grid/sun | care advanced

Load- and Capacity Test

A load and capacity test is usually carried out in the operating condition of a battery, but in some cases (e.g. acceptance tests, customer specifications) prior charging treatment is recommended. The test is carried out in accordance with DIN EN 60896-11 and the available manufacturer's data. It serves to evaluate and analyse the battery with regard to its capacity and its behaviour under load over a predefined period of time. This test can be carried out with connected loads (e.g. safety lighting systems) or with an external load (e.g. Torkel). It can be flexibly defined, taking into account customer interest, duration and capacity discharged, as well as the maximum possible discharge currents of the load bank. Furthermore, such a test can be carried out on any battery system.

  • Placing and removal of the devices, as well as assembly/disassembly of the load and measurement circuits
  • Measuring the total voltage during and at the end of the test
  • Measurement of all cell / block voltages during and at the end of the test
  • Optionally: continuous single cell measurement over the entire duration
  • Check the connectors and screw connections for excessive heat up.
  • Measuring the electrical consumer or load current
  • Measuring the electrolyte temperature at the end of the test

Equalisation Charge

Between the individual cells of a battery it can come to unacceptably large differences of the cell voltage under maintainance charge. In this case an equalizing or calibration charge is necessary to compensate the differences and to bring all cells back to a consistent voltage level. Other reasons for an equalisation charge may be a deep discharge, sulphation of the battery due to insufficient charging or temperature differences between the cells over a longer period of time. Deviations in electrolyte density or voltage values are also characteristics of a necessary equalizing charge. Such charging is carried out in accordance with the manufacturer's specifications and can be carried out using existing charging technology or with the an external charger.

  • Placing and removal of tools and devices
  • Delivery, configuration and programming of the charger (external charger only)
  • Disconnect battery if necessary - Connect the cell connectors/connecting cables
  • Equalization charge up to 400 V
  • Measurement of cell voltages before and after equalisation charging
  • Measurement of electrolyte density and temperature before, during and after charging

Thermography

During a capacity test or a heavy discharge, increased heat generation may occur at connectors or disconnecting devices. One reason for this may be a high transition resistance due to incorrectly tightened pole screws. Increased gassing of a single battery in the overall system can also be determined by temperature development, so that a possible defect can be detected early and action taken accordingly. The measurement is carried out with certified measuring instruments so that even the smallest thermal deviations can be detected and eliminated. The scope of services can be combined with any other service product in order to make as accurate a statement as possible about the test object in question.

  • Placing and removal of tools and devices
  • Analysis of single connectors and the overall system
  • Evaluation of the recorded results
  • Image capturing during the test
  • Transfer of the determined values in a log
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  • Comprehensive assessment of the current state of the battery
  • Fault-identification to avoid downtimes
  • Proof of warranty claims
  • Visualization of temperature curves
  • Recovery after deep discharge or sulphation
  • Determination of cells with increased water consumption

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