Best Practice Procedures for Battery Maintenance and Testing

Best practice procedures for battery maintenance

Industrial batteries are subject to normal and abnormal ageing and occasional manufacturing defects.  

Battery tests and maintenance programs are essential to ensure reliability.

Several battery testing techniques are available both on-site and remotely, each with different costs, as well as with technical strengths and/or weaknesses.  

Considering the importance of the site, the age and size of the battery, and the results of previous tests, it is possible to implement maintenance schedules and testing procedures dynamically during the battery life cycle, to enhance the life and performance of permanently installed lead-acid batteries used in power back-up systems.  

The Institute of Electrical and Electronics Engineers (IEEE) standard 450-2010 – IEEE, sets out the recommended practice for maintenance, testing, and replacement of vented lead-acid batteries for stationary applications. Following these practices assures the best practice standards for UPS battery maintenance. 

This recommended practice provides guidance for determining when batteries should be replaced, and it is applicable to fixed standby service applications, where a charger keeps the battery fully charged and supplies DC loads in a power outage situation.  

Regardless of whether it is a data centre, industrial facility or utility, adherence to following this standard is highly recommended 

Adel System’s CBI series DIN rail mount DC UPS power supplies act as an integrated battery tester inside a battery charger.  

Industrial UPS


It is an effective concept that can work with all types of batteries.  

Let’s look at this technology and talk about Adel’s Battery Care Concept. 

The Adel System CBI range of DC UPS power supplies can carry out the following checks on your batteries: 

Diagnostic Battery Checks During Operation 



Accidental disconnection of cables 

Detects any accidental disconnection and responds by cutting off the output power. 

Battery not connected

If the battery is not connected the battery output is disabled. 

Impedance testing of connection cables

During trickle charging, the resistance on the battery connection is checked every 20 seconds. This is to ensure the cable remains securely connected.

Battery in open circuit or sulphated

In trickle charging mode the internal impedance of the battery is checked every two hours (if enabled).

Reverse polarity check

If the battery is connected with the polarity inverted, the CBI is automatically protected.

Battery connection test

The voltage is checked to ensure the correct type of battery is being used.

End of charge check

When the battery is fully charged, the Adel System CBI unit automatically switches to trickle charging mode.

Short circuit 

Detects any batteries that may have an internal short circuit. 

All the above functions, plus the multi-stage charging algorithms combine to provide an effective battery care management system. Notification of any problems can be made via 2 alarm relays, which are a feature on every CBI model. 

The larger Adel System CBI DC UPS power supplies include a Modbus (or optional CANbus) interface, which can be used in conjunction with the Adel System DPY351 controller to transfer data to a PLC or control system, via a built-in Ethernet gateway.

Adel DPY351 UPS & Battery Charging Controller


The DPY351 can also provide an alarm signal output to a PLC or controller, when the main power source fails and the battery backup is activated.  

For further information on Adel System’s DIN rail mount DC UPS power supplies, please contact ADM on 1300 236 467. 

Adel System

24 July 2020