Battery

BATTERYBATTERYBATTERYBATTERY

INTRODUCTIONINTRODUCTION

• THE BTY HAS THREE MAJOR FUNCTIONS IN THE ELECTRICAL

SYSTEM. THE BTY PROVIDES A SOURCE OF ENERGY FOR

CRANKING THE ENGINE THE BTY ACTS AS A VOLTAGE

STABILIZER FOR THE ELECTRICAL SYSTEM. FINALLY THE BTY

CAN FOR A LIMITED TIME, PROVIDE ENERGY WHEN THE

ELECTRICAL DEMAND EXCEEDS THE OUTPUT OF THE GENR.

MAIN COMPONENTS OF THE BTYMAIN COMPONENTS OF THE BTY• CONTAINER MADE OF HARD RUBBER

OR BITUMINIOUS COMPOUND

• PLATES (A) POSITIVE - PbO2

(B) NEGATIVE - SPONGY LEAD

• SEPARATORS RUBBER , CELLULOIDED

• AND PVC WOOD

• CELL COVERS HARD MOULDED RUBBER

• VENT PLUG PVC

• CELL CONNECTORS PURE LEAD

• PARTITION WALLS HARD RUBBER

• BTY POST PURE LEAD

• ELECTROLYTE DILUTED SULPHURIC ACID AT 1260 SPG

• THE ELECTROLYTE IN A LEAD ACID BTY IS COMPOSED OF ONE PART OF CHEMICALLY PURE SULPHURIC ACID & APPROX TWO AND THREE QUARTER PARTS OF DISTILLED WATER. IT HAS A SP GR OF BETWEEN 1.280 AND 1.300 AT 600 F WHEN THE BTY IS FULLY CHARGED.

• MIXING THE ELECTROLYTE

• WHEN MIXING THE ELECTROLYTE THE FOLLOWING PRECAUTIONS WILL BE TAKEN

• POUR THE SULPHURIC ACID SLOWLY AND CAREFULLY INTO THE WATER NEVER POUR THE WATER INTO THE ACID. USE A GLASS, EARTHENWARE, CHINA OR LEAD VESSEL FOR THIS OPERATION

• WHILE POURING, STIR THE MIXTURE WITH WOODEN PADDLE.

• ALLOW THE MIXTURE TO COOL TO BELOW 900F BEFORE POURING INTO A BTY

ELECTROLYTEELECTROLYTE

CHARGED

POSITIVE ELECTGROLYTE NEGATIVE PLATE PLATE

PbO2 + 2H2 SO4 + Pb

(LEAD (SULPHURIC (SPONGY

PEROXIDE) ACID) LEAD)

CHEMICAL ACTION CHARGE AND DISCHARGECHEMICAL ACTION CHARGE AND DISCHARGE

DISCHARGED

POSITIVE ELECTROLYTE NEGATIVE PLATE PLATE

PbSO4 + 2H2O + PbSO4

(LEAD (WATER) (LEAD

SULPHATE) SULPHATE)

FACTORS EFFECTING THE CAPACITY OF A BTYFACTORS EFFECTING THE CAPACITY OF A BTY

• NO OF PLATES.

• TYPES OF ELECTROLYTE.

• AGE OF THE BTY.

• TEMP IN WHICH USED.

• RATE OF DISCHARGING.

TYPES OF CHARGINGTYPES OF CHARGING

• THERE ARE SEVEN TYPES OF BTY CHARGING

• INITIAL CHARGING - 1/30 CAPACITY OF THE BTY

• NORMAL CHARGING - 1/10 CAPACITY OF THE BTY

• REFRESHER CHARGING - 1/20 CAPACITY OF THE BTY

• TRICKLE CHARGING - 1/50 CAPACITY OF THE BTY

• TAPER CHARGING - ACCORDING TO DYNAMO/ALT RATING

• PARTIAL CHARGING - 1/10 CAPACITY OF THE BTY

• BOOSTER CHARGING - 1/5 CAPACITY OF THE BTY

• INITIAL CHARGING - WHEN A NEW BTY IS RECEIVED FOR FIRST CHARGE IS CALLED INITIAL CHARGING.

• PRE CAUTION TO BE TAKEN : CHECK THE BTY CONTAINER BEFORE FILLING ELECTROLYTE IN BTY. ELECTROLYTE SHOULD BE OF CORRECT SPG AS PER BTY INSTRUCTION -


• CARD WHEN BTY IS FILLED WITH ELECTROLYTE, THEN IT SHOULD BE GIVEN 12HRS REST BEFORE CHARGING CHECK THE LEVEL OF ELECTROLYTE AND MEASURE THE SPG THEN PUT THE BTY ON CHARGE IN CONSTANT CURRENT CHARGING SYSTEM. THE CHARGING RATE MUST NOT BE OVER 1/30 OF CAPACITY OF THE BTY. SPG OF ELECTROLYTE SHOULD BE 1.260 TO 1.275. BTY IS TO BE DISCHARGED ACCORDING TO THE CHARGING RATE IN DISCHARGED CONDITION, THE SPG MUST BE 1100 TO 1140

• NORMAL CHARGE IT IS GIVEN TO RUN DOWN BTY. CHARGING RATE IS 1/10 OF THE CAPACITY OF THE BTY.

• REFRESHER CHARGE IT IS GIVEN TO STORAGE BTY. CHARGING RATE IS 1/20 CAPACITY OF THE BTGY.

• TRICKLE CHARGE IT IS GIVEN TO SULPHATED BTY. CHARGING RATE IS 1/50 CAPACITY OF THE BTY.


• TAPER CHARGE IT IS DONE BY DYNAMO WHICH IS IN VEHICLE. THERE IS NO CONSTANT CHARGING RATE,

• PARTIAL CHARGE IT IS GIVEN TO SINGLE CELL. CHARGING RATE IS 1/10 OF THE CAPACITY OF BTY.

• BOOSTER CHARGE IT IS DONE DURING THE PERIOD OF EMERGENCY CHARGING RATE IS 1/5 OF THE CAPACITY OF THE BTY.

• THERE ARE TWO METHODS OF BTY CHARGING SYSTEM

• 1. CONSTANT CURRENT CHARGING SYSTEM (OR) SERIES CIRCUIT CHARGING SYSTEM.

• 2. CONSTANT POTENTIAL CHARGING SYSTEM (OR) PARALLEL CHARGING SYSTEM.

• CONSTANT CURRENT CHARGING SYSTEM

+ - + - + - + -

A

+VE

110 VOLT DC (CH SOURCE)

- VE

METHOD OF BTY CHARGINGMETHOD OF BTY CHARGING

• GREATER NUMBER OF BATTERIES CAN BE CHARGED AT A TIME

• BATTERIES OF DIFFERENT POTENTIALS CAN BE CHARGED

• ALL KINDS OF BTY CHARGING CAN BE DONE (FOR EX INITIAL CHARGING)

• CHARGING RATE CAN BE CONTROLLED ACCORDING TO THE REQUIREMENTS.

• BEING A SLOW RATE CHARGING SYS, THE LIFE OF BATTERIES IS INCREASED.

• DISADVANTAGES OF CC CHARGING SYSTEM

• CONSTANT ATTENTION TO CHARGING RATE IS NECESSARY,.

• BTY MAY BE OVER CHARGED

• A LOOSE BTY CONNECTION AFFECTS THE CHARGING SYS

ADVANTAGE OF CC SYSTEM

• CONSTANT POTENTIAL CHARGING SYSTEM

METHOD OF BTY CHARGINGMETHOD OF BTY CHARGING

+ - + - + - + -12 VOLT DC (CH SOURCE)

- VE

+ VE

• ADVANTAGES OF CP CHARGING SYSTEM

• BATTERIES CAN BE CHARGED IN SHORT TIME

• CONSTANT ATTENTION TO CHARGING RATE IS NOT REQD, AS IT ADJUSTS IT SELF.

• BTY CAN NOT BE OVER CHARGED

• A LOOSE BTY CONNECTION IN ONE BTY CIRCUIT DOES NOT AFFECT OTHER BTY CIRCUITS

• CHARGING CURRENT DEPENDS UPON THE CONDITION OF BTY.

• THE POLARITY OF GENR IS NEVER REVERSED IN CONSTANT POTENTIAL SYSTEM.

• DISADVANTAGES

• SULPHATED BTY CAN NOT BE CHARGED

• GREATER NO OF BTY’S CHARGING CURRENT CAN NOT BE CONTROLLED ACCORDING TO THE REQUIREMENT

• INITIAL CHARGING AND TRICKLE CHARGE CAN NOT BE CARRIED OUT.

• FILLING THE BTY

• POUR THE ELECTROLYTE SLOWLY INTO EACH CELL UNTIL THE LEVEL IS ABOUT 1/4 IN ABOVE THE PLATES.

• DO NOT ALLOW THE CLEANING SOLVENT TO ENTER THE BTY CELLS.

ELECTROLYTEELECTROLYTE

STARTING POWER AVAILABLE FROM BTY AT DIFFERENT STARTING POWER AVAILABLE FROM BTY AT DIFFERENT TEMPTEMP

BTY CAPACITY TEMP POWER REQD FOR ENGINE

100% 800F 26.70C 100%

65% 320F 00C 155%

40% 0 F -17.80C 210%

18% -200F -28.80C 268%

SPECIFIC GRAVITY FREEZING TEMP

1.100 -80C

1.160 -170C

1.200 -270C

1.220 -350C

1.260 -590C

1.300 -700C

• ELECTROLYTE GRAVITY SHOULD BE MEASURED AT THE STANDARD TEMPERATURE OF 27 DEGREE C. IF THE TEMP IS ABOVE OR BELOW THIS STANDARD, THE READINGS SHOULD BE CORRECTED AS BELOW:

• IF THE TEMP IS ABOVE 270C, ADD 0.004 FOR EVERY 50C TO OBTAIN THE CORRECT READING. SIMILARLY IF THE TEMP IS BELOW 270C, DEDUCT 0.004 FOR EVERY 50C TO GET THE CORRECT READING. IF THE READING IS 1.250 AT 420C ADD 3 X 0.004 OR 0.012 TO GET 1.262 AS THE CORRECT READING.

EFFECT OF TEMPERATURE ON ELECTROLYTE GRAVITYEFFECT OF TEMPERATURE ON ELECTROLYTE GRAVITY

S.NO APPROXIMATE SP GRAVITY STATE OF CHAREGE OF BTY

1. 1.260 - 1.280 FULLY CHARGED

2. 1.230 - 1.260 3/4 CHARGED

3. 1.200 - 1.230 HALF CHARGED

4. 1.170 - 1.200 1/4 CHARGED

5. 1.140 - 1.170 ABOUT RUN DOWN

6. 1.110 - 1.140 DISCHARGED

THE FOLLOWING INSTRUMENTS ARE USED TO TEST A BTY.

• SINGLE CELL TESTING VOLTMETER

• HYDRO METER

• HRD TESTER

• GRAVITY CORRECTION THERMOMETER

• BTY CAPACITY TESTER - 500 A

• SINGLE CELL TESTING VOLTMETER. IT IS USED TO MEASURE THE EMF OF THE CELL IT IS DESIGNED TO MEASURE 0 TO 3 VOLTS ONLY.

• HYDROMETER. IT IS AN INSTRUMENT BY WHICH WE CAN MEASURE THE SPECIFIC GRAVITY OF AN ELECTROLYTE. IT WORKS ON THE PRINCIPLE OF BUOYANCY.

• HRD TESTER IT IS HIGH RATE DISCHARGE TESTER. IT SHOWS THE INTERNAL CONDITION OF THE CELL.

BTY TESTERBTY TESTER

FIG NO -1 FIG NO-2 FIG NO-3

BTY VOLTAGE TESTING . IT IS USED TO MEASURE THE EMF OF THE BTY .(REF FIG NO-1) HYDROMETER. IT IS AN INSTRUMENT BY WHICH WE CAN MEASURE THE SPECIFIC GRAVITY OF AN ELECTROLYTE. IT WORKS ON THE PRINCIPLE OF BUOYANCY.( REF FIG NO –2)BTY LOAD TEST: A BTY LOAD TEST, ALSO TERED A BTY CAPACITY TEST, IS ONE OF THE BEST METHOD OF CHECKING THE BTY CONDITION IT TEST THE BTY UNDER FULL LOAD. THE HYDROMETER AND VOLTAGE TEST WERE GENERAL INDICATORS OF BTY CONDITIONS. THE BTY LOAD TEST, HOWEVER, ACTUALLY MEASURES THE CURRENT OUT PUT AND THE PERFORMANCE OF THE BTY. IT IS ONE OF THE MOST COMMON AND INFORMATIVE BTY TESTS USED IN AUTOMOTIVE GARAGES. (REF FIG NO –3)

PRECAUTIONS NEVER USE HRD TESTER WHEN THE PETROLEUM VAPORS ARE PRESENT

• CONNECT THE HRD TESTER PROPERLY

• DO NOT USE HRD TESTER ON DISCHARGED BTY.

• BCT - 500A THE UNIQUE BTY CAPACITIVE TESTER THIS TESTER HAS BEEN DESIGNED BASED ON THE JAPANESE INDUSTRIAL STANDARD JIS-D 5301 FOR LEAD ACID BATTERIES. THIS IS SPECIFIES THAT AUTOMOTIVE BATTERIES FROM 40AH SHOULD BE TESTED UNDER A DISCHARGED CURRENT OF 150 AMPS 300 AMPS OR 500 AMPS DEPENDING UPON THE AH CAPACITY OF THE BTY. THE BCT-500A TESTER THEREFORE TESTS 12V AUTOMOTIVE BATTERIES UNDER A LOAD OF 150/300/500 AMPS.

• THE BCT-500A COMPRISES THE FOLLOWING: -

TESTING INSTRUMENTS OF BTYTESTING INSTRUMENTS OF BTY

• DIGITAL VOLTMETER THE TESTER HAS 3 1/2 DIGIT 20 VOLTS LED VOLT METER, WHICH IS POWERED BY THE BTY UNDER TEST.

• DIGITAL LOAD DISPLAY THE TESTER HAS 3 LOAD OF 150/300/500 AMPS, ONE OF THE LOAD IS SELECTED BNY MEANS OF A 3 WAY SW THE SELECTED LOAD IS THEN INDICATED BY THE DIGITAL DISPLAY.

• BTY CONDITION INDICATOR ABOVE THE DIGITAL VOLTMETER, AN ELECTRONIC SENSING CIRCUIT WITH 3 COLOUR LEDs HAS BEEN PROVIDED. THIS CIRCUIT IS CONNECTED WHEN THE LOAD TEST IS BEING PERFORMED ON THE BTY AND ONE OF LEDs BLINKS, GIVING AN INDICATION OF THE STATE OF THE CHARGE OF THE BTY.

TESTING INSTRUMENTS OF BTYTESTING INSTRUMENTS OF BTY

• RATING BTY CAPACITY RATINGS ARE ESTABLISHED BY THE BTY COUNCIL INTERNATIONAL (BCT) IN CONJUNCTION WITH THE SOCIETY OF AUTOMOTIVE ENGINEERS (SAE), BTY CELL VOLTAGE DEPENDS ON THE TYPES OF MATERITY DEPENDS ON SEVERAL FACTORS.

• RESERVE CAPACITY RATING THE RESERVE CAPACITY IS THE MAXIMUM LENGTH OF TIME IT IS POSSIBLE TO TRAVEL AT NIGHT WITH THE MINIMUM ELECTRICAL LOAD AND NO GENERATOR OUTPUT. EXPRESSED IN MINUTES, RESERVE CAPACITY (OR RC RATING) IS THE TIME REQUIRED FOR A FULLY CHARGED BTY, AT A TEMP OF 270C (810F) AND BEING DISCHARGED AT A CURRENT OF 25 AMPS, TO REACH A TERMINAL VOLTAGE OF 10.5 VOLTS.

• COLD CRANKING AMPERAGE RATING THE COLD CRANKING AMPERAGE TEST IS EXPRESSED AT A BTY TEMP OF 180C (00F) THE CURRENT RATING IS THE MINIMUM AMPERAGE WHICH MUST BE MAINTAINED BY THE BTY FOR 30 SECONDS AT THE SPECIFIED TEMP WHILE MEETING A MINIMUM VOLTAGE REQUIREMENTS OF 7.2 VOLTS THIS RATING IS A MEASURE OF COLD CRANKING CAPACITY.

• AMPERE - HOUR RATING THE AMPERE HOUR RATING IS THE AMOUNT OF STUDY THAT A FULLY CHARGED BTY CAN SUPPLY FOR 20 HOURS AT 800F (26.780C) WITHOUT THE CELL VOLTAGE FALLING BELOW 1.75 VOLTS. FOR EXAMPLE. IF A BTY CAN BE DISCHARGED FOR 20 HOURS AT A RATE OF 40 AMPS BEFORE ITS TERMINAL VOLTAGE READS 10.5 VOLTS. IT WOULD BE RATED AT 80 AMP HOURS.

• WATT - HOUR RATING THE STARTER MOTOR CONVERTS THE ELECTRICAL POWER SYUPPLIED BY THE BTY IN TO MECHANICAL POWER. SO SOME BTY MANUFACTURERS RATE THEIR BATTERIES USING WATT HOUR RATING. THE WATT HOUR RATING OF THE BTYIS DETERMINED AT 00F (217.70C) BECAUSE THE BTYS CAPABILITY TO DELIVER WATTAGE VARIES WITH TEMPERATRE. WATT HOUR RATING IS DETERMINED BY CALCULATING THE AMPERE - HOUR RATING OF THE BTY TIMES THE BTY VOLTAGE.

• MANY BTYS ARE REFERRED TO AS MAINTENANCE FREE. THIS MEANS THERE IS NO PROVISION FOR THE ADDITION OF WATER TO THE CELLS SINCE THE BTY IS SEALED. THE MAINTENANCE FREE BTY CONTAINS CELL PLATES MADE OF A SLIGHTLY DIFFERENT COMPOUND. THE PLATE MADE GRIDS CONTAIN CALCIUM. CADIUM OR STRONTIUM TO REDUCE GASSING (THE CONVERSION OF THE SOLUTION INTO HYDROGEN AND OXYGEN GAS) AND SELF DISCHARGE. THE ANTIMONY USED IN CONVENTIONAL BTYS IS NOT USED IN MAINTENANCE FREE BTYS BECAUSE IT INCREASES THE BREAKDOWN OF WATER IN TO HYDROGEN AND OXYGEN AND BECAUSE OF ITS LOW RESISTENCE TO OVER CHARGING. THE USE OF CALCIUM, CADIUM OR STRONTIUM REDUCES THE AMOUNT OF VAPORIZATION THAT TAKES PLACE DURING NORMAL OPERATION. THE GRID MAY BE CONSTRUCTED WITH ADDITIONAL SUPPORTS TO INCREASE ITS STRENGTH AND PROVIDE A SHORTER PATH, WITH LESS RESISTANCE, FOR THE CURRENT TO FLOW TO THE TOP TAB.

MAINTENANCE FREE BATTERIES

• EACH PLATE IS WRAPPED AND SEALED ON THREE SIDES BY AN ENVELOP DESIGN SEPRATOR. THE ENVELOPE IS MADE FROM MICROPOROUS PLASTIC. BY ENCLOSED THE PLATE IN AN ENVELOPE. THE PLATE IS INSULATED AND REDUCES THE SHEDDING OF THE ACTIVE MATERIAL FROM THE PLATE.

MAINTENANCE FREE BATTERIES

• THE HYBRID BTY COMBINES THE ADVANTAGES OF THE LOW MAINTENANCE AND

MAINTENANCE FREE BTYS THE HYBRID BTY CAN WITH STAND SIX DEEP CYCLES

AND STILL RETAIN 100% OF ITS ORIGINAL RESERVE CAPACITY. THE GRID

CONSTRUCTION OF THE HYBRID BTY CONSISTS OF APPROXIMATELY 2.75%

ANTIMONY ALLOY ON THE POSITIVE PLATES AND A CALCIUM ALLOY ON THE

NEGATIVE PLATES. THIS ALLOWS THE BTY TO WITHSTAND DEEP CYCLING WHILE

RETAINING RESERVE CAPACITY FOR IMPROVED CRANKING PERFORMANCE. ALSO

THE USE OF ANTIMONY ALLOYS REDUCES GRID GROWTH AND CORRISION. THE

LEAD CALCIUM HAS LESS GASSING THAN CONVENTIONAL BTYS.

• GRID CONSTRUCTION DIFFERS FROM OTHER BTYS IN THAT THE PLATES HAVE A

LUG LOCATED NEAR THE CENTER OF THE GRID. IN ADDITION THE VERTICAL AND

HORIZONTAL GRID BARS ARE ARRANGED IN A RADIAL PATTERN. BY LOCATING

THE LUG NEAR THE CENTRE OF THE GRID AND USING THE RADIAL DESIGN. THE

CURRENT HAS LESS RESISTANCE AND A SHORT PATH TO FOLLOW TO THE LUG.

THIS MEANS THE BTY IS CAPABLE OF PROVIDING MORE CURRENT AT A FASTER

RATE. THE SEPERATORS ARE CONSTRUCT OF GLASS WITH A RESIN COATING.

THIS IS OFFER LOW ELECTRICAL RESISTANCE WITH HIGH RESISTANCE TO

CHEMICAL CONDEMINATION. THIS TYPE OF CONSTRUCTION INCREASED CRANKING

PERFORMANCE & BTY LIFE

HYBRID BATTERIES

• ONE OF THE MOST RECENT VARIATIONS OF THE AUTOMOBILE BTY IS THE RECOMBINATION BTY. THE RECOMBINATION BTY DOES NOT USE A LIQUID ELECTROLYTE. INSTEAD IT USES SEPARATORS THAT HOLD A GEL TYPE MATERIAL THE SEPARATORS ARE PLACED BETWEEN THE GRIDS AND HAVE VERY LOW ELECTRICAL RESISTANCE. BECAUSE OF THIS DESIGN, OUTPUT VOLTAGE AND CURRENT ARE HIGHER THAN IN CONVENTIONAL BATTERIES. THE EXTRA AMOUNT OF AVAILABLE VOLTAGE (APPROX-0.6V) ASSISTS IN COLD WEATHER STARTING ALSO. GASSING IS VIRTUALLY ELIMINATED. THE FOLLOWING ARE SOME OTHER SAFETY FEATURES AND ADVANTAGES OF THE RECOMBINATION BTY.

• CONTAINS NO LIQUID ELECTROLYTE, IF THE CASE IS CRACKED, NO ELECTROLYTE WILL SPILL.

• CAN BE INSTALLED IN ANY POSITION, INCLUDING UP SIDE AND DOWN.

RECOMBINATION BATTERIES

• HAS VERY LOW MAINTENANCE BECAUSE THERE IS NO ELECTROLYTE LOSS.

• CAN LAST AS MUCH AS FOUR TIMES LONGER THAN CONVENTIONAL BATTERIES.

• CAN WITHSTAND DEEP CYCLING WITHOUT DAMAGE.

• CAN BE RATED OVER 800 COLD CRANKING AMPS

• IS CORROSION FREE.

RECOMBINATION BATTERIES

• THE SEALED BTY HAS A BUILT IN TEMP COMPENSATED HYDROMETER IN THE TOP OF THE BTY. THIS HYDROMETER IN THE TOP OF THE BTY. THIS HYDROMETER IS TO BE USED WITH THE FOLLOWING DIAGNOSTIC PROCEDURE.

• WHEN OBSERVING THE HYDROMETER, MAKE SURE THAT THE BTY HAS A CLEAN TOP.

• UNDER NORMAL OPERATION, TWO INDICATIIONS CAN BE OBSERVED.

• GREEN DOT VISIBLE - ANY GREEN APPEARANCE IS INTGERPRETED AS A GREEN DOT MEANING THE BTY IS READY FOR TESTING.

• DARK GREEN DOT IS NOT VISIBLE - IF THERE IS A CRANKING COMPLAINT. THE BTY SHOULD BE TESTED. THE CHARGING AND ELECTRICAL SYS SHOULD ALSO BE CHECKED AT THIS TIME.

BUILT IN HYDROMETER (MAGIC EYE)

• OCCASIONALLY, A THIRD CONDITION MAY APPEAR

• CLEAR OR BRIGHT YELLOW - THIS MEANS THE FLUID LEVEL IS BELOW THE BOTTOM OF THE HYDROMETER. THIS MAY HAVE BEEN CAUSED BY EXCESSIVE OR PROLONGED CHARGING A BROKEN CASE, EXCESSIVE TIPPING, OR NORMAL BTY WEAR. FINDING A BTY IN THIS CONDITION MAY INDICATE HIGH CHARGING BY A FAULTY CHARGING SYSTEM. THEREFORE, THE CHARGING AND THE ELECTRICAL SYSTEMS MAY NEED TO BE CHECKED IF A CRANKING COMPLAINT EXISTS. IF THE CRANKING COMPLAINT IS CAUSED BY THE BTY, REPLACE THE BTY.


• CHARGING PROCEDURE

• BATTERIES WITH THE GREEN DOT SHOWING DO NOT REQUIRE CHARGING UNLESS THEY HAVE JUST BEEN DISCHARGED, SUCH AS IN CRANKING A VEH.

• WHEN CHARGING SEALED TERMINAL BATTERIES OUT OF THE VEHICLE, INSTALL THE ADAPTER KIT. MAKE SURE ALL THE CHARGER CONNECTIONS ARE CLEAN AND TIGHT. FOR BEST RESULTS. BATTERIES SHOULD BE CHARGED WHILE THE ELECTROLYTE AND THE PLATES ARE AT ROOM TEMP. A BTY THAT IS EXTREMELY COLD MAY NOT ACCEPT CURRENT FOR SEVERAL HOURS AFTER STARTING THE CHARGER.

• CHARGE THE BTY UNTIL THE GREEN DOT APPEARS. THE BTY SHOULD BE CHECKED EVERY HALF - HOUR WHILE CHARGING. TIPPING OR SHAKSING THE BTY MAY BE NECESSARY TO MAKE THE GREEN DOT APPEAR.

• AFTER CHARGING THE BTY SHOULD BE LOAD TESTED.


DEFECT OF BATTERY1. SULPHATION :- DURING BTY CHARGING THE NAGATIVE AND POSITIVE PLATES GET CONVERTED INTO LEAD SULPHATE. IF THE BTY IS ALLOWED TO STAND IN A DISCHARGED CONDITION FOR A LONG PERIOD, THE LEAD SULPHATE WILL BECOME HARD. THIS IS KNOWN AS SULPHATION.

2. INTERNAL SHORT CIRCUIT :- THE INTERNAL SHORT CIRCUIT DUE TO DISPLACED ACTIVE MATERIAL LIKES BUCKLED PLATES. THE SHORT CIRCUIT MAY ALSO RESULTS BECOME OF THE FAILURE AT A SEPARATOR. THE INTERNAL SHORT CCT IS ALSO INCLUDED THE IMPURITIES OF WATER

3. BUCKLING:- WHEN EVER THE BTY IS OVER CHARGED THE PLATES OF BTYS ARE BENDS OR DUE TO THE EXPANSION OF PLATES. THIS IS KNOWN AS BUCKLING.

4. BULGING :-THE BULGING OF CASE OF BTY IS DUE TO THE FOLLOWING CAUSES:-

(i) HOT BTYS DUE TO THE OVER CHARGING.

(ii) HOLD DOWN CLAMPS TOO TIGHT.

(iii) BUCKLING OF PLATES.

5. SEDIMENTATION:- THE ACTIVE MATERIALS OF THE BTY IS DEPOSITED ON THE BOTTOM OF THE BTY MUD SPACE DUE TO THE OVER CHARGING, HIGH RATE CHARGING AND MISHANDLING, HAMMERING etc,.

DEFECTS OF BATTERY

PRECAUTIONS FOR USING LEAD ACID CELL1. THE BTY SHOULD NOT BE LEFT IN DISCHARGED CONDITION FOR

A LONG TIME.2. THE LEVEL OF THE ELECTROLYTE SHOULD ALWAYS BE 2CM

ABOVE THE TOP OF THE PLATES.3. EVAPORATION OF ELECTROLYTE SHOULD BE COMPENSATED BY

ADDING DISTILLED WATER FROM TIME TO TIME.4. KEEP THE CELL IN DRY AND CLEAN POSITION.5. THE CHARGE AND DISCHARGE SHOULD BE AT NORMAL RATES.6. WHILE CHARGING, VENT PLUGS SHOULD BE KEPT LOOSE FOR

PASSING OUT OF THE EVOLVED GASES, IF ANY.7. THE NAKED FLAME, NEAR THE BTY, WHILE CHARGING SHOULD

BE AVOIDED.8. WHILE PREPARING ELECTROLYTE, WATER SHOULD NOT BE

POURED INTO THE ACID, BUT ACID SHOULD BE POURED IN WATER DROP BY DROP.

PREVENTIVE MAINTENANCE OF BTY

1. KEEP CLAMPS AND TERMINALS CLEAN ANDKEEP THE TERMINALS CLEAN BY COATING THEM WITH PURE PETROLEUM JELLY.

2. TOP UP ELECTROLYTE REGULARLY AND KEEP VENT PLUG TIGHT.

3. USE DUSTUKKED IF DE-IONISED WATER ONLY.

4. KEEP CABLE CONNECTION TIGHT.

5. KEEP HOLLOW DOWNS CLAMP SECURED.

PULS COILEXCITOR

C

TD1

D2

IGN SW

P/W S/W

SPARK PLUG

DEFECTS CAUSES REMEDIES

1. OVER CHARGING

2. USE OF EXESSIVE

WATER

3. RUN DOWN BTY

4. SULPHATED PLATES

1. HIGH CHARGING VOLT

1. OVER CHARGING

2. CRACKER CONTAINER

3. LEAKAGE AT CONVER –SEAL

1. DEFECTIVE REGULATOR OR GEN

2. FAULTY WIRING CCT

3. EXCESSIVE LOAD DEMAND

1. UNDER CHARGING

1. CHECK GEN RGULATOR

SYS

1. REPLACE BTY OR

CONTAINER

2. REPLACE BTY OR

CONTAINER

3. REPLACE BTY OR RESEAL

AS REQUIRED

1. CHECK BOTH

2. CHECK

3. REDUCE LOAD

1. ADJUST CHARGING

RATE

TROUBLE SHOOTING CHART FOR BTY


5. WIDE VARIATION OF

READING OF DIFF

CELLS.

6. VOLT READINGS DIFF

RENT IN INDIVIDUAL

CELLS

1. MAY VE SHORT CIRCUTED

PARTIALLY

1. SHOT CCT OF CELLS

2. OPERN CCT OF CELLS

3. DEFECTIVE PLATES

1. REPLACE PLATES OR BTY

AS REQUIRED

1. DEFFECTIVE CELL MAY

RECTIFIED AND

REPLACED

TROUBLE SHOOTING CHART FOR BTY


1. SULPHATION

2. BULGING

3. SEDIMENTATION

1. UNDER HARGINF/OVERCHG.

2. BTY LEFT IN DISCHARGED

CONDITION WITH OUT ATTEN-

TION

1. HOT BATTERY

2. HOLD DOWN CLAMPS TOO

TIGHT

1. OVER CHARGING

2. HIGH RATE DISCHARGE

3. MISS HANDELING

1. ADJUST CHARGING RATE

2. BTY MAY BE CHARGED AT

LOW CHG RATE TRICKLE

CHG

1. IF IT IS FROM OVER

CHARGE, REDUCE CHAR-

GING RATE.

2. TIGHTEN CLAMPS

PROPERLY.

1. ADJUST CHARGING RATE

2. CONTROL LOAD.

3. PROPER HANDELING.

TROUBLE SHOOTING LEAD ACID BTY


4. CORROSSION

5. INTERNAL SHORT

CIRCUIT

6. BUCKLING

1. OVER FILLING

2. OVER CHARING

1. PLATES GET BUCKLED

2. USE OF NORMAL WATER

1. OVER CHARGING

1. AVOID OVER FILLING

2. AVOID OVER CHARGING

1. REPLACE CELL

2. USE ONLY DISTILLED

WATER

1. REPLACE CELL

TROUBLE SHOOTING LEAD ACID BTY

FACTORS EFFECTING CAPACITY OF LEAD ACID BTY

1. RATE OF DISCHARGE :- HIGHER THE RATE OF DISCHARGE, SMALLER IS THE CAPACITY.

2. PERMISSIBLE FINAL VOLTAGE PER CELL :- LOWER IS THE FINAL VOLTAGE ON DISCHARGE HIGHER IS THE CAPACITY.

3. NO OF PLATES/ELEMENTS :- A 23 PLATES/ELEMENT BTY DOES HAVE MORE CAPACITY THAT OF A 19 PLATES/ELEMENT AND SOON.

4. AMOUNT OF ACTIVE MATERIAL :- GREAT ISW THE AMOUNT OF ACTIVE MATERIL ON THE PLATES LARGER IS THE CAPACITY.

5. OPERATING TEMPRATURE :- WITH IN GIVEN LIMITS OF OPERATING TEMP A BTY GIVES BETTER CAPACITY IN SUMMER THAN IN WINTER IF THE OPERATING TEMP CROSSES 43º THE BTY CAN BE PERMANENTLY DAMAGED.

6. QUANTITY OF ELECTROLYTE :- IF THE LEVEL OF ELECTROLYTE IS NOT MAIN TAINED PROPERLY THE CAPACITY DECREASES.

7. AGE OF BTY :- THE CAPACITY FALLS WITH THE PASSAGE OF WORKING LIFE OF BTY.

8. SPECIFIC GRAVITY OF ELECTROLYTE :- A POOR SPECIFIC GRAVITY REDUCES CAPACITY OF THE BTY.

• BATTERY CAPACITOR TESTERTHE BTY TESTER BCT 500A IS DESIGNED TO TEST THE COMPLETE THE RANGE OF 12V AUTOMOTIVE BATTERIES FOR A LOAD OF 150/300/500 AMPS.FIVE DIFFERENT TEST CAN BE CARRIED OUT IN BCT 500 A

1. NO LOAD TESTCONNECT THE RED CLIP TO THE POSITIVE TERMINAL AND BLACK CLIP TO THE NEGATIVE TERMINAL OF BATTERY. FOR A FULLY CHARGE BTY THE READING SHOULD BE AROUND 12.5V.

2. LOAD TEST FOR LOAD TEST FIRST SELECT THE LOAD BY KNOB AS UNDER CAR BATTERIES (UP TO 60AH) 150 AMPLCV & TRACTOR BTYS (60 TO 110 AH) 300 AMPBUS & TRUCK BTYS (110 TO 200 AH) 500 AMPCONNECT RED & BLACK CLIP TO THE BTY POSITIVE AND NEGATIVE TERMINAL RESPECTIVELY PRESS THE PUSH BUTTON AND RELEASE IMMEDIATELY ACTIVATE THE TIMER FOR APPLYING THE SELECTED LOAD TO BTY. VOLT METER READING SHOULD BE ABOVE 9.5 VOLT AND GREEN LED SHOULD GLOW TO INDICATE HEALTHY STATE OF BTY.

3. REGULATOR VOLTAGE TEST

CONNECT THE RED AND BLACK CLIP ON THE BTY,

START THE ENGINE AND INCREASE THE SPEED OF ENGINE THE VOLT METER SHOULD BE AS PER RANGE GIVEN IN TESTER.

4. CRANKING VOLTAGE TEST

CONNECT THE RED & BLACK CLIP ON THE BTY, REMOVE THE HIGH TENTION LEAD FROM THE CENTRE OF THE IGNITION COIL, CRANK THE ENGINE DURING CRANKING THE VOLT METER READING SHOULD BE ABOVE 9.6 V, IT INDICATE THAT THE STARTER MOTOR IS DRAWING THE RATED CURRENT, IN CASE THE VOLT METER READING DROPS BELOW THIS VALUE , THERE MAY BE SOME PROBLEM IN THE STARTING SYSTEM.

5. BTY CHARGING CURRENT

THE MODEL BCT500A IS ALSO PROVIDED WITH A DIGITAL AMMETER OF 0-200 AMPS . THIS AMMETER IS USED FOR CHECKING FOR CHARGING CURRENT INTO THE BTY FROM THE ALTERNATOR TO CONNECT THE AMMETER REMOVE THE NEGATIVE TERMIUNAL FROM THE BTY. CONNECT THE RED AND BLACK CLAMPS TO THE BTY NEGATIVE AND POSITIVE .THE BLUE CLAMP IS CONNECTD TO THE DISCONNECTED BTY TERMINAL START THE ENGINE RACE IT GRADUALLY SO THAT CHARGING CURRENT WILL RISE AND STABILIZE, IT INDICATE THE CURRENT WHICH IS BEING SUPPLIED TO THE BTY.

Battery

Engineering

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