Electronic Battery Sensors

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Electronic Battery Sensors

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I nearly posted this in the "Tech" section but then decided to put it here because it's not a Fiat only subject and also I think most of us keep a regular eye on this section so I might get more people reading it.

So, Electronic Battery Sensor? What is he talking about? Well, it's a wee gizmo which started to put in an appearance a few years ago and is now quite common on new cars. It's attached, usually, to the negative battery terminal and has, typically two wires (on the ones I've seen anyway) which disappear into the wiring loom. As far as I know the larger wire goes to a body earth and the thinner goes to an ECU which controls the "smart" alternator (maybe does other stuff too?) We have 2 cars in the "family fleet" which now have this sensor and as one of them is my Ibiza I want to know about it. So I've been asking questions and researching "stuff".

My main interest is in how it affects the way I deal with battery maintenance issues so things like connecting a charger, Jump starting, disconnecting the battery and replacing it if it fails and I need a new one.

This seems to be the one fitted on my Ibiza - just so you have some idea what I'm talking about:

https://www.bosch-mobility-solution...s/body-electronics/electronic-battery-sensor/

First thing to know is YOU CAN DESTROY IT IF YOU JUMP START IN THE "NORMAL" WAY. ie by connecting your jump leads directly to the vehicle battery terminals. I've long connected pos to pos then pos on donor battery/vehicle to block on "flat" vehicle to avoid any possibility of a spark igniting battery gasses These sensors monitor both voltage and CURRENT via a shunt. If you connect the leads directly to the battery the sensor is now not "seeing" the connected battery in the same way. I don't understand it all but I suspect you might get a reverse flow through the sensor? Result seems to be - POP! expensive sensor then needed! I've now seen several pieces of advice that if you must jump start then go pos on doner to pos on the "flat" vehicle then take your black lead connections to engine block on both vehicles. That way the sensors will be in circuit on both vehicles. If jumping with a jump pack or slave battery (as I do) then go pos to pos and neg to the flat car's engine block.

Battery charging is actually what's really motivating me looking into this as I have a smart charger which is supposed to allow charging without disconnecting the battery terminals without any risk of damage to electronics and I want to use it on the Ibiza. I don't want to disconnect the battery because all manor of "strange" things often follow doing that on modern cars. I tried the main dealer who, predictably, said don't jump start and don't connect a charger, end of! So I've held off but then asked on the Seat Cupra forum where I lurk around and was told connect to pos and the big earth bolt on the N/S inner wing. That seemed sensible to me as it follows the rational behind the jump starting instructions. Then, just today, I found a PDF for the Ateca Manual and, lo and behold, there's actually an instruction for battery charging which mirrors the advice given me on the forum.

I was thinking about the jump starting advice and actually I can't see any reason why not to just connect the black jump lead clamps block to block on any vehicle. Of course that is making the chassis earth cables on both vehicles then part of the circuit but as long as they are in good condition and their connections in good order that should make no difference? Think I'm probably just going to do this from now on.

Of course all the other standard advice appertains about making and breaking connections and especially, in my opinion, not to disconnect until the voltages of both flat and slave battery have stabilized. Ie let the cars run for a few minutes (maybe 5 to 10) before disconnecting any jump leads. Doing this minimizes the chance of sparks and surges.

So what have I learned so far (self test my memory)
1) when jump starting go pos to pos - as has always been done - but then black lead goes engine block to engine block. I have read that there might, very occasionally, be a sensor on the pos battery terminal, who knows what you do then?
2) when charging connect charger pos to battery terminal and charger neg to body earth. (almost certainly advisable to use a "smart" charger (I have a Ctek)
3) disconnect battery terminals at your peril as it may take a dealer level diagnostic tool to reprogram the ECU when you reconnect? Actually I don't like disconnecting batteries on modern vehicles anyway as I've found lots of "weird" stuff can happen - for instance my boy's Astra's front electric windows have to be "taught" how to wind up and down again! So I use a "memory saver" but I don't think it will save me with these newer systems?

I'd love for anyone who really understands what's going on with any of this to comment further. Oh, by the way, found this which seems to explain some of it in fairly simple language:

https://www.samarins.com/glossary/battery-sensor.html

Stay safe folks
Jock

PS. All the above is only as I understand it to be. If you go out and connect up your jump leads/battery charger and it all goes ***s up then you'll know I don't know what I'm talking about! In other words you try any of this at your own risk
 
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I have found somewhere, can't remember where now, but the battery has a serial number which has to be input via a diagnostic program when a new battery is fitted. This is the case with my 2015 Fabia, which had a weak battery when I got it, but has recovered nicely, so no need for a new one after all.

Aftermarket batteries of course do not have these serial numbers, but the price of one from a dealer will be extortionate.
Advice from Yuasa was to increment the old battery number by one, and the sensor system would be happy and sort itself out, so perhaps that is just a ploy to try to sell batteries from dealers. That'll work well at ten years old.
 
Is unplugging the sensor not sufficient? On my Punto it just has a locking mechanism which can be released and unplugged. I’ve done it a few times to reset the start/stop system as it also uses the sensor to decide if it’s suitable to stop the engine.
 
Reading all this...I'm extremely glad my car has a very "stupid" electrical system.

It is canbus, it does have a body control module but it behaves like a direct wired system. So if I want to fit L.E.Ds..fine it doesn't care. If the BCM goes out, I can go to scrappy pull another one from the same model year (doesn't have to be the same trim level they are all the same) and plug it in it'll work no proxy alignment needed. When my battery went out, nowhere had the correct one in stock so fitted a much bigger one to cope with my habit of sitting stereo one while little one sleeps in the back, didn’t even use a code keeper..again it didn't care.

Things like lego, could pull the dash put another in or whatever and no special work required.

There's progress and there's too damn clever for it's own good.
 
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Reading all this...I'm extremely glad my car has a very "stupid" electrical system.

There's progress and there's too damn clever for it's own good.

Yup, really miss my old Cordoba Vario - actually understood how it all worked!

If I get fed up with the Ibiza I'll be going for something older. Still got a fancy for a 1.8 i-vtec Civic Estate. Port injection, no turbo, would like cruise though but absolutely nothing like radar controlled emergency brakes and couldn't care less if it doesn't have an infotainment screen - I'd quite like the base version with it's "sensible" tyre sizes.
 
Before long we will be driving battery powered cars that dont break down. Perfection Yay ;) But just in case they do go AWOL, any sort of servicing has to be done at the main dealer for horrendous money. This will only get worse as profits plummet on service work.

Tesla seem to be leading the way. Apple style after service. Oh dear you dont have a warranty, that will be £1800 for a new computer (even though we know it's just a £10 ribbon cable).

Tesla's rebuilt after cosmetic write off are being locked out of fast charging. Not just Tesla's own supercharge system (sort of fair enough) but all fast charging. They could easily provide a diagnostic engineering test to check the car is safe but that would sell fewer new cars.
 
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Tesla's rebuilt after cosmetic write off are being locked out of fast charging. Not just Tesla's own supercharge system (sort of fair enough) but all fast charging. They could easily provide a diagnostic engineering test to check the car is safe but that would sell fewer new cars.

Not technically accurate and it gets a lot more complicated.
 
Interesting stuff isn't it. By the way, anyone know for sure if connecting the charger pos lead to pos battery terminal and charger neg lead to body earth is the right way to do it? I haven't been brave enough to try it yet!
..not me.. :eek:

I isolate the battery from the loom..

Very little risk then

Lost presets..and MPG.. no great inconvenience

But as you say.. for cars that NEED a top.up charge I think a quick and reliable fixed coupling would need setting up.
 
Interesting stuff isn't it. By the way, anyone know for sure if connecting the charger pos lead to pos battery terminal and charger neg lead to body earth is the right way to do it? I haven't been brave enough to try it yet!
Probably have more luck asking on a Seat specific forum. My 2013 Punto has no issue with the battery being disconnected, just loses the time and date. As I mentioned above the battery sensor can be plugged easily taking it out of the loop anyway.

Apparently this is one on a Golf, which looks to just unplug.
 
Thanks for the last two posts and I take on what you are saying. It would be annoying to loose the stored settings etc but what's worrying me more is that my Ibiza has a "clever" smart charging system so it varies it's charge rate depending on whether you are accelerating, in the cruise, coasting, decelerating or braking. The ECU also monitors the battery parameters and learns about it's performance as it ages, and - more to the point - alters charging and other "things" I don't know about to make most effective use of the aging battery. My understanding is that it's this stored info which can be corrupted by either disconnecting the battery or connecting, wrongly, a charger or slave battery. It's this learning function which has to be reprogrammed when a new battery is fitted otherwise the car treats the new battery as if it's the old one and there are reports of new batteries being unusable within a month or so of fitting if the reprogramming is not carried out?

The Ibiza manual says nothing about connecting a charger, Although it is very specific about the unusual jump starting connections. I found out about the problems on the Seat Cupra forum, but the Ateca manual I found on line has shed quite a bit of light. I just feel very nervous about trying it - usually you only get one chance with electrical "stuff"! I'll feel happier when I've had a chat with the lads at AVW once they reopen but that doesn't get over the immediate problem about keeping the battery healthy during this lock down.

PS. Don't you think all this stuff is getting just a little too "silly" for the extremely marginal gains obtained? When any of it goes wrong it will typically wipe out any monies saved and often the pollution from manufacturing and transporting the replacement part needed (no one mends stuff now do they) will go a long way to negating the environmental saving
 
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Thanks for the last two posts and I take on what you are saying. It would be annoying to loose the stored settings etc but what's worrying me more is that my Ibiza has a "clever" smart charging system so it varies it's charge rate depending on whether you are accelerating, in the cruise, coasting, decelerating or braking. The ECU also monitors the battery parameters and learns about it's performance as it ages, and - more to the point - alters charging and other "things" I don't know about to make most effective use of the aging battery.

Fiat's Twinair engines (and possibly others) also features a smart charging system, all in the aim of saving fuel i suppose. From my observations 13.5v under acceleration, 13.9/14v whilst cruising and 14.5v when coasting/braking. This is with a 'charged' battery.
The Fiat system will reset when the sensor is unplugged (I left it unplugged overnight to be certain) and it will 'relearn' the battery when connected again. I haven't read up on jump starting with the Fiat system though. Obviously I'm not sure how much if any of this would apply to VAGs setup.
 
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Fiat's Twinair engines (and possibly others) also features a smart charging system, all in the aim of saving fuel i suppose. From my observations 13.5v under acceleration, 13.9/14v whilst cruising and 14.5v when coasting/braking. This is with a 'charged' battery.
The Fiat system will reset when the sensor is unplugged (I left it unplugged overnight to be certain) and it will 'relearn' the battery when connected again. I haven't read up on jump starting with the Fiat system though. Obviously I'm not sure how much if any of this would apply to VAGs setup.
That's very useful to know. As you say, don't know how similar the system is to the VAG one, but it's all knowledge.
SEAT have already got back to me - I'm quite impressed - but it was only to say could I supply the VIN which they'll pass to their tech department. I'm not holding my breath. Anyone want to bet they tell me not to charge on the vehicle? Whatever the outcome I'll keep you all updated. Contacted ctek too.
 
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That's very useful to know. As you say, don't know how similar the system is to the VAG one, but it's all knowledge.
SEAT have already got back to me - I'm quite impressed - but it was only to say could I supply the VIN which they'll pass to their tech department. I'm not holding my breath. Anyone want to bet they tell me not to charge on the vehicle? Whatever the outcome I'll keep you all updated. Contacted ctek too.

Probably something along the line of it fitted with a smart charging system and to visit a main dealer for any problems
 
All the manufacturers need to be able to answer this question. With so many vehicles unused for days or weeks, there are going to be a lot of flat batteries, and many people wishing to fit chargers. An instruction to visit the dealer, when the car won't start and the dealer is shut, will not be helpful.
Hopefully we'll get a meaningful answer. If they give poor advice, and the sensor is destroyed as a result, their email makes it their fault. So they'll be careful. Presumably Jock's the first to ask, or they'd have had the answer ready. They will ask for the VIN to prove you are an owner.
 
Disconnect battery and charge direct to the terminals but as you say there will be a lot of folks trying this (or jump leads) and frying the fancy circuitry
 
Had a reply back from SEAT. It's from the person who said they would forward my query to their tech department. She tells me she's spoken to an internal Master Technician who advises, as long as it's a trickle charger (which is, I suppose, what the CTEK is?) just connecting directly to the battery terminals on both positive and negative. It's disappointing that I didn't end up with a direct technical contact - I'd be happier hearing it from the "horses mouth" but I suppose I should accept the advice.

I'm still rather nervous about the instruction on the terminal protector/shield not to connect to the negative terminal:

P1090270.JPG

P1090271.JPG

Which seems to be pretty convincingly saying to connect to the domed nut earth point on the inner wing? But what do I know? I've replied requesting clarification on this. Wonder if they'll get back to me?
 
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