How the Battery Lab HRD Tester Works
A battery that passes formation, charging, and plate assembly can still fail to start an engine, hold a generator ready, or carry a fleet vehicle through its service interval. The failure is not always visible. Intercell welding faults, plate sulphation, and degraded active material all produce a battery that reads acceptable on an open-circuit voltmeter — and collapses under a real cranking load. The only way to confirm cranking capacity is to apply the load and measure what happens.
ELIND’s Battery Lab HRD Tester runs a constant current high-rate discharge on a single 12V battery at currents from 30A to 3000A, for a standard test duration of 6 to 10 minutes. During that discharge, it measures four parameters: on-load voltage, discharge current, test time, and Ampere-Hours (AH) delivered. Together, these four readings confirm whether the battery’s cranking capacity matches its rated specification under IS 5154 and IEC 60095-1 test conditions.
The test cycle is PLC-controlled and fully automatic. The operator sets the discharge current and end voltage before the test begins. The system applies the load, monitors voltage throughout the discharge, and stops automatically when the battery reaches end voltage or the set test duration expires. Total AH delivered and time to end voltage are displayed at the end of the cycle. Every result is logged on the unit and can be exported via USB to a spreadsheet for batch analysis, service records, or compliance documentation.
The unit is wheel-mounted, runs on single-phase 200–240V AC, and operates in QA labs, on factory floors, and at field service locations without requiring a fixed installation.
Battery Lab HRD Tester — Technical Specifications
| Parameter | Specification |
| Input Voltage | Single Phase AC, 200–240V |
| Input Frequency | 50 Hz |
| Battery Type | 12V Lead Acid (SLI, VRLA, Tubular) |
| Discharge Mode | Constant Current DC |
| Duty | Continuous |
| Discharge Current Range | 30–300A (HRD 12-300) | 60–600A (HRD 12-600) | 100–1000A (HRD 12-1000) | 150–1500A (HRD 12-1500) | 300–3000A (HRD 12-3000) |
| Current Accuracy | ±1% from 10% to 100% of full-scale range |
| Voltage Accuracy | ±1% |
| AH Measurement Accuracy | ±1% |
| Standard Test Duration | 6–10 minutes |
| End Voltage Setting | 6V to 15V (user-settable) |
| Display Parameters | Battery Voltage | Discharge Current | Test Time | AH Discharged |
| Data Recording | 25,000 rows | USB 2.0/3.0 compatible | Windows 7/10/11 |
| PC Interface | USB 2.0 / USB 3.0 |
| Enclosure | MS cabinet, powder coated | Wheel-mounted (portable) |
| Dimensions (approx.) | 1000mm × 600mm × 600mm (varies by model) |
| Weight (approx.) | 120–150 kg |
| Operating Temperature | 0–65°C |
| IP Rating | IP20 |
| Efficiency | >90% |
| Compliance Standards | IS 5154 (cranking performance) | IEC 60095-1:2018 Clauses 9.3 and 9.3.1 |
† Note on CCA testing at low temperature: IEC 60095-1 defines the CCA rating at −18°C. ELIND’s HRD tester conducts the discharge test at ambient temperature. If your test protocol requires low-temperature CCA certification, a temperature-controlled test chamber is needed alongside this instrument. Confirm the requirement with our technical team before specifying.
What the Battery Lab HRD Tester Measures
An open-circuit voltage reading tells you the battery is charged. It does not tell you whether the battery can deliver current under load. The HRD test at full discharge current is the only method that confirms a battery’s cranking capacity against its rated specification. ELIND’s Battery Lab HRD Tester produces three measurements that give the complete diagnostic picture.
On-load voltage throughout the discharge duration. A battery that holds above the set end voltage for the full test period has the internal impedance and plate capacity its rating specifies. One that drops to end voltage early has a measurable internal fault — intercell weld degradation, active material loss, or plate sulphation — regardless of what its OCV reading showed before the test. This is the primary test output for CCA conformance and battery acceptance decisions.
Total Ampere-Hours (AH) delivered. The AH count confirms how much energy the battery released at the test current. For batteries validated against IS 5154 or IEC 60095-1, this value anchors the conformance record. For QA teams grading incoming battery stock or evaluating reconditioning candidates, it separates batteries above 90%, 80–90%, and below 80% of rated capacity with a single test.
Time to reach end voltage. At a fixed discharge current, the time a battery holds above end voltage is a direct indicator of its condition. A battery that reaches end voltage at 4 minutes on a 6-minute test protocol is measurably weaker than one that holds through the full duration. This metric supports fleet maintenance scheduling and incoming battery grading where relative performance comparison is more important than exact AH precision.
Pre-Dispatch Testing
Every Battery Lab HRD Tester undergoes ELIND’s internal test standard before it leaves the Peenya campus. This covers:
- No-load and on-load voltage verification across the full rated current range
- Discharge current regulation accuracy verified from 10% to 100% of full-scale range
- End voltage cutoff confirmed at multiple user-set points against reference batteries
- AH measurement accuracy verified against a known reference load
- USB data export and spreadsheet compatibility confirmed — Windows 7/10/11
No unit is dispatched without passing all five checks.
Applications of the Battery Lab HRD Tester
Fitness certification at automotive service centres (Maruti, Hyundai, Bosch ASC). A service centre battery decision is binary: replace or retain. An OCV reading does not support that decision with enough precision to protect the service centre from a comeback. An HRD test at the battery’s CCA rating — typically 150A to 600A for standard passenger vehicle batteries — produces a discharge record in under 10 minutes. The technician retains a battery that passes and replaces one that does not, with a logged result to support the recommendation to the customer.
Genset battery validation in data centres and hospitals. A diesel generator starting battery that fails to crank the engine during a power outage is a safety event. Annual or quarterly CCA verification at the Cummins or Kirloskar genset’s rated cranking current confirms the battery will perform when it needs to. The test result log becomes part of the facility’s scheduled maintenance record — relevant for ISO 27001 data centre audits and NABH hospital accreditation requirements where backup power reliability is documented.
Fleet maintenance for commercial vehicles and mining equipment. Fleet operators at the scale of TCI, VRL Logistics, and mining operations at Vedanta and Coal India replace starting batteries on schedules that do not depend on actual battery condition. A lab HRD tester at the fleet workshop enables a test-before-replace protocol: batteries that hold above 80% of CCA rating continue in service; batteries that fall below threshold are scheduled for replacement before the next planned maintenance window. For a fleet of 200 trucks, this approach eliminates both premature replacement spend and unplanned roadside failure.
Defence vehicle battery qualification and DGQA acceptance testing. Battery acceptance for military vehicles — tanks, APCs, military trucks — requires a discharge test that generates a traceable conformance record per the procurement specification. ELIND’s HRD tester produces a logged CSV record showing OCV, on-load voltage, AH delivered, and pass/fail against the set parameters. For BEML, Tata Defence, and Ashok Leyland Defence supply programmes, this record supports DGQA inspection without requiring a third-party test lab.
Why Battery Labs and QA Teams Choose ELIND
Constant current electronic load bank — discharge accuracy held throughout the test. Resistive load banks are simpler but their resistance changes with temperature as the load bank heats during the test, which means the discharge current drifts. ELIND’s electronic load bank holds the set current within ±1% of full scale from the start of the test to end voltage. That accuracy matters when the result is used in a conformance record, an incoming quality grade, or a DGQA acceptance report. A test run at 580A instead of 600A is not the same test.
Wheel-mounted — operates in labs, on the factory floor, and at field service locations. The unit does not require a fixed installation or dedicated test bay. It connects to single-phase supply wherever a 200–240V socket is available. For battery manufacturers whose QA lab and production floor are not co-located, for service centres testing batteries at multiple workstations, and for fleet workshops where the test comes to the vehicle rather than the vehicle coming to the test, portability eliminates duplicate instrument investment.
25,000-row data record with spreadsheet export — no manual transcription. Every test cycle logs battery voltage, discharge current, test time, AH delivered, and the result automatically. The record exports to USB and opens directly in Excel. For QA managers maintaining incoming inspection records, for fleet managers scheduling replacement cycles, and for compliance teams generating batch conformance documentation, the test log is complete before the operator disconnects the battery. From the same Peenya campus since 4 decades — ELIND’s service team is reachable by phone when a question arises and by road if the unit needs attention.
- Set required discharge current.
- Set required end voltage.
- Start the test.
- The system discharges the battery at constant current.
- The PLC continuously monitors voltage and current.
- When end voltage is reached, the test stops automatically.
- Total AH discharged and total time taken are displayed.
Battery Lab HRD Tester — Available Models
ELIND’s Battery Lab HRD Tester is available in five discharge current ratings for 12V batteries. All units are built to order.
| Model | Discharge Current Range |
| HRD 12-300 | 30A – 300A |
| HRD 12-600 | 60A – 600A |
| HRD 12-1000 | 100A – 1000A |
| HRD 12-1500 | 150A – 1500A |
| HRD 12-3000 | 300A – 3000A |
Configuration Options
| Parameter | Options |
| Battery Voltage | 12V |
| Discharge Current | 300A | 600A | 1000A | 1500A | 3000A |
| Mounting | Wheel-mounted, portable |
| PC Software (Optional) | Real-time monitoring, automatic CSV storage, Windows 7/10/11 compatible |
| PC Interface | USB 2.0 / USB 3.0 |
Model designation: HRD 12-600 = Battery Lab HRD Tester, 12V battery, 600A maximum discharge current.
Standard lead time: 3–4 weeks from confirmed order and advance receipt. Minimum order quantity: 1 unit.
Get a Quote or Technical Datasheet for the Battery Lab HRD Tester
Share your battery type, AH rating, required discharge current, and any data logging or integration requirements. Send us an email or call us / drop us a message on WhatsApp for more details. A configured technical proposal will be returned within 48 hours.
Frequently Asked Questions
Q1: How do I choose the right discharge current model for my battery?
The correct model depends on your battery’s rated CCA or cold cranking ampere value and the test standard you are applying. For most standard passenger vehicle SLI batteries, the HRD test is run at the battery’s EN or SAE CCA rating — typically 150A to 600A. Commercial vehicle and larger inverter batteries will require 1000A or above. Heavy truck, mining, and traction batteries may require the HRD 12-1500 or HRD 12-3000. Share your battery’s model and rated CCA with ELIND’s technical team and they will confirm the correct discharge current and model designation.
Q2: What is the difference between the Battery Lab HRD Tester and the Battery HRD Production Line Tester?
The two instruments serve different test purposes and operate at different time scales. The Battery Lab HRD Tester runs a 6–10 minute constant current discharge that measures actual cranking capacity (AH delivered and on-load voltage) against the battery’s rated specification. It is the correct instrument for QA labs, service centres, fleet workshops, and defence acceptance testing where a complete CCA record per IS 5154 or IEC 60095-1 is required.
The Battery HRD Production Line Tester runs a 3–10 second discharge and is engineered for end-of-line 100% quality gates on a battery production conveyor. It detects intercell welding faults and OCV anomalies before batteries reach packaging — it does not generate a full CCA conformance record. If you need both end-of-line screening and lab-grade CCA validation, ELIND supplies both instruments and the test protocols complement each other.
Q3: What compliance standards does the tester support?
The Battery Lab HRD Tester supports the following standards:
- IS 5154 — Cranking performance test; the battery must hold ≥7.5V during a 30-second high-rate discharge at the rated current.
- IEC 60095-1:2018 Clause 9.3 — Cranking performance at standard temperatures.
- IEC 60095-1:2018 Clause 9.3.1 — Standard cranking test: hold ≥7.5V at 10 seconds; continue to 30 seconds holding ≥7.2V.
Note: IEC 60095-1 defines the CCA rating at −18°C. ELIND’s tester conducts the discharge at ambient temperature. If your test protocol requires low-temperature CCA certification, a temperature-controlled chamber is needed alongside the tester. Confirm this requirement at enquiry stage.
Q4: Does the lab HRD tester log test data, and in what format?
Yes. Every test cycle is automatically recorded. The data log captures battery voltage, discharge current, test time, AH discharged, and the test result. The log stores up to 25,000 rows on the unit and exports via USB pen drive in spreadsheet format, compatible with Excel on Windows 7, 10, and 11. For customers who need real-time monitoring during the test, the optional PC software provides a live dashboard and automatic CSV storage at a pre-set recording interval.
Q5: How long does installation and commissioning take?
The Battery Lab HRD Tester does not require a fixed installation. It connects to a single-phase 200–240V supply and is operational as soon as the operator has set the discharge current and end voltage on the controller. The operating manual provided with each unit covers parameter setup, test procedure, and data export. For most customers, commissioning support is handled over a video call. On-site commissioning visits are available on a chargeable basis and are arranged at order stage for customers outside Bengaluru.
Q6: What is ELIND’s service arrangement for plants outside Bengaluru?
ELIND’s service team operates from the Peenya campus in Bengaluru. Because ELIND designs and manufactures this equipment in-house, the majority of faults can be diagnosed and resolved remotely via phone or video call — without waiting for a third-party service agent. Where a physical visit is required, ELIND arranges this on a case-by-case basis. Spare parts are held in stock at the Peenya facility and can be dispatched by courier to any location in India within standard transit times.