Four-terminal measurement
Separate source and sense leads reduce the influence of test-lead resistance, while contact checking monitors the connection to the DUT.
TH2523 – Battery Tester for Internal Resistance and Voltage up to 300 V
For quality and life testing of cells and battery packs with AC internal resistance and DC voltage measurement.
The TH2523 series combines 1 kHz AC resistance measurement using a four-terminal method with simultaneous DC voltage acquisition. Two variants cover batteries with input voltages up to 65 V or 350 V and support fast single, sorting and long-term measurements.
Up to 350 V
TH2523 accepts input voltages up to 65 V; TH2523A extends the range for high-voltage batteries to 350 V.
Up to 50 measurements/s
Fast measurement supports short cycle times; internal, manual, external and bus triggering adapt the sequence to the application.
Sorting and analysis
Limit comparison, PASS/FAIL output, the Handler interface and statistical functions support repeatable test and sorting processes.
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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 is designed for combined measurement of battery AC internal resistance and DC voltage. A sinusoidal 1 kHz constant-current source excites the DUT, while the four-terminal method separates source and sense paths to minimise the influence of voltage drops in the test leads. The resistance display range extends from 1 µΩ to 3.5 kΩ. TH2523 uses two DC voltage ranges with input voltages up to 65 V, whereas TH2523A provides ranges up to 350 V for high-voltage batteries. In addition to R and V, the instrument measures impedance, reactance, inductance, capacitance, quality factor, dissipation factor and phase angle. Measurement rates up to 50 measurements per second, limit comparison, statistics, trace recording and multiple trigger and communication methods support laboratory testing and automated sequences. Operation uses a 4.3-inch colour display with 480 × 272 pixels.
Key benefits
Minimise lead resistance
The four-terminal method separates test current and voltage measurement, supporting very low resistance measurements down to the microohm range.
Measure AC internal resistance
A 1 kHz sine source with stepped constant currents measures AC resistance while reducing DC and thermoelectric contributions.
Check two quantities together
Measurement groups such as R-V combine resistance and voltage in one test; further groups cover impedance, LCR and phase parameters.
Short test cycles
Fast mode reaches up to 50 measurements per second. Front-panel, external and bus triggering coordinate the instrument with the process.
Sort directly
Nine configurable bins plus an OUT result, PASS/FAIL indication and Handler signals transfer the decision directly to a sorting or test system.
Evaluate production data
Up to 30,000 results can be analysed using mean, deviation, minimum/maximum, pass counts, Cp and Cpk.
Battery tester measurement principle
Via the LCUR, LPOT, HPOT and HCUR terminals, the TH2523 series applies a defined sinusoidal test current and measures the voltage drop on a separate path. Depending on the selected measurement group, magnitude and phase are used to determine resistance, impedance and LCR parameters. DC battery voltage can be acquired simultaneously as a separate result.
The constant-current levels of 100 mA, 10 mA, 1 mA, 100 µA and 10 µA are assigned to six resistance ranges. Automatic range selection simplifies work with changing DUTs, while HOLD keeps a selected range fixed for repeatable comparison measurements. REL, short correction and reference functions compensate for systematic influences of the measurement setup.
Important connection condition: The low test terminal is connected to earth. The DUT and test setup must therefore be checked for suitable grounding and potential relationships before connection.
Models, voltage ranges and measurement scope
| Model | DC voltage ranges | Maximum display value | Maximum input voltage | Typical use |
|---|---|---|---|---|
| TH2523 | 6 V / 60 V | 65.000 V | 65 V | Cells, modules and low-voltage battery packs |
| TH2523A | 30 V / 300 V | 350.00 V | 350 V | High-voltage batteries and larger packs |
| AC resistance range | Maximum display value | Resolution in 5-digit mode | Test current |
|---|---|---|---|
| 30 mΩ | 33.000 mΩ | 1 µΩ | 100 mA (±10%) |
| 300 mΩ | 330.00 mΩ | 10 µΩ | 100 mA (±10%) |
| 3 Ω | 3.3000 Ω | 100 µΩ | 10 mA (±10%) |
| 30 Ω | 33.000 Ω | 1 mΩ | 1 mA (±10%) |
| 300 Ω | 330.00 Ω | 10 mΩ | 100 µA (±10%) |
| 3 kΩ | 3.5000 kΩ | 100 mΩ | 10 µA (±10%) |
Further display ranges are 0.2 nH to 1 H for inductance, 0.001 to 9,999.9 for Q, −179.99° to 179.99° for phase angle in degrees and −3.1416 to 3.1416 in radians.
Accuracy, resolution and speed
Slow and medium modes display resistance and voltage with five digits, while fast mode uses four digits. The highest measurement rate is 50 measurements per second. Averaging from 1 to 255 measurements and a programmable delay from 0 to 60 s provide a trade-off between throughput and stable indication.
| Quantity | Condition | Basic accuracy for 6 months | Note |
|---|---|---|---|
| R, Z, X, L | SLOW/MED, 20 °C ±5 °C | 30 mΩ range: ±(0.3% of reading + 0.01% of full scale) | 1 µΩ resolution |
| R, Z, X, L | SLOW/MED, 20 °C ±5 °C | 300 mΩ to 3 kΩ: ±(0.1% of reading + 0.01% of full scale) | Additional temperature coefficient ±0.05%/°C outside the reference condition |
| DC voltage | SLOW/MED, 20 °C ±5 °C | ±(0.05% of reading + 0.01% of full scale) | Additional temperature coefficient ±0.005%/°C outside the reference condition |
The accuracy specifications require at least 30 minutes of warm-up and correctly shorted and corrected test leads. FAST mode has lower resolution and different accuracy specifications.
Measurement functions and programmable sequences
| Function | Operation | Benefit |
|---|---|---|
| 11 measurement groups | R, R-V, V, R-Q, L-Q, L-R, R-X, C-D, Z-θ°, Z-θr and R-C | Suitable primary and secondary parameter combinations for battery and component tests |
| REL and deviation | Direct display, absolute deviation or percentage deviation from a reference | Fast comparison with a golden sample, nominal value or initial condition |
| Contact and I/V monitor | Checks test-lead contact and displays signal quantities measured at the DUT | Reveals contact problems and makes measurement conditions visible |
| Trigger and delay | Internal, manual, external or bus trigger; delay up to 60 s | Synchronisation with a manual workstation, foot switch or test system |
| BIN/Compare | Nine limit sets with absolute or percentage evaluation, plus an OUT result | Direct classification and PASS/FAIL decision |
| Trace | Series with total time, interval, minimum/maximum display and automatic stop limits | Monitors changes over time without continuous operator input |
| Statistics | Analysis of up to 30,000 results including mean, standard deviation, Cp and Cpk | Evaluation of variation and process capability across a measurement series |
| File management | Up to 100 instrument configurations; USB storage of results as CSV and screen captures as GIF | Repeatable setups and external documentation of test results |
Typical applications
Button cells and individual cells
AC internal resistance and DC voltage are combined in a compact test for fast comparison and sorting of cells.
Battery packs and e-mobility
TH2523A acquires internal resistance parameters and DC voltage on high-voltage batteries with input voltages up to 350 V.
Development and lifetime evaluation
Trace measurements record resistance and voltage changes at defined intervals; stop limits can terminate the recording automatically.
Online UPS testing
A battery can be checked in situ for voltage and AC internal resistance when potential relationships and input voltage are suitable.
Supercapacitor ESR
The 1 kHz resistance and impedance functions support evaluation of the equivalent series resistance of supercapacitors.
Contact and component resistance
Six ranges, four-terminal measurement and automatic ranging enable AC resistance checks on contacts and general components.
Interfaces, storage and automation
| Interface | Availability | Function |
|---|---|---|
| 36-pin Handler | Standard | External trigger, handshake, BIN, PASS/FAIL and end-of-measurement signals for automated sorting and test systems |
| RS232C | Standard | Serial remote control from 9,600 to 115,200 baud |
| USB Device | Standard | USBTMC instrument communication or USBCDC virtual serial port |
| USB Host | Standard | Storage of configurations, CSV measurement results and GIF screen captures on USB media |
| GPIB | Optional | IEEE-488.2 communication and integration into existing GPIB test systems |
| SCPI | Command set | Programs measurement function, range, trigger, comparator, statistics, trace and file functions |
| Trigger input | Standard; foot switch optional | Starts individual measurements from an external signal or foot switch |
Installation and measurement preparation
| Characteristic | Requirement or value |
|---|---|
| Test connection | Four-terminal connection via LCUR, LPOT, HPOT and HCUR; the low terminal is earthed |
| Warm-up time | At least 30 minutes for specified measurement accuracy |
| Operating environment | 0 to 40 °C; up to 75% relative humidity |
| Dimensions without sheath | 215 × 87 × 335 mm (W × H × D) |
| Dimensions with sheath | 235 × 105 × 360 mm (W × H × D) |
| Weight | approx. 3.6 kg |
For precise results, use the designated four-terminal test cables, keep contact surfaces clean, and correctly short and correct the leads before measurement. Keep test leads away from strong electromagnetic fields.
TH2523 FAQ
What is the difference between TH2523 and TH2523A?
Both models have the same AC resistance ranges. TH2523 measures DC voltage in 6 V and 60 V ranges with inputs up to 65 V; TH2523A uses 30 V and 300 V ranges with inputs up to 350 V.
Why use four-terminal measurement?
Test current flows through one lead pair while a second pair senses the voltage drop. This greatly reduces the influence of lead resistance on low resistance values.
How fast does the TH2523 series measure?
Fast mode provides up to 50 measurements per second. Averaging, trigger delay and slower modes allow a trade-off between stability and process timing.
Can the instrument be automated?
Yes. Handler, RS232C and USB Device are provided, while GPIB is optional. SCPI commands control measurement function, ranges, trigger, comparator, statistics and trace.
How are batteries sorted?
Nine bins have individual upper and lower limits; an additional OUT result identifies values outside the bins. Handler signals pass the classification to the system.
What preparation is needed for accurate measurements?
Allow at least 30 minutes of warm-up. Then correctly short the four-terminal test leads and perform SHORT and REL correction.
Can TH2523A test high-voltage batteries?
Yes, provided the input voltage does not exceed 350 V and the earthed low test terminal is compatible with the setup. Its DC voltage ranges are 30 V and 300 V.
Can degradation and lifetime be tracked?
Trace records measurements over a defined total time and at selected intervals. Stop limits can terminate the measurement series automatically.
Can supercapacitor ESR be measured?
Yes. The 1 kHz AC resistance and impedance functions support supercapacitor ESR testing within the available measurement ranges.
Technical consultation and project enquiry
Selecting TH2523 or TH2523A depends on maximum battery voltage, expected internal resistance, required measurement speed and automation needs. Please also provide the DUT, cycle time, limit logic, interfaces and intended measurement setup.
