Practical No.

13 : Test a lead acid battery for Open Voltage and SpecificGravity

I PracticalSignificance
Battery testing is an important part of electrical system service. It helps a technician
tounderstand the state of charge of battery, and the also the energy that can be stored
inbattery. Battery testing enables us to decide if the battery can be put into use in
vehicleor not. Battery tests help us to locate weak cells and faults in battery. Visual
inspectionis important aspect of battery testing. Slow engine cranking and dim
headlights
aresomeofthesignsthatindicateaweakordischargedbattery.Lackofmaintenanceleadstopre
maturefailureofbattery.Testingavoidsprematurefailureofbattery.

II RelevantProgram Outcomes(POs)
PO1-Basicknowledge:Apply knowledge
ofbasicmathematics,sciencesandbasicEngineeringtosolvethebroad-basedMechanical
Engineering problems.
PO3-Experimentsandpractice:Plantoperformexperimentsandpracticestousetheresults
tosolve broad-basedMechanicalEngineeringproblems.

III CompetencyandSkills
One of the main competency that a mechanical engineering student should posses
is‘Perform the job of Mechanical supervisor in Automobile Industry’ . To
inculcatethis competency following skills are developed in the student after conducting
thepracticalof this laboratorymanual
1. Inspectgiven component/assemblyofthegivenvehicle
2. Testgiven battery ofan automobile.

IV RelevantCourseOutcome(s)
 Preparesimpleelectrical-electroniccircuitsforautomobilesystems.

V Practical Outcome
 TestaLeadAcidBatteryforOpenVoltageandSpecificGravity

VI Relative Affective Domain-

 Followtheroadandworkshopsafetypractices.
 Practicegoodhousekeeping.
 Practiceenergyconservation.
 Maintaintools,equipmentandservicerecords.

VII MinimumTheoreticalBackground
Dependingontheconstructionofthebattery,stateofchargeofbatterycanbedeterminedin
the following ways:
1. Specificgravitytest
2. VisualInspectionofbatterywithabuilt-inhydrometerand
3. Opencircuitvoltagetest.

1. SpecificGravityTest:Onunsealedbatteries,thespecificgravityoftheelectrolyte in
each cell can be measured to give a fairly good indication of thebattery’s state of
 charge.A hydrometer consists of a glass tube or barrel, rubberbulb, rubber tube,
and a glass float or hydrometer with a scale built into its upperstem. The glass tube
encases the float and forms a reservoir for the test
electrolyte.Squeezingthebulbpullselectrolyteintothereservoir.
Whenfilledwithtestelectrolyte,thesealedhydrometerfloatbobsintheelectrolyte. The
depth to which the glass float sinks in the test electrolyte indicatesits relative
weight compared to water. The reading is taken off the scale by
sightingalongthelevelofthe electrolyte.
The electrolyte of a fully charged battery is usually about 64 % water and 36
%sulfuric acid, which corresponds to a specific gravity of 1.270. Specific gravity
isthe weight of an equal volume of water. Pure water has a specific gravity of
1.000,while battery electrolyte should have a specific gravity of 1.260 to 1.280 at
26.7ºC.Inotherwords,theelectrolyteshouldbe1.260to1.280timesheavierthanwater.
The specific gravity of the electrolyte decreases as the battery discharges. This
iswhy measuring the specific gravity of the electrolyte with a hydrometer can be
agoodindicator of how much chargeabatteryhaslost.

2. Visual Inspection of battery with a built- in hydrometer: If the battery has

abuilt-in hydrometer, observe the indicator colour. A green indicator means
thebattery is over 65% charged. If the hydrometer indicator is dark, the battery is
lessthan 65 % charged. Under this condition, the battery should be charged and
loadtested. A clear hydrometer indicator means the battery is low on electrolyte. If
thiscondition is present on a battery with removable filler caps, add distilled water
tothe cell(s) as required. When a clear hydrometer is present in a maintenance-
freebattery,replace the battery.

3. OpenCircuitVoltageTest:Anopencircuitvoltage checkcan beusedasasubstitute for

the hydrometer specific gravity test. As the battery is charged
ordischarged,slightchangesoccurinthebattery’svoltage.Sobatteryvoltagewithnoload
appliedcangivesomeindication of the stateof charge.

VIII Experimentalsetup

Figure No 13.1: Specific Gravity Test: Indicates state of charge of

battery.SpecificGravityTestisperformedonbatterywithremovablefillerca
ps
 FigureNo.13.2:Hydrometer,CalibratedFloatandReading

Figure No 13.3:Specific Gravity reading is corrected if the temperature is above

orbelowcertaintemperature(Approx.27ºCorasspecifiedbybatterymanufacturer)

Table-1:Electrolytespecificgravityasrelatedto
charge
SpecificGravity PercentageofCharge
1.265 100 %
1.225 75 %
1.190 50 %
1.155 25 %
1.120orlower Discharged
 FigureNo.13.4OpenVoltageTestofBattery

Table-2: Battery open circuit voltage as an

indicatorofstateofchargeofbattery
Opencircuitvoltage Stateofchargeof battery
12.6orgreater 100%
12.4to12.6V 75-100%
12.2to12.4V 50-75%
12.0to12.2V 25– 50 %
11.7to12.0V 0–25 %
11.7Vorless 0%

FigureNo13.5:VisualInspectionofSealedmaintenancefreebattery:
 ATemperaturecompensatedIn-builtHydrometerisbuiltintothebatterycover

IX ResourcesRequired

S. Name of Resource Suggested Broad Specification Quantity

No.
1. Lead Acid Battery 100AH battery or a suitable battery of a car 02
2. Hydrometer Standard, Specific gravity measurement value1.100 02
to1.300, float with colour zones
3. Digital Multi-meter Voltage: DC: 600 volts; AC: 600 volts; DC 02
Accuracy: ± 0.5% + 3 digit; AC Accuracy: ± 1% +
3digit
Resistance: 40 M ohm; Resistance Accuracy:
±1.5%+ 3digit
Capacitance:100μF
AC/DC voltage, resistance, capacitance, frequency
measurement
4. Battery Charger Vehicle Compatibility: Passenger cars, 01
Automatic detection of battery types whether 12V
or24V,
Regulative function for deeply discharged batteries,
Trickle charging for optimum battery care,
Allows supportive charging and supplies mobile
devices with power,
Dust and splash water proof.

X PrecautionstobeFollowed
1. DuringSpecificGravityTest,followingprecautionsshouldbetaken:Wearsuitable eye
protection goggle. Use hand gloves to protect from sulfuric acid.
Thehydrometershouldbewashed withcleanwaterafteruseandstoredsafely.
2. During Open Voltage test, following precautions should be taken. The
battery’stemperatureshouldbebetween15.5ºCand37.7ºC.Thevoltagemustbeallowedt
ostabilizeforatleast10minuteswithnoloadapplied.Onvehicleswithhighdrain
(computer controls, clock, and accessories that always draw a small
amountofcurrent),itmaybenecessarytodisconnectthebatterygroundcable.Onbatteries
that have just been recharged, apply a heavy load for 15 seconds
toremovethesurfacecharge.Thenallowthebatterytostabilize.Oncethevoltagehas
stabilized, use a voltmeter to measure the battery voltage to the nearest one-tenthof
a volt. Be sure toremove the surface charge completely.

XI Procedure
 SpecificGravity Testprocedure:
 Removecoversorventcapsfrombatterycells.
 Squeezethesuctionrubberbulbandinsertthepickuptubeintothecellclosesttothebattery’
spositive terminal.
 Slowlyreleasethebulbtodrawinonlyenoughsampleofelectrolytetocausethefloattorise.

 Donotremovethetubefromthecell.Readthespecificgravityindicatedonthefloat.Besure
 thefloatrisesfreely.
 Notedownthereadingsandrepeatthestepsforremainingcells.
Table-
1listsspecificgravityreadinginvariousstagesofchargewithrespecttoabattery’sabilityto
crankanengineatatemperatureof26.7ºC.

 OpenCircuitVoltageTest Procedure:
 Remove the surface charge from battery, if any. Refer precautions section for
thesteps to remove surface charge. If vehicle is not available, certain load may
beappliedtoremovethesurfacecharge.
 Connectthedigitalvoltmeteracrossthebatteryterminals.
 Notedownthe voltmeterreading ofa 12-Vbattery.
Use the following table-2 to interpret the results. Minor changes in the
batteryopencircuitvoltagecanindicatemajorchangesin the stateofcharge.

XII ResourcesUsed

S. Name of Broad Specifications Quantity Remarks

No. Resource Make Details (If any)
1. Lead Acid AMRON 100AH battery or a suitable 1
Battery battery of a car
2. Hydrometer Standard, Specific gravity 2
measurement value1.100
to1.300, float with colour
zones
3. Digital Multi- EMTE Capacitance:100μF 3
meter CH AC/DC voltage,
resistance, capacitance,
frequency measurement

4. Battery Charger Dust and splash water proof. 4

XIII Actual Procedure Followed

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1) Specific Gravity Test procedure
2)Open Circuit Voltage Test Procedure
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XIV PrecautionsFollowed
.............................................................................................................................................
1. During Specific Gravity Test, following precautions should be taken: Wear
suitable eye protection goggle. Use hand gloves to protect from sulfuric acid. The
hydrometer should be washed with clean water after use and stored safely.
2. During Open Voltage test, following precautions should be taken. The battery’s
temperature should be between15.5ºC and 37.7 º C.The voltages must be allowed
to stabilize for at least 10minutes with no load applied. On vehicles with high drain
(computer controls, clock, and accessories that always draw a small amount of
 current)

XV Observations Table
Specific Gravity Test
Sr.No. Cell No. Cell Specific Gravity Percentage Charge
1 1 1.220-1.230 100%
2 2 1.200-1.210 75%
3 3 1.175-1.185 50%
4 4 1.150-1.160 25%
5 5 1.125-1.135 20%
6 6 1.100-1.110 FULLY
DISCHARGE

Open Circuit Voltage Test

Sr. No. Voltmeter Reading in Volts State of Charge of Battery
1 0.01VOLT 0.010

XVI Results
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When specific gravity of electrolyte decreases as battery discharge.
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XVII Interpretation of Results

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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 multimeter 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.
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...................................

XVIII Conclusions
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Signs Your Car Battery is Failing
1) Dim headlights. If your car battery is failing, it's not going to be able to fully power your
vehicle's electrical components – including your headlights. ...
2) Clicking sound when you turn the key. ...
3) Slow crank. ...
3) Needing to press on the gas pedal to start. ...
4) Backfiring.
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XIX Practical Related Questions

Note:Belowgivenarefewsamplequestionsforreference.Teachersmustdesignmoresuchque
stions so as to ensure the achievement ofidentified CO.
1. State the significance of Open Voltage test and specific gravity test.
2. Enlist the precautions while handling hydrometer. State the effect of temperature
 on the specific gravity reading.
3. List precaution to be taken before conducting Open circuit voltage test on battery.
4. List precaution should be taken before conducting Specific Gravity test.

[SpaceforAnswer]
.........................................................................................................................................................
Ans01- Specific gravity is used to check the state of charge of a battery, essentially it's the ratio of
the weight of a solution to the weight of an equal volume of water. Testing the specific gravity of a
cell is done using a hydrometer, the best of these automatically compensate for temperature. As the
ratio of water to sulphuric acid inside the battery changes with activity the density of the electrolyte
also changes, this is what the hydrometer measures
Specific Gravity Test
I. Do not add water at this time.
II. Fill and drain the hydrometer 2 to 4 times before pulling out a sample.
III. There should be enough sample electrolyte in the hydrometer to completely
support the float.
IV. Take a reading, record it, and return the electrolyte back to the cell.
V. To check another cell, repeat the 3 steps above.
VI. Check all cells in the battery.
VII. Replace the vent caps and wipe off any electrolyte that might have been
spilled.
VIII. Correct the readings to 80° F

Open-Circuit Voltage Test

For accurate voltage readings, batteries must remain idle (no charging, no discharging)
for at least 6 hrs, preferably 24 hrs.
I. Disconnect all loads from the batteries.
II. Measure the voltage using a DC voltmeter.
III. Check the state of charge with Table 1.
IV. Charge the battery if it registers 0% to 70% charged.
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Ans02- hygrometer is an instrument used to measure the amount of humidity in the atmosphere.

Precautions :

1.) No source of heat nearby when taking readings.

2.) Bulbs of thermometers should be wiped out properly so as to make it dust / dirt free.

We do this since impurities affect evaporation rate of water.

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Ans03-
1. Avoid bringing metal into contact with batteries. ...
2. Never allow both terminals to make contact with an item (particularly
yourself) simultaneously. ...
3. Do not hand-guide batteries during lifting/moving process. ...
 4. Practice safe and appropriate lifting procedures.

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Ans04-
1. The soil sample to be tested for specific gravity must be completely free from lumps. ...
2. Two main reasons for error in the calculation are weighing inaccuracies and the presence of
entrapped air. ...
3. The soil sample taken for testing have to be completely oven dried.

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XX References/SuggestionsforFurtherReading
1. https://www.youtube.com/watch?v=jn12gsvfAlIOpenvoltagetestofbattery
2. https://www.youtube.com/watch?v=tUDw1TYU2u8 Specific gravity test
ofbattery

XXI AssessmentScheme

Performance Indicators Weightage

ProcessRelated(10Marks) (40%)
1 Handlingofthebatteryandrelevantinstruments 20%
2 Observations 20%
ProductRelated(15Marks) (60%)
3 Interpretationofresult 20%
4 Conclusions 20%
5 Practicalrelatedquestions 20%
Total(25Marks) 100%

Namesof Student Team Members

1.……………………..
2.……………………….
3. …………………………
4.…………………………

MarksObtained Dated signature

ofTeacher
ProcessR ProductR Total
elated(10) elated(15) (25)