TEKNIK TENAGA

LISTRIK

Departemen Teknik Mesin

Universitas Indonesia

Lecture 1 1
Automotive Electrical
Notes

Ir. Amien Rahardjo, MT

 Electron theory
 the electrical phenomenon is
produced by a flow of electrons from
one area to another.
 Flow of electrons

 The flow of electrons is caused by

having an excess number in one
area, shortage in another
surplus negative
short supply positive
Matter

 anything that
takes up space
and has mass:
solid, liquid or
gas
 Molecule

 smallest portion of matter and retain

all original properties of the original
matter, it is made up of atoms
Atoms
 100 + different types
 one molecule of water
made up of one atom
of oxygen, two atoms
of hydrogen H20
 Atom make up

 proton - positive charge

 electron - negative charge
 neutron - no charge (neutral)
more protons in atoms then electrons- it
is a positive charged atom
proton and neutron in center; electrons
orbit
size of atom ?
 Bound electrons
 Are in the inner orbits Bound
electrons are very difficult to remove
from their orbit
 Free electrons
 outer orbits only, one, two or three
electrons, are easily knocked out
of their orbit
 Conductors
 Have 1-3 electrons in outer orbit,
easily knocked out of orbit. Materials
such as silver, copper, aluminum,
gold make good conductors.
 Semi-Conductors
 4 electrons in outer orbit
 Not a good conductor
 Not a good insulator
 Non conductors
 Insulators, 5 or more electrons in
outer orbit, glass, ceramics, plastics,
rubber, fiber, porcelain, paper and
wood are common Insulators. Hard to
knock the electrons out of orbit if they
have a strong magnetic pull to the
protons in the nucleus of the atom.
 Current

 movement of free electrons through

a conductor current flow is measured
in amperes(Amps). Must have
shortage of electrons at one end,
surplus at other one electron does
not go the whole distance moves and
bumps others.
 Voltage
(electromotive force, EMF)

 pressure differential causes current

to flow, this pressure is known as
voltage
 voltage is a measure in volts with
voltmeter.
 Resistance
 caused by electrons bumping into
other atoms, a poor conductor has
greater resistance than a good
conductor. Poor conductor has
greater resistance than a good
conductor. poor conductors will
heat up (like a heaters).
 Larger conductors (wire size) offers less
resistance then a smaller one,
 resistance is measured in ohms
 current will flow in the one path with least
resistance.
 Current will flow from negative to positive,
negative has surplus of electrons, positive
has short supply.
 Which way does it flow ? Ask the experts
 Circuits
 must have a power source
 a load (something to operate such as
a light bulb or motor)
 wiring for path of electron flow
(Conductor)
 Switch
 circuit protection

Thanks Kevin http://www.autoshop101.com/

 Series circuit, only one path for
current to flow

Series Circuit
 Parallel circuit, more than one path
for current to flow, current flows
through all units at once

Parallel Circuit
 Series parallel, combination of both
circuits

Series Parallel
 Circuit Problems
 Open circuit, Wire is broken
 Short to ground, Wire is touching ground
 Short to voltage, wire is touching a hot
wire. Load device is on even though
switch is off.
 High resistance, current is being slowed
by corrosion or a poor connection
 Car frame
 acts as a ground wire, some cars like
corvette have to run ground wires
because of fiberglass body
 ground symbol:
 Ohms law
 amperes = I -Intensity
 volts = E -Electromotive force
 ohms = R -Resistance

 to find E = IxR
I = E/ R
E
R = E/ I
IXR
 Magnetism
 Materials that have this are called
Magnets
 Some are Natural
 Some are made
 Magnetic Domains
 These small sections of a magnet
must all line up to be a strong
magnet.
If not, they will cancel each other out
and the piece of metal will be
unmagnetized
Lines of Flux Electromagnetic
 leave north pole, enter south
 unlike poles attract
 like poles repel
 left hand rule, know which way
current flows, fingers point in
direction magnetic field is moving
 magnetic fields surround any
conductor carrying an electrical
current
Lines of Flux Electromagnetic
 magnetic effects of parallel
conductors,
 magnetic effects of conductors with
current flowing in opposite direction,
spark plug wires
 magnetic field in coils compared to
single wire left hand rule for coils
thumb points north
 soft iron core in coils, lines of force
increase several hundred times
 Solenoid
 can be used to push or pull iron core
if off set will be drawn into the
middle
 Battery (Electro Chemical Device)
 4 functions
 1. provides electrical energy to start car.
 2. provides electrical energy to ignition system
 3. provides electrical energy to accessories when
demands exceed alt. output
 4. voltage stabilizer absorbs abnormal voltages
created by electrical components
Top post Side post
 A side and top post is becoming very
common today because it will fit so
many cars.
 Battery Construction
 Elements consist of two groups of
plates
 one more negative than positive
plates 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)
 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 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
 Charged
 positive plate negative
plate
electrolyte
H2S04
pb02 pb
lead peroxide lead
 Discharge

 oxygen and hydrogen form water,

lead and sulfate form lead sulfate
 pbso4 H20 pbSo4
 charging send electrons through
opposite way reversing the cycle
 sulfated plates refer to plates harden
with lead sulfate
 slow long charge to correct sulfated
plates sometimes can't
 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
 to replace add distilled water
 Battery types
 WET CHARGE shipped with
electrolyte must charged during
storage
 DRY CHARGE shipped empty
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 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
 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
 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
 Battery leakage test
 Volt - at negative post
 Volt + across battery
 No voltage should be present anywhere
if it is clean the battery.
 Battery voltage test
 Measure what the voltage with the key
off find out it’s state of charge. It is a
good starting point should be at least
12.6 volts
 12.6 = fully charged
 12.4 = 3/4 charged
 12.2 = 1/2 charged
 12.0 = 1/4 charged
 Battery Terminals
 Side terminal
 Post or top terminal
 L terminal used on import
 Marine
 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
 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
 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 cannot get
into some. No way to add water or
check specific gravity.
 Charging Batteries
 clean up 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 change batteries
 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 find and 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
 Always hook up the ground cable last
Hooking batteries in series
Voltage goes up
Hooking batteries in parallel
Voltage stays the same
amperage goes up
Generator
electromagnetic devise
produces electricity to run
accessories and charge
battery
 wire passed through magnetic field
voltage is generated
 passed opposite direction
current flow reversed
To increase Volts and Amps
 1. increase strength of magnetic field
 2. increase the speed wire moves
through the magnetic field
Basic AC operation current
flows positive, negative
Basic DC operation current
flows one way,
accomplished by split ring
 Charging Indicators
 ammeter

 indicator light

 Voltage Monitor
 Alternator
 generators - moving conductor
through
stationary field - induced voltage
 alternator - a permanent magnet is
rotated inside a stationary conductor
maximum voltage occurs when
conductor cuts heaviest lines of
force
Alternator
 Alternators
 more efficient at lower speeds
 lighter - aluminum construction
 requires only 2 or 3 amps passing
through slip rings compared to high
amperage in D.C. generator
 governs its own maximum current
output
 Generators - moving conductors
through stationary field to induce
voltage
 Alternators - moving field across
stationary conductor to induced
voltage
 maximum voltage occurs when
conductor cuts heaviest lines of
force
Parts of a Alternator
The End