Empowering Safety and Reliability: Practical Testing Methods and Efficient Solutions for Battery Energy Storage Systems

With the shared objective of achieving net-zero emissions by 20501, governments and companies worldwide are diligently collaborating to drive advancements in energy storage technologies. Their aim is to develop efficient energy storage systems that optimize energy utilization. This commitment has led to a flourishing market for energy storage, with the global distributed energy storage system projected to reach USD 12.44 billion by 20322. In energy storage systems, batteries play a central role as they are one of the most widely used technologies, commonly referred to as Battery Energy Storage Systems (BESS).

Battery Energy Storage System Overview

BESS encompass a range of technologies that enable the efficient storage energy for later use, ensuring a balance between electricity supply and demand. A comprehensive BESS comprises several essential components. Firstly, temperature control systems are employed to maintain optimal operating conditions for batteries. Fire extinguishing systems are implemented as critical safety measures. Power conversion systems (PCS) are utilized to convert stored energy into the desired output. Energy management systems (EMS) are responsible for monitoring and controlling energy flow within the system. Battery management systems (BMS) regulate battery performance and ensure safety. Lastly, the batteries are organized and interconnected to form battery modules, which are then integrated with BMS to create a complete battery system. The quality of batteries directly impacts the risks associated with BESS, including fire, explosion, and electrical shock. In this issue, let's learn more about the electrical safety testing methods and efficient solutions for batteries and Battery Management Systems (BMS) that can ensure BESS’ safety and reliability.

Recognizing the importance of safety, the IEC 62933-5-2 (Safety Requirement for BESS) places significant emphasis on BESS safety through a series of testing requirements. One critical test is the Hipot test, which evaluates both the battery module and BMS. This test is essential for identifying potential faults and ensuring optimal performance of these components to ensure their safety and reliability.

Battery Module and BMS Testing Methods

The specific Hipot testing methods may vary depending on whether the battery modules or the BMS are being tested. Typically, during the testing process, battery modules undergo a Hipot test with a voltage range of 1 to 3kVAC, determined by the working voltage. The test voltage is applied from the positive terminal to the chassis and from the negative terminal to the chassis. The duration of this test is usually around 60 seconds.

The BMS require higher testing voltages, potentially reaching up to 3.8kVAC. It is crucial to perform Hipot tests on various critical points, including the input terminals connecting the energy source to the chassis, as well as the communication terminals. Similarly, the output terminals linking the battery's positive and negative terminals to the chassis and the communication terminals should also undergo the Hipot test. The duration of this test is also 60 seconds.

Ikonix Efficient Solution on BESS

When it comes to conducting electrical safety tests on batteries and BMS, many customers encounter challenges at multiple testing points. The complexity and abundance of these points can lead to errors and disruptions during the production process. To address this issue, it is crucial to automate the testing procedure and minimize the likelihood of mistakes. Additionally, efficient recording of results from these multiple testing points is essential for maintaining accuracy and productivity.

Our HypotULTRA® Series Electrical Safety Tester is the optimal choice for battery modules and BMS. With a maximum output of 5kVAC, HypotULTRA® provides the necessary performance to meet your testing requirements. When working with high voltages, prioritizing operators' safety is paramount. HypotULTRA® are equipped with SmartGFI® features that effectively prevent operators from experiencing electrical shocks. To further enhance safety, we highly recommend utilizing personal protective equipment (PPE), such as insulation mats, to provide an additional layer of protection for operators during testing procedures.

Some of customer requires multi-point testing on the BMS. The HypotULTRA® can integrate to SC6540 Multiplexers that further enhance testing efficiency. SC6540 is specifically designed to create a comprehensive and efficient multiple testing solution, it eliminates the need for frequent switching of testing leads and resolves complex cable connections. This integration saves valuable time, significantly improves testing efficiency, and reduces the chances of unnecessary mistakes.

To further automate your testing process, our Withstand® software offers advanced features that enable remote control of your instrument and barcode scanning to automate the loading of testing files, eliminating manual errors. Moreover, the software facilitates secure data storage and tracking, giving you the ability to efficiently manage your test data either in the cloud or in your computer.

Would like to know more about BESS testing? Contact us today to learn more about Ikonix complete solutions in optimizing your overall testing workflow.


  1. https://www.un.org/en/climatechange/raising-ambition/renewable-energy
  2. https://www.precedenceresearch.com/distributed-energy-storage-system-market