parts technician first period material identification and calculations 270103g battery fundamentals

Parts Technician

First Period

Material Identification and Calculations

270103g

Battery Fundamentals

© 2013, Her Majesty the Queen in right of the Province of Alberta

Table 1 - Common chemical equations.

Compound Symbol

Lead peroxide PbO2 Lead Pb Water H2O Sulphuric acid H2SO4 Hydrogen H Oxygen O


CAUTION

Top up electrolyte levels with distilled water if necessary. Do not add electrolyte once the battery has been put into service.


Figure 1 - Maintenance battery.


Figure 2 - Low-maintenance battery.


Figure 3 - Maintenance-free battery.


CAUTION

Batteries used for vehicle and equipment electrical systems are designed as high cycle batteries. Permanent battery damage will result if batteries are repeatedly discharged below 75% of full charge for long periods of time.


Figure 4 - Deep cycle battery.


Figure 5 - Hybrid battery plate.


Figure 6 - Wound cell battery.


Figure 7 - 42- and 36-volt batteries.


CAUTION

As the electrolyte mixture can have dire effects on skin and clothing, be sure to adhere to all safety precautions.


Figure 8 - Always wear eye protection: safety glasses and/or a face shield.


Figure 9 - Always wear appropriate protective equipment.


Figure 10 - Sources of combustion must be avoided.


Figure 11 - Methods of checking electrolyte level. (Courtesy General Motors of Canada Limited and Toyota Canada Inc.)


NOTE

Maintenance and low-maintenance type batteries can be topped up with distilled water.


Figure 12 - Very dangerous practice if the negative (ground) cable is still connected.


Figure 13 - Plate grid for a maintenance-free battery.


Figure 14 - Positive plate.


Figure 15 - Positive plate group.


Figure 16 - Positive plate group with envelope separators.


Figure 17 - Battery element. (Courtesy Toyota Canada Inc.)


Figure 18 - Battery elements using envelope separators.(Courtesy General Motors of Canada Limited)


Figure 19 - Battery showing internal and external components.


Figure 20 - Cell connectors.


Figure 21 - Six cells connected in series.


Figure 22 - Adding plate mass and area.


Figure 23 - One battery cell in a fully charged state. (Courtesy Toyota Canada Inc.)


Figure 24 - Chemical reaction during discharge. (Courtesy Toyota Canada Inc.)


Figure 25 - Chemical reaction during charge. (Courtesy Toyota Canada Inc.)


CAUTION

If a battery charger continues to push current through a battery after the battery is charged, large volumes of H2 and O2 are produced in the battery. Since hydrogen gas in the presence of oxygen is very explosive, any source of ignition near a charging battery can cause an explosion.


Figure 26 - BCI group numbers.


Figure 27 - Batteries connected in parallel.(Courtesy General Motors of Canada Limited)


Figure 28 - Booster cables.


Table 2 - Common booster cable sizes.

Length Gauge Size Clamp Amperage

25 feet 2 600 20 feet 4 500 16 feet 4 400

12 feet 6 350 8 feet 8 200


Figure 29 - Exploded battery due to improper boosting procedure.


DANGER

Failure to follow the guidelines for battery boosting will result in a battery exploding.


Figure 30 - Order of connection and disconnection of cables for boosting.


DANGER

Never attempt to charge a frozen or suspected frozen battery, as it may explode.


Figure 31 - Slow charger connected to charge three batteries in series


Figure 32 - Fast charger connected to three batteries in parallel.


CAUTION

High charge rates can easily damage battery plates. If the battery temperature approaches 52C (125F), reduce the charge rate to prevent damage.


Figure 33 - Charge rates and times.


Table 3 - State of charge.

Voltmeter Open Circuit Voltage

Approximate State-of-Charge

Hydrometer Average Cell

Specific Gravity

Electrolyte Freeze Point

12.65 100% 1.265 -59.4°C (-75°F)

12.45 75% 1.225 -48.3°C (-55°F) 12.24 50% 1.190 -36.7°C (-34°F) 12.06 25% 1.155 -26.7°C (-16°F)

11.89 Discharged 1.120 -23.3°C (-10°F)


Figure 34 - Hydrometer used to test specific gravity. (Courtesy Toyota Canada Inc.)


Figure 35 - Built-in electrolyte level and specific gravity tester. (Courtesy General Motors of Canada Limited)


NOTE

This built-in hydrometer only measures one of the six cells in a 12-volt battery.


Figure 36 - Correct and incorrect methods of connecting to side terminal batteries.


CAUTION

Before the tester is connected to a battery, always ensure that the carbon pile is turned off. Failing to turn the carbon pile off results in heavy arcing at the battery terminal when the tester is connected and could result in battery explosion.


Figure 37 - Battery load tester.


Figure 38 - Battery load tester schematic.


Figure 39 - Battery handles.


CAUTION

The safest method of moving a battery from the shelf to a customer is a two-wheeled cart. There is a very good possibility that carrying a battery close to your body will result in electrolyte spilling on to your clothing. The electrolyte will eat holes into your clothing unless it is protected by a rubberized apron and tripping with a battery case full of acid is a possibility.

NOTE

Electrolyte should be stored in a cool open area with ample ventilation. Large containers should be secured and placed on a level surface to prevent tipping.


NOTE

Batteries should not be stacked higher than eye level for safe removal from the shelf.


CAUTION

Sulphuric acid is a dangerous pollutant when it is spilled or leaked to the environment. Be sure that no electrolyte is allowed to enter the shop floor drain system; even if you know the battery is fully discharged.


Figure 40 - Used battery storage.

parts technician first period material identification and calculations 270103g battery fundamentals

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