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The common battery as found in motor vehicles was invented by a Frenchman some 100years ago...It has changed very little over that time.Below is a picture of such a battery printed in 1925.You will notice that the plates etc are just the same as modern plates, the only difference is that this 75 yrs old battery is much better made then one of this time.

But like all chemicals it should be kept out of reach of children.Safety first.... It is an eye irritant... the remedy wash with plenty of clean water.

It contains none of the following substances and is harmless to any battery.Aluminium sulphate.Sodium sulphate.Magnesium sulphateMagnesium Oxide.Cadmium sulphateThis chemical has a trade name as Dissolvine NA – 2There are other types of the same product, but normally all are sold in large quantities.20KG being about the smallest lot.

How docs it work?This battery restorer has the ability to dissolve the hard skin of lead sulphate crystals from the battery plates ,that is referred to as lead sulphation and keep this particular form of lead sulphate from forming.NoteThe restorer can do nothing for a battery that is mechanically damaged internally there for is open or short circuited.

You need to mix a level teaspoon of this chemical for each cell you treat, so for a 12 volt battery place 6 tea spoons in one litre of tap water and dissolve then add this solution in equal amounts to each cell then top up with water until the plates are fully covered.This is after you have washed the battery out.

What is a lead - acid battery?

The battery we are talking about is the common vehicle battery and/ or the battery oftenfound in DC electrical power systems.The case is normally made of a plastic.There are two main types of construction thereforThe 6 volt type... this battery is made up of 3 separate cells.Or the 12 volt type this has 6 separate cellsEach cell [ 2 volts.... really 2,2 volts] is a battery in itself.Each cell is connected in series to the next so the battery ends up with 2 output terminals.The electrolyte [ the diluted acid in the cell] is made up of approximately 2 parts water one part sulphuric acid.

Note

Water is lost from evaporation and chemical reaction.... not the acid.Each cell consists of a pack of plates half of which are the positive the other half the negative.

The information that follows is information on the structure of early type batteries ... but very little has changed in battery manufacturing, some materials have been superceded by others.

Worth notingWhen fully charged a cell is 2.2 volts, so when a 12 volt battery is fully charged it will read over 13 volts.When charging the input voltage must be greater then 13.2 volts, it is usually exceeding 14 volts.

GLOSSARY TO THE STORAGE BATTERY INSTRUCTIONThis glossary is provided for reference, in case the reader is not familiar with words or terms used. Acid: As used in this book, this word refers toSulphuric acid (H2SO4), the active component of the electrolyte.

Active material: The active portion of the batterylead peroxide of lead on the positives, and spongy metallic lead on the negatives.

Alternating current: Electric current which does not: flow in one direction only (like direct current) It rapidly reverses its direction or "alternates" in polarity, so that it will not charge a battery.

Ampere: The unit of measurement of the rate of flow of electric current.

Ampere hour: The unit of measurement of the : quantity of electric current. Thus, 2 amperes flowing for ½ hour, equals 1 ampere-hour.

Arc burning: Making a joint by means of electric current which melts together the metal of the parts being joined.

Battery: Any number of complete cells assembled in one case.

Battery terminals: Devices attached to the positive post of one end-cell and the negative of the other end cell, by means of which the battery is connected to the circuit.

Buckling: Warping or bending of battery plates.

Burning strip: A convenient form of lead in strips, for joining up the joint in making burned connections.

Case: The containing box, which holds the battery cells.

Cell: The battery unit, consisting of an element complete with electrolyte in its container, with cover.

C ell connector: The metal link which connects the positive post of one cell to the negative post of the adjoining cell.Charge: Passing direct current through a battery, in the direction opposite to that of discharge, in order to put back the energy used on discharge.

Charging methods: "Series" method and "Constant Potentional method

Charge rate: The proper rate of current to use in charging a battery from an outside source. It is expressed in amperes and varies for different sized units

Corrosion: The attack of metal parts by acid from electrolyte; the result of lack of cleanliness.

Cover: The rubber or plastic cover which closes each individual cell; it is flanged for the sealing compound, to insure an effective seal.

Diffusion: The act of spreading or circulating in every direction. The action of the acid mixing with the water that is within the pores of the plates and at the surface of the plates when discharge, is explained as follows: When the battery is fully discharged, the acid in the pores of the plates and right at the surface of the plates breaks up into water and sulphates, the sulphate going into the plates as lead sulphate, this leaves water in the pores of the plates and at the surface of the plates. In order for the storage-battery action to continue, extra acid must be obtained from the reserve outside or in the cell, and this is accomplished by this outside acid diffusing or mixing with this water and forming electrolyte . again in the pores of the plates and at the surface of the plates.

Dry-storage battery: A type of battery using a paste or other substance instead of liquid electrolyte.

Discharge: The flow of electric current from a battery through a circuit. The opposite of "charge."

Electrolyte: The fluid in a battery cell, consisting of specially pure sulphuric acid, diluted with pure water.

Element: One positive group, and one negative group, with separators, assembled together.

Filling plug: The plug which fits in and closes the orifice of the filling tube, in the cell cover.

Flooding: Overflowing through the filling tube. this can usually occur only when a battery is charged, with the filling plug out.

Freshening charge: A charge given to a battery which has been standing idle, to insure that it is in a fully charged condition.

Gassing: The bubbling of the electrolyte caused by the rising of gas set free toward the end of charge.

Generator system: Equipment, including a generator or alternator, for automatically recharging the battery; in contradiction to a straight storage system where the battery has to be removed, to be recharged.

Gravity: A contraction of the term "specific gravity," which means the density, compared to water as a standard. See "Specific gravity" below.

Grid: The metal framework of a plate, supporting the active material, and provided with a lug for conducting the current and for attachment to the strap.

Group: A set of plates, either positive or negative, joined to a strap. Groups do not include separators.

High-gravity battery: The electrolyte used in automotive batteries where freezing of water occurs, or in cooler climates, should have between 1.275 and 1.300 specific gravity when fully charged. The temperature should not be raised above 110° F.

Hold-down clips: Brackets, for the attachment of bolts, for holding the battery securely in position on the car.

Hydrogen flame: A very hot and clean flame of hydrogen gas and compressed air, used for making burned connections.

Hydrogen generator: An apparatus for generating hydrogen gas for lead burning.

Hydrometer: An instrument for finding the specific gravity of the electrolyte.

Hydrometer syringe: A glass barrel enclosing a hydrometer and .provided with a rubber bulb for drawing up electrolyte.

Jar:[ term no longer used] The hard-rubber container, holding the element and electrolyte.

Lead burning: Making a joint, by melting together the metal of the parts to be joined.

Low-gravity battery: The electrolyte used in automotive batteries in tropical climates, where freezing of water seldom occurs, should have a specific gravity 70 points lower than for "high-gravity batteries." For example, in cooler climates, in a discharged battery the electrolyte has a sp. gr. of 1.150, while in tropical climates the sp. gr. of electrolyte should be 1.080. For low-gravity batteries the temperature limit may be raised from 110°F. to 125° F.

Lug: The extension from the top frame of each plate connecting the plate to the strap.

Maximum gravity: The highest specific gravity which the electrolyte will reach by continued charging; indicating that no acid remains in the plates.

Normal charging rate: Usually the charging rate is assigned by the battery manufacturer. The safe rate depends upon the state of charge. For a discharged cell it may be much greater than for a charged cell.

Oil of vitriol: no longer used an obsolete name for sulphuric acid (1,835 specific gravity). This is never used concentrated in a battery and would quickly ruin it.

Plates: Metallic grids, supporting active material. They are alternately positive (brown) and negative (gray).

Polarity: Electrical condition. The positive terminal of a cell or battery, or the positive wire of a circuit, is said to have positive polarity; the negative, negative polarity.

Post: The portion of the strap extending through the cell cover, by means of which connection is made to the adjoining cell, or to the circuit.

Rectifier: Apparatus for converting alternating current into direct current.

Resistance: Material (usually lamps or wire) of low conductivity, inserted in a circuit to retard the flow of current. By varying the resistance, the amount of current can therefore be regulated.

Rubber sheets: Thin, perforated hard-rubber sheets, used in combination with the wood separators in some types of batteries. They are placed between the grooved side of the wood separators and the positive plate.Wood and rubber are rarely used now.

Sealing compound: The acid-proof compound, used to seal the cover to the battery.

Sealing nut: The notched round nut which screws on the post and clamps the cell cover.

Sediment: Active material which gradually falls from the plates, and accumulates in the space below the plates, provided for that purpose.

Short circuit: A metallic connection between the positive and negative plates within a cell The plates may be in actual contact or material may lodge and bridge across. If the separators are in good condition, a short circuit is unlikely to occur.

Spacers: Wood or plastic strips, used in some types to separate the cells in the case, and divided to provide a space for the tie bolts.Specific gravity: The density of the electrolyte compared to water as a standard; often abbreviated as "gravity" or "sp. gr." or "S. G."

Starvation: The result of giving insufficient charge, in relation to the amount of discharge, resulting in poor service and injury to the battery.

Strap: The leaden casting to which the plates of a group are joined.

Sulphated: Sometimes spelt as Sulfate. The condition of plates having an abnormal amount of lead sulphate, caused by ''starvation," or by allowing the battery to remain discharged.

Tie bolts: Bolts which, in some types, extend through the battery case between the cells, and clamp the jars in position.

Top nut: The hexagon nut which, in batteries with bolted connections, screws on the post, and holds the connectors and sealing nut in place.


The following page will give you some idea of how a lead / acid battery works.

But because it is old knowledge, it has some obsolete terms.You will note it refers to 6 volt systems but in general it is worth reading.

The object of this explanation is to point out how the acid passes to the plates when discharging, forming lead sulphate (PbSO4), which covers the plates, and to show how, if left in this condition, the lead sulphate which is in fine crystalline form, would, in time, act on the plates to such a depth that it would recrystallize into larger and harder crystals which are difficult and sometimes impossible to change back again to lead peroxide and lead sulphate. This is one of the most dangerous of storage battery diseases. It results not only from the battery being left for a long period fully discharged, but also from other causes, as explained under "Sulphation of Plates."

It is quite in order, however, during the discharge process, for the lead sulphate to form on the plates, but the plates should not be left in this condition, which can be avoided by immediately recharging. If the discharging continues after the voltage of a cell drops below 1.8, an excessive formation of sulphate will result. [This is 10.8v for a 12v battery.]

Even though a battery is charged and not used, it should be charged at a low rate occasionally, as a charged battery will, in time, become discharged; and when discharged, the action is to form lead sulphate over the active material. The result will be that this sulphate will finally have the same action as stated above, on a discharged cell.The active material is what was formed on the plates when under the process of "pasting" and "forming," which is lead (Pb) on the negative plate, and lead peroxide (Pb02) on the positive plate.

Action of a Charged CellA fully charged cell on open circuit is shown here For the purposes of illustration, only two plates are used, a positive (+), and a negative (—).

A charged cell on open circuit… Note that the acid is in the solution and not in the plates. The active material on the negative plate is Pb, and on the positive PbOa. The active material is not now covered with lead sulphate, as the SO4 is in the solution.

When a cell is in a charged condition, the plates are not covered with lead sulphate (PbS04), as the SO4 is then in the solution, which forms the electrolyte, which in turn consists of chemically pure sulphuric acid (H2SO4) diluted with pure distilled water, thus giving H2SO4+H2O=2H2+S04.This acid was driven out of the plates when charged, and if a hydrometer is placed in the solution, it will be found that the solution is dense or thick and that the hydrometer will not sink as deep into the solution. The specific gravity would therefore be higher, and the specific-gravity reading will be between 1.280 and 1.300 when the solution is fully charged.Another point, while on the subject of the solution as chemical changes take place, it is clear that if water, which has metal in it, for instance, water taken from a metal roof, or if the water is not distilled, this would cause a different chemical action, and so be injurious to the plates.The positive plate above, which is supposed t« be in a fully charged condition, is in the original condition as when formed, and has an active material_ of lead peroxide (PbQ2) in its grid. It is of a dark-brown color. Thus it is in a charged and in healthy; condition.It is in a diseased condition when it fails to throw off all of the lead sulphate (PbSO4) when being charged (the lead sulphate having been diffused over the active material when it was discharged).The negative plate has thrown off the lead sulphate with which it was covered when discharge during the process of charging, and is now a finely divided, spongy, gray-colored, soft lead plate

Action of Cell When DischargingNote that when the cell is discharging the current flows out of the (+) plate, through the lamps, or other apparatus, into the (—) plate through the electrolyte to the (+) plate.Let us assume that the plates were in a fullv charged condition, when the circuit was closed, that is, the negative Pb, the positive Pb02, and the solution H2S04.

Above Discharging. Note that the acid is going into the plates and will form lead sulphate (PbSO<0 and cover over the active material (Pb and PbOs) on the plates. The solution will finally lose its acid and become water.The active material (Pb, of the negative plate is combining with the acid (SO, of the electrolyte, and is converting the active material on the negative plate into lead sulphate (PbS04).The positive plate active material (Pb02) is combining as shown: the Pb with SO4, and the 02 with 2Ho, and is thus being converted into lead sulphate (PbS04). relative to the "ionic principle.The ionic principle recognizes the law that every substance as well as liquids is made up of positive (+) and negative (—) electricity, and that if separated by chemical action, the positive will attract the negative. Note that when water is divided into its two parts, as hydrogen (Ha) and oxygen (0), the hydrogen particles are (+) and the oxygen particles are (-).

The active material on the negative lead plate (Pb) is now covered over entirely with lead sulphate PbSO4).

Fully discharged. Above.Note that the acid (SO4) is out of the solution and into the plates, thus having combined with the lead of the plates (Pb) and having formed lead sulphate PBSO1 over the active material on both plates. The solution is now water, and is not dense.

As the acid has gone into the plates, this now water around the plates as solution. Thisaccounts for the fact that a storage battery will freeze quickly when in a discharged condition,If a hydrometer is now placed in the solution it will sink deep, as the water, without acid, is not as dense as with acid.

The nearer a cell approaches a charged condition from a charged condition, the less will the density become, until it approximates density of water. When fully discharged the specific gravity will be about 1.150. The battery should be recharged before it is discharged this low.

Action When Charging a Fully Discharged CellA fully discharged cell just starting to be chargedIs shown below. The active material (Pb) on the negative plate is covered with lead sulphate . The active material (PbO4) on the positive plate is also covered with lead sulphate,The passing of "direct current" through the cell, from the (+) terminal of the dynamo to the (+) positive plate. positive plate, through the cell, to the (—) negative plate, to the (—) terminal of the dynamo generator causes the lead sulphate to be carried from the plates to the solution.Inasmuch as the lead sulphate (PbSO4] merely covering the plates is quite accessible, it is driven off with slight difficulty, and the -voltage rise in the cell during this period is very slight,

Charging. Note that the direction of the charging current is as indicated by the arrow, or the reverse of that when discharging. The lead sulphate (PbsO4) which over the active material in the lead plate when discharging is now b«ing driven off by the charging current, and the SO4 is combining; with the water. Thus the solution is gradually increasing in density or specific gravity. Note that the acid (SO4) is passing from the plate on each side, and is combining with the H2O (water)As the charging continues the lead sulphate which is buried deeper into the plates is more difficult to drive out with the charging current. The voltage is gradually rising,After all lead sulphate has been removed from the plates, continued charging decomposes the water into hydrogen and oxygen which passes off in the form of gases. The voltage of the cell is then approximately 2,5 volts.As the charging continues, the lead sulphate in the interior of the plates is more difficult to reach by the charging current, and the voltage of the cell rises as high as 2.65 to 2.70 volts.If the charging is continued further, the temperature of the cell will rise and hydrogen and oxygen gases will pass off freely and thus the charging current is wasted and the cell is heated,When the cell is fully charged, the acid will be in the solution as 2H2SO4, and the active material Pb, on the negative plate, and PbOa on the positive plate, will be exposed to the action of electrolyte.

Paths of Current Outside and Inside Storage Battery Cells

The external circuit of a battery discharging is as shown as below: from the {+) terminal of the battery to the starting switch, to the starting motor to the (—) terminal of the battery.

Internal Circuit of a Cell Being ChargedThe internal circuit of a battery cell being charged is shown below. 11-plate cell, with 5 positive (+) plates (P), and 6 negative (—} plates (N). Note the separators (S) between the negative and positive plates, and note also that the negative plates are on the outside.Each of the negative (—) plates are connected together, and each of the positive (+) plates are connected together; thus we have a positive (+) terminal and a negative (—) terminal to each cell.The separators are placed between the negative and positive plates to insulate them, from one another. The separators are porous and thus do not prevent the electrolyte or electric charges from acting on the plates, but merely serve to keep the plates from touching. In time, the separators rot, break, or become clogged, and permit the plates to touch. This causes an internal short circuit, which produces heat, and heat causes the plates to expand and to press against or through the separators more firmly.Note in Fig. 28 that when the cell is being charged,the positive (+) current from the (+) side of the charging circuit flows into the positive (+) plates of the cells, to the negative (—) plates, and out to the (—) side of the charging circuit.

Internal Circuit of a Cell Being DischargedThe internal circuit of a battery cell being discharged is shown below. Note that the current path is in the opposite direction to that shown in as above when the cell is being charged.

Voltage Drop of a CellDrop in voltage: Each of these actions tends to produce internal resistance, until finally a point is reached where the plates are fully coated, or changed to lead sulphate (PbSO4), and where the acid is almost entirely out of the electrolyte.The internal resistance is then so great, that the voltage is affected until it has dropped to about l.6 if fully discharged. A cell, however, should not be discharged below 1.8 volts, and should be recharged immediately, otherwise it will be difficult for the charging action to throw off the lead sulphate from the plates, which was formed on them during the discharge action.

Electrolyte test: As the acid is withdrawn from the electrolyte during the discharge action, and replaced in the electrolyte during the charging action, it is clear that the most reliable test for determining the charged or discharged condition of a cell is to take a hydrometer reading of the cell,

Voltage of a Charged and Discharged CellWhen the battery is fully charged and before the charging circuit is opened, the voltage of each cell will be about 2.5 to 2.7.When opening the charging circuit, the voltage of a cell drops to approximately 2.1 volts.If the battery is then discharged at a continuous normal rate, it will gradually drop to 2 volts, which voltage will be maintained until it is about one-half discharged. From this point on, it will drop more .rapidly to about 1.6 volts. The voltage of the cells, 'however, should not be permitted to drop lower than 1.8 volts per cell.If the discharge rate is heavy, the voltage will drop much more rapidly. If a high discharge rate is given, as when using the starting motor, the heavy discharge is only momentary. The result will be that the voltage will drop, probably to 1.8 to 1.6, at, say, a 200-ampere discharge, but will regain its normal voltage quickly when the circuit is opened—that is, if the battery is not already more than half discharged when the high rate of discharge is applied.

Sulphation of PlatesWhen cell plates are sulphated, it means that both plates are covered with lead sulphate (PbSO4), the condition in which they are when discharged. This sulphation can act on the plates to such a depth that ordinary charging will not cause it to separate from the plate. In such a case, the battery will not hold a charge or give very much of a charge for any length of time, depending on the depth to which the plate is sulphated.A sulphated plate has the appearance as. white chalky substance forms on the negative plate. This is a non-conductor and insoluble. This is usually caused by leaving a battery in a discharged condition for a long period of time and without water over the plates.The remedy is to charge and discharge several times at a low rate. Owing to the sulphate on the plates, the chemical action which takes place is very slow. The sulphate covers the active material, and thus only a small current can be absorbed by the active material; and if charged at a high rate, the water will be decomposed and form gas and give the impression that the battery is fully charged. (The active material referred to is Pb on the negative plate and Pb02 on the positive plate, which is covered over with sulphate.)It is more difficult to restore the negative plate than the positive plate. Only long-continued slow charging will tell. If this does not remedy the trouble, the plates should be examined; most likely new plates are necessary.

SedimentsAny impurities that the water contains are left behind in the cells by the evaporation of the water, and thus they settle to the bottom of the cell .Mud and sediment will accumulate in the bottom the battery and will eventually accumulate to such a height as to cause an internal short circuit of the plates, if any other than distilled water is used. The paste, or active material, falling off the plates will also result in the collection of sediment.When cleaning the sediment from a cell, it is generally wise to replace the separators at the same time. The need for cleaning is usually indicated by lack of capacity, excessive evaporation of the electrolyte, and excessive heating when charging.

Some of the causes are: Dead short circuit, as between starting motor and battery, thus causing overheating; overcharging, and at an extremely high rate, thus overheating; violent discharging and short circuits inside of the battery, which also produces excessive heat.When the battery does not hold its charge, it is usually due to one or more defects internal of the battery, as just described, and each cell should be tested.It will thus be observed that heating is the principal cause of buckling of the plates. Heat causes the plates to expand, and if heat is excessive and continued for a long enough period, the plates will assume a shape which will cause the plates to cut through the separators.As a plate discharges, lead sulphate is formed on it, and thus occupies more space than the active material on it. If it expands equally, it will do no harm, but if the battery is over-discharged or charged at a very high rate, the active material will expand and heat, because the portion of the plate on which there is least sulphate will carry most of the current and thus overload this section of the plate. The result is excessive heat which results in expansion and "buckling."Plates which are not buckled too badly can be straightened by putting them in a press.

OverheatingOverheating caused by overcharging may occurif the regulation system goes wrong and permits the generator / alternator to deliver excessive current.It is well to feel the battery occasionally, particularly the lead links and cover, after a long, hard drive. Should you suspect overheating, remove the vents from the cells and insert a thermometer, of the type made for insertion into liquids, into the electrolyte of each cell.The battery temperature should never be allowed to exceed 110° F. Garage men who make a practice of charging batteries in their plant should enforce this rule rigidly,Overheating should be avoided, because it expedites evaporation of water from the electrolyte, causes deterioration of plates and separators, and tends to buckle the plates. Overheating of one-half the battery should be guarded against.Sometimes heat will be produced at the connectors, where they are welded to the posts of the plates, owing to improper welding. This, of course, would then necessitate re-welding, and would be external of the cell.

SeparatorsWhere a high rate of discharge is required from a battery, as with a starting motor, a freer and more rapid circulation of the electrolyte with the active material on the plates is necessary.If a battery is used solely for low rates of discharge, as for ignition, then thick plates and perforated hard-rubber separators are generally used, which give a very long life to the battery.Where a very high discharge is required at times, which in many instances may be over 200 amperes, then, as stated above, the rapid circulation of the electrolyte can better be accomplished through the pores of certain woods. The thin plates are used and many of them, in order to give sufficient plate area, and thus the action of the electrolyte on the plates is more rapid.The materials used for separators between the plates of various automotive starting and lighting batteries may be grouped as follows:1. Wood.2. Combination of perforated hard rubber and wood.3. Threaded rubber insulation.4. plasticsVarious kinds of wood, and various methods of treating wood separators are employed by different manufacturers of storage batteries for starting, lighting, and ignition purposes combined. Those woods, which are porous and will withstand the chemical acid are such woods as cypress, white cedar, California redwood, Douglas fir, poplar, basswood, cherry, etc.

The Exide battery uses a grooved, specially treated wood separator of a very porous nature. The separators are given a special treatment to remove substances which would be harmful to the plates. They are also grooved on the side, which goes against the positive plate, and, in some types, a perforated rubber sheet is inserted between the wood separator and the positive plate. In other cases, a threaded rubber separator (no wood) is used. The Willard battery uses separators made of hard rubber sheets pierced by hundreds of cotton threads. The electrolyte is carried through the thread from one side to the other by capillary action. They are termed "threaded rubber insulation."When wood is used for separators, it is specially treated after sawing and grooving. The separators are placed in a warm alkaline solution of about 3 per cent caustic potash. This neutralizes the acetic acid which wood contains (and which if permitted to go into the cell would tend to dissolve the lead and cause it to crumble), and also removes resin from the pores. The pores must be fully open in order that the acid can act through them.The alkali is removed by soaking for about two to three days, and then washing in running water. The separators can then be used. If separators are not used after treating, then place them in a weak acid solution of about 1.025 or 1.050 sp. gr. The separators have a tendency to expand in the solution, and therefore, if they are not kept wet, they will shrink.When new separators are received, they should be soaked for about five days in a solution of electrolyte of about 1.250 sp. gr., so that they will expand to the proper proportions outside of the cell instead of allowing them to expand in the cell. Separa

Battery Internal Short CircuitsBattery short circuits may be external or internal.External battery short circuits may be due to acid on the top of the battery forming an electrolyte between terminals to battery terminals being sulphated, or in contact with the top of the metal battery box, or to the battery wire connections being acid-soaked.Internal battery short circuits may be due to theinternal condition of the battery, such. as plates warped or buckled, or a collection of sediment at the bottom of cells due to disintegrating plates, although the latter is rare because of the height of the plates above the bottom of the container The usual cause is broken or rotted separators, which permit the plates to touch.

Group: A set of plates burned [ burned is the old term for melting lead]to a strap is known as a "group," either positive or negative.Fig. 24 shows a negative group of seven negative plates.

The Exide battery is now using a composition case called gammite,[ 75 yrs ago] which is a very hard and durable substance in which some of the batteries are being assembled. This case takes the place of the rubber jars formerly used with each cell and of the early wood case. The case is made with three compartments so that the plate elements are put right into these compartmentsA positive group would be arranged in the same manner, except that there would be one less plate of the positive group, or six plates.

Element: A positive and a negative group together with the separators constitute an "element," as explained above. The plates in each cell are made like a grid .The material held in the grid is called sponge lead if the plate is negative and is fully chargedIt`s called lead peroxide in the positive plate when fully charged.When the battery is fully discharged then both plates are lead sulphate.

Electricity is stored within the plates when the plates have released the absorbed acid andreturned it to the water.So in a fully charged battery all the acid is in the water.In a totally discharged battery the electrolyte is just water and all the acid is trapped in theplates as lead sulphate.The stored electricity is referred to as direct or DC current... not AC current.

Only the so-called flooded battery can be successfully restored.This is the old type... the one with a row of tops so you can replace lost water.The other two types are not considered worthwhile this is because of the way they are constructed.

The FLOODED type normally has plates made from an alloy of lead and antimony, [older types lead and tin]

The so-called maintenance free type and the low maintenance type have plates made from lead and calcium, these batteries have a built in 'self destruct` system... the plates just fall to pieces at a certain age.

The GEL type cannot be restored... these self destruct also [the busbar oxidizes away from the plates ]

Worth notingIt is in the battery manufacturers interest for a battery to fail once the warranty runs out.It is a fact that a certain manufacture has this down to a fine art... whereby the battery in most cases will fail with 4 weeks after the warranty has expiredIt is the Calcium in the lead alloy that causes this type of battery to retain its water, unfortunately it's the same calcium that causes it to fail. On the rare occasion you might find a low maintenance battery of this type that responds to treatment.And it is always worthwhile to try.

Why do batteries fail?Most batteries fail due to the lead sulphate crystallization that forms a thin skin over eachplateThis is due to the battery being left in a partly discharged state.

Worth noting is that the average vehicle battery spends its whole life only about 80%charged.This skin becomes not only insoluble but also a non conductor of electricity thus stopping the passing of electrons.There are other reasons common to battery failure most are mechanical …thus from vibration fatigue and heat.Direct sunlight causes premature failure quickly.

How to determine which battery to restore.First you need access to the Flooded type discarded battery, the best place for these is a service station that sells new batteries, most will give you the old batteries, but if not the most you need to pay is the scrap value currently $1.00.

Test all batteries before taking them.Make sure the casing is sound, as are both terminals... that each cell contains electrolyte.That the plates do not look unduly buckled [slight buckling is normal]That they are the flooded type

Next using a voltmeter or a multi- meter check the voltage.Don't bother with any 12 volt battery that shows a voltage of less then 11.8volts.

Or a 6 volt battery showing less then 5.5 volts.

Note here even a dead flat 12 volt battery in good condition will show not less then 11.8 volts, most will show 12 to 12.5 volts even if flat.Of the batteries you finally pick on only expect 50% of these to be really any good. Your best results will come from batteries that read very close to 12 volts or more.

Next mix the required chemical with water and add this equally in each cell until the plates are submerged.(top up with water if required to achieve this.}Leave the battery for 6 to 8 hours... but not longer then 10 hrs. then empty the spent liquid out... there is no need to fully drain.

Next decant the electrolyte belonging to that battery away from the sludge and return it to the battery cells equally [ often there is too much if so discard safely because the plates have absorbed the chemical]. Quite often the electrolyte is very dark take no notice of this.Replace the cell bungs and wash the battery down.

Charging for the first timeCharge the battery for about 24 hours at 2 amperes to a maximum of 4 amperes.Don’t go any higher then this in amperes.

Do not charge it on a vehicle...A trickle charger or a low amp mains charger is ideal... do not let the battery get hot.For a normal car battery charge for 24 hrs at this rate.... For large batteries charge for 36 hours at this rate.Because of the unknown specific gravity of the batteries electrolyte that you have treated, you will find a hydrometer of little or no use. So use a voltmeter.You will know you have a reasonable battery that will give you from 6 mths to 18 mths service from the voltage readings... a battery that shows between 12 volts and 13 volts after being charged and rested for say 6 hours is deemed useable.

In practice you would drive the alternator at around 1000 - 1500 rpm.... Using a ½ hp motor rpm.1420Worth noting is many cheap electric motors are high speed 2000rpm or more,The most common rotates at 1450 rpm.

Most alternators can be driven in both directions, but its best to drive them as they were on the vehicle, that is clockwise when looking at the pulley.

Electric motors will burn out fast if overloaded... keep in mind that the charger will run for longperiods. If using a motor that is very near its capacity, then keep the belt loose so it can slip, if the load is too great.It`s better by far to operate a motor that has more capacity, then that required.

By using your voltmeter you can progressively lower the driven speed of the alternator until itsoutput is no less then 13,5 voltsJust bear in mind that the output voltage must not be less then 13.5 volts to charge a 12 volt battery better to be nearer 14 volts.....The slower you rotate the alternator, the lower the voltage output, the lower the voltage output, the lower the amperage.... The lower the wattage output , the lower the input required.Once you have assembled your motor driven alternator... .you need to have a method of belt adjustment ... '.

Wiring your battery charger.

Now to wire.up.Use about 2mm diameter insulated wire [wire that has the ability to carry 35 amps without getting hot] for both the earth /negative cable & the battery positive output cable... the earth can be the casing of the alternator or the frame its attached to. Use a battery clamp or clip to fasten this to the negative side of the battery. [negative is marked with a minus sign as _ ]Now it-depends on the type of alternator you have, as to where the positive wire is connected.

Normally there is a terminal marked 'positive' or has a + sign ..or a `B' or 'Bat' or battery Fit the positive cable to this & to the battery terminal marked '+`

For the alternator to start generating electricity, you need to energize the field windings, this is achieved by finding the terminal on the alternator of the voltage regulator that is marked `F` or 'field'... attach a thin insulated wire [that has the ability to carry 5 amps without getting hot] to the terminal & then to the battery. Once this circuit is made the field windings are energized & the alternator will start producing.Note here, that even if the alternator is rotating, it cannot generate electricity, without the field being energized.... But once it is generating then its possible for the alternator to actually energize itself.... This is proved by the fact that you can disconnect the battery on a vehicle & the engine will still operate. This is only possible while the alternator is generating, if you bring the speed down low, the engine will stop.So that you don’t forget to switch off the field when not charging… an idea is to use a press switch like a horn switch… start the system hold the field circuit closed until the amp-meter is reading the disconnect the field… saves flat batteries.The dotted lines in the figure above, represent the two alternatives in respect to voltageregulators.You need to disconnect the field wire from the battery, when the motor is stopped, otherwise it will flatten the battery.

In the event you are contemplating charging more then one or two batteries at the same time, make a larger battery charger... but keep in mind the power required to do the work. / have a 3hp -3phase motor fitted with a four rope pulley.., it drives 4x35 amp alternators easily all day long...../ can charge up to 20 batteries at anyone time... or just charge one battery.

Note you can charge batteries that you have reconditioned, at low amperage by connecting the batteries in "Parallel”... that is connect the positive terminal of one battery to positive terminal of another...the negative terminal to that of another... you can do this as many times as you like.Just supposing you have five batteries... connect them in parallel...lets say your alternator has an output of 35 amps... then in theory each battery is receiving about 7 amps.The same goes using your 4 amp mains charger.,. connect the 5 batteries in parallel & keep them charged with a trickle of about half an amp each..

Connecting batteries in parallel means that if all the batteries are 12volt, then when connected they become just one large 12-volt battery.

WHEREAS If you connect batteries in 'series'Then you are multiplying by 2, each 12-volt battery you connectThus 2 batteries are 24 volts... 3 are 36 volts & so on.More then 4 x l2 volt batteries connected in series becomes very dangerous, as not only is the voltage high, but so is the amperage.As example...Your normal household outlet might be fused at 10 amps.This can kill.In theory the fuse will melt when the output exceeds 2200-2400 watts.Take 5x12 volt 100 amp hr batteries fully charge in series this is a battery of 60 volts ... its output [short circuit] can be anything from 4800 watts up to over 9,000 watts.Such energy may not kill you, but will seriously burn..

NOTE ONLY AUSTRALIAN RESDIDENTS CAN BUY, USING DIRECT BANKING,OR PAY WITH A CHEQUE OR A MONEY ORDER.ELSEWHERE IN THE WORLD YOU CAN ONLY PAY USING PAYPAL....SORRY BUT NO EXCEPTIONS.

Thank you for your time.