Batteries:
Theory, Diagnosis, and Service
Basic Battery Theory
Do now
Describe What different types of batteries are
used in todays vehicles?
Charging
• Restores chemical nature of cells.
• A chemical reaction causes current flow
within the cells.
• Each battery has own charging requirement.
• Follow charging procedures to prevent
battery damage.
Cell Arrangements
• Voltage depends on cell materials and
chemicals used.
• Most produce between 1.2 – 4.0 volts.
• To produce higher voltage, cells are
connected together.
Series Connections
Battery Hardware
• Battery Cables
– Must be able to carry current to meet demands
– 12-volt cables 4 or 6 gauge
– Connections can be top or side post
– Must be clean and tight
– HV cables on hybrid vehicles are orange
Battery Hardware (cont’d)
• Battery Hold-Downs
– Batteries must be securely held to prevent
damage
– A loose battery can short against vehicle
– Excessive vibration destroys plates
– Can be either metal or plastic
Recycling Batteries
• Do not discard batteries with trash.
• 98% of lead-acid batteries are recycled.
• Additional information:
– Interstate Batteries
– BCI
– EPA
Battery Ratings
• Voltage rating may be expressed as open
circuit voltage – the voltage measured
when there is no load on the battery.
• Operating voltage is measured with the
battery under a load.
Battery Ratings (cont’d)
• Cold Cranking Amps (CCA) Rating
– The load in amperes that a battery can deliver
for 30 seconds at 0°F (-17.7°C) without the
voltage dropping below 7.2 volts.
• Cranking Amps (CA) Rating
– Current a battery can deliver for 30 seconds at
32°F (0°C) without the voltage dropping below
7.2 volts.
Safety Issues
• HV circuits identifiable by size and color.
• Cables may be enclosed in orange shielding
or casing.
• HV battery pack and other components
have warnings.
• Some accessories, such as the A/C, can be
powered by the HV system.
Lead-Acid Battery Construction
• Grids • Electrolyte
• Positive plates • A container
• Negative plates • Cell covers
• Separators • Vent covers
• Elements • Cell containers
Basic Construction (cont’d)
• Grids are lead alloy
frames that support
the active material
of each plate.
Basic Construction (cont’d)
• An element is a
group of positive
and negative plates
formed into a
group.
Basic Construction (cont’d)
• Electrolyte is a solution of sulfuric acid and
water.
• The sulfate reacts with the lead and lead
peroxide to release energy.
• Also acts as the carrier for electrons as they
move.
• Desired solution is 65% water and 35% acid.
Casing Design
Terminals
• Two terminals
• Specified by the Battery Council
International (BCI)
Discharging and Charging
Charging
Maintenance-Free and
Low-Maintenance Batteries
• Low-maintenance battery is a heavy-duty
normal lead-acid battery.
• Have vents which allow water to be added.
• Maintenance free batteries do not have
external caps.
• Water is not added.
Factors That Affect Battery Life