1.

Batteries and Fuses Theory Support

Batteries and Fuses

Automotive – Electrical Systems

Topics covered in this presentation:

 Battery Operating Principles
 Battery Construction
 Fuse Types and Operation
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1. Batteries and Fuses Theory Support

The Battery
The electrical systems on a
Automotive – Electrical Systems

vehicle require electrical

power to function.

When an engine is
running, electrical power is
provided by an alternator.

When an engine is
stationary, electrical power
is provided by a battery.

The starter motor turns an

engine, so that it starts. This
action requires a large amount of
battery power, so good battery
maintenance is essential. 2 of 16
1. Batteries and Fuses Theory Support

Batteries - Active Materials

The plates of a battery contain Electrolyte Load
Automotive – Electrical Systems

active materials that react with

electrolyte, when charging or
discharging takes place.
Negative
Container plate

On the positive plates,

lead peroxide is the active
material and on the Positive
negative plates, porous plate
lead is the active material.

Separator Fundamental battery cell

The electrolyte is made from
sulfuric acid and distilled water. 3 of 16
1. Batteries and Fuses Theory Support

Batteries - Cell Construction

Positive plates Straps / connectors
Plates
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Plates are made from grids. Each grid

contains active material within its borders.
The grids conduct electricity between the
active material and lead straps.
Plate Groups
To provide the required cell voltage,
positive and negative plates are placed Grid
alternatively, next to each other. Alternative
plates are joined by lead straps to form
groups. Typically, 7, 9, 11 or 13 plates are
required to make up a cell. Separators

Separators
Separators prevent the positive and negative plates Negative
touching each other and causing short circuits. They plates
are porous so the electrolyte can flow freely. 4 of 16
1. Batteries and Fuses Theory Support

Batteries - Cells
An element is made up of a positive plate group, a negative plate group and
Automotive – Electrical Systems

separators, and is known as a cell. Each cell produces approximately 2V, so

for a 12V battery, six cells are required.
The cells are connected together in series by lead cell connectors (straps).
The straps at the end cells are constructed as part of the battery terminals.
A cell divider separates each cell.
Battery
terminals

Lead
connectors

Cell (x6)

5 of 16
1. Batteries and Fuses Theory Support

Batteries - Discharging and Charging

(described using conventional current flow techniques)
Discharging
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When current flows out of a battery, it

is discharging.
An electric current is produced by a
battery when a load is placed across its
terminals. The battery converts stored
chemical energy into electrical energy.

Charging
When current flows back into a
battery, it is charging. Caused by
application of an external voltage that
is higher than the battery voltage.
On a vehicle, this is provided by an
alternator. Current flow converts electrical
energy to chemical energy that is stored. 6 of 16
1. Batteries and Fuses Theory Support

Batteries - Chemical Action

In a battery, the electrolyte (H2SO4)
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chemically reacts with the positive

(PbO2), and negative (Pb) lead plates.

Discharging

Electrolyte divides into hydrogen (H2) and

sulfate (SO4). The hydrogen combines
with positive plate oxygen to form water
(H2O), reducing acid in the electrolyte. The
sulfate combines with the lead of both
plates to form lead sulfate (PbSO4).
Charging
Current flow forces lead sulfate (PbSO4)
back into the electrolyte (H2SO4). Action
continues while charging voltage is applied,
until all lead sulfate is converted. 7 of 16
1. Batteries and Fuses Theory Support

Batteries - Ratings
Labels are often provided on a battery case that indicate its rating.
Automotive – Electrical Systems

Capacity - Ampere-Hour Rating

This is used to indicate battery power and is a measurement of how much
current the battery can produce for 20 hours @ 80°F (27°C), with the battery
voltage above 10.5V.
HEAVY DIN
Capacity - Cold Start Rating DUTY 085 EQUIV 54317
AMP CCA
This is a measurement of the HOUR .44 AH SAE 370 AMPS
current provided by the battery OTHER
for 30 seconds @ 0°F ( -18°C) EQUIV
IEC 245 AMPS
while the battery voltage RESERVE
62 MINS
CCA
210 AMPS
CAPACITY DIN
remains at 7.2V.

Capacity - Reserve Capacity Rating

This is the time that the battery can supply 25A @ 80°F
before the individual cell voltages drop below 1.7V. 8 of 16
1. Batteries and Fuses Theory Support

Batteries - Case
The case is typically made of
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polypropylene (plastic) or a
hard rubber compound.

The case is light and strong,

and is molded with thin walls
and the cell dividers. The
number of dividers determines
how many cells the battery has.

Ribs are molded into the

bottom of each cell
cavity.These collect sediment
that sheds from the plates as
they deteriorate over time. 9 of 16
1. Batteries and Fuses Theory Support

Batteries - Case
A molded cover is sealed
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to the top of the case.

Openings are provided above

each cell in low-maintenance
batteries for screw-in plugs or
snap-in caps. This allows the
electrolyte level to be topped-up.

10 of 16
1. Batteries and Fuses Theory Support

Batteries - Terminals and Cables

Battery Terminals
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A battery has positive and

negative terminals (posts,
lugs) for cable connection. Post terminal
The positive post is usually
Side terminal
bigger than the negative post.

The most common types of

terminals are known as post
terminals, side terminals
and ‘L’ or lug terminals. Lug or L Cable end
terminal
Battery Cables
Cables connect to batteries using cable ends. These cables
carry large currents and are very thick. Because of this, the
cables should be kept as short as possible for ease of routing. 11 of 16
1. Batteries and Fuses Theory Support

Batteries - Maintenance Free Batteries

Maintenance free batteries are similar in appearance to low-
Automotive – Electrical Systems

maintenance batteries, except they are sealed for life, and do

not need to be topped-up with electrolyte.

A built-in relative density indicator is

included, the color shown indicates
the state of charge of the battery. A
green dot shows the battery is fully
charged, a black dot shows the
battery requires charging, and a
yellow dot shows the electrolyte is too
low and the battery needs replacing.

A reservoir in the top of the battery collects

evaporated water, as gassing occurs during the
chemical reaction. This water is returned to the
main reservoir as the battery cools. 12 of 16
1. Batteries and Fuses Theory Support

Fuses
It is inevitable that during the life Bulb illuminated
Good
Automotive – Electrical Systems

of a vehicle, an electrical circuit fuse

will fail. Each circuit is protected
by a fuse, incase a failure results
in a short circuit.

A fuse contains a thin wire Bulb off

element that will burn out. The Fuse element
‘blows’ and
fuse ‘blows’ open circuit, when
stops current
the specified current limit for flow
the circuit is exceeded.

There are many different types of

fuses on the market. Generally, a fuse
is marked with the maximum amount
of current (Amperes) that it will allow
to flow in a circuit, without blowing. 13 of 16
1. Batteries and Fuses Theory Support

Fuses - Types of Fuse

Glass Cartridge
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Earliest type of fuse invented.

Some types have a clear glass
body, so that the fuse wire between
the metal caps can be seen.

The metal caps are printed with fuse

rating (the current that the fuse can
carry) and fuse type information.

Ceramic (European/Continental)

The fuse wire runs in a groove in the

ceramic body, between two metal caps.
The fuse rating is identified by the color of the
body. It may also be printed on the body. 14 of 16
1. Batteries and Fuses Theory Support

Fuses - Types of Fuse

Flat Blade
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The body is made from plastic, the color of

which identifies the fuse rating. The fuse
rating is often printed on the top of the body.
The fuse wire is connected
between two metal blades that
are enclosed in the plastic body.

In-Line Fuse Holder

These fuses are typically used to protect an

accessory, fitted after vehicle production.
They are made of a two piece
plastic holder and contain a
glass cartridge fuse. 15 of 16
1. Batteries and Fuses Theory Support

Fuses - Fuse Boxes and Panels

Most fuses are located together in a
Automotive – Electrical Systems

fuse box or panel, either under the

hood, and or under the dashboard.

Fuses and relays may be

combined in a relay/fuse
box. Some types of fuse
boxes contain spare fuses
and a tool for fuse removal.

The fuse box in an engine bay is contained in a

weatherproof plastic housing. The internal fuse box is often a
drop-down flap or pull-out tray, under the dashboard. Fuse
boxes may be found in other locations around a vehicle. 16 of 16