Hioki 3551 User Manual

Page 1
3550 Series Battery HiTESTERs
User's Guide
September 1999
HIOKI E. E. CORPORATION
Author: R&D OFFICE II
Editor: Technical Sales Sup p o rt Section
81 Koizumi
os-com@hioki.co.jp
http://www.hioki.co.jp
Page 2
2
CONTENTS
1 Display
……………………………
2
Q 1 - 3
2 Printer Output/Memory
……………………………
2
Q1 - 8
3 Comparator
……………………………
4
Q1 - 7
4 Input Protection
……………………………
6
Q1 - 3
5 Leads
……………………………
7
Q1 - 15
6 Resistance Measurement
……………………………
9
Q1 - 14
7 Voltage Measurement
……………………………
14
Q1
8 Temperature Measurement
……………………………
14
Q1 - 2
9 Batteries
……………………………
15
Q1 - 13
10 Miscellaneous
……………………………
19
Q1 - 19
11 References
……………………………
23
Questions & Answers
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3550 Battery HiTESTER Series
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1 Display………………………………………………………………...
Q1. Why does the 3550 series
comparator display a warning when it finds the resistance of a battery to be between the upper and lower limits, i.e., (lower limit resistance value) <resistance < (upper limit
resistance value)
?
A1. When a battery is new, it has a low internal
resistance, but as the battery deteriorates the internal resistance becomes larger. This is due to corrosion on the plates, loss of electrolytic solution, etc. Theref ore, when the comparator is found to be in the "IN "con ditio n dur ing batte ry maintenance work, a warning is generated. However, when the battery is shipped fr om the factory, it passes inspection as long as it falls between the upper and lower limits for both resistance and voltage. At HIOKI, we use these units in combination with the 3225 and the
3236.
Q2. If a negative voltage is displayed,
the comparator makes an incorrect evaluation if the polarity of the test leads is reversed when connected to the battery. (To be more precise, rath er than incorrectly evaluating the voltage, it judges the voltage low.) Is it possible to ignore the negative polarity for the evaluation?
A2. Although it is not possible with the 3550 series,
we will consider im plementing such a c apability in a future BATTERY HiTESTER/AC mHiTESTER.
Q3. After inserting batteries in the
3551 (or connecting the AC adapter), power does not come on immediately. Is this a defect?
A3. When batteries are first inserted or when
batteries were fully depleted and are replaced (or when the AC adapter is connected), the unit will not come on for abou t 15 seconds. This is because the inter nal backup capacitor is b eing charged. It is not a defect. Information about this point is included in the manual.
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2 Printer Output/Memory………………………………………………
Q1. How can I load data stored in
memory into a personal computer?
A1. Refer to the reference mater ial at the end of
this sales guide. The material describes how to use the 3550 and 3551's printer outp ut to load data from memory into a personal computer. The method that is described uses a commercially available RS- 232C converter to load the data into a personal computer running under Windows 95.Hyper Terminal, provided with Windows 95, is the software that is used. Note:Units (, V, C, etc.) are also output.
Q2. Is conversion of output to
Centronics - RS- 232C possible?
A2. At present, the 3550 can store 26 0, 3551 can
store 250 items of data i n mem ory. Because the memory in the u nit is already be ing used to the fullest extent possible, it is not p ossible to increase the amount of data that can be stored in memory.
Q3. Is it possible to increase the
amount of data that can be stored in memory?
A3. When batteries are first inserted or when
batteries were fully depl eted and are r eplaced (or when the AC adapter is connected), the unit will not come on for about 15 seconds. This is because the inter nal backup capacit or is being charged. It is not a defect. Information about th is point is includ ed in the manual.
Q4. I have imported the data to a PC
and want to process them with Microsoft Excel, but the unit symbols prevent proper calculation or graph display. What should I do?
A4.
Unit symbols such as "", "V", or "C" can be deleted using the global replace function of Excel.
Q5. Can measurement data be
selectively deleted or added?
A5. With the 3550 and 35 51, it is on ly possible t o
delete the latest data or all data. T he 3551 has a new function which allo ws over writing data selectively.
Q6. Can I print out measurement
data selectively?
A.6 This is not possible. The 3550 and 3551
send all data to the 9203 in one operation, and the 9203 prints all of these data.
Refer to the reference material at the end of guide.
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3550 Battery HiTESTER Series
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Q7. I want to externally control
EXT.HOLD and EXT.MEMO. Where is the circuit common point? Is it possible to perform control with 0/5 V (CMOS level)?
A7. Refer to the circuit configuration of EXT.HOLD
and EXT.MEMO shown below.The internal circuit operates at 5 V. Con trol at the CMO S level is therefore possible.
Q8. Does the printout differ,
depending on the software version of the 9203?
A8. The software ver sion and compatible m odels
are listed below. Ver.1.00:3227 Ver.1.01:3550, 3227 Ver.1.10:3550, 3551, 3227 When version 1.10 is used and the 3550 is connected, "NG" is displayed as "- - ". When the 3551 is connected, printout is as explained in the m anual. W hen version 1.01 is used and the 355 1 is connected, the 3 m range cannot be printed. For details, please contact the HIOKI Head Office.
3 Comparator…………...………………………………………………
Q1. Is it possible for HIOKI to
research the battery data and write the comparator values to memory?
A1. Although HIOKI is engaged in battery
charging and discharging tests, the data generated by these tests is intende d only for reference purposes. Users m ust provide the data on individual batteries.
Q2. Is it possible to increase the
number of comparator?
A2. Yes. It is possib le to increase the num ber of
comparator numbers up to 3 0(3550 and 3555 but 3551 is not possible). Such cases are handled as special orders.
Q3. Is it possible to input upper and
lower limit values for a voltage comparator?
A3. This is not possible with the 3550 series.
Inspections conducted by the battery manufacturer when the batteries are shipped from the factor are perf ormed with upper and lower limit values. However, if the voltage is higher than normal during maintenance
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3550 Battery HiTESTER Series
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work, a failure in o ne of the other batteries that is connected in series in a UPS could b e causing a relative increase in the battery voltage, or the charger could be malfunctioning. Increases in a battery's voltage that are discovered during maintenance appear n ever to be the result of a problem with the battery itself.
Q4. Is it possible to use the
comparator for voltage only?
A4. Set the upper and lower limit values of the
comparator to 3000 (3550 and 3555), 3100 (3551) in the resistance range that is being used. It is then possible to set the voltage range and voltage comparison value to the desired value. If the voltage exceeds the comparison value, the PASS indicator lights; if the voltage is equal to or less than the comparison value, the WARNING indicator flashes. However, if the resistance value is too large and a constant cur rent error occur s, [- - - - ] is displayed and no LED lights.
Q5. Can the battery t ype number be
displayed instead of the comparator number?
A5. This is not possible, because it wo uld require
not only a software upgrade but also a new LCD.
Q6. I want to measure a 48 V battery
assembly. Since voltage evaluation is not needed, can evaluation be based on impedance only?
A.6 The maximum input voltage is 50 V DC for the
3550 and 3555 and 60 V DC for the 3551. Therefore the impedance of a 48 V battery assembly can be measured if voltage evaluation is not required. Use the comparator setting screen and set t he vo ltag e comparator value to - 3000dgt (3551: ­3100dgt).
Q7. Is it possible to obtain separate
comparator outputs for resistance and voltage?
A7. Because resistance and voltage comparator
output is obtained by software, it is not possible to obtain separate comparator outputs for resistance and voltage.
4 Input Protection….…...………………………………………………
Q1. Is input overvoltage protection
implemented, and how?
A1. Basically, in the case of both the 3550, 35 55
and the 3551, it is not possible to input voltage in excess of 50V DC (3551:6 0V DC), nor is it possible to input AC voltage or current. If such voltage or current is input, the unit will be damaged. Although a design change that adds a fuse will be implemented in new lots in the near future in order to minimize the number of failures resulting from such mis­operation, the fuse will not be user replaceable. Note that any unit failures caused by overvoltage input will only be repaired for a fee.
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3550 Battery HiTESTER Series
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Q2. Can maximum allowable input
voltage be increased?
A2. This is a frequently expr essed request f or the
3550 and 3551. However, for reasons of safety and because extensive parts modifications would be required, it is not possible to increase the rated m aximum input voltage of the 3550 series models. The 3551 has passed overload tests up to 400 V DC. When a voltage of about 330 V or more is applied, an intermittent warning tone will be heard. However, when high voltage is applied, sparks ar e produced when the input coupling capacitor is charged, which can be dangerous. The rated maximum input voltage therefore is 60 V DC.
Q3. What type of damage wil l occur
for various types of mis­operation?
A3. If AC voltage is input, depending on the
amount of voltage, the surge abs orber will be damaged, and the fuse will be damaged (once the design change for adding the fuse is implemented).In some cases, the A/D converter will also be damaged. If overvoltage is inp ut, the capacitor and surge absorber will be damaged. If a battery is inserted with reversed polarity, the battery will leak and the power supply circuitry will be damaged.
5
Leads……...…………...……………………………………………
Q1. Will the spring pressure of the
9460 be increased
?
A1. Compared to when the product was initially
released, the diameter of the spri ng has been increased, resulting in greater strength.
Q2. Will the tip of the 9461 pin be
made rounder? A
nd will the spring pressure of the pin tip be reduced?
A2. The pin tip has been made rounder, and the
spring pressure has been reduced. As a result, the tip wil l be less likel y to damage ba ttery terminals.
Q3. Will the tip of the 9461 pin be
made thinner?
A3. The 9174- 02 semi- s tandard product can be
used with the 3550 and 3555. However, because the probes are not red and black, the user must mark them b y wrapping them with red or black tape, as appropriate. In addition, the 9461 can be m odified for special orders . However, because pin tip 1172 is a four­terminal probe that was developed for in­circuit testing, it offers extremely high accuracy, but is susceptible to dam age when used manually.
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9465 PIN-TYPE
LEADS
Q4. Is it possible to special order the
9460 CLIP- TYPE LEADS WITH TEMPERATURE SENSO
R with a wider opening between the jaws?
A4. We provided 9467 LARGE CLIP TYPE
LEADS. But it can not measure temperature.
Q5. Is it possible to extend the
leads?
A5. We have confirmed that it is possible to
extend the leads up to 5m.However, only the thick, bundled portion between the points where the leads branch out at each end can be extended. Note also that extending the leads results in increased susceptibility to external noise, so in som e environments the measured values may fluctuate.
Q6. Describe the pin ar rangements,
including shielding, so that we can produce our own leads.
A.6 The pin arrangements are indicated on the
3550 and the 3555 themselves . In addit ion, the shielding wires in the 9460 and 946 1 are connected to SENSE- LO.
Q7. Can the 9287 CLIP- TYPE
LEADS be used With the 3550 series?
A7. Yes, with some restrictions. Because the
9287 leads are test leads for low- resistance meters, they are not designed to be used to test objects to which voltage is being input. Therefore, they cannot be used in the maintenance of batteries used in a UPS, for example. When c hecking a battery by itself (less than absolute maximum input voltage), the 9287 leads can be used without any problems.
Q8. Can the 9461PIN- TYPE
LEADS be used with the 3550 and 3551?
A8. Yes, with some restrictions. Because the
9461 leads are test leads for the 3555, they are designed to be used at l ess than 50V DC. Therefore, they cannot be used in the maintenance of batteries used in a UPS, for example. When c hecking a battery by itself (less than absolute maximum input voltage), the 9461 leads can be used without any problems.
Q9. Can the 9465 PIN- TYPE
LEADS be extended?
A9. When the 3551 is used, no extension is
possible because m easurement values would become unstable. With the 3550 and 35 55, extension for up to five meters is possible. Only the heavy- gauge par t bet ween j unc tio ns can be extended.
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Q10. Can the 9173 FOUR-
TERMINAL LEADS be modified to use banana plugs?
A10. This is possible only when used with the
3555.Precision assurance with the 3550 and 3551 is not given. The 9173 is available as a special- order option with banana plugs .
Q11. The pin tip of the 9465 PIN-
TYPE LEADS has become damaged. Is it possible to replace the pin tip only?
A11 The measurement leads cannot be rep aired.
A new lead must be p urchased. 3550 series BATTERY HiTESTER
Q12. What are the usage limitations
of the 9287 CLIP- TYPE LEADS and 9467 LARGE CLIP TYPE LEADS?
A12. The 9287 can only be used with the
3555.Because the 9287 has no barri er at the clip section, measuring a UPS battery involves a risk of electric shock and is therefore not allowed with the 3550 and 3551.The 9467 can be used with all models, but with the 3551, measurement results will differ by about 15dgt.in the 3 m range, due to measurement lead length.
Q13. Can the lead of the 9466
REMOTE CONTROL SWITCH incorporated in the 9465 PIN­TYPE LEADS?
A13. This is not possible. Internally, the
EXT.MEMO/EXT.HOLD and measurement terminal wiring circu its are ins ulate d, but if the 9466 lead is run together with the 9465 lead, the 2.3 kV rms r ating will no l onger appl y and a risk of electric shock exists.
Q14. Can the zero adjustment board
also be used with the 9 461 PIN­TYPE LEADS? Can zero adjustment be performed by using a thick metal plate in place of the zero adjustment board?
A14. The zero adjustment board can also be used
with the 9461.A thick metal plate cannot be used in place of the zero adjustment board, because the resistance of that plat e would be measured.
Q15. Can the 9465 PIN- TYPE
LEADS be used with the 3550?
A15. Yes, but not for temperature measurements.
Zero adjustment m ust be performed with the zero adjustment board.
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6 Resistance Measurement…...………………………………………
Q1. Can the impedance of a battery
not be measured with a DC type ohmmeter?
A1. A DC type ohmmeter appli es a constant DC
current and measures the voltage reduction caused by the load to determine the resistance. In the case of a battery, its electromotive force prevents correct measurement of impedance using such a setup. In order to eliminate the influence of the battery's electromotive force, an AC type ohmmeter must be used.
Q2. Why is testing conducted with a
1kHz AC current?
A2. There is no standard or rule that requires
battery testing to be conducted with a 1kHz current. The reason why testing is conducted at 1kHz is due to the current flow of existing AC- type resistance meters. AC­type resistance meters were developed for measuring contact resistance. Contact resistance meters conform to IEC512- 2,JIS C 5402,and JIS C 5441,and one item in these standards calls for testi ng to be conducted at 1kHz. Accordingly, the majority of AC resistance meters are designed for 1kHz testing. Because commercially available resistance meters are frequently used for measuring the internal resistanc e of a ba ttery, a considerable amount of data on measurements taken at 1kHz has been accumulated. Therefore, in order to maintain compatibility wit h this previousl y accumulate d data, we decided to d esign the 35 50 series to take measurements at the 1kHz frequency. While we realize the internal resistance of a battery is frequency- dependent, there are indications that this char acteristic is relativel y flat between 100Hz and 1kHz.
Q3. Can the range used by the 3550
series be changed?
A3. It is not possible at present to change the
testing range.
Q4. Can the testing current be
changed?
A4. If the testing current is changed, the voltmeter
gain must also be ch anged at the sam e time. Changing the gain is an extremely delicate proposition, since it is accompanied by changes in the temperature characteristics, noise characteristic s, etc . Therefore, it is not possible to change the testing current. We will study this issue when we develop future AC m ΩHiTESTERs.
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Q5. Describe the equivalent circuit
for a battery.
A5. The equivalent circuit for a battery is shown
below. In the diagram, "E" represents the electromotive force, "L" represents the inductance of the plates and conductors, "R1"represents the resistanc e of the e lectr o de plates and the electrolytic solution,"R2"represents the resistance of the movement of the e lectric charge b etween the electrode plates and the electrolytic solution, and "C" represents the electric double layer capacitance. This shows that internally, a battery exhibits not just resistance, but also impedance that includes capacitance and inductance. Synchronous wave detection is a method of measuring just the real impedance. The 3550 series uses synchronous wave detect ion to measure real impedance.
Q6. Is the resistance displayed by
the 3550 series impedance, or is it pure resistance?
A.6 A battery's internal resistance is the vector
sum of a resistance component and a reactance component. Because the 3550 series uses the synchronous wave detection method, the reactance is eliminated by analog means and only the (real) resistance component is displayed. Therefore, the measured value is not impedance, nor is it pure resistance; it is the real component of the impedance (the effective resistance).
Q7. What is "synchronous wave
detection?"
A7. This method detects the test signal by using a
reference signal that is in phase with the test current. This method is much like a type of filter circuit. This method demonstrates excellent frequency selectivity characteristics for the frequency of the reference signal. Another characteris tic of this method is th at it cancels out the reactance component (the false portion of the impedance), eliminating that component from the test results.
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Q8. Why do the 3550 series use the
AC four-terminal method?
A8. There are basically two general methods for
checking battery deterioration: the charging/discharging test method, and measuring the internal resistance. Each method has its own strengths and weaknesses. The charging/discharging test method is capable of accurately measuring the discharge capacit y of the b atter y. On the other hand, this method requires a considerable am ount of time. Measuring t he internal resistance, however, evaluates the deterioration of the batter y on the bas is of the correlation between the measured internal resistance and the discharge capacity of the battery. While the accuracy of the m easured results suffers somewhat, the test can be conducted very quickly and the test equipment can be fairly small. In resistance measurement, the four- terminal method is used to measure items, such as batteries, that have very low resistance. The AC four­terminal method is illustrated below. The input impedance of the voltmeter is lar ge, so practically no test current flows to the voltmeter. As a result, it is possible to measure the resistance of the subject only, with the lead resistance and the contact resistance excluded.
Q9. Why does the zero adjustment
board have to be removed at least 10 cm from the unit when performing zero adjustment?
A9. The electromagnetic field generated in the
loop formed by the zero adjustment board and the measurement leads would otherwise affect operation of the unit. Care must also be taken not to have any other m etal objects in the vicinity of the zero adjustment board, because magnetic influences can falsify the measurement.
Q10. After performing zero
adjustment with the 9460 CLI P­TYPE LEADS WITH TEMPERATURE SENSOR, is it possible to change leads and take a measurement with the 9465 PIN- TYPE LEADS?
A10. Measurement precision is assured only with
the same lead that was used for zero adjustment. However, in the 300 mΩ,3 ,and 30 ranges, the measurement lead influence can be largely disregar de d.
Q11. Performing renewed zero
adjustment every time is a bother. Is it possible to retain adjustment data whi le t he un it is turned off?
A11 Zero adjustment data are written to volatile
memory and are therefore lost when power is turned off. Zero adjustment must be performed every time when the unit was turned off.
Q12. Why is the display value
different from the calibration value when performing calibration? *See also Q 6 and A 6.
A12. [Resistance measurement]
Is the AC 1 kHz resistance value being used for calibration? The AC calibr at ion va lu e an d DC calibration value do not necessarily match. The DC calibration value is a true resistance value, whereas the AC 1 kHz calibration value is an rms value. These will normally be
R1 to R4: Lead resistance and contact
resistance
C: Coupling Capacitor
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different. The 3550, 3555, 3551, and 3225 measure the AC 1 kHz resistance value. [Voltage measurement] Is the SOURCE- Hi terminal connec ted to the generator? When all four terminals are connected, the constant c urrent generated b y the 3550 series unit may cause malfunction, preventing correct voltage from being output. Information about th is point is includ ed in the manual.
Q13. When measuring a battery
connected to and operating UPS, do ripple voltage components caused by the charging process affect the measurement?
A13. The 3550 and 3551 use noise canceling
technology to reduce the influence of ripple voltage components on the measurement. However, if ripple voltage components are very large, the indication may fluctuate and will not be correct. The allowable ripple voltage rating is listed at the end of the documentation for the 3550 and 3551.
Q14. Why does the 9465 pin type
lead use curled cables?
A14. Resistance measurements can be affected b y
electromagnetic induction from nearby metallic objects. This problem becomes more pronounced when small resistance values are to be measured and when the loop area of the divided section of the measurement leads is large. The 94 65 uses curled cables to keep the loop area of the divided section as small as possible.
7 Voltage Measurement…...…………..………………………………
Q1. Why is voltage measurement
necessary?
A1. Voltage measurement is performed
simultaneously with the measurement of specific gravity during maintenance for lead storage batteries and alkaline storage batteries. If the voltage is extrem ely low, the battery may be damaged (it may have in internal short circuit). In addition, if the voltage is high, it is pos sible that a c harger or another battery connected in series with the battery in question could suffer damage. The 3550 and 3551 detects battery deterioration through the battery's int ernal resistance, and checks whether the battery is damaged according to its voltage and temperature (on ly
3550). The internal resistance of a battery differs during charging a nd recharging. The 3555 check for excessive discharging according to the battery voltage .The 3550 and 3551 also checks whether the battery is damaged in the same manner.
Refer to the reference material at the end of guide.
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End of a 9640 Clip-type Lead with Temperature Sensor
8 Temperature Measurement…...……………………………………
Q1. Why is temperature measured? A1. Temperature measurement is important for
two reasons. One is because the internal resistance changes according to the temperature. This allows workers to us e the temperature of the electrolytic solution to determine the extent of battery deterioration. Another reason is to discover damaged batteries. A battery with an internal short circuit will reveal its e lf b y heating up when it is charged. Although the 355 0 and 3551 is not able to measure the temperature of the electrolytic solution, it is able to measure the temperature of the term inal, which is close to the temperature of the electrolytic solution. However, in a 12V lead storage battery,6 individual batteries are connected in series; we have heard that even if one of those batteries is damaged internally, the terminal temperature does not rise very much.
Q2. Why is the temperature
measurement sensor inside the probe?
A2. This was done in order to av oid adding to the
work that the work er must do. Bec ause the temperature sensor is b ui lt into the tes t pro be, the terminal temperature can be measured simply by clipping t he probe onto the terminal. In addition, measuring the terminal temperature rather than the ambient temperature provides a clearer picture of the degree of battery deterioration.
9 Batteries………………….…...………………………………………
Q1. Does the internal resistance of a
battery change after c harging or after discharging?
A1. Yes. When measuring the internal
resistance of a battery with the 3555,the most accurate measurements can be taken when the battery is fully charged. Because maintenance is perf orm ed on a U PS wit h th e 3550 and 3551 when the battery is in a normally charged state, this issue is not a concern.
Q2. Does the internal resistance of a
battery change according to its temperature?
A2. The internal resistance does change
according to the temperature. Sample measurements taken by HIOKI f or reference purposes are included at the end of this sales guide in the paper on "Applying Low Resistance Measurem ent Techniques to the Evaluation of the Performance of Backup Batteries."
Refer to the reference material at the end of guide.
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3550 Battery HiTESTER Series
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Q3. What is the relationship
between the charging interval and the internal resistanc e, and between the number of cycles and the internal resistance?
A3. When a battery is charged f or a long tim e, or
as the charging/discharging cycle is repeated, the discharge capacity of the battery decreases due to corrosion on the plates and loss of electrolytic solution. An example discharge c urve is ill ustrated belo w. The curve differs according to the battery type. It is also s aid that t em peratur e has a n effect on how fast a battery deteriorates.
Q4. Does the AC signal used for
measurement cause battery deterioration?
A4. Normal small- size batteries and larger
batteries will not be affected, because the measurement current is very sm all (50 mA) and the 1 kHz AC signal does not cause a chemical reaction in the battery.
Q5. What is the importance of the
specific gravity?
A5. For wet- type lead storage batteries and
alkaline storage ba tteries, th e temperatur e of the electrolytic solution and the specific gravity are measured and used to evaluate the deterioration of the battery. Specific gravity is measur ed with a densitometer, but because the value changes according t o the temperature of the solution, this value is customarily converted to the value at a temperature of 20°C and then compared to the value specified by the manufacturer of the battery. If the specific gravity is low, it indicates that the batter y is depleted and that its discharge capacity is low. The internal resistance of the bat tery tends to be high in this case. Conversely, if the specific grav ity is high, it indicates that the battery is overcharged.
Q6. What types of batteries can be
tested by the 3550 series?
A.6 Basically, the 3550 series can be used to test
any type of battery. However, batteries with a resistance of sever al h undre d m , such as button- type batteries, will be out of range. The 3550 series also can not be used to test batteries with a total voltage of 50V(3551:60V DC) or more, such as batteries used in industrial machinery. Although lithium ion batteries can also be tested, those that are part of a package are c onnected in series to a PTC device as a saf ety mechanism . T his device has an internal resistance of over 100mIn addition, there is also an FET for current control that is inserted in the path of
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3550 Battery HiTESTER Series
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the current; this FET has an ON resistance of over 30m . These values are large enough in comparison with the internal resistance of the battery that th ey cannot be ignored. The difference in resistance between a good lithium ion battery and a deteriorated lithium ion battery is also sometimes quite small compared to other batteries. Some nickel- metal hydride batteries also include a PTC device.
Q7. What protection measures are
used for rechargeable nickel­metal hydride batteries and rechargeable lithium- ion batteries?
A7. Nickel- metal hydride batteries have a low
hazard rating and are normally only fitted with a safety valve to prevent explosion. Lithium- ion batteries us e organic electrolyte and have a high energy density. Under extreme conditions, such batteries may explode or ignite. Therefore the following protection measures ar e used: (1) Shutdo wn separator (Separator holes close when temperature rises above a certain level.) (2)PTC elements (Resistance rises when temperature rises.) (3)Safety valve (Reduces internal pressure in battery.) (4)Protection circuit (FET or similar is used for temperature, current, or voltage control.)
Q8. What is sulfation occurring at
the electrodes of lead batteries?
A8. Lead sulfate (PbSO4, and insulating
substance) is deposited on the electrodes, which reduces their effective area and increases the impedance of the battery.
Q9. What is the dry- up
phenomenon?
A9. The reduction of electrol yte is called the dr y-
up phenomenon. It occurs mainly when a battery is overcharged.
Q10. What is dendrite? A10. Dendrite is a leaf- shaped crystalline metal
growth that can occur on the electrodes of a battery. When it advances, the electrodes may become short- circuited.
Q11. What is the memory effect? A11 When a battery is repeatedly discharged
partially and then charged again, the so­called memory effect can develop which causes a reduction in apparent capacity of the battery. This occ urs mainly with alkali ne type batteries (Ni-Cd, Ni-MH), not with lead type and lithium-ion type batteries. The memory effect can be countered by several cycles of deep discharge and full charge.
Q12. What are rechargeable alkaline
batteries?
A12. The term rechargeable alkaline batteries
normally refers to nickel-cadmium (Ni- Cd) batteries.
Q13. The resistance value of a
rechargeable lead battery differs with every measurement. What is the cause for this?
A13. The following causes are possible:
(1)The probe is appli ed to different points on the battery terminals. (2)The battery charge condition differs.
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3550 Battery HiTESTER Series
17
(3)The battery terminals are not in proper contact, so that measurem ent is not carried out for all 4 terminals. (4)The measurement lead is broken. (5)The battery temperature is different. (6)There is a large rippl e voltage across the battery terminals.
10 Miscellaneous………….…...………………………………………
Q1. Up to what capacity is testing
possible?
A1. It depends on how many valid digits the user
requires. Batteries have a smaller internal resistance the larger their capacity is. As a guide, in the case of a lead storage batt ery with a capacity of about 400Ah, the resistance is approximately 0.5m . W hen m easured with t he 3550 or 3551,the result would be about 50 counts or 500 counts. Alk aline stor age batter ies have an even smaller resistance.
Q2. What is the relationship
between the deteriorated state and the internal resistance?
A2. According to a JAPAN STORAGE BATTERY
ASSOCIATION Technical Reference (SBA3508-
1984), once the capacity drops below 80%, it decreases at an accelerating pace; therefore, the point at which the capacity drops below 80%is regarded as a guide for determining when a battery has reached the end of its operational life .At this point, the internal resistance of the battery is about 1.5 to 2 times greater than when it was a new battery. Accordingly, even if you do not know what the internal resistance of the battery should be when the battery is in good condition, it is possible to measure the internal resistance at regular intervals and use the extent of the trend towards increased resistance to estimate the deterioration of the battery.
Q3. Can a battery other than an
alkaline battery be used for the power supply?
A3. Manganese dry cells can also be used.
Although ni-cad dry cells can also prob ably be used, the system shuts down soon after the battery indicator first appears, so from the standpoint of saving data, we cannot recommend the use of ni-cad batteries.
Q4. Aside from AC resistance
measurement, what are methods are available for diagnosing batteries?
A4. There are basically two m ethods for evaluating
the deterioration of a bat tery. One is to directly measure the discharge capacity of the battery by conducting charging/discharging testing. The other is to meas ure the internal resist ance and use that information to estimate the deterioration of the battery. There are furthermore two method for conducting charging/dischargi ng testing: discharging a full y charged battery until it is completely discharged, and discharging a fully charged battery for a few minutes and then using that information to
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3550 Battery HiTESTER Series
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estimate when the battery will be fully discharged. There are also two methods for measuring resistance. One is the AC measurement method, and the other entails causing a momentary short circ uit between the battery terminals and then calculating the resistance based on th e drop in voltage. All of these different methods have their advantages and disadvantages.
Q5. Where are the 3550 series
used?
A5. The 3550 and 3551 are primarily used for UPS
maintenance. The 3555 seem to be used in service departments that service small electronic devices.
Q6. Do you have materials for user s
to use to calibrate the testers? Are there any points that req uire special consideration?
A.6 A calibration manual is available. Contact our
International Sales and Marketing Department. A standard resistor is used for calibration. Because the calibration values are slightly different for DC and AC, always use the calibration value for AC 1kHz when calibratin g the 3550 series.
Q7. Is testing in accordance with
IEC512- 2, JIS C 5402,and JI S C 5441 possible?
A7. The requirements of these standards are as
follows:
1.Frequency:1kHz ±200Hz
2.Ampere execution:1A or less
3.Voltage peak:20mV or less
4.Accuracy:within ±10% The 3550 series fail to satisfy No.3. Therefore, testing in accordance with these standards f or contact resistance testing is not possible.
Q8. Can these units measure the
contact resistance of a relay?
A8. Although they can m easure contact res istance,
they cannot do so in accordance with the test standards mentioned above.
Q9. Can you provide a block
diagram for the 3550 series testing systems and digital systems?
A9. These block diagr ams are provided at the end
of this guide. Note that the 3555 is not capable of temperature measurement.
Q10. I would like to retrieve the
comparator output. Is it possible to modify the units in order to do so?
A10. No. At present, we would recommend that you
use the 3225 and the 3236 in combination. The 3225 model revision was planned with th is capability in mind.
Q11. Is it possible to coll ect da ta from
the batteries that pass testing and use those data as the comparation values?
A11 It should be possible f or the user to set these
values. Through battery maintenance it is necessary to collect data on a regular basis, and it should be possible to estimate the degree of deterioration in a bat tery on the basis of the rise in the curve of its internal resistance data.
Q12. What do "CE" and "CAT - I"
mean?
A12. The CE mark displayed on the unit indicates
that the product complies with the CE mark requirements for safety , which are necessary for marketing a product in the EU. The "CAT- I"
Refer to the reference material at the end of guide.
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3550 Battery HiTESTER Series
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indication shows the installation category (voltage proof category) of the product. UPS battery installations correspond to category I. The following four installation categories are defined. Installation category I: Signal levels, special equipment or part of equipment, communication equipment, electronic technology, etc. Installation category II: Local levels, tools, portable equipment, etc. Installation categor y III: D istrib ution le vels, f ixed installations Installation category IV Primary power levels, power lines, cable systems, etc. The 9287 and 9467 do not comply with CE marking requirements.
Q13. To which point of the battery
terminals should the pin type leads be applied?
A13. The resistance of battery terminals is higher
than commonly assumed and may differ depending on the contact point. Be sure to apply the pin tips always to the same position.
Q14. Which points should be
considered when measuring t he impedance of a battery pack?
A14. Many battery packs have protective circuitry
that is located between the battery and the external terminals. Some representative types of protection circuits are: (1)PTC element (Resistance rises when temperature rises.); (2)Diode; (3)Battery control IC. If only a PTC element is installed, the measured value will be the combined resistance of the PTC element and battery impedance. If diodes or a battery control IC are installed, correct impedance measurement is not possible.
Q15. How can the 3550 and 3551
measure the impedance of a battery that is being charged? Why can the 3555 not m easure the impedance of a batter y that is being charged?
A15. The 3550 and 3551 incorporate bandpass filters
which remove the influenc e of signals (such as UPS ripple voltage) other than the measurement frequency. The 3555 does not have such bandpass filter circuitry and can therefore not reliably measure a battery in a noisy environment such as in a UPS. The 9461 pin type lead s upplied with the 3 555 also has no barrier and is not allowed for measurements in hazardous equipment such as a UPS.
Q16. Can IEC R6 rechargeable ni-
cad batteries be used in place of IEC R6 alkaline batteries?
A16. Rechargeable ni-cad batteries can be used, b ut
the unit does not have a facility for recharging such battries. A separate charger is required.
Q17. How long can the unit operate
on six IEC R6 manganese batteries?
A17. 3550:about 2.5 hours
3551:about 1.5 hours
Q18. Is there a carrying cas e for the
AC adapter?
A18. The carrying case for the logic probe of the
8800 series has just the right size and can be used for the AC adapter.
Q19. Can the LCD be equipped for
backlighting?
A19. The LCD used in the 3551 is a reflective type
that cannot be adapted to backlighting.
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3550 Battery HiTESTER Series
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1
Transfer r ing Data Stored in the Me mor y of the 3550 or 3551 BATTERY HiTESTER to a Personal Computer
……….. 21
Windows NT4.0,Windows 95/EXCEL(Microsoft)
2
Technical Report: To Evaluate the Performance of Secondary Batteries Using Low Resistance Measurement Techniques
………… 23
Proceedings of 7th Shinshu meeting of SICE, p.p.1-4 (June 1996)
3
Allowable ripple voltage graph
………… 30
4
Block diagram for the 3550
………… 31
References
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3550 Battery HiTESTER Series
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Transferring Data Stored in the Memory of the 3550 and 3551
BATTERY HiTESTER to a Personal Computer
Although the data stored in the memory of the 3550 and 3551 BATTERY HiTESTERcan normally be output to a pri nter vi a a Centronics interface, it is a lso pos s ible to output the data to a personal computer b y using a Centr onics-RS- 232C converter unit. T he m ethod for doing s o is described below.
1. Equipment required
3550 or 3551 BATTERY HiTESTER
Personal computer (A DOS/V personal computer with Windows 95 installed is assumed.)
Centronics-RS-232C converter unit
9425 c onnecting cable, or a PC98 printer cable (for connecting the 3550 or 3551 to the
converter unit)
RS-232C cable (25-pin D-sub, crossed type)
RS-232C converter connector (25-pin/9-pin D-sub, straight type)
2. Equipment connections
Connect the equipment as shown in Fig. 1.
3. Equipment settings
(1) Centronics-RS-232C converter unit settings
Communications speed: 9600bps
Flow control: Hardware
Data length: 8 bits
Parity: none
Stop bits: 2
(For details on the functions set, refer to the converter unit manual.)
Transferring Data
Fig. 1 Equipment Connections
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3550 Battery HiTESTER Series
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(2) Personal computer settings Preparation
Use the communicatio ns software "HyperTerminal" that is included with Windows 95 to receive the data stored in the 3550 or 3551's memory. HyperTerminal can be found under "Accessories" in the Program menu accessed through the Start button.
(If "HyperTerminal" is not found, open "Add/Remove Applications" in the Control Panel, and then select the "Windows F iles" tab. Select "Com munications" for "File Type", click the "Details" button and then select "HyperTerminal" in order to install the software.
Fig. 2 Sample Display of a Retrieved File
(Japanese version shown)
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3550 Battery HiTESTER Series
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To Evaluate the Performance of Secondary Batteries Using Low
Resistance Measurement Techniques
Hiroshi Kutsukake - Kenji Kobayashi - Mitsuyoshi Tanaka
HIOKI E.E.CORPORATION
Abstract
As portable communications terminals for individuals (typified by devices such as cellular telephones and notebook computers), uninterruptible power supplies (UPSs), and other types of equipment that use secondary batteries become widespread, there is a growing need to be able to easily evaluate the per f ormance of secondary batteries. In this paper, we propose us in g th e internal resistance of a secondary battery as a guide for the evaluation of secondary battery performance. The internal resistance of a secondary battery is m easured with low resistanc e measurement techniques. Development of such a tester has already completed.
1. Introduction
The advances made in the miniaturization of electronic devices and in constructing the communications infrastructure have led to the rapid spread of compact, high-performance cordless equipment, such as portable telephones and notebook computers. In addition, uninterruptible power su pplies (UPSs) are being installed in facilities wh ere equipment cannot be allowed to stop o perating due to a power failur e. Sec ondary batteries that allow rep eated use through recharging ar e used in such c ordless equipm ent and UPSs , and dem and for such batteries is increasing as the market for such equipment expands. As a secondary battery undergoes repeated charge/discharge cycles, the capacity of the battery begins to decrease due to the effects of deterioration of the chemical matter inside the battery. Consequently, the continuous discharge time of the battery is reduced, which can hinder the operation of the equipment in which it is be ing used. This phenom enon is specif ically seen as deter ioration in the performance of the secondary battery.
Generally, in order to accurately evaluate the deterioration of a secondary battery, it is necessary to perform a charge/discharg e test and measure the capacity of the batter y. While this method can accurately determine the state of the secondary battery, the test takes a good deal of time to perform. Therefore, there is a need for a test method that can be used to evaluate the performance of a sec ondar y battery easil y and q uickly. Research now indicates tha t th er e is a correlation between a dec rease i n a seco ndar y batter y's capac it y and an increas e in its inter nal
Technical Report
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3550 Battery HiTESTER Series
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resistance.1 T herefore, we have develop ed a secondary batter y internal resistance tester that utilizes low resistance measurement techniques, and we measured internal resistances of secondary batteries with varying the state of those.
2. Overview of Secondary Batteries
A secondary battery is one that can be used repeatedly after recharging, and differs from primary batteries, such as manganese dry cells, that cannot be re-used once they are discharged. Another distinction of secondary batteries from primary batteries is that secondary batteries are capable of disc harging larg e current; as a resu lt, the y are used for equi pment that requires large current. Typical secondary bat ter ies ar e l ead-acid batteries and nickel cadmium (Ni-Cd) batteries. However, in order to address environmental concerns and the need for batteries that can power sm aller devices for longer periods of time, new nickel metal hydride (Ni-MH) and lithium ion (Li-ion) batteries were developed an d put into use; these b atteries are smaller, provide a large capacit y, and pose little dang er of polluting the environment. Table 1 shows characteristics of the secondary batteries described above. This table lists characteristics for each type of batter y, including volta ge per cell, the energ y density by m ass (Wh/kg) and the energy density by volume (Wh/l). In this table it is found that lithium ion batteries offer a high energy density and excellent performance. In practice, the type of secondary battery tha t is used in a particular application depends on the requirements of the equipment in which it will be used.
Table 1. Characteristics of Typical Secondary Batteries.
2
Energy density
Battery type
Voltage
Wh/kg Wh/l
Features (V/cell)
Lead-Acid 2.0 30 - 40 70 - 100 Low cost, high reliability
Nickel cadmium (Ni-Cd)
1.2 45 - 70 100 - 150
Capable of rapid charging/discharging, withstands excessive charging and discharging well
Nickel metal hydride (Ni-MH)
1.2 50 - 65 150 - 200
Superior characteristics compared to nicad batteries without polluting the environment
Lithium ion (Li-ion) 3.6 60 - 90 150 - 220 High energy density, high voltage
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3550 Battery HiTESTER Series
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R1 to R4: Lead and contact resistance
C: Coupling Capacitor
Fig. 1: Measuring Resistance with the AC
Four-terminal Method
3. Measuring the Internal Resistance of Secondary Batteries
3.1 Principles of Measurement
While the internal resista nce of secondar y batteries varies acc ording to the batter y type and its capacity, the figure generally ranges from several m to several hundred . Generally, in order to accurately measure a low resistance, the four-terminal method is used, in which a constant current is applied to the resistor that is being measured, and the resistance is calculated from the voltage dr op that is detected. For secondar y batteries, internal r esistance is measured by applying a constant alternating current, in order to avoid any effects from the DC voltage generated by the secondary battery. This method is called the "AC four-terminal method," and is distinguished from the DC four-terminal method in which direct current is applied. Fig.1 illustrates the principles of the AC four-terminal method. A constant alternating current "is" is supplied to the resistor that is being measured, and the voltage drop "
vis
" generated across the resistor is detected. In this case, "is" is always constant, regardless of the resistance being measured, the wiring resistance, and the contact resistance between the wires and the resistor being measured. In addition, because the input impedance of the voltmeter is sufficiently large, practically no current flows t o the v olt meter so i t is p o ssi bl e to detect only the voltage drop due to the resistor being measured. Therefore, it is possible, with this method, to measure the resistance without any effect from wiring resistance or contact resistance.
3.2 Equipment Configuration
Fig. 2 illustrates the configuration of the internal resistance measuring equipment. The AC four-terminal method s hown in Fig. 1 is bein g applied to a secondar y battery. When a 1k Hz constant alternating current "is" is applied to the secondary battery, the voltage drop "
vis
" due to the internal resistance of the b attery is detected. In order to obtain the volt age drop that is due only to the battery's internal resistance, a synchronous detector circuit is used. This circuit operates to filter out the effects of reactance within the secondary battery and in the test system without any effects from external noise. In addition, the DC terminal voltage "VT "of the secondary battery is a lso measured. Then the CPU switches be tween the internal resistance output "VR "a nd the term inal voltage output "VB "as the input to the A/D converter so t hat bot h the internal resistance of the battery and the terminal voltage can be displayed simultaneously.
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3550 Battery HiTESTER Series
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Fig. 3: Synchronous detection circuit
The synchronous detection method used with this measuring equipment is the detection method to determine the signal level of the in-phase components of a given signal and a reference signal.
Fig. 3 shows a simple example of the circuit configuration of a synchronous detection circuit. This circuit consists of a multiplier, which multipli es together the two signals, and an LPF that removes just the DC component of the output from the multiplier. Assuming "v1" as the voltage of the reference signal for the constant alternating current ge nerated by the m easuring eq uipm ent, and "v2"as the voltage of the sig nal in which synchronous detection is to be performed, these values can be expressed by the following equations:
v
1 =
Asin
ωt……..……(1)
v
2 =
Bsin
(ωt + θ)……(2)
where A and B are the amplitudes of "v1" and"v2" , respectivel y, and θ in equ ation (2) is the phase difference from "v1" due to reactance. If synchro nous detec t ion as s ho wn in F ig . 3 is performed using "v1" and "v2", the result can be expressed by the following equation:
v
1 x v2
= ABsinωt sin(ωt
+ θ
)
=
1/2
ABcos
θ - 1/2
ABcos(2ωt
+ θ)………(3)
Fig. 2: Configuration of Internal Resistance Measuring Equipment
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3550 Battery HiTESTER Series
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Fig. 4: Change characteristics of the
internal resistance in a Ni-cd battery while
recharging
The output of the multi pl ier c irc uit is g iv en b y equati on ( 3). In this e qua tio n, the first element is the DC voltage component, and the second element is the AC voltage component. By inputting these output voltages into the LPF, it is possible to obtain just the DC voltage component. Assuming the secondar y battery impedanc e Z is
Z = R + jX
(where R is the interna l res istance
and X is the reactance), and considering that R = Z
cos
θ, we find that the DC voltage component is the real part of Z, that is, the voltage drop caused by the internal voltage R. Therefore, by using the synchronous detection method, it is possible to measure internal resistance without any effect from the reactance component.
4. Experimental Results of Internal Resistance Measurement
4.1 Change Characteristics of the Internal Resistance in Secondary Batteries While Discharging
As a battery continually discharges itself in order to supply power to an external load, its capacity decreases and its terminal voltage drops. In order to find out how the internal resistance changes under these conditions, we used a prototype internal resistance tester to take measurements. After charging a var iet y of brand ne w bat tery packs (Ni-cd, Ni-MH, and lithi um ion) intended for use in portable telephones fully, we measured their internal resistance and terminal voltage as they were discharged at a constant current for one hour in an ambient temperature of 23°C. We set the constant alternating current "is" generated by the equipment at 5mA (rms). Figs. 4, 5, and 6 show the measured results for each of the batteries. While observing that the internal resistance increased as discharging continued in the case of both the Ni-cd and lithium ion batteries, we saw that the oppos ite was true in the case of the Ni- MH battery. When we tested other batteries of different capacities, we observed the same phenomenon, making it likely that this characteristic is dependent on the type of the battery.
Making a judgement based only on these results, it would seem that if a battery is required to output a large curr ent when it has little capacity remaining, the internal voltage drop in a Ni-cd or lit hium ion batter y increases and the actual output voltage drops, while in the case of a Ni-MH batter y it is ab le to outpu t a large current wit hout dropping in the outp ut voltage. The terminal voltage gradually decreased for all of the batteries.
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3550 Battery HiTESTER Series
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Fig. 5: Change characteristics of the
internal resistance in a Ni-MH battery
while recharging
(Discharge current: 950mA)
Fig. 6: Change characteristics of the
internal resistance in a Lithium Ion battery
while recharging
(Discharge current: 800mA)
Fig. 7: Temperature characteristics of the
internal resistance in a Ni-cd battery.
4.2 Temperature Characteristics of the Internal Resistance in Secondary Batteries
A battery's perform ance depends on the tem per ature of the env ironm ent i n whic h it is use d. It is reported that at low temperatures the amount of output current decreases, and at high temperatures the operatio nal life of the battery is reduced.
3
Then, after charging a variety of batteries (Ni-cd, Ni-MH, and lithium ion) fully , we measured their internal resistance and terminal voltage while changing t he ambient tem perature from -10°C to +40°C. F igs. 7, 8, and 9 s how the measured results for each of the batteries. While the change in terminal voltage was sm all for all of the batteries, we observed that as the temperature increased, the internal resistance of the Ni-cd and Ni-MH batteries decreased. On the other hand, the change in the internal resistance of the l ithium ion batter y was small. This means that a lthough the perf ormance of Ni-cd and Ni-MH batteries suff ers at low tem per atures s ince the amount of current that they can output is limited, a lithium ion battery can output a stable amount of current even at low temperatures.
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3550 Battery HiTESTER Series
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Fig. 8: Temperature characteristics of the
internal resistance in a Ni-MH battery.
Fig. 9: Temperature characteristics of the
internal resistance in a Lithium Ion battery.
5. Conclusion
We developed an int ernal r esistance tester in order meas ure internal resis tance as a means to quickly and easily evaluate the deterioration of secondary batteries. In this tester, low resistance measuring tec hniques based on the AC four -terminal method and the synchronous detection method were used. In our experiment using this tester to measure the internal resistance of a variety of types of secondary batteries, it was found that there are different characteristics for each t ype of battery. These differences may arise from differ ences in the materials of which the batteries are made. We did confirm that it was possible to use this tester to measure battery characteristics. Even if making a precise evaluation of the deterioration of a secondary battery on the bas is of th e r esu lts of a c har ge/ dis char g e tes t, it s h ou ld be p os s ible to provide information that can be used as a guide for determining the state of a battery by simultaneously measuring the internal resistance and terminal voltage. We now need to conduct long-term charge/dis charge cycle testing on secondary batteries in order to confirm in detail the relationship between the change in internal resistance and decrease in battery capacity due to battery deterioration, and also to confirm whether internal resistance is related to other parameters of secondary battery performance.
References
1. M. Yamanaka, et al: "O perational Life Indicator for Sea led Lead Storage Batteries," Yuas a Jiho, No. 72, p.p. 29 - 36 (April 1992).
2. M. Kanda: "Backup Battery Performance and Applications," Proceedings of '96 Battery Technology Symposium (April 1996).
3. T. Fukushima: Suitabilit y of Batt er ies f or Data- r e lat ed Equ ipment," Proceedings of '96 Battery Technology Symposium (April 1996).
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3550 Battery HiTESTER Series
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3550 and 3551 Allowable Ripple Voltage
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3550 Battery HiTESTER Series
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Page 32
HIOKI 3550 Series Battery HiTESTERs
User's Guide
Publication date: September 1999 Edition 1
Edited and published by HIOKI E.E. CORPORATION Technical Support Section
All inquiries to International Sales and Marketing Department
81 Koizumi, Ueda, Nagano, 386-1192, Japan TEL: +81-268-28-0562 / FAX: +81-268-28-0568 E-mail: os-com@hioki.co.jp URL http://www.hioki.co.jp/
Printed in Japan
• All reasonable care has been taken in the production of this
guide, but if you find any points which are unclear or in error, please contact your supplier or the International Sales and Marketing
Department at HIOKI headquarters.
• In the interest of product development, the contents of this
guide are subject to revision without prior notice.
• Unauthorized reproduction or copying of this manual is prohibited.
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