BATTERY –TESTING

AND SERVICE

@Autogurukul
 Energy Storage
• Distributed resources (DR) and distributed generation (DG):
• DG can be defined as “a subset of DR” [T. Ackermann, G. Andersson, and L. Söder, “Distributed generation: A
definition.” Electric Power Systems Research, vol. 57, issue 3, pp. 195-204, April 2001]

• DR are “sources of electric power that are not directly connected to a bulk
power transmission system. DR includes both generators and energy storage
technologies” [T. Ackermann, G. Andersson, and L. Söder, “Distributed generation: A definition.” Electric Power Systems
Research, vol. 57, issue 3, pp. 195-204, April 2001]

• DG “involves the technology of using small-scale power generation technologies

located in close proximity to the load being served” [J. Hall, “The new distributed generation,”
Telephony Online, Oct. 1, 2001 http://telephonyonline.com/mag/telecom_new_distributed_generation/]

• Microgrids are electric networks utilizing DR to achieve independent control

from a large widespread power grid

• Prevailing technologies:
• Batteries
• Flywheels
• Ultracapacitors
@Autogurukul
 Energy Storage
• Uses of energy storage devices in DG (focus is on elements with electrical output):
• Power buffer for slow, bad load followers, DG technologies.
• Energy supply for stochastic generation profiles.
• Improved availability

• Power vs. Energy

dE
P
dt
• Power delivery profile: short, shallow and often energy exchanges.
• Flywheels
• Ultracapacitors

• Energy delivery profile: long, deep and infrequent energy exchanges.

• Batteries

• For the same energy variation, power is higher during short exchanges.

@Autogurukul
 Battery technologies
• Batteries stores energy chemically.

•Main technologies:
• Lead Acid
• Nickel-Cadmium
• Nickel-Metal Hydride
• Li-ion

@Autogurukul
Battery technologies

@Autogurukul
 Lead-acid batteries
• Lead-acid batteries are the most convenient choice based on cost. The
technology that most of the users love to hate.

• Lead-acid batteries are worse than other technologies based on all the
other characteristics. Disposal is another important issue.

• In particular, lead-acid batteries are not suitable for load-following

power buffer applications because their life is significantly shortened
when they are discharged very rapidly or with frequent deep cycles.

@Autogurukul
Lead-acid batteries

http://polarpowerinc.com/info/operation20/operation25.htm
@Autogurukul
Lead-acid batteries

http://polarpowerinc.com/info/operation20/operation25.htm
@Autogurukul
 Lead-acid batteries life
• Lead-acid batteries are very sensitive to temperature effects. It can be expected that
battery temperature exceeding 77°F (25°C) will decrease expected life by
approximately 50% for each 18°F (10°C) increase in average temperature. [Tyco
Electronics IR125 Product Manual]

@Autogurukul
 Lead-acid batteries
• Positive electrode: Lead dioxide (PbO2)

• Negative electrode: Lead (Pb)

• Electrolyte: Solution of sulfuric acid (H2SO4) and water (H2O)

H2O
PbO2 Pb
H2O

H2O
H2O H2O

@Autogurukul
 Lead-acid batteries
• Chemical reaction (discharge)

2H2O H2SO4
2e- 2H+
O22- SO42- Pb2+
2H+
PbO2 H2SO4 PbSO4 Pb
Pb2+ SO42- 2e-
PbSO4
H2O

H2O
H2O
H2O H2O

@Autogurukul
 Lead-acid batteries
• Chemical reaction (discharge)

• Negative electrode Pb Pb 2+ + 2e-

Pb2+ + SO42- PbSO4

• Electrolyte 2H2SO4 4H+ + 2SO42-

• Positive electrode PbO2 + 4H+ + 2e- Pb2+ + 2H2O

Pb2+ + SO42- PbSO4v

•Overall Pb + PbO2 + H2SO42- 2PbSO4 + 2H2O

• The nominal voltage produced by this reaction is about 2 V/cell. Cells are usually
connected in series to achieve higher voltages, usually 6V, 12 V, 24 V and 48V.

@Autogurukul
 Lead-acid batteries
• As the battery discharges, sulfuric acid concentration decreases.

• At the same time, lead sulfate is deposited on the electrode plates.

• Charging follows the inverse process, but a small portion of the lead sulfate remains
on the electrode plates.

• Every cycle, some more lead sulfate deposits build up on the electrode plates,
reducing the reaction area and, hence, negatively affecting the battery performance.

• Electrode plates sulfatation is one of the primary effects that affects battery life.

• To avoid accelerating the sulfatation process, batteries need to be fully charged after
every discharge and they must be kept charged at a float voltage higher than the
nominal voltage. For lead acid batteries and depending their technology the float
voltage is between 2.08 V/Cell and 2.27 V/cell. For the same reasons, lead-acid
batteries should not be discharged below 1.75 V/cell

@Autogurukul
 Lead-acid batteries models

“A New Battery Model for use with Battery

Energy Storage Systems and Electric
“A New Dynamic Model for Lead-Acid
Vehicles Power Systems”
Batteries”
H.L. Chan, D. Sutanto
N. Jantharamin, L. Zhangt

• All models imply one issue when connecting batteries of different capacity in
parallel: since the internal resistances depend on the capacity, the battery with the
lower capacity may act as a load for the battery with the higher capacity.
@Autogurukul
 Lead-acid batteries models
• Most circuit parameters depend on:
• State of charge

http://www.mhpower.com.au/images/tecfig23.gif
SONNENSCHEIN
Lead-acid batteries models
• Most circuit parameters depend on:
• Charge / Discharge rate
• Temperature

“Internal Resistance and Deterioration of VRLA Battery - Analysis of Internal

Resistance obtained by Direct Current Measurement and its application to
VlRLA Battery Monitoring Technique”
Isamu Kurisawa and Masashi Iwata
http://www.mhpower.com.au/images/tecfig23.gif
SONNENSCHEIN
Lead-acid batteries models

“Internal Resistance and Deterioration of VRLA Battery - Analysis of Internal Resistance obtained by Direct Current
Measurement and its application to VlRLA Battery Monitoring Technique”
Isamu Kurisawa and Masashi Iwata
http://www.mhpower.com.au/images/tecfig23.gif
 Lead-acid batteries capacity
• Battery capacity is often measured in Ah (Amperes-hour) at a
given discharge rate (often 8 or 10 hours).

• Due to varying internal resistance the capacity is less if the

battery is discharged faster (Peukert effect)

• Lead-acid batteries capacity ranges from a few Ah to a few

thousand Ah.

http://polarpowerinc.com/info/operation20/operation25.htm

@Autogurukul
Lead-acid batteries capacity

http://polarpowerinc.com/info/operation20/operation25.htm

@Autogurukul
 Lead-acid batteries capacity
• Battery capacity changes with temperature.

• Some manufacturers of battery chargers implement algorithms that increase the

float voltage at lower temperatures and increase the float voltage at higher
temperatures. http://polarpowerinc.com/info/operation20/operation25.htm @Autogurukul
 Lead-acid batteries discharge
• The output voltage changes during the discharge due to the change in internal
voltage and resistances with the state of charge.

Coup de Fouet

Patent 6924622
Battery capacity measurement
Anbuky and Pascoe

Tyco Electronics 12IR125 Product Manual

@Autogurukul
 Lead-acid batteries charge
• Methods:
• Constant voltage
• Constant current
• Constant current / constant voltage

• Cell equalization problem: as the number of cells in series increases, the voltage
among the cells is more uneven. Some cells will be overcharged and some cells will be
undercharged. This issue leads to premature cell failure

• As the state of charge increases, the internal resistance tends to decrease. Hence,
the current increases leading to further increase of the state of charge accompanied
by an increase in temperature. Both effects contribute to further decreasing the
internal resistances, which further increases the current and the temperature….. This
positive feedback process is called thermal runaway.

@Autogurukul
 Lead-acid batteries efficiency
• Consider that during the charge you apply a constant current IC, a voltage VC during a
time ΔTC. In this way the battery goes from a known state of charge to be fully
charged. Then the energy transferred to the battery during this process is:
Ein = ICVC ΔTC

• Now the battery is discharged with a constant current ID, a voltage VD during a time
ΔTD. The final state of charge coincides with the original state of charge. Then the
energy delivered by the battery during this process is:
Eout = IDVD ΔTD

• So the energy efficiency is VD I D TD

E   VC
V I TC
• Hence, the energy efficiency equals CtheCproduct of the voltage efficiency and the
Coulomb efficiency. Since lead acid batteries are usually charged at the float voltage of
about 2.25 V/cell and the discharge voltage is about 2 V/cell, the voltage efficiency is
about 0.88. In average the coulomb efficiency is about 0.92. Hence, the energy
efficiency is around 0.80

@Autogurukul
 Li-ion batteries
• Chemical reaction (discharge)
LiCoO2 Li1-x CoO2 + xLi+ + xe-
• Positive electrode
Through electrolyte

Through load
• Negative electrode xLi+ + xe- + 6C Li x C6

LiCoO2 + C6 Li1-x CoO2 + C6Lx

•Overall

• In the above reaction x can be 1 or 0

• With discharge the Co is oxidized from Co3+ to Co4+. The reverse process (reduction)
occurs when the battery is being charged.

@Autogurukul
 Lead-acid batteries calculations
• Most calculations are based on some specific rate of discharge and then a linear
discharge is assumed.
•The linear assumption is usually not true. The nonlinearity is more evident for faster
discharge rates. For example, in the battery below it takes about 2 hours to discharge
the battery at 44 A but it takes 4 hours to discharge the battery at 26 A. Of course,
26x2 is not 44.
• A better solution is to consider the manufacturer discharge curves and only use a
linear approximation to interpolate the appropriate discharge curve.
• In the example below, the battery can deliver 10 A continuously for about 12 hours.
Since during the discharge the voltage is around 12 V, the power is 120 W and the
energy is about 14.5 kWh

10 A continuous
discharge curve
approximation

Discharge
limit
Nominal curve
@Autogurukul
 Li-ion batteries
• Positive electrode: Lithiated form of a transition metal oxide (lithium cobalt oxide-
LiCoO2 or lithium manganese oxide LiMn2O4)

• Negative electrode: Carbon (C),

usually graphite (C6)

• Electrolyte: solid lithium-salt electrolytes

(LiPF6, LiBF4, or LiClO4)
and organic solvents (ether)

http://www.fer.hr/_download/repository/Li-ION.pdf

@Autogurukul
 Li-ion batteries
• Contrary to lead-acid batteries, Li-ion batteries do not accept well a
high initial charging current.

• In addition, cells in a battery stack needs to be equalized to avoid

falling below the minimum cell voltage of about 2.85 V/cell.

• Thus, Li-ion batteries need to be charged at least initially with a

constant-current profile. Hence they need a charger

• Typical float voltage is above 4 V

(typically 4.2 V). Lower than nominal
float voltages reduce capacity but
improves lifetime.

@Autogurukul
 Li-ion batteries

“Advanced Lithium Ion Battery Charger”

V.L. Teofilo, L.V. Merritt and R.P. Hollandsworth @Autogurukul
 Li-ion batteries

Saft Intensium 3 Li-ion battery

@Autogurukul
 Li-ion batteries
• Effects of temperature:

http://www.gpbatteries.com/html/pdf/Li- ion_handbook.pdf
@Autogurukul
Li-ion batteries

• Controlled charging has 2 purposes:

• Limiting the current
• Equalizing cells

Increased Performance of Battery Packs by Active Equalization”

“
Jonathan W. Kimball, Brian T. Kuhn and Philip T. Krein

Saft Intensium 3 Li-ion battery @Autogurukul

 Li-ion batteries

“Advanced Lithium Ion Battery Charger”

V.L. Teofilo, L.V. Merritt and R.P. Hollandsworth
@Autogurukul
Li-ion batteries

“Advanced Lithium Ion Battery Charger”

V.L. Teofilo, L.V. Merritt and R.P. Hollandsworth @Autogurukul
 Li-ion batteries

• Factors affecting life:

• Charging voltage.
• Temperature
• Age (time since
manufacturing)

• Degradation process:
oxidation

@Autogurukul
 Li-ion batteries
• Advantages with respect to lead-acid batteries:
• Less sensitive to high temperatures (specially with solid electrolytes)
• Lighter (compare Li and C with Pb)
• They do not have deposits every charge/discharge cycle (that’s why the efficiency is
99%)
• Less cells in series are need to achieve some given voltage.
• Disadvantages:
• Cost

@Autogurukul
 Ni-MH batteries

• Negative electrode: Metal Hydride such as AB2

(A=titanium and/or vanadium, B= zirconium or
nickel, modified with chromium, cobalt, iron,
and/or manganese) or AB5 (A=rare earth
mixture of lanthanum, cerium, neodymium,
praseodymium, B=nickel, cobalt, manganese,
and/or aluminum)

• Positive electrode: nickel oxyhydroxide

(NiO(OH))

• Electrolyte: Potassium hydroxide (KOH)

Cobasys batteries

@Autogurukul
Ni-MH batteries

Cobasys batteries @Autogurukul

 Ni-MH batteries
• Chemical reaction (discharge)

• Positive electrode NiO(OH) + H2O + e- Ni(OH)2 + OH-

Through electrolyte Through load

•Negative electrode MH + OH- M + H2O + e-

•Overall NiO(OH) + MH Ni(OH)2 + M

• The electrolyte is not affected because it does not participate in the reaction.

@Autogurukul
 Ni-MH batteries
• It is not advisable to charge Ni-MH batteries with a constant-voltage method. Ni-MH
batteries do not accept well a high initial charging current.
• Float voltage is about 1.4 V
• Minimum voltage is about 1 V.

Cobasys Nigen battery

@Autogurukul
Ni-MH batteries

Saft NHE module battery

@Autogurukul
Ni-MH batteries

Saft NHE module battery

@Autogurukul
 Ni-MH batteries
• Effects of temperature:

Saft NHE module battery

http://www.panasonic.com/industrial/battery/oem/images/pdf
/panasonic_nimh_overview.pdf
@Autogurukul
• Effects of temperature: Ni-MH batteries

http://www.panasonic.com/industrial/battery/oem/images/pdf
/panasonic_nimh_overview.pdf
@Autogurukul
 Ni-MH batteries
• Advantages:
• Less sensitive to high temperatures than Li-ion and Lead-acid
• Handle abuse (overcharge or over-discharge better than Li-ion bat

• Disadvantages:
• More cells in series are need to achieve some given voltage.
• Cost

@Autogurukul
 Ni-Cd batteries

• Negative electrode: Cadmium (Cd) – instead of the MH in Ni-MH batteries

• Positive electrode: nickel oxyhydroxide (NiO(OH)) – the same than in Ni-MH

batteries

• Electrolyte: Potassium hydroxide

(KOH) solution

Saft batteries

@Autogurukul
Ni-Cd batteries

Saft batteries @Autogurukul

 Ni-Cd batteries
• Chemical reaction (discharge)

• Positive electrode 2NiO(OH) + 2H2O + 2e- 2Ni(OH)2 + 2OH-

Through electrolyte
Through load
• Negative electrode Cd + 2OH- Cd(OH)2 + 2e-

•Overall 2NiO(OH) + Cd + 2H2O 2Ni(OH)2 + Cd(OH)2

• The electrolyte is not affected because it does not participate in the reaction.

@Autogurukul
 Ni-Cd batteries
• It is not advisable to charge Ni-Cd batteries with a constant-voltage method. Ni-Cd
batteries do not accept well a high initial charging current, but they can withstand it
sporadically.
• Float voltage is about 1.4 V
• Minimum voltage is about 1 V.

Saft Ultima plus @Autogurukul

 Ni-Cd batteries

http://www.saftbatteries.com/doc/Documents/telecom/Cube788/tel_t
m_en_0704.26962445-6b1b-44fb-aea7-42834c32be40.pdf @Autogurukul
 Ni-Cd batteries

http://www.saftbatteries.com/doc/Documents/telecom/Cube788/tel_tm_en_0704.26962445
-6b1b-44fb-aea7-42834c32be40.pdf @Autogurukul
• Effects of temperature: Ni-Cd batteries

http://www.saftbatteries.com/doc/Documents/telecom/Cube788/tel_t
m_en_0704.26962445-6b1b-44fb-aea7-42834c32be40.pdf
@Autogurukul
• Effects of temperature:
Ni-Cd batteries

http://www.saftbatteries.com/doc/Documents/telecom/Cube788/tel_tm_en
_0704.26962445-6b1b-44fb-aea7-42834c32be40.pdf
@Autogurukul
 Ni-Cd batteries
• Due to their better performance at high temperatures, Ni-Cd batteries
are replacing Lead-acid batteries in outdoor stationary applications. But,
they do not resist hurricanes very well, yet……(AT&T’s DLC at Sabine Pass
CO, Saft NCX batteries)

@Autogurukul
 Ni-Cd batteries
• Advantages:
• Less sensitive to high temperatures than all the other batteries
• Handle some abuse (overcharge or over-discharge better than Li-ion bat)
• Disadvantages:
• More cells in series are need to achieve some given voltage.
• Cost

@Autogurukul
 Ni-Cd batteries
• Comparison with Ni-MH batteries (not much of a difference)

Portable NiCd- and Ni-MH-Batteries for Teiecom Applications

J. Heydecke and H.A. Kiehne @Autogurukul
 Ni-Cd batteries
• Comparison with Ni-MH batteries (not much of a difference)

Portable NiCd- and Ni-MH-Batteries for Teiecom Applications

J. Heydecke and H.A. Kiehne @Autogurukul
Battery technologies

Cobasys: “Inside the Nickel Metal Hydride Battery” @Autogurukul

 OBJECTIVES
1. List the precautions necessary when working
with batteries.
2. Explain how to safely charge a battery.
3. Discuss how to perform a battery drain test.

@Autogurukul
 BATTERY SERVICE SAFETY CONSIDERATIONS

• Batteries contain acid and release explosive gases (hydrogen

and oxygen) during normal charging and discharging cycles.
• To help prevent physical injury or damage to the vehicle,
always adhere to the following safety procedures.

@Autogurukul
 BATTERY SERVICE SAFETY CONSIDERATIONS
1. When working on any electrical component on a vehicle,
disconnect the negative battery cable from the battery.
When the negative cable is disconnected, all electrical
circuits in the vehicle will be open, which will prevent
accidental electrical contact between an electrical
component and ground. 2.
Wear eye protection when working around any battery.
3. Wear protective clothing to avoid skin contact with battery
acid.
4. Always adhere to all safety precautions as stated in the
service procedures for the equipment used for battery
service and testing.
5. Never smoke or use an open flame around any battery.

@Autogurukul
 WHAT ARE SYMPTOMS OF A WEAK OR DEFECTIVE BATTERY?

• There are several warning signs to

indicate that a battery is near the
end of its useful life, including:
– Uses water in one or more cells.
– This indicates that the plates are
sulfated and that during the
charging process, the water in the
electrolyte is being turned into
separate hydrogen and oxygen
gases.

FIGURE 1 A visual inspection of this battery

showed that the electrolyte
level was below the plates in all cells.

@Autogurukul
 WHAT ARE SYMPTOMS OF A WEAK OR DEFECTIVE BATTERY?

• Excessive corrosion on battery

cables or connections. Corrosion is
more likely to occur if the battery is
sulfated, creating hot spots on the
plates.
• When the battery is being charged,
the acid fumes are forced out of the
vent holes and get onto the battery
cables, connections, and even on
the battery tray underneath the
battery.
FIGURE 2 Corrosion on a battery cable could be
an indication that the battery itself is either
being overcharged or is sulfated, creating a lot
of gassing of the electrolyte.

@Autogurukul
 WHAT ARE SYMPTOMS OF A WEAK OR DEFECTIVE
BATTERY?

• Slower than normal engine cranking.

• When the capacity of the battery is reduced due to damage or
age, it is less likely to be able to supply the necessary current
for starting the engine, especially during cold weather.

@Autogurukul
 BATTERY MAINTENANCE
• Most new-style batteries are
of a maintenance-free design
that uses lead-calcium instead
of lead-antimony plate grid
construction.
• Battery maintenance includes
making certain that the
battery case is clean and
checking and adding clean
water, if necessary.
FIGURE 3 Many maintenance-free batteries can be opened
to check the electrolyte level without damaging the
battery. Notice the surface dirt, which could cause the
battery to self-discharge.

@Autogurukul
 BATTERY MAINTENANCE
• Do not overfill a battery, because normal bubbling (gassing) of
the electrolyte will cause the electrolyte to escape and start
corrosion on the battery terminals, hold-down brackets, and
battery tray.

@Autogurukul
 BATTERY MAINTENANCE
• Another method is to fill the battery until the water becomes
“puckered,” indicating that the electrolyte level is even with the
bottom of the filler tube.

FIGURE 4 The electrolyte level is

correct if the liquid looks curved
when observed from above.
This curve is called the
meniscus and is formed when
the liquid clings to the surface
of the fill tube in each cell (if
equipped).

@Autogurukul
 BATTERY VOLTAGE TEST
• Testing the battery voltage with a voltmeter is a simple method
for determining the state of charge of any battery.

FIGURE (a) A battery voltage

of 12.28 volts is definitely not
fully
charged and should be charged
before testing.

(b) A battery that measures

12.60 volts or higher after the
surface charge has been
removed is 100% charged.

@Autogurukul
 BATTERY LOAD TESTING
• Many battery manufacturers recommend performing the load
test twice, using the first load period to remove the surface
charge on the battery and the second test to provide a truer
indication of the condition of the battery.

@Autogurukul
 BATTERY LOAD TESTING

FIGURE 6 A Sun Electric VAT-40 (volt amp tester—Model 40) connected to a battery for load
testing. The technician turns the load knob until the ammeter registers an amperage
reading equal to one-half of the battery’s CCA rating. The load is maintained for 15 seconds,
and the voltage of the battery should be higher than 9.6 volts at the end of the time period
with the load still applied.
@Autogurukul
BATTERY LOAD TESTING

FIGURE 7 A typical battery load tester hookup.

@Autogurukul
 BATTERY LOAD TESTING

FIGURE 8 This battery has cold-cranking amperes (CCA) of 550 A,

cranking amperes (CA) of 680 A, and load test amperes of 270 A listed right on
the top label. Not all batteries have all of this information.
@Autogurukul
 BATTERY LOAD TESTING

FIGURE 9 An alternator regulator battery starter tester (ARBST) automatically loads the
battery with a fixed load for 15 seconds to remove the surface charge, then removes the load
for 30 seconds to allow the battery to recover, and then reapplies the load for another 15
seconds. The results of the test are then displayed.
@Autogurukul
 BATTERY LOAD TESTING

FIGURE 10 The minimum capacity test voltage varies with battery

temperature. @Autogurukul
HOW SHOULD YOU TEST A VEHICLE EQUIPPED WITH TWO BATTERIES?
• Many vehicles equipped with a diesel engine use two batteries.
• These batteries are usually electrically connected in parallel to
provide additional current (amperes) at the same voltage.

FIGURE 11 Most light-duty vehicles equipped with two batteries are connected in
parallel as shown. Two 500 A,12 volt batteries are capable of supplying 1,000
amperes at 12 volts, which is needed to start many diesel engines. @Autogurukul
HOW SHOULD YOU TEST A VEHICLE EQUIPPED WITH TWO BATTERIES?
• Some heavy-duty trucks and buses connect two batteries in series to
provide about the same current as one battery, but with twice the
voltage.

FIGURE 12 Many heavy-duty trucks and buses use two 12 volt batteries
connected in series to provide 24 volts.
@Autogurukul
 ELECTRONIC CONDUCTANCE TESTING
• Conductance is a measure of how well a battery can create current.
• The unit can determine the CCA, state of charge, (soc) and voltage
of the battery and detect all defects, such as shorts and opens.

FIGURE 13 The display on an electronic battery tester showing that the battery
tested was good. It compares the rated CCA rating with the measured CCA capacity
to help determine if the battery is good. @Autogurukul
 ELECTRONIC CONDUCTANCE TESTING

• Connect the unit to the positive and negative terminals of the

battery and, after entering the CCA rating (if known), push the
arrow keys.
• The tester determines one of the following:
– Good battery. The battery can return to service.
– Charge and retest. Fully recharge the battery and return it to service.
– Replace the battery. The battery is not serviceable and should be
replaced.
– Bad cell—replace. The battery is not serviceable and should be
replaced

@Autogurukul
 BATTERY CHARGING
• If the state of charge of a battery is low, it must be recharged.
• It is best to slow-charge any battery to prevent possible overheating
damage to the battery.

FIGURE 14 Battery charging guide. Battery charging times vary according to state of
charge, temperature, and charging rate.

@Autogurukul
 BATTERY CHARGING
• Remember, it may take eight hours or more to charge a fully
discharged battery.

FIGURE 15 A typical industrial battery charger. Be sure that the ignition switch is in
the off position before connecting any battery charges. Connect the cables of the
charger to the battery before plugging the charger into the outlet. This helps
prevent a voltage spike that could occur if the charger happened to be
accidentally left on. Always follow the battery charger manufacturer’s instruction.
@Autogurukul
 CHARGING AGM BATTERIES
• Absorbed glass mat batteries
are usually used as auxiliary in
hybrid electric vehicles when
the battery is located inside
the vehicle.

@Autogurukul
 BATTERY CHARGE TIME
• The time needed to charge a completely discharged battery
can be estimated by using the reserve capacity rating of the
battery in minutes divided by the charging rate.
• Hours needed to charge the battery = Reserve capacity ÷
Charge current

@Autogurukul
 ALWAYS USE ADAPTERS ON SIDEPOST BATTERIES

• Side-post batteries require

that an adapter be used when
charging the battery, if it is
removed from the vehicle.
• An adapter or a bolt with a
nut attached is needed to
achieve full contact with the
battery terminals.

FIGURE 16 Adapters should be used on

side-terminal batteries when charging.
@Autogurukul
•
JUMP STARTING
To jump start another vehicle with a dead battery, connect good-
quality copper jumper cables

FIGURE 17 Jumper cable usage guide. Notice that the last connection should be
the engine block of the disabled vehicle to help prevent the spark that normally
occurs from igniting the gases from the battery.
@Autogurukul
 JUMP STARTING
• Even if using a battery jump box, the last connection made should
always be on the engine block or an engine bracket as far from the
battery as possible.

FIGURE 18 A typical battery jump box used to jump start vehicles. These hand-
portable units have almost made jumper cables obsolete. @Autogurukul
 BATTERY DATE CODES
• All major battery manufacturers stamp codes on the battery
case that give the date of manufacture and other information.
– A = January
– B = February
– C = March
– D = April
– E = May
– F = June
– G = July
– H = August
– J = September
– K = October
– L = November
– M = December

@Autogurukul
 BATTERY DATE CODES
• The shipping date from the manufacturing plant is usually indicated
by a sticker on the end of the battery.
• Almost every battery manufacturer uses just one letter and one
number to indicate the month and year.

FIGURE 19 The code on the Delphi battery indicates that it was built in 2005 (5),in
February (B), on the 11th (11),during third shift (C), and in the Canadian plant (Z).
@Autogurukul
 BATTERY ELECTRICAL DRAIN TEST
• The battery electrical drain test determines if some
component or circuit in a vehicle is causing a drain on the
battery when everything is off.
• This test is also called the ignition off draw (IOD) or parasitic
load test.

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 BATTERY ELECTRICAL DRAIN TEST
• This test should be performed when one of the following
conditions exists.
– When a battery is being charged or replaced (a battery drain could
have been the cause for charging or replacing the battery)
– When the battery is suspected of being drained

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 IT COULD HAPPEN TO YOU!
• Before disconnecting the battery, check to be certain that the owner has the
security code for a security-type radio.
• A “memory saver” may be needed to keep the radio powered up when the
battery is being disconnected.

FIGURE 20 (a) Memory saver. The part numbers represent components from Radio
Shack. (b) A schematic drawing of the same memory saver. Some experts
recommend using a 12 volt lantern battery instead of a small 9 volt battery to help
ensure that there will be enough voltage in the event that a door is opened while
the vehicle battery is disconnected. Interior lights could quickly drain a small 9 volt
battery. @Autogurukul
 PROCEDURE FOR BATTERY ELECTRICAL DRAIN TEST
• The fastest and easiest method to measure battery electrical drain
is to connect an inductive DC ammeter that is capable of
measuring low current (10 mA).

FIGURE 21 This mini clamp-on digital multimeter is being used to measure the
amount of battery electrical drain that is present. In this case, a reading of 20 mA
(displayed on the meter as 00.02 A) is within the normal range of 20 to 30 mA. Be
sure to clamp around all of the positive battery cable or all of the negative battery
cable, whichever is easiest to get the clamp around.
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 PROCEDURE FOR BATTERY ELECTRICAL DRAIN TEST
• Following is the procedure
for performing the battery
electrical drain test using a
DMM set to read DC
amperes.
1. Make certain that all lights,
accessories, and ignition are
off.
2. Check all vehicle doors to be
certain that the interior FIGURE 22 Parasitic load tool. After connecting
courtesy (dome) lights are off. the shut-off tool, start the engine and operate
all accessories. Stop the engine and turn
3. Disconnect the negative (-)
battery cable and install a everything
parasitic load tool. off. Connect the ammeter across the shut-off
switch in parallel. Wait 20 minutes. This time
allows all electronic circuits to “timeout” or
shutdown.
Open the switch— all current now will flow
through the ammeter. A reading greater than
specified (usually greater than 50 milliamperes
[0.05 ampere]) indicates a problem that should
be corrected. @Autogurukul
PROCEDURE FOR BATTERY ELECTRICAL DRAIN TEST
4. Start the engine and drive the vehicle about 10 minutes,
being sure to turn on all the lights and accessories including
the radio.
5. Turn the engine and all accessories off including the
underhood light.
6. Connect an ammeter across the parasitic load tool switch
and wait 10 minutes for all computers and circuits to shut
down.
7. Open the switch on the load tool and read the battery
electrical drain on the meter display.

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 PROCEDURE FOR BATTERY ELECTRICAL DRAIN TEST
• Be sure to reset the clock and
antitheft radio if equipped.

FIGURE 23 The battery was replaced in this

Acura and the radio displayed “code” when
the replacement battery was installed.
Thankfully, the owner had the five-digit code
required to unlock
the radio.
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 BATTERY DRAIN AND RESERVE CAPACITY

• It is normal for a battery to self-discharge even

if there is not an electrical load such as
computer memory to drain the battery.
• The calculation used is the reserve capacity of
the battery divided by 4; this equals the
maximum allowable battery drain.

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 FINDING THE SOURCE OF THE DRAIN
• If there is a drain, check and temporarily disconnect the
following components.
– Light under the hood (Some lights under the hood are hot all the time
and light by means of a mercury switch when the hood is opened.)
– Glove compartment light
– Trunk light

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 WHAT TO DO IF A BATTERY DRAIN STILL EXISTS

• If all the fuses have been disconnected and

the drain still exists, the source of the drain
has to be between the battery and the fuse
box.
– The generator. Disconnect the generator wires and retest. If the
ammeter now reads a normal drain, the problem is a defective
diode(s) in the generator.
– The starter solenoid (relay) or wiring near its components. These are
also a common source of battery drain, due to high current flows and
heat, which can damage the wire or insulation.

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 HIDDEN BATTERIES
• Many vehicle manufacturers today
place the battery under the
backseat, under the front fender, or
in the trunk.

FIGURE 24 Many newer vehicles have

batteries that are sometimes difficult to
find. Some are located under plastic
panels under the hood, under the front
fender, or even under the rear seat. The
battery in this Lincoln LS was located in
the trunk next to the spare tire. The
jump start instructions indicate that the
spare tire hold-down bolt is to be used
as the ground connection if jump
starting is necessary.

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 BATTERY SYMPTOM GUIDE
• The following list will
assist technicians in
troubleshooting
batteries.

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BATTERY LOAD TEST
Step-by-Step

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BATTERY LOAD TEST
Step-by-Step

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 BATTERY LOAD TEST
Step-by-Step

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 BATTERY LOAD TEST
Step-by-Step

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 BATTERY LOAD TEST
Step-by-Step

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 BATTERY LOAD TEST
Step-by-Step

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 SUMMARY
1. All batteries should be securely attached to
the vehicle with hold-down brackets to
prevent vibration damage.
2. Batteries can be tested with a voltmeter to
determine the state of charge. A battery load
test loads the battery to one-half of its CCA
rating. A good battery should be able to
maintain higher than 9.6 volts for the entire
15-second test period.
3. A battery drain test should be performed if
the battery runs down.

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 CHAPTER QUIZ
1. Technician A says that distilled or clean drinking
water should be added to a battery when the
electrolyte level is low. Technician B says that
fresh electrolyte (solution of acid and water)
should be added. Which technician is correct?
a) Technician A only
b) Technician B only
c) Both Technicians A and B
d) Neither Technician A nor B

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 CHAPTER QUIZ
2. All batteries should be in a secure bracket
that is bolted to the vehicle to prevent
physical damage to the battery.
a) True
b) False

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 CHAPTER QUIZ
3. A battery date code sticker indicates D6.
What does this mean?
a) The date it was shipped from the factory was
December 2006.
b) The date it was shipped from the factory was
April 2006.
c) The battery expires in December 2002.
d) It was built the second day of the week
(Tuesday).

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 CHAPTER QUIZ
4. Many vehicle manufacturers recommend
that a special electrical connector be
installed between the battery and the
battery cable when testing for _____.
a) Battery drain (parasitic drain)
b) Specific gravity
c) Battery voltage
d) Battery charge rate

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 CHAPTER QUIZ
5. When load testing a battery, which battery
rating is usually used to determine how
much load to apply to the battery?
a) CA
b) RC
c) MCA
d) CCA

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 CHAPTER QUIZ
6. When measuring the specific gravity of the
electrolyte, the maximum allowable
difference between the highest and lowest
hydrometer reading is _____.
a) 0.010
b) 0.020
c) 0.050
d) 0.50

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 CHAPTER QUIZ
7. A battery high-rate discharge (load capacity) test is being
performed on a 12 volt battery. Technician A says that a
good battery should have a voltage reading of higher than
9.6 volts while under load at the end of the 15 second test.
Technician B says that the battery should be discharged
(loaded) to twice its CCA rating. Which technician is correct?
a) Technician A only
b) Technician B only
c) Both Technician’s A and B
d) Neither Technician A nor B

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 CHAPTER QUIZ
8. When charging a maintenance-free (lead-
calcium) battery, _____.
a) The initial charging rate should be about 35
amperes for 30 minutes
b) The battery may not accept a charge for several
hours, yet may still be a good (serviceable)
battery
c) The battery temperature should not exceed
125°F (hot to the touch)
d) All of the above are correct

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 CHAPTER QUIZ
9. Normal battery drain (parasitic drain) with a
vehicle with many computer and electronic
circuits is _____.
a) 20 to 30 milliamperes
b) 2 to 3 amperes
c) 150 to 300 milliamperes
d) None of the above

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 CHAPTER QUIZ
10. When jump starting, _____.
a) The last connection should be the positive post
of the dead battery
b) The last connection should be the engine block
of the dead vehicle
c) The generator (alternator) must be disconnected
on both vehicles
d) Both a and c are correct

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 ANSWER QUIZ
• 1) a
• 2) a
• 3) b
• 4) a
• 5) d
• 6) c
• 7) c
• 8) d
• 9) a
• 10) b

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 END

THANK YOU

@Autogurukul