Automated vs. Manual BatteryTesting

The Battery Council International Standard defines a failed or inefficient battery or cell as one that fails to supply at least 80 percent of its rated six-hour capacity. The BCI Standard insures that all testing is performed to a common denominator and defines the minimum accepted industry standard of what constitutes a viable versus a failed battery.

Comparison Summary

Manual TestingAutomated MCBA Testing
Takes several hours of technician’s time.Takes less than 10 minutes of technician’s time.
Can only perform one test at a time.Performs multiple tests simultaneously.
Data is recorded by technician and may not be accurate to provide a sound basis for warranty claims or budgets.
Data is recorded automatically and accurately with little or no technician input.
Process is labor-intensive and not cost-effective to use as a preventative tool.Very effective as part of a preventative maintenance program to optimize efficiency.
Only provides insight on the current test results with no established battery profile to aid in decision making.Provides comprehensive data management to quickly determine which batteries need to be budgeted for replacement or repair.
More likely that substandard batteries are inadvertently accepted for continued use.Accurate data identifies defective cells for sound maintenance decisions.

Testing Time

There is no shortcut to the time the BCI Standard test requires.  However, automated testing removes about 90 percent of the labor associated with manual testing.

Manual TestingAutomated MCBA Testing
Total Testing Time: up to 6 hoursTotal Testing Time: up to 6 hours
Labor Hours: 1-2 hours (setup, recording, and administrative time)
Labor Hours: less than 10 minutes setup time
Reporting is automatic

Setting up the Test

Using the BCI recommended capacity test, the only way to know what is going on inside the battery cells is via a correctly performed capacity/load test.

Manual TestingAutomated MCBA Testing

Load test involves charging and cooling the battery and using a resistive style load bank to discharge.

  • Technician measures and records the beginning voltage of each cell using a voltmeter, and the specific gravity and temperature of each cell determined.
  • Then, connects the battery to the discharge load bank and sets the current.

Using a fully charged and cooled battery.

  • Technician uses a digital hydrometer to read and record the specific gravity for each cell.
  • Attaches numbered cell-scanner leads to each cell and inserts a temperature probe into the battery.
  • The battery load cable is attached.
  • The battery serial number/file number is located on the computer screen, highlighted, and accessed by pressing “Enter” (using Windows-based software).

The analyzer will perform a self-diagnosis to insure that all cell leads are attached.  The system will then call for the hydrometer (specific gravity) readings. These are downloaded and incorporated into the test via an infrared port.

Running the Test

Manual TestingAutomated MCBA Testing

Discharge begins at the designated current draw.

  • Every 30 minutes, the technician reads the voltage and records it for each cell and the total battery.
  • Because resistive-style load banks cannot maintain a constant current draw, the current must be reset at each reading to try to simulate the proper demand on current as closely as possible.
  • When total voltage reaches 1.8 volts times the number of cells, readings must be taken on all cells every five minutes until either the total battery reaches its predetermined failure point or six hours, whichever comes first.

At this point, the test operator is free to go about his business performing other tasks.

  • The capacity test, scheduled to run up to six hours or to the battery voltage failure point, will shut off automatically when either of those conditions occurs.
  • At the end of the test, visual and audible alarms will alert the operator.

Reporting Test Results

Manual TestingAutomated MCBA Testing
  • Technician compiles all data
  • Performs calculations to determine load capacity test results and viability of the battery.
  • Manually documents findings.  
  • Using the onboard inkjet printer, test results are obtained to determine the viability of the battery.
  • In order to minimize manual record keeping, all tests are archived within the MCBA to be viewed and printed anytime for repair or replacement decisions.
  • Each test is automatically summarized  to be compared to previous tests and other batteries tested or ranked according to capacity percentages.
  • Budgetary decisions based upon accurate data

< Read about Inventory ManagementRead about BCI Testing Standards >
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