Industrial Battery Testing Techniques: A Deep Dive into Diagnosis and Analysis

August 11, 2023 5:05 pm Published by Leave your thoughts

Industrial Battery Testing Techniques: A Deep Dive into Diagnosis and Analysis

Industrial batteries play a crucial role in providing reliable power backup in various industries. To ensure their optimal performance and longevity, regular battery testing and analysis are essential. Battery testing techniques help diagnose any potential issues, assess the state of health, and provide insights on maintenance and replacement decisions. In this blog post, we will explore some of the common industrial battery testing techniques and their importance in diagnosing and analyzing battery performance.

1. Open Circuit Voltage (OCV) Testing

Open Circuit Voltage (OCV) testing is a simple and commonly used technique to assess the state of charge of a battery. It involves measuring the voltage across a battery’s terminals when no load is connected. The OCV reading provides an estimate of the battery’s remaining charge.

Importance: OCV testing helps identify partially discharged or fully discharged batteries, allowing for proper recharging. It also assesses the consistency of individual cell voltages within a battery bank.

2. Internal Resistance Testing

Internal resistance testing measures a battery’s ability to deliver current by analyzing the resistance within the cells. It involves applying a load to the battery and measuring the voltage drop. The magnitude of the voltage drop corresponds to the internal resistance of the battery.

Importance: Internal resistance testing helps identify batteries with high internal resistance, which can indicate poor performance or impending failure. High resistance can lead to voltage drops, reduced capacity, and increased heat generation.

3. Capacity Testing

Capacity testing involves discharging a battery to determine its actual capacity and compare it with its rated capacity. There are different methods for capacity testing, including constant current discharge tests and constant power discharge tests.

Importance: Capacity testing helps assess a battery’s ability to deliver the expected amount of power. It detects capacity loss, enabling preventive maintenance and replacement planning. This technique is particularly crucial in industries where downtime due to battery failure can result in significant financial losses.

4. Load Bank Testing

Load bank testing is a comprehensive technique that applies a simulated load to the battery to evaluate its performance under real-world conditions. It involves connecting the battery to a load bank, which mimics the electrical load that the battery would experience in actual operation.

Importance: Load bank testing provides a comprehensive assessment of a battery’s capacity, voltage response, temperature performance, and overall health. It helps detect weak or failing batteries, identifies potential issues with voltage regulation, and verifies the backup runtime of the battery system.

5. Conductance Testing

Battery conductance testing measures a battery’s ability to conduct electrical current. It uses a conductance tester to measure the conductance value, which is inversely related to the internal resistance of the battery.

Importance: Conductance testing is a quick and non-invasive method to assess battery health and identify early signs of degradation. It provides a relative indication of a battery’s state of health, allowing for timely maintenance or replacement decisions.

6. Electrochemical Impedance Spectroscopy (EIS)

EIS is an advanced battery testing technique that evaluates a battery’s electrochemical behavior by measuring its impedance response to an applied alternating current (AC) signal across a range of frequencies.

Importance: EIS provides comprehensive information about a battery’s internal electrochemical processes, including resistance, capacitance, and inductance. It helps assess a battery’s state of health, detect degradation mechanisms, and identify potential failure modes.


Industrial battery testing techniques are critical for ensuring reliable power backup systems in various industries. OCV testing, internal resistance testing, capacity testing, load bank testing, conductance testing, and EIS provide valuable insights into battery performance, state of health, and potential issues. By regularly diagnosing and analyzing batteries, businesses can take proactive maintenance actions, optimize battery life, minimize downtime, and reduce the risk of costly failures. Implementing a comprehensive battery testing and analysis program will maximize the reliability and efficiency of industrial battery systems, contributing to the seamless operation of critical equipment and uninterrupted power supply.

Got Questions? Let Us Help!

Remis Power Systems Inc has been a family-owned and operated business since 1980. We have become an industry-leading supplier of industrial batteries and chargers. We proudly maintain an impressive inventory of new and certified reconditioned Deka products for all your industrial battery needs. When you do business with, Remis Power Systems, you will find honest and experienced professionals who see things your way! We recognized each one of you had different needs and will work with you to customize our services to your needs. Whether you are in the market for a new or used battery, service program or unplanned service breakdown, we will be there to find the right solution for YOU! Contact us today!

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