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Predicting Battery Performance Using Internal Cell Resistance Predicting Battery Performance
Using Internal Cell Resistance
Presented By:
Glenn Albér, President
Albércorp
990 South Rogers Circle, Ste. 11
Boca Raton, FL 33487
Tel: (561) 997-2299
www.alber.com
e-mail: alber@alber.com PREDICTING BATTERY PERFORMANCE
USING INTERNAL CELL RESISTANCE
Glenn Albér
President
Albércorp
990 So. Rogers Circle, Ste. 11
Boca Raton, FL 33487
INTRODUCTION
Predicting whether a battery system will perform its intended backup mission or not is a major challenge
faced by all battery users. There are very few battery users today who have absolute confidence in their
backup system. Ask any UPS or Telco operations manager if he or she would dare test a system by
deliberately disconnecting primary AC power!
The lack of confidence in battery systems has grown considerably since the introduction of VRLA
batteries. These maintenance-free wonders, promising 20 year life, have caught many a user by surprise,
typically failing in three to four years, and rarely lasting more than six years.
TEST SOLUTIONS
With todays technology, there is no reason why anyone should not have full confidence in their systems.
There are both test equipment and procedures available to accurately determine how a battery is going to
perform during an emergency. Unfortunately, though, a lot of battery users perceive performance testing
as both complicated and expensive.
Load Testing
The most reliable test to prove a batterys ability to perform is to load test the entire string. This test
should be performed with automated test equipment that can log data on all the individual cells while
subjecting them to a load current that matches the normal operating load. Such a load test performs a
100% integrity check and will identify any problems that exist with either the cells or the external
conductance path.
Resistance Testing
A new test, based on looking at a cells internal resistance, is proving to be a very reliable indicator of
state of health and should offer a cost-effective supplement/replacement solution to load testing.
The internal resistance of a cell is closely related to its capacity and can, therefore, be used to predict the
cells performance during a discharge. Even though there is a close correlation between a battery cells
internal resistance and its capacity, it is not completely linear. The resistance measurement is, therefore,
not used as a direct indicator of capacity, but, rather, as a warning indicator that signals if a cell has
deteriorated to a level that will affect the operating integrity of the system.
Field testing on all types of batteries has proven that, if a cells internal resistance increases to more than
25% above its known good base line value, that cell will fail a capacity test.
Page 1 UNDERSTANDING CELL RESISTANCE
To understand why cell resistance is a good indicator of a cells state of health, it is important to know:
* What a battery looks like internally.
* How resistance measurements are made.
* What parameters influence a cells resistance.
* What cell problems can be detected.
Internal Battery Parameters
The total conductance path through a cell includes the metallic or ohmic path, as well as the path that is
involved electrochemically, as illustrated in Figure 1.
The ohmic path includes the resistance of the terminal posts, the strap, the grid structure, and the grid to
paste connection. The electrochemical path includes the paste, electrolyte, and the separators. The
capacitor C
P
is the result of all the parallel plates with a dielectric between them. Capacitor value is a
substantial 1.3 to 1.7 farad per 100 ampere hours of battery rating, depending on battery design. The
inductance of the battery has been ignored, since its effect is negligible for the frequency range used by
todays battery instruments.
Looking closer at the equivalent circuit, it is obvious that the capacitive reactance (X
C
) effectively shunts
R
E
(the electrochemical part of the path), masking the changes that may take place in this part of the
path. This part of the path includes the paste and the electrolyte, which is where the energy is stored.
The resistance of the internal circuit path is what influences the capacity/performance of a cell and is,
therefore, the important parameter that needs to be measured.
Figure 1: Simplified Model of a Lead-Acid Cell.
Page 2 How Measurements Are Made
Instruments presently available use either an AC current injection method or a momentary load test (DC
measurement). AC injection instruments, better known as impedance or conductance meters, apply a test
signal through the battery and then measure the resulting AC voltage and current. The impedance reading
V/I varies with the frequency or the value of capacitive reactance X
C
, which in turn lowers
electrochemical resistance R
E
.
The problem with AC measurements is that they are susceptible to charger ripple currents and other
noise sources. Some instruments cannot be used while the battery is on-line (i.e., connected to the
charger and load in a normal full float operation). A particularly bad choice of test current frequency is
60Hz in the United States and 50Hz in the majority of the rest of the world, since this is the primary
charge ripple and noise source frequency. It is not uncommon to have RMS ripple currents in excess of
30A flowing through large UPS batteries.
The DC load test instruments, which measure resistance, subject the battery to a momentary load current
and then measure the instantaneous change in battery terminal voltage. Figure 2 shows what happens
when a battery is subjected to a load for a few seconds. The instantaneous drop when the load is applied,
or the instantaneous voltage recovery when the load is removed, is due to the internal resistance.
A resistance meter, such as the Albércorp Cellcorder, reads the current and cell voltage just prior to
removal of load and then measures the recovered cell voltage. The resultant resistance is simply Rcell =
V/I. Present day A/D converters can effectively measure the DC values while totally ignoring any AC
signals flowing through the battery at the same time; thus, this type of instrument is capable of operating
on-line even in high noise environments.
Figure 2: Typical Load Response of a 340Ah Plante Cell.
Page 3 What Parameters Affect Cell Resistance?
The following more common factors have an effect on a cells internal resistance:
Corrosion - As the grids and straps corrode, the metallic path is reduced and the internal resistance
increases.
Grid Growth - Grid growth associated with corrosion/battery aging causes the active material (paste) to
break loose from the grid structure, leading to a high resistance connection problem.
Sulfation - As part of the active material converts to lead sulfate, the paste resistance increases.
Dry Out - This condition, which is unique to VRLA cells, eventually causes a complete break in the
conduction path between adjacent grids.
Manufacturing - Manufacturing defects, such as bad lead burns and pasting problems, cause high
metallic resistance and capacity problems.
State of Charge - From a fully equalized condition, all the way to 20% partially discharged, there is very
little effect on a cells internal resistance. Lab testing that deliberately removed 20% of the stored energy
at a slow rate showed less than 3% change in resistance.
Temperature - High temperatures up to 102°F have very little effect on resistance (less than 2%). Low
temperatures do have some effect on resistance, but it is minimal until the electrolyte gets below 65°F.
What Problems Can Be Detected
Almost all cell problems that influence a cells ability to perform can be detected. The problems can be
divided into metallic and electrochemical problems. Figures 3, 4 and 5 clearly illustrate the impact on a
cells performance for each of these problems.
Figure 3: Typical Discharge Curve - Healthy Cell.
Page 4 The typical discharge curve of a battery is shown in Figure 3 above. Note that there is an instantaneous
voltage drop, due to the internal resistance of the battery, followed by an exponential voltage decay and
subsequent recovery, known as the coup de fouet phenomena, before the voltage stabilizes. Once the
voltage stabilizes, it is sustained by the electrochemical reaction which, as mentioned above, is fueled by
the available active ma