Unit 36 worksheet: Automotive batteries

Competency unit: AURETR025 Test, charge and replace batteries and jump-start vehicles

Activity summary:

This worksheet will be used as evidence regarding your work within the following
competencies:

1. Identify safety precautions when working with automotive 12-volt batteries.

2. Describe the basic operation of an automotive lead acid battery.
3. Explain the purpose of an automotive battery.
4. Describe battery service procedures.

Reference material:

Automotive Mechanics: 10e, Chapter 41.

Safety precautions:

1. Personal protective equipment (PPE) must be worn.

2. Remove all jewellery before working on electrical systems.
3. Follow all standard operating procedures (SOP) when using workshop
tools and equipment.
4. Carry out a risk assessment prior to attempting repairs to electrical circuits.
5. Beware of flammables before disconnecting electrical circuits.
6. Keep naked flames and sparks away from batteries.
7. When disconnecting a battery, remove the negative terminal first. When
reconnecting, fit the negative terminal last.
8. Ensure that the main power is turned off while connecting and disconnecting
a battery from a charger.
9. Follow all electrical test equipment safety instructions.
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Mr Hemand Kumar

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Name of workplace:

Student name: Ajit

Student signature: Ajit

Date: 04-07-2019
1. A battery has three main purposes within a motor vehicle. Provide a brief
explanation of each purpose.
 To provide electrical power to start the engine: A battery’s primary function is engine
starting. Batteries with less capacity are capable of starting a large displacement engine,
but they may not do so reliably, especially in colder climates.
 To supply additional current when the charging system can’t keep up with electrical
demand. A battery’s second function is to supply current when the charging system is
overworked. This usually occurs (though not always) when the engine is being run at
lower than normal operating speeds.
2. To act as a voltage stabilizer for the charging system: The third function of a battery is to
act as a voltage stabilizer for the charging system. Vehicle charging systems need something
to push against to keep from producing excessive voltage
3. Explain how a lead acid battery creates an electrical charge?
Lead acid storage battery is formed by dipping lead peroxide plate and sponge lead plate
in dilute sulfuric acid. A load is connected externally between these plates. In diluted sulfuric
acid the molecules of the acid split into positive hydrogen ions and negative sulfate ions. The
hydrogen ions when reach at PbO2 plate, they receive electrons from it and become
hydrogen atom which again attack PbO2 and form PbO and H2O (water). This PbO reacts
with H2 SO4 and forms PbSO4 and H2O (water).

4. Cells within a battery are made up of two different plates which are:-
The lead acid battery is made up of several identical cells, each of which contains two plates,
one positive, and the other negative. Both plates are immersed in an electrolyte that is a
mixture of sulfuric acid and water. Two types of cell construction are common: flat plate and
tubular plate.

5. What is the name given to the fluid that mixes with the plates within a battery cell?
Electrolyte or Active Material: The material in a cell which takes active participation in a
chemical reaction (absorption or evolution of electrical energy) during charging or
discharging is called the active material of the cell. The active elements of the lead acid are:
Lead Peroxide (PbO2): It forms the positive material and has dark chocolate broom color.
Sponge Lead: It forms the negative active material and has grey color.
Dilute Sulphuric Acid (H2SO4): It is used as electrolyte and contains 31% Sulphuric acid.

6. What is used between the electrode plates within a battery, and why?
Separators: The separators are thin sheets of non-conducting material made up of
chemically treated lead-wood, porous rubbers, or mat of glass fiber and are placed between
the positive and negative to insulate them from each other. Separators are grooved vertically
on one side and are smooth on the other side.
7. What is the electrolyte mixture in a lead acid battery?
The electrolyte is composed of a solution that consists of up-to 40 percent sulfuric acid, with
the remainder consisting of regular water. Lead and lead dioxide, the active materials on the
battery's plates, react with sulfuric acid in the electrolyte to form lead sulfate. The
lead sulfate first forms in a finely divided, amorphous state, and easily reverts to lead,
lead dioxide and sulfuric acid when the battery recharges.

8. In what configuration are the cells electrically connected within an automotive battery?
Single Cell Applications: The single-cell configuration is the simplest battery pack; the cell
does not need matching and the protection circuit on a small Li-ion cell can be kept simple.
Series Connection: Portable equipment needing higher voltages use battery packs with two
or more cells connected in series.
Parallel Connection: If higher currents are needed and larger cells are not available or do
not fit the design constraint, one or more cells can be connected in parallel. Most battery
chemistries allow parallel configurations with little side effect.
Series/parallel Connection: The series/parallel configuration shown enables design
flexibility and achieves the desired voltage and current ratings with a standard cell size. The
total power is the sum of voltage times current.

9. If a battery consists of six cells with each cell producing 2.1 volts, what would be the
battery voltage?
Battery voltage would be: 6 cells x 2.1volts = 12.6 Volts or 12 volts Approx.

10. Identify the following battery components:

Component Number Component Name

1 Positive and Negative Terminal Posts
2 Vent Plug
 3 Cover Plate
4 PE Separator
5 Battery Container or Outer body

11. What is meant by the term specific density?

Specific density is the ratio of the weight of a solution (sulfuric acid in this case) to the
weight of an equal volume of water at a specified temperature. This measurement is usually
measured using a Hydrometer.

12. There are two major electrical characteristics of a battery. These are:
 Battery capacity" is a measure (typically in Amp-hr) of the charge stored by the battery,
and is determined by the mass of active material contained in the battery. The battery
capacity represents the maximum amount of energy that can be extracted from
the battery under certain specified conditions.
 Ampere-hour efficiency: The ratio of the ampere-hour output supplied during discharge
of a secondary cell or battery to the ampere-hour input required during charge, under
specified conditions.

13. What does the term battery voltage open circuit mean?
Open circuit voltage (or potential) is voltage which is not connected to any load in a circuit.
Open-circuit voltage is the difference of electrical potential between two terminals of a
device when disconnected from any circuit. There is no external load connected. No external
electric current flows between the terminals. Alternatively, the open-circuit voltage may be
thought of as the voltage that must be applied to a solar cell or a battery to stop the flow of
current. It is sometimes given the symbol Voc.

14. Provide an explanation of cold cranking amps (CCA).

Automotive batteries will frequently have a specification known as cold cranking amps. The
specification is often abbreviated to ‘CCA’. Batteries that specify cold cranking amps are
generally referred to as starting batteries.
This specification is the measure of a battery’s ability to supply a lot of power for a short
period of time. The specification tells us how much current the lead acid can supply for 30
seconds, at zero degrees Fahrenheit, before the voltage dropping to below 7.2 Volts.
For example, a Battery labeled as being able to provide 300 CCA is a battery that can supply
300 Amps of current for 30 seconds, at zero degrees Fahrenheit, without dropping below 7.2
volts.
15. Explain the ampere hour @20 Hr rating.
For deep cycle batteries the standard Amp Hour rating is for 20 hours. Actually, the detail is
so common that most battery labels don’t incorporate this data. The Amp Hour rating would
mean, for example, that if a battery has a rating of 100AH @ 20 Hr rate, it can be discharged
 over 20 hours with a 5 amp load. If it has the rating of 200 AH, it can handle a 10 amp load
for 20 hours.

16. What happens to the battery voltage when it is placed under a heavy circuit load?
Voltage drops occur when loads are increased because an increase in current occurs, which
depletes source capacity. As we introduce loads to the circuit, by closing load paths to the
supply/return lines, each load becomes its own registrable voltage drop.
If enough loads are added to the circuit where capacity is at maximum, or capacity is
overloaded, then no more drops in voltage should be registrable. The more loads in the
circuit, the more current flows, current (movement of charges) supply is limited to a given
capacity due to limitations of ability to produce charge imbalances, and thus the more the
potential difference is depleted.

17. How can a maintenance-free battery be identified?

Maintenance-free batteries should never be topped up; therefore there are no filler caps on
top. The filler cap is replaced by an over-pressure valve that is normally closed. Any gas that
forms ends up being recombined in the cell as water. This way there is always sufficient
electrolyte in the battery. Naturally the user never forgets to carry out maintenance.
Maintenance-free batteries have to be charged up with a charger that is suitable for this
type of battery.
The maintenance-free group of batteries includes types where the acid is in a gel form (Gel)
as well as batteries that use glass fiber mats (AGM = Absorbent Glass Mat). Provide a
minimum of three visual checks you could carry out on a battery fitted to motor vehicle.

18. Provide a minimum of three visual checks you could carry out on a battery fitted to
motor vehicle.

 Physical size and mounting style

 Battery surface is free of dirt and moisture.
 Make sure the battery connections are clean and corrosion free. This includes the frame
and body ground connections and connections at the starter motor, starter solenoid and
alternator. Make sure the battery cables are properly sized.
 Check that the battery is properly secured and the mounting hardware is not too tight.

19. What are the two tests that can be carried out on a battery to determine its condition?
Test to check the Volts of Battery: Fully charged automotive batteries should measure at
12.6 volts or above. When the engine is running, this measurement should be 13.7 to 14.7
volts. If you don’t have a multi meter to tell you the voltage of your battery, you can do a test
of your electrical system by starting the car and turning on the headlights. If they are dim,
that indicates the lights are running off the battery and that little or no charge is being
produced by the alternator. If the lights get brighter as you reverse the engine, it means the
alternator is producing some current, but may not be producing enough at idle to keep the
battery properly charged. If the lights have normal brightness and don’t change intensity as
 the engine is revved, your charging system is probably functioning normally. If you’ve been
experiencing problems with your battery system and the headlight test checks out okay, you
should check whether or not the battery is holding a charge, or if something on the vehicle is
discharging it.
Load Test: To pass a load test, the battery must maintain 9.6 volts at 15 seconds when tested
at one-half the CCA rating and 70°F (or above). This test must be done with a true load
(carbon pile) and not one of the hand-held testers that work off a conductance algorithm. The
test must be run with the battery in a high state of charge. Be sure to read and follow all
safety and handling instructions on the battery, this website and your battery tester. If you
would like your battery tested, use our Find a Retailer for a location near you.

20. If you were replacing a battery, which lead would you disconnect first and reconnect
last? Explain your answer.
The negative terminal of the battery is to be removed first as the negative terminal of the
battery is connected to the entire car chassis in virtually all modern cars. That means that any
part of the engine compartment, the engine, the hood, and the fenders are all negative ground.

21. What is the cause of battery terminal or hold-down strap corrosion?

Hydrogen gas leakage: The battery turns acid into electric current. There moments the
hydrogen gas in the battery leaks and finds its way to the atmosphere. It reacts with other
substances, and you have battery terminal corrosion.
Depending on which side it forms, you can diagnose various battery problems if it is on the
negative terminal; this is a sign of undercharging while if it is on the positive terminal, it is
due to overcharging. Most batteries suffer from undercharging, and this is the reason you see
it more on the negative side.
Corrosion in the copper clamps: Copper is a good conductor and does not corrode easily.
However, when electric currents pass through the copper terminals, there is the production of
copper sulfate, which leads to battery terminal corrosion.
A bluish precipitate on the copper terminals can identify copper sulfate. Copper sulfate does
not conduct electricity well, and that is why you will start experiencing trouble starting your
car.
Electrolyte leakage: This problem is synonymous with lead-acid batteries. Due to age or
damage, the electrolyte in the battery can leak and accumulate on the battery terminals. The
probability of the electrolyte leaking is increased if you overfill the battery water.
Overcharging and overfilling battery: If you overfill your battery with water, it can cause the
electrolyte to leak through the vents and corrode the terminals. Ensure that you put the right
amount of battery water.

22. Where corrosion of terminals is evident, explain the process you would use to remove
and clean the corrosion?
Baking soda – water solution: If you want to remove copper sulfate that has accumulated on the
terminals, you will need some baking soda water solution and a brush. First, ensure that the
car’s ignition has been turned off. Remove the battery terminals and use your brush to
remove some of the corrosion.
 Soda: Most of the soft drinks that we take have some carbonic acid in them. Pour some of the
soda on the terminals and use a soft sponge to remove the residue. This works well in the
absence of a baking soda-water solution.
Cleaning heavy corrosion: If your battery has excessive corrosion on the terminals, you will
need to use baking soda-water solution and an old toothbrush. Start by removing the battery
terminals – the negative should be first. Mix your baking soda solution and place it in cups.
Soak each of the terminals in the solution and let it soak for the next 20 minutes.
Using Copper compression terminals: These clamps are one of the best in the market and will
help prevent further battery terminal corrosion. The clamps are made from tinned copper and
ensure that the whole clamp gets into contact with electric current.
Battery charging: One of the causes of battery terminal corrosion is a battery that is
overcharged or undercharged. The manufacturer’s manual often has the recommended
battery voltage. You should adhere to this if you want to prevent corrosion forming on the
terminals.
23. After the clamps are replaced, what can they be coated with to help reduce corrosion?
Dielectric grease: Dielectric grease is electrically insulating and does not break down when
high voltage is applied. It is often applied to electrical connectors, particularly those
containing rubber gaskets, as a means of lubricating and sealing rubber portions of the
connector without arcing.

24. What should be added to a battery cell when its electrolyte level is low?
Battery electrolyte is sulfuric acid and water, and a certain amount of the lead electrolyte in
solution. Low electrolyte levels caused by normal electrolysis in the battery should be topped
off with nothing else except distilled or dematerialized water.

25. Why should the correct procedures be followed when replacing the battery in later-
model vehicles, particularly ISS vehicles?
Generally conventional batteries are used in later model vehicles which are not suitable for
Ideal start and stop (ISS) vehicle.
Conventional batteries cannot handle the cycling requirements of ISS system. Use of
conventional batteries in ISS system may affect ISS system and CO2 emission control which
lead to premature battery failure.
Fitting a conventional battery in ISS technology vehicle could potentially damage the
vehicle’s electrical system.
There are chances of wrong polarity which may cause damage to equipments in car and
sometimes explosion of battery.

26. When jump-starting a vehicle with a flat battery, the correct procedures must be
followed. The following table provides a range of instructions for these procedures.
Provide the reasoning for each:

Instruction Reasoning
 Both the booster battery and the discharged
battery must be of the same voltage.
Both batteries must have the same polarity.
Where filler caps are fitted to a battery, place
a cloth over the filler caps of both batteries.
With the red jumper lead, connect the
positive terminal of the discharged battery to
the positive terminal of the booster battery.
Attach one end of the black jumper lead to
the negative terminal of the booster battery
and the other end to an earth on the engine
away from the battery.
With difference in battery voltage may cause
harmful effects on circuits, and may cause
explosion in batteries.
If both batteries do not have same polarity
then they may cause damage to electric
circuits and appliances in vehicle.
Whenever jump-starting a flat battery, vent
plug may occur to loosen and the electrolyte
can be flown out and may cause damage to
battery parts.
The positive terminal of the battery is to be
connected first as the negative terminal of the
battery is connected to the entire car chassis
in virtually all modern cars. That means that
any part of the engine compartment, the
engine, the hood, and the fenders are all
negative ground.

Due to start up of engine electric energy of

booster battery is consumed and other we
Allow both engines to run for a few minutes. already have discharged battery. So for
charging of both the batteries we have to run
the engine for few minutes.

27. Provide an explanation of the term sulphation:

Sulfhation is a buildup of lead sulfate crystals and is the number one cause of early battery
failure in lead-acid batteries. Sulfhation occurs when a battery is deprived of a full charge; it
builds up and remains on battery plates.

28. List the main advantages of gel batteries:

 Maintenance Free –Less maintenance means more time for relaxation. They are
maintenance free. Since the battery system is designed to eliminate the emission of gases,
the volume of free electrolyte (battery acid) that could be released is very small. There is
therefore no need to check the level of the electrolyte or top off water lost due to
electrolysis.
 Leak-Proof Battery –no leaks mean any rust. The VRLA batteries are leak-proof and
will not leak even if the container is cracked or broken. In these sealed lead-acid
batteries, a glass-mat separator absorbs the electrolyte and holds it between the lead
plates. Because the acid electrolyte is held by the absorbent mat, the battery will not leak
or spill.
  Rechargeable with a proper Battery Charger – Using the right charger is required
with Gel Cell batteries. Gel or VRLA battery requires no maintenance once the charging
system has been properly set up. It is finicky when it comes to being recharged, so it is
important that the correct battery charger be used on a gel cell battery, otherwise poor
performance may result.
 Additional Safety Gear not Required – Shipping gel cell batteries is simple and safe.
The gel / VRLA batteries require no additional safety gear to carry on board a ship and
no special handling precautions when being shipped since they do not leak, spill or
corrode and their contents are completely sealed.
 Easy Operation in Most Temperatures– Wrap up and enjoy the outdoors without
worrying about battery failure. The VRLA batteries can operate in a variety of
temperatures from very high to very low (between -40 degrees Fahrenheit to 140 degrees
Fahrenheit) and may last a bit longer in hot weather applications than other batteries.
 Worry-Free, Heat and Shock Resistant – They are non-corrosive so there is no worry
about sulfuric acid leaking from it. Because plastic cases of VRLA batteries are ruggedly
built, these batteries can also withstand vibration, heat and shock.

29. Explain the benefits of an Absorbed Glass Mat (AGM) battery:

 When you turn the battery upside down, the electrolyte will not spill out of an A.G.M.
battery.
 An A.G.M. battery never needs any water, and is considered to be maintenance free.
 A.G.M. batteries do not give off any gas (hydrogen) when being charged, so there is less
concern about ventilation when charging them. This allows them to be used safely inside
a motor home.
 A.G.M. batteries can stand very low temperatures without freezing.
 These batteries are also very resistant to vibration, due to their sandwich construction.

30. Why are calcium batteries claimed to have more strength than other batteries?
A calcium battery is a lead acid battery with no antimony in its grids. Instead, a
calcium component (around 1%) is added to both the positive and negative plates. This
works to reduce water loss through gassing in the battery and allows the battery container to
be fully sealed and maintenance-free.

31. The main advantages of calcium batteries are that they:

 More resistant to corrosion.
 Resistant to overcharging.
 More resistant to gassing.
 Less usage of water.
 Calcium batteries are self-discharging batteries.
 These batteries have larger electrolyte reserve area above the plates.


32. Provide four aspects of an AGM battery that make it a very versatile component:
 Leak proof: AGM batteries have high performance and are designed for high demands.
In principle, the structure of an AGM battery is the same as that of a wet cell battery. The
large contact area contributes to the power output and also makes the battery leak-proof.
 Spill-Free Convenience: Other battery types depend on liquid mixtures to create an
electrical charge between internal plates. An AGM battery has a different concept ruling
their power design. Sulfuric acid that normally runs as a liquid is now absorbed into a
fiberglass mat. Its fixed position allows AGM batteries to be spill-free designs.
 No Gassing during Charging: During charging, chemical reactions occur within the
battery. Most gasses produced during this process are confined to the battery’s interior
space.
If any gasses do build up, this scenario occurs:
 A low-pressure safety valve opens up
 Gasses slowly seep from the battery
 The valve reseals itself for use at another time
 Vibration Resistance: Using AGM batteries in deep-cycle applications means that some
heavy-duty components are in play. Boats, wheelchairs and cars can all use these
specialized batteries because of their vibration resistance. The electrolyte remains
suspended in the fiberglass mat. The surrounding components can shake and shimmy, but
the battery continues to power your machine.
 Quick-Charging Capabilities: The physical structure of an AGM battery creates low
resistance. In layman’s terms, electricity flows easily through the cells. With this fact in
mind, it makes sense that electricity being sent into the cells will move with incredible
speed.
 Powerful Startup: Electricity that flows so easily also benefits your power-hungry
components, especially in gadget-filled cars. Powerful currents race through the batteries
so that you can start a car without any hesitation. Older technologies don’t fare as well as
the AGM batteries.
 Long Lifespan: Life span of AGM battery is much longer than the other batteries.

33. What is the main disadvantage of an AGM battery?

 Higher Cost: Dry cell batteries, like the AGM, cost relatively more than the other
variations. This could be one factor that may discourage buyers from purchasing the
product.
 Intolerant to Overcharging: This is perhaps the main weakness of the AGM battery.
Because of the fact that you cannot replace the water within the battery, if it becomes
overcharged, it loses the electrolyte, which may lead to its failure. Special care has to be
taken to ensure that the battery is never overcharged.