Combined measurement parameters
Resistance, voltage, impedance, reactance, inductance, phase angle and further parameters can be displayed individually or in combinations.
TH2523 – Battery Tester for Internal Resistance and Voltage Measurements up to 300 V
For fast quality, development and lifetime testing of individual cells, battery packs and energy-storage devices.
Four-terminal measurement separates the current and voltage paths, reducing the influence of lead and contact resistance. A sinusoidal 1 kHz test signal determines AC internal resistance while the DC voltage of the device under test can be acquired simultaneously.
Contact inspection
Test-contact verification detects faulty connections between the DUT, measurement leads and test fixture.
Comparison and statistics
Limit comparison, binning, trace curves and statistical values support quality control and production testing.
Automated integration
RS232, USB, Handler, external triggering and optional GPIB support integration into automated test stations.
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ART. NO.
Description
TH 2523
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Description
TH2523 – Präzisions-Batterietester für AC-Innenwiderstand und DC-Spannung, 1 µΩ–3,5 kΩ, 100 µV–65 VDC, 1 kHz, bis 50 Messungen/s
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Battery Tester
TH2523A
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Description
TH2523A – Präzisions-Batterietester für AC-Innenwiderstand und Hochvolt-DC-Spannung, 1 µΩ–3,5 kΩ, 100 µV–350 VDC, 1 kHz, bis 50 Messungen/s
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Battery Tester
TH2523 battery tester overview
The TH2523 series combines AC internal-resistance measurement with DC battery-voltage acquisition. The TH2523 provides 6 V and 60 V ranges, while the TH2523A extends the measurement capability to 30 V and 300 V. Six impedance ranges from 30 mΩ to 3 kΩ cover low-resistance lithium cells as well as complete battery packs. The sinusoidal 1 kHz test signal uses constant currents from 10 µA to 100 mA depending on the selected range. Four-terminal measurement reduces the influence of test leads. In addition to individual measurements, the instruments provide limit comparison, binning, trace recording, statistical analysis and data export. Typical applications include development, incoming inspection, quality assurance, production, lifetime evaluation and automated end-of-line testing.
Key benefits
Fine resistance resolution
Minimum resolution of 1 µΩ supports evaluation of low-resistance cells, contacts and electrical joints.
Precise voltage display
Voltage display starts at 100 µV, allowing internal resistance and open-circuit voltage to be evaluated together.
Fast production measurement
Up to 50 measurements per second reduce cycle times in sorting, production and end-of-line systems.
Defined AC test signal
The sinusoidal constant-current source measures AC internal resistance at a frequency of 1 kHz ±0.2 Hz.
Kelvin measurement principle
Separate drive and sense leads reduce measurement errors caused by cables, contacts and connection resistance.
Integrated statistics
Up to 30,000 results can be evaluated for mean, deviation, limit distribution and Cp or Cpk values.
Battery internal-resistance and voltage measurement principle
AC internal resistance is measured using a sinusoidal constant current. The resulting voltage drop is acquired through separate sense leads and used to determine impedance. The DC voltage of the device under test can be monitored at the same time.
AC internal-resistance measurement
The 1 kHz test current provides rapid evaluation of the dynamic internal resistance of cells and battery packs.
DC voltage measurement
Two model-specific voltage ranges measure the open-circuit or terminal voltage of the connected energy-storage device.
Signal-level monitoring
Voltage and current at the DUT can be displayed in addition to the selected primary and secondary parameters.
Automatic range selection
Impedance and voltage ranges can be selected automatically or held for repeatable test conditions.
Models and technical specifications
The TH2523 is suitable for individual cells and low-voltage battery packs. The TH2523A extends the voltage range for high-voltage batteries and larger series-connected packs.
| Specification | TH2523 | TH2523A |
|---|---|---|
| DC voltage ranges | 6 V and 60 V | 30 V and 300 V |
| Voltage display range | 100 µV to 65 V | 100 µV to 350 V |
| Maximum permissible input voltage | 65 V | 350 V |
| AC impedance ranges | 30 mΩ, 300 mΩ, 3 Ω, 30 Ω, 300 Ω and 3 kΩ | 30 mΩ, 300 mΩ, 3 Ω, 30 Ω, 300 Ω and 3 kΩ |
| Test frequency | 1 kHz ±0.2 Hz | 1 kHz ±0.2 Hz |
| Basic resistance accuracy | 0.1% | 0.1% |
| Basic voltage accuracy | 0.05% | 0.05% |
| Maximum measurement speed | 50 measurements/s | 50 measurements/s |
Measurement ranges and test currents
Test current is adapted to the selected impedance range. Low resistance is measured using higher current, while smaller currents are applied to higher-resistance devices.
| Impedance range | Minimum resolution | Constant current |
|---|---|---|
| 30 mΩ | 1 µΩ | 100 mA |
| 300 mΩ | 10 µΩ | 100 mA |
| 3 Ω | 100 µΩ | 10 mA |
| 30 Ω | 1 mΩ | 1 mA |
| 300 Ω | 10 mΩ | 100 µA |
| 3 kΩ | 100 mΩ | 10 µA |
| Parameter | Display range |
|---|---|
| Resistance, impedance and reactance | 1 µΩ to 3.5 kΩ |
| Inductance | 0.2 nH to 1 H |
| Quality factor Q | 0.001 to 9,999.9 |
| Phase angle in degrees | −179.99° to +179.99° |
| Phase angle in radians | −3.1416 to +3.1416 |
Measurement speed and triggering
Multiple speed settings balance short cycle time against stable measurement display. Measurements can be continuous, manually initiated, externally triggered or started by the test-system controller.
| Function | Implementation | Practical benefit |
|---|---|---|
| FAST | Up to 50 measurements/s | Short cycle times in automatic sorting and production testing. |
| MED | Approx. 10 measurements/s | Balanced measurement speed and display resolution. |
| SLOW | Slower measurement for stable and higher-resolution display | Suitable for development, analysis and manual quality inspection. |
| Internal trigger | Continuous automatic measurement | Ongoing monitoring of a connected DUT. |
| Manual trigger | Single measurement using the TRIG button | Controlled data acquisition in laboratory operation. |
| External trigger | Triggering through Handler, trigger input or optional foot switch | Synchronisation with a fixture, sorter or operator. |
| Bus trigger | Measurement initiated through a communication interface | Timed acquisition within automated test software. |
| Averaging | 1 to 255 measurements | Reduction of measurement variation for sensitive devices. |
Measurement functions and evaluation
| Function | Implementation | Application |
|---|---|---|
| Measurement parameters | R, V, R-V, R-Q, L-Q, L-R, R-X, C-D, Z-θ°, Z-θr and R-C | Selection of individual or combined battery and impedance parameters. |
| Direct and deviation display | Direct value, absolute deviation and percentage deviation | Comparison with a reference or nominal value. |
| REL function | Relative measurement against a stored reference value | Compensation of baseline values and systematic offsets. |
| Short correction | Short-clear operation with the four-terminal fixture shorted | Reduction of fixture and lead influence. |
| Comparator and binning | Up to 10 bins with upper and lower limits, pass/fail and audible indication | Automatic classification of cells and components. |
| Trace function | Time curve with interval, total duration, limits and automatic stop | Observation of discharge, drift and ageing behaviour. |
| Statistical evaluation | Mean, maximum, minimum, standard deviation, Cp, Cpk and limit counters | Process evaluation and quality monitoring during batch measurement. |
| File management | Up to 100 configurations plus measurement data and screenshots on USB storage | Rapid changeover between test tasks and external documentation. |
Typical applications
Combined battery internal-resistance and voltage testing supports evaluation of performance, contact quality, ageing and production variation.
Button cells and individual cells
Internal resistance and cell voltage are measured together for incoming inspection, sorting, quality control and development comparisons.
Battery packs and modules
Higher voltage ranges support testing of complete series connections and preassembled energy-storage systems.
Batteries for automotive and e-mobility
Cell, module and contact resistance supports evaluation of traction batteries, e-bike packs and electrical interconnections.
Ageing and lifetime analysis
Trace and statistical functions document changes in voltage and internal resistance during degradation and cyclic stress.
UPS and standby batteries
Electrical condition assessment supports maintenance and inspection of batteries used in uninterruptible power supplies.
Supercapacitors and components
Resistance, impedance and ESR-related parameters support testing of supercapacitors and general electronic components.
Contact and connection resistance
Four-terminal measurement evaluates welds, contacts, cables, connectors and low-resistance cell interconnects.
Production and end-of-line testing
Fast measurement, limit comparison and Handler signals support automated pass/fail and sorting processes.
Interfaces, data storage and automation
The TH2523 series can be operated locally or integrated into PC-controlled, sorting and production systems through several interfaces. Remote operation uses SCPI commands for measurement functions, triggering, limits, statistics and trace procedures.
| Interface or function | Implementation | Integration benefit |
|---|---|---|
| RS232C | Baud rates from 9,600 to 115,200, eight data bits, one stop bit, no parity | Serial remote control and measurement transfer to PC or PLC systems. |
| USB Device | USBTMC-USB488 or USBCDC virtual COM port | Direct PC connection through a measurement protocol or virtual serial interface. |
| USB Host | Front-panel connection for USB storage devices | Storage of CSV measurement data, configurations and screenshots. |
| GPIB | Optional, IEEE 488.2, adjustable bus address | Integration into existing laboratory and ATE systems with GPIB infrastructure. |
| Handler | 36-pin interface with bin, pass/fail, trigger, index and end-of-measurement signals | Connection to automatic sorters, fixtures and production equipment. |
| External trigger | Trigger input and optional foot-switch operation | Synchronised single measurement initiated by a fixture or operator. |
| SCPI | Remote commands for parameters, ranges, triggering, comparator, statistics and trace | Implementation of customer-specific automated procedures. |
| LabVIEW connection | Instrument access through the USBTMC interface | Integration into graphical measurement, test and automation software. |
Installation and infrastructure
| Installation specification | Requirement or value |
|---|---|
| AC voltage ranges | 100 to 120 V AC or 198 to 242 V AC |
| Line frequency | 47 to 63 Hz |
| Power consumption | Max. 15 VA |
| Operating temperature | 0 to 40 °C |
| Relative humidity | ≤90% RH |
| Dimensions without protective enclosure | 215 × 87 × 335 mm |
| Dimensions with protective enclosure | 235 × 105 × 360 mm |
| Weight | Approx. 3.6 kg |
| Warm-up time for accurate measurement | At least 30 minutes |
| Cooling | Air cooling; side ventilation openings must remain unobstructed. |
Safe operation and measurement setup
| Specification | Requirement or note |
|---|---|
| Protective earth | The instrument must be operated with a reliable protective-earth connection. |
| Low measurement terminal | The low test terminal is connected to ground and must be considered when designing the test circuit. |
| Maximum input voltage, TH2523 | 65 V |
| Maximum input voltage, TH2523A | 350 V |
| Test fixture | Suitable four-terminal measurement leads and clean contact surfaces are required for repeatable results. |
| Short correction | The fixture must be shorted correctly according to the four-terminal arrangement before short-clear operation. |
| Electromagnetic environment | Measurement leads should be kept away from strong electromagnetic fields and interfering power cables. |
| Service access | The enclosure may only be opened and serviced by qualified personnel. |
Before connecting the DUT, verify the instrument model, voltage range, polarity and maximum permissible input voltage. Suitable touch-protected fixtures are particularly important when using the TH2523A with high-voltage batteries.
TH2523 series FAQ
What is the difference between the TH2523 and TH2523A?
The TH2523 provides 6 V and 60 V ranges. The TH2523A provides 30 V and 300 V ranges for high-voltage batteries and larger packs.
Does the instrument measure DC or AC internal resistance?
Internal resistance is measured using a sinusoidal 1 kHz AC test signal. The DC voltage of the DUT is acquired separately.
Why is four-terminal measurement used?
Separate current and sense leads reduce the influence of cables, clamps and connection resistance on the result.
How fast can measurements be performed?
Up to 50 measurements per second are available in the fast measurement mode.
Can cells be sorted automatically?
Yes. Comparator, binning and Handler functions provide limit evaluation, pass/fail signals and control of automatic sorting systems.
Can ageing curves be displayed?
Yes. The trace function records selected parameters over time and can stop automatically when defined limits are reached.
Which interfaces are available?
RS232, USB Host, USB Device and Handler are provided. GPIB is available as an option.
Can measurement data be stored externally?
Yes. Measurement values can be saved as CSV files and screenshots can be stored on a USB storage device.
Technical consultation and project enquiry
Are you planning a test station for individual cells, battery packs, high-voltage batteries, contact resistance or supercapacitors?
ET System supports model selection, four-terminal fixture design, limit definition and integration into automated production and quality systems.
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