Keysight Technologies

Battery Testing

Application Note
Introduction

An electronic load can be used to discharge batteries of various chemistries

to determine actual capacity, capacity retention, and internal impedance.

Increasing demand for portable dc power has risen from improvements in

battery and motor design technology. More than ever before, portable dc
powered products have become available in many diverse applications.
Rechargeable batteries appear in all types of products from analytical
electronic equipment to power tools and toys. In some instances, these
diverse applications pose different requirements on the source of dc Power.
Fortunately, availability of many types of battery chemistries yield unique
characteristics. Table 1 contains just some of the different battery types
and their advantages. Whether testing batteries in R&D or production
environments, the test requirements for each of the different battery types
are basically the same. Figure 1 shows a common test configuration. In
general, the testing of a battery involves discharging it over a period of time
A
to determine several specifications. This application note will concentrate +
on the test of secondary batteries because they require additional tests
+ CONTSTANT
involving recharging. Nickel-cadmium batteries, in particular, are discussed DMM CURRENT
because they are the most universally used type of secondary battery in LOAD
–
today’s demanding applications. –

Figure 1. Common Test Configuration

Table 1. Characteristics and Applications of Different Battery Types

Nickel- Gelled Lead Lithium Carbon Alkaline Silver Mercuric

Cadmium Acid Zinc Oxide Oxide
Volts/Cell 1.2 2.0 1.5 to 1 1.5 1.5 1.5 1.4
Applications portable standby service, memory backup, average use good general button-sized button-sized
equipment, rechargeable pacemakers, purpose battery cells for cells for
rechargeable electronic watches and watches and
door locks, hearing aids hearing aids
emergency
locator
transmitters
Charge CC CV, float charge N/A N/A N/A N/A N/A
Method
Cycle Life 500+ cycles 200 cycles N/A N/A N/A N/A N/A
Life 3 mos. 1 year 5 to 10+ years 1 to 5 years 5% loss/yr. 6% loss/yr. 4% loss/yr.
(Charged) (–2%/day)
Operating 20°C to 70°C –20°C to 65°C –55°C to 75°C –5°C to 55°C –30°C to 55°C –20°C to 55°C –10°C to 55°C
Temp.
Performance high discharge high capacity flat discharge, low cost, good energy flat discharge, flat discharge
Comments rate, quick long life, wide sloping density, more energy
charge rate temperature discharge, sloping per unit
range, good low energy discharge volume than
energy density density mercuric oxide
03 | Keysight | Battery Testing - Application Note

Application Overview
and Test Implementation

Seven standard test procedures1 Note that a battery temperature specified minimum termination
are used to verify certain electrical rise of more than 5 degrees C above voltage (volts). See Figure 2. A
characteristics ambient may require supplemental battery is considered completely
of secondary batteries: cooling to prevent battery discharged when it attains the
performance degradation specified minimum voltage called the
1. Rated capacity due to elevated temperatures. “end of discharge voltage” (EODV).
2. Capacity retention The EODV for nickel-cadmium
3. Effective internal resistance Rated Capacity batteries is typically 1.1 to 0.9 Volts.
4. Discharge rate effect on
capacity at –20°C The principal measurement The term C, or C-rate, is used to
5. Discharge rate effect on of a battery’s performance is its define the discharge current rate (in
capacity at 23°C rated capacity. Capacity amperes), and is numerically equal
6. Life cycle performance ratings are attained in an accelerat- to rated capacity, which is expressed
7. Extended overcharge ed test approximating the battery’s in ampere-hours. The term 1C is
capacity in typical use. The capacity defined as the rate of discharge that
Other miscellaneous tests of a fully charged battery, at a fixed allows a battery to provide its rated
and procedures also involve dis- temperature, is defined as the prod- current over a period of one hour.
charging a battery such as: start-up uct of the rated discharge current (in
voltage test, forced-discharge test, amperes) and the discharge time (in
timed fast charge and dump-timed hours) to a
charge. Most battery tests typically
require only about 1% accuracy
unless otherwise specified.While
battery tests do not require high
accuracy, the tests must be very
repeatable. Battery characteristics
change with temperature so it is
important to be able to control and
monitor the temperature, usually
to within ±2 degrees C. Other
equipment requirements to consider
are: a current source for charging
secondary batteries, a voltage
monitor, a current monitor, a load
for discharge current, and a time
keeping device. More information
about test equipment is given in the
“Test Equipment Require-ments”
section later in this application note.

Figure 2. Typical Discharge Curve

1. A s specified in ANSI® C18.2-1984,

American National Standards
04 | Keysight | Battery Testing - Application Note

Rated Capacity (continued)

Capacity varies with the rate of

discharge as shown in Figure 3.
Testing for how discharge rate
affects capacity is discussed later
in more detail. Generally, lower
discharge rates over longer periods
of time yield higher values of total
capacity. It is important to realize
that since discharge rate affects how
the value of C is determined, battery
manufacturers must decide on a
standard time of discharge. Since
different values for capacity can
be obtained for the same battery,
capacity is generally determined over
a “standard” period of time—from 5
to 20 hours at discharge rates from
C/5 to C/20. A complete specifica-
tion for capacity should therefore
have a C rate and the period
of time that was used to determine
the capacity. For example, Capacity:
450 mAh @ 5 hour rate.

Average and maximum capacities

are obtained by putting the battery Figure 3. Effect of Discharge Rate on Capacity
through five successive charge/
discharge stabilizing cycles. The
batteries are given five stabilizing
The value of the capacity used in the The procedure to determine the
cycles where they are charged,
following tests is the value obtained effective capacity retention of
discharged and rested at an ambient
in the fifth stabilizing cycle. Also, the a battery is relatively simple.
temperature of 23 degrees C. Batter-
capacity obtained in the last three Immediately following the 5 cycles of
ies are charged at C/10 A for a period
cycles must not be less than that capacity measurement, the battery
of from 20 to 24 hours and rested
stated by the manufacturer as rated is fully recharged. It is then stored
for a period of from 2 to 4 hours. The
capacity (1C). open circuit for a period of days at
batteries are then discharged at a
a specific temperature. Then it is
constant current of 1C amperes to
Capacity Retention discharged at a constant current
an EODV of 0.9 volts.
rate to an EODV of 0.9 V as
This test characterizes how much of before. The capacity obtained should
a fully charged battery’s capacity is not be less than 37% of the rated
retained over a long period of time capacity for the battery. The number
under specific conditions. This time of days of shelf life are typically
is sometimes referred to as provided for values of temperature
the “shelf life” of the battery. This from 23 degrees C to 50 degrees C.
test is not to be confused with an
attempt to characterize
the self-discharge effect of the
spontaneous internal chemical
actions in batteries. Self-discharge
occurs regardless of the battery’s
connection to an external circuit.
05 | Keysight | Battery Testing - Application Note

Effective Internal The effective internal For each of the six discharge cycles,
resistance (Re) is then the manufacturer supplies the value
Impedance
calculated as follows: of capacity to be expected as a
Battery impedance is dependent on Re = ∆V VL–VH percent of C1. Charging and dis-
temperature, its state of charge, and =
∆I IH–IL charging at temperatures below the
the load frequency. The effective specification sheet recommendation
IH, VH = the current and
internal impedance is lower for a voltage, recorded should be avoided.
fully charged battery than it is for just prior to
a discharged one. Having a switching Life Cycle Performance
low internal resistance is very IL, VL = the current and
important when the battery must maximum voltage, Life cycle testing is a measure of ex-
support a high current for a short recorded after pected battery performance in actual
time. Low temperature, use, and switching service. Life cycle performance is
long storage periods all increase a characterized by dynamically loading
battery’s internal resistance. Nickel- Impedance Test the battery in a simulated “real-life”
cadmium batteries also have situation for 50 or more charge and
The battery must be fully charged as
a high effective capacitance. discharge cycles as follows:
outlined above. An ac current source
Their total effective impedance
(~1 kHz) is applied to the terminals of
is so low that, in applications The battery is given five stabilizing
the battery. The ac current through
where they are continuously being cycles in accordance with the
the battery and the voltage across
“trickle-charged” at rates from 0.01C previously outlined procedure.
it are measured. The impedance is
to 0.1C, they make excellent ripple
simply calculated as V/I. An interest-
filters. Resistance and impedance
ing alternative testing method that Life Cycles 1 through 48
tests are explained in the following
yields the same result is to place a 1. Charge 11 hours and
paragraphs.
varying(~1 kHz) load across the fully 20 minutes at C/10
charged battery instead of the ac 2. Discharge immediately at
Resistance Test power source. 1C for 40 minutes
The battery must be fully charged as 3. No rest
outlined above. Batteries rated 5 Ah Discharge Rate Effect on
orless are discharged at 10C for Capacity Life cycles 49 and 50
2 minutes and then switched
The rate of discharge has an effect 1. Charge for 20 hours at C/10
to 1C. The battery voltage is record-
on the total capacity of a battery. 2. Rest 2 to 4 hours
ed just prior to switching and again
Heavy discharge rates decrease the 3. Discharge at 1C to 0.9 volts
upon reaching its maximum value
total available capacity of a battery. 4. EODV
after switching. All voltage mea-
surements are made at the terminals The test is done at two tempera-
of the battery independently of the tures: –20 degrees C and 23 degrees
contacts used to carry current. C.The battery is first fully charged at
23 degrees C and then
immediately stored for 24 hours
at an ambient temperature
of –20 degrees C. It is then
discharged at an ambient
temperature of –20 degrees C at a
constant current rate of 1C to an
EODV of 0.8 volts. Then the proce-
dure is repeated at discharge rates
of 5C and C/5. The whole test is
then repeated at a temperature of 23
degrees C to an EODV of 0.9 volts.
06 | Keysight | Battery Testing - Application Note

Repetition of Life Cycles advanced plate and cell One fast-charge method involves
construction. The low internal charging the battery at a rate
Repeat cycles 1 to 50 resistance of nickel-cadmium exceeding the specified maximum
as desired. batteries yields high discharge charge rate for a finite period of
currents. If they are discharged time, after which the charge rate is
The capacity at cycle 50, and continuously under short circuit reduced to currents below C 10. This
multiples thereof, should be no lower conditions, however, selfheating may method, called “timed fast charge,”
than that stated for this procedure do irreparable damage. Continuous can indeed give a quick “boost”
by the manufacturer. discharge at rates greater than charge to a partially discharged
1C should be prevented to avoid battery, but unfortunately has the
Extended Overcharge potentially hazardous conditions potential of permanently destroying
due to high internal gas pressure the battery. The destruction occurs
The ability of a battery to withstand
build-up. due to overcharging the battery
overcharge is determined by
because its unused capacity is
charging the battery at a constant
Very high currents (>2C) can be unknown prior to charging.
current of C/10, or at the maximum
withdrawn in low duty cycle pulses
overcharge rate recommended by
providing that internal temperatures A safer variation of the timed fast
the manufacturer, at an ambient
and pressures are maintained. charge method is called “dump
temperature of 23 degrees C for 6
Output capacity in any type of pulse timed-charge” where the battery is
months. The battery should at no
discharge application is difficult first fully discharged (“dumped”) to
time show either electrolyte leakage
to predict because of the infinite its EODV before recharging via the
or visual evidence of distortion beyon
number of possible combinations of “timed fast charge” method. The
the standard maximum dimensions
discharge time, rest time, and EODV. “dump timed-charge”method has
for that battery. When discharged at
Simulation of actual events, as in the the advantage of knowing just how
a constant current of 1C to an EODV
Life-Cycle test, is the best way to much energy must be pumped back
of 0.9V, the battery should have a
quantify a battery exposed to such into the battery to bring it to full
capacity equal to or greater than the
conditions. capacity; the risk of overcharging is
extended overcharge capacity
therefore eliminated.
specification.
Many cells can be quickcharged at
a rate up to C/3 in as little as 3 to
Miscellaneous Tests 5 hours instead of the standard 12
In addition to the tests already to 15 hours at the C/10 rate. High
mentioned, there are also other rate charging should be done under
miscellaneous tests performed on controlled conditions where tem-
nickel-cadmium batteries. These perature, voltage, pressure, or some
tests usually involve high rate charge combination of these parameters
and/or discharge. can be monitored to assure they are
within specifications.
High rate discharge and charge
of nickel-cadmium batteries is
possible with today’s new and better
designed cells having
07 | Keysight | Battery Testing - Application Note

Test Equipment
Requirements

One final test, called the “forced From the various tests described In battery or single cell testing the
discharge test,” determines the so far, we can see some common electronic load only has to function
safety of a battery under certain requirements for test equipment. All down to the EODV, not zero volts.
abusive conditions. This test is very the tests require a discharge cycle See Figure 5. If the minimum load
dangerous because, during the test, using a constant current. A constant operating voltage is above the EODV
the battery is very likely to explode. discharge current cannot be attained for the battery being tested, two
The test must be done under with a simple resistor because the alternatives are available: stack more
extremely well controlled conditions battery voltage changes as current than one battery in series until the
in an explosion proof safety chamber is drawn from it. An active device is required voltage is
to prevent personal injury. The required, such as an electronic load
test involves connecting a current with a constant current mode of
source in series with the battery. The operation. Also note that, because
polarity is in the same direction as many levels of constant current are
normal or short circuit current flow. used from test to test, you should be –
See Figure 4. The current source is able to control the electronic load +
DC
set to a value such that the resultant dynamically as the test demands. i POWER
SUPPLY
current flow is greater than the –
+
short circuit current flow. This test The ability to control the load with
simulates what may happen if a a computer is important because
battery were improperly installed in discharge is typically over a long
a circuit where it may not be the only period of time and, if the test were Figure 4. Forced Discharge
source in the application. Ideally the not automated, constant attendance
battery should withstand the stress, would be an unproductive use of an
with some degree of margin, when operator’s time. Long term tests also
the test currents are similar to actual bring about another requirement:
conditions. reliability. The electronic load must
be very reliable because, if it should + +
fail, the test would take a long time Vb BATTERY LOAD

to repeat. – –

EODV>Vmin

Figure 5. Single Battery Test Configuration

08 | Keysight | Battery Testing - Application Note

Test Equipment Battery Testing with

Requirements Keysight Electronic
(continued) Loads

reached (Figure 6) or place a dc The second alternative (Figure 7) Keysight Technologies, Inc.
power supply (of sufficient voltage shows that using a power supply may Electronic Loads are ideally suited
and current) in series with the be more desirable because timed for battery test
battery (Figure 7). A power supply fast charge, dump-timed charge, applications. Their many
applied in this way is sometimes and forced discharge tests all features make the test system
called an “offset supply.” require a dc power source anyway. easy to configure and provide safe,
Additionally, a constant current reliable, and repeatable operation.
The first alternative (Figure 6) power supply could then be used
requires a method of scanning to test ampere-hour efficiency of The Keysight N3300A Series
the voltage of each battery in the secondary batteries. This rating is Electronic Load Mainframe and
stack so that when any one battery simply the ratio of the ampere-hours the 6060B and 6063B Single
reaches its EODV, either the test can delivered during discharge to the Input Electronic Loads have the
be halted or the battery switched ampere-hours required to restore required constant-current modes
out of the circuit and replaced by a the initial state of charge to the as well as constant resistance
short circuit. Even as each battery battery. and constant-voltage modes.
is switched out of the circuit, the Built-in voltmeters and ammeters
discharge current will remain the Voltage and current must be eliminate the need for external
same if the load has a monitored throughout all the tests meters and provide measurement
constant current mode because actual battery voltage accuracy which, in most cases,
of operation. varies with the battery chemistry greatly exceeds the 0.5 to 1% that is
as well as the discharge rate typically required.
involved. Therefore, a voltmeter and
ammeter are required. They should These electronic loads can be
be computer controlled so that the controlled from their front panel,
+ various tests can be halted when from a computer via GPIB, or by a 0
Vb1 the EODV is reached. If an ammeter to 10 volt
– is unavailable, a current shunt can analog signal. By varying the analog
+ +
be used in conjunction with either a control input (up to
Vb2 LOAD second voltmeter or a scanner. Test 10 kHz), a battery’s effective internal
– – Equipment Requirements impedance can be
+
Vb3 easily measured. The electronic
load’s built-in GPIB interface makes
–
it simple to connect any computer
∑ EODV>Vmin that supports GPIB. Keysight’s
electronic loads are not limited to
Figure 6. Batteries in Series just being controlled over the bus.
Measured
current, voltage, power and
complete status can also be
+

+
+
DC LOAD
POWER VPS –
SUPPLY
–

(VPS + EODV)>Vmin

Figure 7. Using an Offset dc Power Supply

09 | Keysight | Battery Testing - Application Note

Battery Testing with

Keysight Electronic
Loads (continued)

read back over the bus so that time (see Figure 8). This figure shows Keysight’s full featured Electronic
consuming discharge tests can be that at 0.9 volts the Keysight 6060A Load Family offers quality and
attended automatically. Keysight’s Electronic Load is capable of reliably reliability. Refer to
electronic loads truly provide a “One drawing up to 27 amperes. That www.keysight.com/find/power
Box” solution. means an 80 Ah battery could be or the current Keysight Power
discharged to an EODV of 0.9 volts Products Catalog for more informa-
Testing cells down to an EODV of at a discharge rate of C/3. For tion about Electronic Loads.
0.9 volts is easily done with Keysight applications requiring V/I character-
Electronic Loads. While the operat- istics below the operating curve of
ing characteristics of these loads are Figure 8, Keysight offers a full family
guaranteed to meet all specifications of dc power supplies to be used as
above 3 volts, the dc operating an offset supply.
characteristics extend below 3 volts

Figure 8. Operating Characteristics of a Keysight Electronic Load

10 | Keysight | Battery Testing - Application Note

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© Keysight Technologies, 2017
Published in USA, December 2, 2017
5952-4191
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