Hv Batteries

8/16/2019 Hv Batteries

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Starting Batteries

How do batteries work?

Each cell has a number of positive plates

made of lead (sponge lead?)

And negative plates of ???




When the two dissimilar metal plates are

immersed in acid the create a voltage

!his voltage is created b the concentrating

"egative #ons on the negative plates and

$ositive #ons on the positive plates




As batteries discharge the acid is turned to

water and the lead plates are turned into

lead sulfate

When both plates are turned to lead sulfate the

batter is discharged or dead



How man volts does one batter cell produce?

%&' volts

How man cells in a '% volt batter?

cells

How man volts in a '% volt batter?

'%&How can ou get '%& volts out of a bunch of %&' volt cells?

wire them in series



What comes out of a batter?Electrical $WE*

what is power?

Watts + volts , Amps

How do ou get more volts out of a batter?

add more cells in series

How do diesel vehicles get %- volts for starting

wiring %.'% volt/ or

-. volt batteries in series



What happens as all the amps get used up?

!he electolte turns to water and&&&

&&&the lead and sponge lead plates turn to 0ead

sulfate and&&&&&&the acid will no longer strip electrons from

the positive plates1

&&&and add them to the negative plates

!he batter will go 2EA2



How can we build a batter to suppl more amps?

add more lead plates to each individual cell

more lead plates in a cell will increase1?

&&&cranking amps

1amp hour rating



So what batter should # use?

') A batter with the proper voltage1

&&& volt/ '% volt/ %- volt

%) A batter with enough amp capacit&&&

13old 3ranking Amps/ or amp hour rating

4) A batter with that will fit in the carrier1

&&&B3# 5roup rating



B3# 5roup rating

How tall is the batter

How wide is the batter

How long is the batter

Where are the terminals located



#f the batter is the correct B3# 5roup&&&

1is it correct batter?

"6 it must meet vehicle specific capacit

7anufacturer will specif a minimum 33A&&& orAmp hour rating

Adding plates to a cell increases the amp capacit

Adding plates (surface area) will lengthen the service life of the batter

Adding plates increases price&



2eep 3cle batteries

Some *8 and 7arine batteries are different

!he are intended to operate smaller electrical loads(lights/ '% volt accessories/ trolling motors etc&) for

long periods of time without being recharged&

!he are called 2eep 3cle batteries as the canwithstand man ccles of long slow discharging

followed b long slow charging&



2eep 3cle batteries

*apid discharging (like the hundreds of amps

pulled b a starter motor) will ruin a 2eep

3cle batter1

&&&it will overheat the plates&



Starting Batteries

!he function of the batter is to start the engine

!hen the generator will run all electrical loads&

Some *ecreational 8ehicles use both a starting

batter and a deep ccle batter&

!he deep ccle batter is not hooked to the starter

motor&



Starting Batteries

#f ou allow a starting batter to slowl go dead it will

9S:0;A!E<

!his happens when lead sulfate (formed when a batter discharges) crstalli=es on the surface of the

lead plates&

!his will not allow the batter to full recharge

Sometimes a sulfated batter will not recharge at all&



What tpe of batter do # sell

to the customer?$roper B3# 5roup number

So it will fit in the vehicle

!he proper tpe batter

3ranking or 2eep 3cle

!he more 33A the better

7ake sure it meets the minimumre>uired b the manufacturer



When do # add batter Acid?

nl for filling dr charged batteries

2o not add acid to a batter alread in service

Some batteries are assembled but the acid is left

out until it is read for sale (2r 3harged)

!he acid is added ust before it is installed

in the vehicle



Storing Batteries

When a batter is new the lead and acid will begin to react and it will slowl

discharge&

An batter that sits unused for several months will slowl go dead and beginto sulfate&

!his will ruin the batter&&

All batteries be periodicall recharged&

"ew batteries/ awaiting sale/ are given a 9trickle charge< on a regular schedule



What do # add to a batter with low electrolte?

2istilled (or de.minerali=ed) water&

Adding tap water will encourage electrolsis

!his will speed up the loss of that water when

charging and discharging

#t will also encourage corrosion on the batter cables



How full do # fill the batter

;ill until the electrolte ust touches

the fill ring

$ractice this1@ou can see ust when it touches

#f ou overfill1@ou can pull the etra out1

1it our sringe is clean (use a hdrometer)



30EA" 30EA" 30EA"

Be sure an item that touches the electrolte

is washed

3lean batter hdrometer with plent of water

after each use



How can # make the batter live longer?

') make sure the batter hold down is solid

1vibration will knock material off the lead plates/ lower the ampcapacit/ and short out cells&

%) keep the batter clean

1as the batter ccles acid gets all over the case/

this will corrode the cables1

&&&and also provides a path for current to slowl discharge the batter between terminals

(this can be measured with a volt meter)



%) eep the batter clean

Alwas clean the batter with the vent caps on to avoid

contaminating the cells&

Baking soda and water works well to neutrali=e an

batter acid as do batter cleaning spra cans&

*inse with lots of water after neutrali=ing the acid

Soap and water works great to clean a batter




4) keep the batter full1&&&use distilled water and do not over fill&

#f the batter is etra low check the charging sstem forovercharging

#f low electrolte with no removable vent caps&&&

&&&replace the batter after double checking the charging sstem&




-) eep the batter full charged1

&&&make sure the cables are not corroded

C) 3heck for parasitic drains &&&&&A parasitic draw of up to &DCD amps is acceptable&

) 2o not allow the batter to free=e1

&&&a dead batter can free=e at 'C °;

1a full charged batter will survive FCD°;



;ro=en Batteries2 "! A!!E7$! ! G:7$ S!A*! * 3HA*5E A ;*E"

BA!!E*@

A charging batter forms Hdrogen gas that will be trapped b the iceand can cause the batter to eplode&

A fro=en batter is ruined due to the ice breaking up the sponge lead plates

nce thawed out it will soon fail&



;ro=en Batteries

*eplace fro=en batteries&

A fro=en batter will have a bulged out case that willnot reform

An overcharged batter can also cause the case to bulge or distort&

#f the case looks distorted test the batter and thecharging sstem



How can # test the batter?

I') ou can onl accuratel test a full charged

batter

An undercharged batter might fail the load test

0oad testing an undercharged batter ma leadto unnecessar batter replacement



How do # determine the batter

State of charge?:se a hdrometer and compensate for the temperature of the

batter

As a batter discharges the acid turns to water

Acid is thicker and will float the hdrometer scale higher

A full charged batter cell has a 9specific gravit< of '&%Cat JD degrees



Hdrometer !esting

A colder batter will measure higher as cold li>uid is thicker

A cold batter ma look charged actuall be undercharged

3heck each cell1

1#f the lowest cell is &DCD points lower than the highest cell the batter

is defective

#f water has ust been added to the batter it will give a false hdrometer

reading



What if there are no removable vent caps?

Some batteries include a built in hdrometer&

!his checks one cell onl

#ndicates the batter is at least KCL charged when green(or not blackMclear)

@ou can also test a batter state of charge with a voltmeter



!esting the batter state of charge

with a volt meter '%& 8 + a full charged batter

'%&- 8 + KCL charged

'%&% 8 + CDL charged



7 batter reads '4&% 8olts1

&&&#s it overcharged?Some recombinant batteries maintain a slightl higher

open circuit voltage

"ormal batteries will also register a surface charge&

!his is not an accurate reading of the state of charge



How do # accuratel get an

open circuit voltage reading ?!o remove the surface charge place a %CD amp load on

the batter/ or crank the engine (without starting) for

'C seconds/

0et the batter recover for five minutes/ with the keoff and all accessories turned off&

A vehicle that has not been run for several hours willhave an accurate open circuit voltage reading



2o # reall have to do all this

before testing the batter?nl if the batter fails the load test

#f the batter passes the capacit or load test1

&&&the batter is good&

#f the batter fails the load (or capacit) test1

&&&let it sit for five minutes1

&&&recheck the open circuit voltage&

#f voltage is below '%& volts/ recharge the batter and run asecond load test



How do # recharge the batter?

!he best wa is with a slow (or trickle) charge&

0eave the charger unplugged when connecting the batter/ to avoid sparks and potential eplosion

Batteries are most prone to eplosion after load testing/

ump starting/ or cranking th engine!rickle charging will give the most complete charge andis easiest on the batter



# donNt have time for a slow charge6

WhatNs wrong with >uick charging?"othing1

&&& #; @: ;00W SA;E!@ $*E3A:!#"S1

1to protect the batter and the vehicle

!o protect vehicle computers from high voltage&&&

&&&ou should unhook the vehicle ground before

turning on the charger



What can go wrong when #

unhook the batter ground cable?#nsure the ignition ke is turned off&

!his will protect the computers from a voltagespike when power is unepectedl interrupted

Be sure to suppl an additional power source to thevehicle to protect the computerNs learnedoperation strateg



Back to fast charging

nce the batter is isolated1

&&& ou can turn the charger on high1

&&&after connecting the charging leads&



How long do # leave it on fast charge?

0eaving a batter on high charge is risk&

#f it is sulfated the voltage will >uickl rise above 'C volts andoverheat the batter&

Also if the batter has a shorted cell the voltage ma sta lowit will begin to gas ecessivel

!his will create hdrogen gas that ma eplode&



# take vent caps off when charging/

#s this &&?8ent caps have built in flame arrestors

!hese can keep a batter from eploding

should sparks or flames come close

0eave the caps " while charging

7"#!* the batter during a fast charge



How do # monitor the batter?

3heck the voltage across the terminals with the charger on&#f it gets over 'C volts turn off the charger or slow the rate of

charge&

;eel the case of the batter/if it gets hot it is overcharging

all batteries will get warm/

practice to know hot from warm

H d # it th b tt ?



How do # monitor the batter?

0ook listen and smell for gassing&

#f ou see lots of bubbles through the batter case (white

case) turn down the charger&

#f ou smell the gas/ turn down the charger&

0eave the vent caps on&

!urn off and unplug the charger BE;*E removing the

charging cables from the batter&



2o # need to monitor the batter if

m charger has a voltage regulator?

@es

A shorted cell in the batter will fool the

voltage regulator and ma lead to damage



&& "ow # have a charged batter

How do # tell if itNs an good?!he best test is the load or capacit test&

!o perform this test ou must measure battervolts and amps



0oad !esting or

Batter 3apacit !estingI' hook up the test leads

I% look up the capacit of the batter&&&

&&&that should be placed in that vehicle

#t will be in 3old 3ranking Amps1

&&&or in Amp Hours



0oad !esting or

Batter 3apacit !estingI4 $lace a load (high drain) on the batter

the load should be O the 3old 3ranking Amp rating

&&&or three times the Amp Hour *ating of the batter

&&&look it up to be sure



0oad !esting or

Batter 3apacit !estingI- Watch the voltage of the batter&

#t should not go below P& volts within 'C seconds

do not load the batter longer than 'C seconds&

A strong batter will maintain 'D volts&



0oad !esting or

Batter 3apacit !estingIC #f batter barel passes or fails the test1

&&&leave everthing off for C minutes or longer&

*echeck the open circuit voltage/

if it is under '%&C volts recharge and test again&



0oad !esting or

Batter 3apacit !esting#f the batter recovers up to '%& volts1

&&&and it barel passed the load test1

#t is &&/ but close to the end of itNs service life

1*ecommend replacement if in a cold climate&



0oad !esting or

Batter 3apacit !esting#f the batter recovered to '%& volts1

&&& but dropped below P& volts during the loadtest

*ecommend a new batter



Load Test the Battery



Amp probe around either test cable



When must you isolate the battery?

Only when batteries are in parallel

How many volts for fully charged battery?



y y g y

Is this battery over charged?

o! This is a surface charge"

How do you remove the surface charge?



Load battery to about #$% amps for &$ seconds

After loading' wait one or two full



g

minutes for the battery to recover

Is this battery fully charged?



(olt readings are not accurate without

)*ternal Leads



)*ternal (olt +eter Leads

Load Battery to , --A



Is this a bad battery?



O! .ou must select (OLT/ )0T)1AL

/ame test with (olts )*ternal

What tells you this is a good battery?

, -old -ran2ing Amps' Over 3"4 (olts'



&$ seconds' Load is still O



What do # do with the old/

unk batter?Batteries contain ha=ardous lead

(and other nast things)

!he are ver harmful to the environment&

#t is illegal to place them in the trash or landfill&



What do # do with the old/

unk batter?An business that sells batteries1

&&& is legall obligated to reccle them&



!his batter was onl three ears old/

what caused it to fail?8ibration1

&&&3heck hold down

vercharging1

&&&look for bulged case/ low electrolte1

&&&voltage with engine running1

&&&after batter is full charged



!his batter was onl three ears

old/ what caused it to fail?2ischarged (sulfated)

1look for dirt batter case1

1and corroded batter cable ends

*ecommend more fre>uent batter cleaning



What 3auses Sulfation?

13heck voltage drop across positive andnegative batter cables during cranking

should have less that D&4 volts

3heck for parasitic draw

Should have less than CD milliamps



What 3auses Sulfation?

13heck for low voltage with engine running

&&&after batter is full charged

1#nsure voltage stas up with all accessoriesturned on and engine running at %/DDD *$7

1Qui= customer on driving habits1

&&&short trips will not allow batter to full charge



*eplace the entire batter cable

What is wrong with ust replacing the cable end?

Shorter cables do not room for engine tor>ue1

&&&and ma pull on batter during acceleration

3orrosion often works down cable1

1and creates starting . charging problems

3onnection at end of cable ma provide unwanted voltage drop

What is wrong with this batter?3orrosion on this terminal93ustom< terminal end that ma



What is wrong with this batter?3orrosion on this terminal3ustom terminal end that ma

cause voltage drop



"ow ou are !he&&&

Batter Epert6

Hv Batteries

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