Sponsored by EA Elektro-Automatik

In at the moment’s fast-paced world the necessity to create faster, extra cell mechanical gadgets is steadily growing. One main technique for doing that is to interchange conventional gas-powered or plugged-in gadgets with battery energy. Batteries have grow to be smaller and more and more environment friendly in consequence. In an effort to sustain with the speed of technological development, the gear used to check superior know-how should even be superior, versatile and responsive. For these causes, the PSB bidirectional programmable DC energy provide collection by EA Elektro-Automatik is an ideal match for superior battery take a look at. The PSB bidirectional provide can seamlessly swap between offering energy to cost the battery and controlling the discharge of the battery. Specifying simply the appropriate gear, the next will present some primary steerage and concerns on the best way to construct a sturdy battery take a look at system to make sure the protection and correct functioning of all take a look at gear and batteries below take a look at. 

For a quick overview of the advantages of EA’s bidirectional programmable DC energy provide, watch this 2 minute video:

Vital Tools 

The very fact stays that it’s doable to check a battery with merely a DC energy provide and a few cables, however the danger of injury to you, the facility provide or the battery will probably be fairly excessive. The sensible and accountable strategy to take a look at a battery with a DC energy provide is to have the right monitoring and security gear to significantly cut back the danger of issues. The correct gear for creating a totally purposeful battery take a look at rig might be damaged down to three primary classes: management, monitoring and security. Principally, you must have a plan, a strategy to confirm all the pieces is working correctly and a backup if there’s surprising habits. 


Similar to the class implies, we should first have the ability to have full management over the battery checks that will probably be carried out. In an effort to try this we should management the next variables of cost/discharge present, voltage and energy. The entire answer for engaging in this can be a programmable DC energy provide paired with a programmable DC load. Much more splendid is having each of these features in a single unit just like the Elektro-Automatik PSB collection. The PSB is bidirectional, that means it could possibly supply (present) or sink (take up) present and regenerate that present to the native energy grid with as much as 95% effectivity. That’s proper, the digital load operate is regenerative, making this a really inexperienced answer on prime of minimizing take a look at gear house and funding. The PSB has the identical controls and options of a standard, programmable DC energy provide or digital DC load to simply management the cost/discharge voltage, present and energy going to and from the battery. 

A second and essential part of a battery cost/discharge system is a strategy to management the bodily connection of the PSB to the battery. That is vital for a few causes: to keep away from sparks when connecting the battery and the flexibility to shortly disconnect from the battery for security causes. A contactor, relay or swap are the standard decisions for this operate. If going for a contactor fashion connection, we advocate utilizing a hermetically sealed DC contactor. These have sealed contactors surrounded by an inert gasoline which permits the person to open or shut the contactor whereas below load. If a standard contactor is closed or opened below load the ensuing arc will sometimes weld the contacts closed. Subsequently to keep away from changing your contactor after every take a look at, ensure the one you select is rated for the DC voltage and present you propose to have current throughout your take a look at. 


The subsequent class of important gear fills the necessity to monitor the battery and gear throughout testing to make sure all the pieces is working correctly. The variables which should be measured are: battery polarity, battery temperature, voltage and present to/from the battery. Of those, battery polarity is crucial variable from the very starting. If a battery is related on to the enter terminals of a PSB the gadget might be immediately broken. For this reason the polarity verify is so vital. The battery take a look at system wants to have the ability to verify the polarity of the hooked up battery and forestall the connection to the PSB if the polarity is reversed. Later, within the security part, we are going to focus on a disconnect relay or contactor between the battery and the PSB. Determine 1 exhibits the location polarity checker and the protection contactor. In an effort to allow the protection contactor, the polarity checker should give a sign that the polarity is right. This can guarantee an operator can’t join a battery to the PSB except the polarity is right. 

Battery temperature also needs to be monitored to make sure the battery is working accurately and never heating up because of some drawback. The battery producer will have the ability to present protected and unsafe battery temperature ranges that can be utilized to set battery temperature alarms inside your battery take a look at system. Like battery temperature, battery cost present and voltage should be watched carefully to make sure correct operation throughout all checks. Each might be simply monitored from the PSB, the place you may as well program restrict and over protections to make sure the facility provide will monitor these values for regular ranges and instantly shut off the facility provide output if any variable will get uncontrolled. 

Supreme setup for prime energy battery charging and administration


Whereas all variables being monitored contribute to the protected testing of a battery utilizing a bidirectional programmable DC energy provide, there’s one part that’s important for the protection of the operator and the gear. That part is a DC contactor or relay that may isolate the battery from the remainder of the take a look at system. This relay, from the start of the take a look at acts like a gatekeeper from the battery to the facility provide. By utilizing the polarity verify to allow the contactor to shut ensures the battery won’t injury the facility provide by means of a spike in detrimental voltage. The second vital function of the relay or contactor is to disconnect the battery from the PSB if an issue happens, resembling an overtemperature situation on the battery below take a look at. The safety options for the PSB can ship a sign to open the contactor in roughly 10us to make sure the PSB and battery are shielded from one another. 

Optimizing the Battery Connection 

One final vital consideration for a battery take a look at system utilizing a PSB bidirectional DC energy provide is the method of connecting the battery to the facility provide. To do that correctly you must confirm the polarity of the battery connection is right and match PSB voltage to the battery terminal voltage. Figures 2 and three present these two configurations with the notice “sparks when connecting.” If there’s a distinction in voltage potential of greater than 1-200mV, a spark will happen when connecting the battery to the PSB. Batteries wish to discharge into one thing and when they’re related to the PSB they may discharge into the PSB which costs the enter capacitors. That fast burst of vitality ends in sparking and may injury the battery terminals. This could additionally injury the contacts of a contactor or relay related between the PSB and battery. Equally, when the battery is related with reverse polarity, you’ll get sparks when connecting the battery. As well as, the PSB will more than likely be broken because it can’t defend itself from a detrimental voltage on its output terminals. 

No setup: injury because of false polarity connection
No setup: injury because of connection to PSU with discharge caps (i.e. >200 millivolt distinction)


A very powerful factor to recollect is to plan out your take a look at process and setup earlier than trying to make use of a programmable DC energy provide for battery testing. A simplified strategy may fit for some, however most might want to defend their battery below take a look at, the DC energy provide and naturally the operator. Planning with 3 components in thoughts: management, monitoring and security will provide you with the very best probability at growing a whole and protected battery take a look at answer. Utilizing the EA PSB will additional simplify a system by having the ability to cost and discharge from one unit, avoiding the necessity to transfer the battery round or using a number of relays to change between an influence provide and cargo going to the battery. To get extra info on the PSB collection or to find out your ROI on the PSB collection, please go to:

e mail us at [email protected] or name 858-836-1300. 

Sponsored by Elektro-Automatik