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Testing Batteries for UPS Systems and Backup Emergency Generators

Battery testing for stationary power generation, uninterruptible power supply (UPS) and backup generators is crucial for ensuring system reliability across various applications. These stationary power generators are critical to various public and private service sectors such as healthcare, emergency services, military, telecommunications, government, data centers, research facilities, transportation, grid balancing, and more. The reliability of these applications depends heavily on consistent and dependable power generation technologies augmenting base load operations.
Ensuring the reliability of UPS systems and backup emergency generators is crucial for maintaining power continuity during outages. A key component of ensuring reliability is the performance of the batteries that power these systems. Mechanical, functional and analytical testing of batteries can prevent unexpected failures and extend their operational lifespan. Below is a comprehensive guide to testing batteries for UPS systems and backup emergency generators.

Types of Battery Tests

• Load Testing: Simulates a full load to measure the battery’s performance under actual operating conditions.
• Voltage Testing: Measures the voltage levels to identify weak or failing cells.
• Impedance Testing: Assesses internal resistance to predict battery life and potential failures.
• Charge-Discharge Testing: Batteries undergo repeated charge-discharge cycle test to determine the number of cycles the battery can endure while maintaining specified performance levels.
• Capacity Testing: Batteries are tested to determine their actual capacity compared to their rated capacity ensuring that the batteries meet the required energy storage specifications.
• Short Circuit Testing: Batteries are subjected to short circuit conditions to evaluate their safety features and the ability to withstand internal faults without prompting failures.
• Dielectric Testing:  Dielectric testing known as high potential test, hipot test, or insulation test applies a high level of voltage to the insulation barrier and measure the reaction.
• Isolation Testing:  Isolation testing ensures batteries are free from unwanted electrical connections that could lead to short circuits particularly in high-voltage applications.
• Overcharge Testing:  Overcharge testing is vital, particularly for Lithium-Ion batteries, for ensuring the safe use in consumer electronics, electric vehicles, eMobility, industrial, military and other applications.
• Seismic Testing: Simulates the operating environment ensuring the battery generator, battery back-up or UPS system will operate despite the effects of an earthquake.
• Vibration Testing: Batteries are subjected to a vibration profile emulating the vibration cycle in the field of operation.
• Mechanical Shock Testing: Batteries are subjected to mechanical shocks to verify the structural integrity of the battery housing and its components.
• Destructive/Abuse Testing:  Batteries are subjected to thermal runaway, drop test, penetration test and crush test to assess how batteries react to harsh conditions
• Electromagnetic Compatibility (EMC/EMI) Testing: Batteries are tested for electromagnetic emissions and interference to ensure they do not interfere with other electrical and electronic systems.
• Thermal Cycling: Batteries undergo heating and cooling cycles simulating the thermal stress determining the reaction to standard and critical operating conditions.
• Material & Chemical Analysis:  Clark provides a complete profile of the elemental analysis and chemical properties of the base raw materials and battery cell.

Common Qualification Specifications

• IEEE 323, IEEE 344 & IEEE 693
• GR63 CORE
• UL 2580
• AC-156
• GB 38031
• OSHPD