The document discusses lead-acid batteries, including their components, electrolyte, charging methods, and testing. It provides details on: - The three main functions of a battery in a vehicle's electrical system. - The components of a battery, including plates, separators, cell covers, and electrolyte. - Methods of charging batteries, including initial charging, normal charging, and trickle charging. - Instruments used to test batteries, such as hydrometers and load testers. - Factors that affect battery capacity and performance, including temperature, age, and charging/discharging rates.

1. BBAATTTTEERRYY

2. IINNTTRROODDUUCCTTIIOONN
• 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.

3. MMAAIINN CCOOMMPPOONNEENNTTSS OOFF TTHHEE BBTTYY
• 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

4. EELLEECCTTRROOLLYYTTEE
• 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

5. CHEMICAL ACTION CHARGE AANNDD DDIISSCCHHAARRGGEE
CHARGED
POSITIVE ELECTGROLYTE NEGATIVE
PLATE PLATE
PbO2 + 2H2 SO4 + Pb
(LEAD (SULPHURIC (SPONGY
PEROXIDE) ACID) LEAD)
DISCHARGED
POSITIVE ELECTROLYTE NEGATIVE
PLATE PLATE
PbSO4 + 2H2O + PbSO4
(LEAD (WATER) (LEAD
SULPHATE) SULPHATE)

6. FACTORS EFFECTING THE CCAAPPAACCIITTYY OOFF AA BBTTYY
• NO OF PLATES.
• TYPES OF ELECTROLYTE.
• AGE OF THE BTY.
• TEMP IN WHICH USED.
• RATE OF DISCHARGING.

7. TTYYPPEESS OOFF CCHHAARRGGIINNGG
• 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 -

8. TTYYPPEESS OOFF CCHHAARRGGIINNGG
• 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.

9. TTYYPPEESS OOFF CCHHAARRGGIINNGG
• 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.

10. MMEETTHHOODD OOFF BBTTYY CCHHAARRGGIINNGG
• 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

11. ADVANTAGE OF CC SYSTEM
• 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

12. MMEETTHHOODD OOFF BBTTYY CCHHAARRGGIINNGG
• CONSTANT POTENTIAL CHARGING SYSTEM
+ VE
+ - + - + - + - 12 VOLT DC
(CH SOURCE)
- 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

13. • 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.

14. EELLEECCTTRROOLLYYTTEE
• 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.

15. STARTING POWER AVAILABLE FFRROOMM BBTTYY AATT DDIIFFFFEERREENNTT
TTEEMMPP
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

16. EFFECT OF TEMPERATURE ON EELLEECCTTRROOLLYYTTEE GGRRAAVVIITTYY
• 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.
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

17. BBTTYY TTEESSTTEERR
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.

18. 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)
FIG NO -1 FIG NO-2 FIG NO-3

19. TTEESSTTIINNGG IINNSSTTRRUUMMEENNTTSS OOFF BBTTYY
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: -

20. TTEESSTTIINNGG IINNSSTTRRUUMMEENNTTSS OOFF BBTTYY
• 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.

21. • 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.

22. • 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.

23. MAINTENANCE FREE BATTERIES
• 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.

24. 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.

25. HYBRID 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

26. RECOMBINATION 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.

27. 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.

28. BUILT IN HYDROMETER (MAGIC EYE)
• 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.

29. 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.

30. BUILT IN HYDROMETER (MAGIC EYE)
• 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.

31. e

32. DEFECT OF BATTERY
1. 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

33. DEFECTS OF BATTERY
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,.

34. PRECAUTIONS FOR USING LEAD ACID CELL
1. 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.

35. 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.

36. EXCITOR PULS COIL
D1 T
C
D2
IGN SW
P/W S/W
SPARK PLUG

39. TROUBLE SHOOTING CHART FOR BTY
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

40. TROUBLE SHOOTING CHART FOR BTY
DEFECTS CAUSES REMEDIES
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

41. TROUBLE SHOOTING LEAD ACID BTY
DEFECTS CAUSES REMEDIES
1. SULPHATION
2. BULGING
3. SEDIMENTATIO
N
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.

42. TROUBLE SHOOTING LEAD ACID BTY
DEFECTS CAUSES REMEDIES
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

43. 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.

44. 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.

45. • BATTERY CAPACITOR TESTER
THE 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 TEST
CONNECT 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 AMP
LCV & TRACTOR BTYS (60 TO 110 AH) 300 AMP
BUS & TRUCK BTYS (110 TO 200 AH) 500 AMP
CONNECT 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.

46. 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.