1.

Batteries and Fuses

Batteries and Fuses

Automotive – Electrical Systems

Topics covered in this presentation:

 Battery Operating Principles
 Battery Construction
 Fuse Types and Operation
ClassAct SRS enabled.
1. Batteries and Fuses

The Battery
Electrical systems
Automotive – Electrical Systems

require electrical
power to function.

Alternator provides
electrical power when
engine is running.

Battery provides
electrical power when
engine is stationary.

A large amount of
battery power is required
to start an engine. Next >
1. Batteries and Fuses

Question 1
When is the most electrical power required from an automobile battery?
Automotive – Electrical Systems

A) When the headlights are turned on

B) When the engine is started

C) When the horn is used

D) When the automobile is stationary

1. Batteries and Fuses

Batteries - Active Materials

Load Electrolyte
Battery plates contain
Automotive – Electrical Systems

active materials that react

with the electrolyte.
Positive plate
Positive plate active
Negative
material is lead
plate
peroxide, negative
plate active material
is porous lead.

Electrolyte is made Container

from sulphuric acid
and distilled water.

Separator Fundamental battery cell

Next >
1. Batteries and Fuses

Question 2
What does the positive plate of a car battery contain?
Automotive – Electrical Systems

A) Lead

B) Lead sulphate

C) Lead peroxide

D) Lead nitrate
1. Batteries and Fuses

Batteries - Cell Construction

Positive plates Lead straps / connectors
Plates
Automotive – Electrical Systems

Plates contain grids that hold

the active material and
provide an electrical path.

Plate Groups
Alternate positive and negative
plates are grouped together, Grid
and connected by straps.

Separators
Separators
Insulate the plates from
each other, but allow Negative
electrolyte to flow freely. plates
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1. Batteries and Fuses

Batteries - Cells
An element contains plate groups and separators, and is commonly known
Automotive – Electrical Systems

as a cell.
Each cell produces about 2V, so 6 cells are required for a 12V battery.
Cells are connected in series by lead straps.
Straps across end cells are part of the terminals.
Battery
terminals

Lead straps

Cell (x6)

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1. Batteries and Fuses

Question 3
What voltage, in V, approximately, does each cell of a battery produce?
Automotive – Electrical Systems

Enter your answer and press SEND.

1. Batteries and Fuses

Batteries - Discharging and Charging

(described using conventional current flow techniques)
Discharging
Automotive – Electrical Systems

Discharging occurs when

current flows out of a battery.
Current is produced when a load
is placed across battery terminals.
Battery converts stored
chemical energy into
electrical energy.

Charging
Charging occurs when
current flows into battery.
Requires an external voltage that
is higher than the battery voltage.
On a vehicle, the charging voltage
is provided by an alternator. Next >
1. Batteries and Fuses

Question 4
Which of the following correctly describes the main energy change
Automotive – Electrical Systems

occurring when a battery is discharging?

A) electrical to chemical

B) potential to kinetic

C) chemical to electrical

D) chemical to heat and light

1. Batteries and Fuses

Batteries - Chemical Action

Electrolyte chemically reacts with lead plates.
Automotive – Electrical Systems

Discharging
Electrolyte hydrogen combines with
positive plate oxygen to form water.
Electrolyte sulphate combines with
lead on plates to form lead sulphate.

Charging
Current flow reverses chemical action.
Sulphate is forced back into electrolyte
and combines with hydrogen, while
oxygen returns to the positive plate to
form lead peroxide.
Process continues while voltage is
applied, until all lead sulphate is converted. Next >
1. Batteries and Fuses

Question 5
As an automobile battery discharges the electrolyte becomes more
Automotive – Electrical Systems

dilute. Is this true or false?

Answer True or False.

1. Batteries and Fuses

Batteries - Ratings
Labels on battery case indicate battery ‘rating’.
Automotive – Electrical Systems

Capacity - Ampere-Hour Rating

Amount of current a battery can supply over a
given period of time (20 hours) @ 27°C (80°F).
HEAVY DIN
DUTY 085 EQUIV 54317
Capacity - Cold Start Rating AMP CCA
HOUR .44 AH SAE 370 AMPS
Current battery can provide
OTHER
over a set period of time EQUIV
IEC 245 AMPS
(30s) @ -18°C (0°F). RESERVE CCA
210 AMPS
CAPACITY 62 MINS DIN

Capacity - Reserve Capacity Rating

Time battery can supply 25A @
27°C (80°F) before the individual
cell voltages drop below 1.7V.
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1. Batteries and Fuses

Question 6
Which of the following units measures the capacity of a battery?
Automotive – Electrical Systems

A) Ampere

B) Volt

C) Watt

D) Ampere-hour
1. Batteries and Fuses

Batteries - Case
Case is made of
Automotive – Electrical Systems

polypropylene (plastic) or
a hard rubber compound.

Dividers help
separate cells.

Ribs at bottom of each

cell collect excess
material from plates.

Next >
1. Batteries and Fuses

Batteries - Case
Cover is sealed to
Automotive – Electrical Systems

the top of the case.

Openings above each cell

for screw-in plugs or
snap-in caps, in low-
maintenance batteries.

Next >
1. Batteries and Fuses

Batteries - Terminals and Cables

Battery Terminals
Automotive – Electrical Systems

Battery has terminals for cable

connections.
Positive terminal is usually bigger.
Common types are:

Battery Cables
Cables connect to battery
using cable ends.
Battery cables carry large
currents and are very thick.
Cables should be kept short
Postor
Side
Lug terminal
L terminal
for ease of routing.

Next >
1. Batteries and Fuses

Question 7
Why are battery cables very thick?
Automotive – Electrical Systems

A) Because they carry large currents

B) Because vibration causes thin cables to fracture

C) Because they must not bend easily

D) Because they have to be attached to large connectors

1. Batteries and Fuses

Batteries - Maintenance Free Batteries

Sealed for life, no need to
Automotive – Electrical Systems

top-up with electrolyte.

Built-in relative density indicator.

 Green = fully charged.
 Black = requires charging.
 Yellow = electrolyte low.

Reservoir to collect
evaporated water.

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1. Batteries and Fuses

Fuses
Fuse element ‘blows’
A fuse protects an
and stops current flow
Automotive – Electrical Systems

electrical circuit against

short circuit failure. Bulb
Bulb illuminated
off
Good
fuse
It contains a thin wire
element that burns out, when
excessive current flows.

Each type of fuse is

marked with a
current rating.

Next >
1. Batteries and Fuses

Question 8
A fuse is always connected in parallel with the part it is protecting.
Automotive – Electrical Systems

Is this true or false?

Answer True or False.

1. Batteries and Fuses

Fuses - Types of Fuse

Glass Cartridge Fuse wire
Automotive – Electrical Systems

Earliest type of fuse.

Cap with
Some types have clear glass body to information
view fuse wire, between metal caps.

Metal caps contain fuse

rating information.

Ceramic (European/Continental)
Fuse wire runs in groove in the
ceramic body, between metal end caps.

Fuse rating identified by body colour.

Next >
1. Batteries and Fuses

Question 9
What information will you obtain from the fuse "rating"?
Automotive – Electrical Systems

A) Size

B) Maximum current

C) Wire diameter

D) Type of connector
1. Batteries and Fuses

Fuses - Types of Fuse

Flat Blade Fuse wire
Automotive – Electrical Systems

Colour coded plastic body

with enclosed metal blades.
Fuse wire connects
between metal blades.

Blade

In-Line Fuse Holder

Two piece plastic holder
contains glass fuse.

Next >
1. Batteries and Fuses

Fuses - Fuse Boxes and Panels

Most fuses are mounted
Automotive – Electrical Systems

together in a fuse box or panel.

Some fuse boxes contain

spare fuses and tools.

Engine bay fuse boxes

are weatherproof.

Fuse boxes under the

dashboard may be drop-
down flaps or pull out trays.
Drop down relay / fuse box

Next >
1. Batteries and Fuses

Question 10
Where in an automobile are you most likely to find most of the fuses?
Automotive – Electrical Systems

A) In the fuse box

B) In the boot

C) In the engine compartment

D) In the passenger compartment

1. Batteries and Fuses

Summary
You should now be aware of:
Automotive – Electrical Systems

 Battery Operating Principles

 Battery Construction

 Fuse Types and Operation

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