranking
Amps. It will give you a higher reading but it
misleads you because it is tested at a higher
temperature.
• Cranking amps are the numbers of amperes
a lead-acid battery at 32 degrees F (0
degrees C) can deliver for 30 seconds and
maintain at least 1.2 volts per cell (7.2 volts
for a 12 volt battery).
Recommended Minimum battery
size to buy when you replace it.
• 4-cylinder 400 CCA
• 6-cylinder 500 CCA
• 8-cylinder 575 CCA
Battery checking visual Inspection
Battery checking visual Inspection
• Cracked or leaking case
liquid level, add water use distilled water
preferred (No minerals) or ice melted out of
a freezer
• Voltage can discharge across top from post
to post
• Clean battery top and post and cables,
battery hold downs
Visual Inspection
Cleaning The Battery
• Mix baking soda and water to clean batteries
• clean post and cable with a terminal brush or
post cutter
• coat all connections with grease or use a spray
like NOCO NCP-2 Battery corrosion spray
• Safety Glasses
Battery leakage test
• Voltmeter (– negative) lead at negative post
• Voltmeter (+ positive) lead drag across battery
– No voltage should be present anywhere. If it is
clean the battery.
Battery Open Circuit Voltage Test
• Measure what the voltage is with the key off Find
out it’s state of charge. It is a good starting point,
should be at least 12.66 volts
• 12.66 = fully charged
• 12.4 = 3/4 charged
• 12.2 = 1/2 charged
• 12.0 = 1/4 charged
Battery Terminals & Bolts
•
•
•
•
•
Post or top terminal
Side terminal
L terminal used on import
Marine
Stud
Terminal Test
• This is the first step.
• Take a voltmeter
• DVOM (Digital volt ohm
meter)
• Turn to DC Volts
• Hook up like picture on
next page.
Terminal Test
• This is just a voltage drop test done on the
battery terminals. You must disable the
ignition and crank over the engine.
• Should be under .2 volts.
Make sure you do both
terminals
Positive & Negative
Battery Drain test
or System drain test
This is done When a battery goes
dead for no apparent reason.
Charging system seems to work OK
Yet after charging the battery it is
dead after several nights.
Battery Drain test
or System drain test
• Ammeter is hooked in series at the
battery post with everything off
Make sure you close the door or
the courtesy lights will be on
Battery Drain test
Make sure you change the leads
Battery Drain test
• Battery Drain Key off
• Hook up a ammeter in series reading should
not exceed the following
• 77 older cars .01 amps, 10 ma (milliamps)
• 78-85 .02 amps-.025 amps, 20-25 ma
• 1986 & newer .05 amps, 50 ma
Open Circuit Voltage Test
Battery Voltage with the car off.
•
•
•
•
Sealed batteries
Remove surface charge
12.66 = fully charged
12.4 = 3/4 charged
A battery Must be 3/4 charged
before doing a battery capacity test
Before load testing - Check
the temp.
The right battery for the vehicle
Before load testing you must
know what the battery is, or
should be rated at
Ratings
• Cold cranking Amperes rating CCA
• Cranking Amperes rating CA
• Ampere-hour rating
• Reserve capacity rating
• Watt hour rating
Formula for load testing
Three times the
ampere-hour rating
P - L130 Capacity Test
Formula for load testing
Cold cranking amps
divided by
2
Three minute charge test
Tests for a sulfated battery
• 40 amps for three minutes
• Should be below 15.5 volts
Testing specific gravity
• Hydrometer check before adding water fully
charged battery should read 1.270
should not vary more than 50 points
between cells if it does recharge and check
again
• Maintenance free batteries are sealed,
cannot get into some. No way to add water
or check specific gravity.
State of charge testing
Hydrometer
•
Ball Style
Hydrometer
•
float Style
Battery Refractometer
Charging batteries
• Clean up Battery first
• Unhook cables - check liquid level
• Don't charge over 16 volts. If plates are
sulfated or if battery has been discharged for
some time
• Slow charge for a long period 24 hours
don't allow temperature to exceed 100
• Never fast charge batteries
• Make sure that the battery charger is shut off
or unplugged when hooking up and removing
the charger.
Factors Affecting Charging
•Temperature
•0’ = 40%
•Charge
•Plate area
•Impurities
•Gassing
Causes of battery failure
Causes of failure
•
•
•
•
Electrolyte level
Overcharging
Undercharging
Corrosion
• Cycling
• Temperature
• Vibration
• Most batteries in cars are 12 volt with
negative ground.
• 6 volt older cars and 18 wheelers may have
positive ground
SAFETY: do not allow battery acid
to contact eyes skin or fabrics if you
do flush with lots of water, and get
teacher or medical help flush eyes
for 15 minutes
Jump starting cars
• positive to positive
• negative to negative
• Hook up negative cable last on car with dead
battery on a good ground. Not on the battery.
If sparks occur no Hydrogen to blow up
battery date tags
Did You Know Batteries Lose Power
While Sitting on the Shelf?
A battery can permanently lose some of its capacity when it's stored in a partly or
fully discharged state. Periodic charging during storage can minimize the
deterioration, but not all battery distributors and dealers do the necessary charging.
That's why you may want to know how to read the date codes, which show when the
product was manufactured, on a new product, to help you make sure you're really
buying a fresh battery.
So, how do you read a date code?
Most Brands of Batteries
JOHNSON CONTROLS, INC. - INTERSTATE BATTERIES,
Motorcraft, East penn - Deka, GNB -Champion, Stowaway:
The letters and numbers are on a sticker affixed to the battery or hot-stamped
into the case cover along the top edges of the battery. The ship date codes
begin with a letter: A stands for January, B for February and so on (some
shipping codes skip the letter I, so it cannot be confused with the number 1.
In those cases, J would represent September, K - October, L - November and
M - December). The next digit is a number which represents the year the
battery was shipped. Therefore, an A6 would mean the battery was shipped in
January of 1996.
Exceptions DELCO - Freedom, Voyager, and some Sears brands:
The code dates are stamped on the cover, usually near the posts.
The first character represents the year (0-9) and the second shows
the month (A-M, skipping I). For example, 4CN1 would stand for
1994, March.
EXIDE - Napa Legend, Edge, Power-Tron and Titan:
The fourth or fifth character may be a letter code for the
month and the following character a number code for
the year (i.e. RO8F3B stands for June 1993)
Last 3 pages © 2000 Interstate Battery System of America, Inc.
Removing Batteries
• Always Disconnect the ground cable
first. (Negative Cable on cars)
• Always hook up the ground cable
last
• If you disconnect the positive first
and touch ground you will have
sparks.
Removing Batteries
• Always make sure you have a way to keep
the memory alive (Computer, radio, etc)
when you replace the battery.
Hooking batteries in series
Voltage goes up
Hooking batteries in parallel
Voltage stays the same
Amperage goes up
The End
That's all for this
battery