Types of tests done on heavy-duty battery:

For dry/ Gel type battery:

1. Load Voltage Test:
The condition of the battery is tested where the battery voltage is
subjected to reduce when it is put under load (42A coil acting as load). The voltage
difference values without-load and with-load are noted down using which the condition
and the battery’s quality is been observed.
The duration upon which the battery is kept be at load during testing is about 5sec-7sec
for a portable load-voltmeter (42A coil load present internally).
Usually voltage difference values without-load and with-load obtained must be around
2V.
Load Voltage test is the common test performed for all types of batteries.

For Wet/ Acid type battery:

1. Load Voltage Test:
The condition of the battery is tested where the battery voltage is
subjected to reduce when it is put under load (42A coil acting as load). The voltage
difference values without-load and with-load are noted down using which the condition
and the battery’s quality is been observed.
The duration upon which the battery is kept be at load during testing is about 5sec-7sec
for a portable load-voltmeter (42A coil load present internally).
Usually voltage difference values without-load and with-load obtained must be around
2V.
Load Voltage test is the common test performed for all types of batteries.

2. Specific-Gravity Test:
The battery’s state of charge can be measured by the knowledge of
the electrolyte’s specific gravity. Since Wet battery’s contain 15:7 ratio of distilled water
and sulfuric acid mixture (ie; 65% distilled water and 35% sulfuric acid), the specific
gravity of the electrolyte changes with respect to the charge and discharge content of
the battery, inturn affecting the performance and its efficiency of power delivery.
A Hydrometer is used as a measuring tool for the measurement of the electrolytes
specific-gravity.
The Specific-Gravity test also specifies the quality of the electrolyte. Depending on the
results obtained; sulfuric acid or distilled water to be added is decided.
3. Shedding Test:
Spontaneous chemical reaction of Lead plates and sulfuric acid in the
battery responsible for the DC power generation leads to oxidation of lead plates
further forming sulfation of lead between plates. The oxidized Lead particles settle at
the bottom the battery which cannot be determines visually. Therefore, whenever a
forced circulation(stirring) of electrolyte is possessed in each cell, the lead particulates
settled at the bottom tend to get composited with electrolyte, then which the
particulates can be visualized throughout the electrolyte.
Hence Shredding test is performed to verify the quantity of sulphation possessed by the
lead plates during the battery’s overall use. Sulphation of lead plates occurs due to
extensive heavy-use and ageing in time of the battery.
Overall, Sulphation gives on to depletion of Lead plates, when in time of total depletion
may lead to Short-circuit of plates giving rise to exponential rise in temperature and fire
hazards internally, post-processing to leakage, external damage and even extensive
burning of the battery. Making the important test to be done if the age of the battery is
more than 3-4 years in use.
Testing/ Measuring instruments used for testing:
1. Load-Voltmeter [Load Voltage Test]:

2. Hydrometer [Specific-Gravity test]:

3. Lamp-Load Discharge: