Integration of Remote Capacity Testing And Smart Lithium Batteries ----Innovation in Substation Backup Power Operation And Maintenance Mode

In substations, the DC system serves as the "lifeline" for critical equipment such as control circuits, relay protection, and emergency lighting. The battery bank, as its core energy storage unit, acts as the "last line of defense" during grid failures. However, traditional battery maintenance relies on manual expertise, leading to issues such as inspection blind spots, high safety risks, and inefficiency. DFUN Technology has introduced lithium battery PACK products and solutions integrated with remote capacity verification, enabling cloud-based unified management of distributed sites and hybrid lead-acid/lithium battery systems. This technological integration marks a paradigm shift from passive response to proactive predictive maintenance. This article explores how intelligent solutions can enhance safety and efficiency, based on industry standards and DFUN’s practical applications.

I. Battery Replacement: From Manual Inspection to Smart Error Prevention

Core Requirements:

1.Pre-installation Inspection:
○ Check for casing deformation, leakage, terminal corrosion, and safety valve integrity.
○ Verify polarity (positive: brown/negative: blue) and ensure bolt connections are rust-free.
○ Internal resistance deviation ≤ ±10% to avoid the "barrel effect" caused by mismatched new/old batteries.

Intelligent Upgrades:

DFUN DFCS4200 Battery Monitoring System:
○ High-precision sensors monitor abnormalities (leakage, swelling), replacing visual checks.
○ Automatic polarity recognition with audible/visual alarms to prevent misconnections.
○ Online internal resistance detection with ±10% deviation alerts for consistency.

PBAT81 Monitoring Module:
○ Compatible with 2V/12V lead-acid or Ni-Cd batteries. IP65 and UL94-V0 certified for extreme environments.

II. Safety Protection: From Passive to Active Defense

Core Requirements:

1.Operational Safety:
○ Use insulated tools and non-metallic workwear.
○ Avoid live disconnection to prevent short circuits or electric shocks.
○ Disconnect charging circuits during capacity verification to prevent overload.

Intelligent Upgrades:

DFUN 48V Smart Lithium Battery (DFPA48100-S):
○ Built-in fire suppression module validated by dynamic impact tests, eliminating explosion/fire risks.
○ High-temperature-resistant, flame-retardant enclosure for substation environments.

Remote Capacity Verification System (DFCS4300):
○ Auto-locks charging circuits during verification, ensuring uninterrupted power supply.
○ Dual authentication (facial recognition + physical U-Key) to prevent misoperations.

III. Mixed Usage & Capacity Verification: From Labor-Intensive to One-Click Efficiency

Core Requirements:

1.Battery Replacement Process:
○ 100% full-capacity discharge test for old batteries; label pass/fail.
○ Dynamic discharge tests (impact tests) for new batteries to verify reliability.
○ Prohibit mixing brands or capacities.

Intelligent Upgrades:

DFUN 48V Smart Lithium Battery (DFPA48165-S):
○ Supports hybrid use with lead-acid/new/old lithium batteries; auto-adjusts bus voltage (43.2V–54V) to extend lead-acid lifespan.
○ Parallel connection of up to 32 groups avoids capacity imbalance.

Remote Capacity Verification System (DFCS4300):
○ Real-load discharge completes verification in 4 hours, generating capacity curves and SOH reports (80% efficiency gain).
○ Shallow charge/discharge strategies delay battery passivation; AI-driven balancing corrects voltage deviations (e.g., float voltage <2.18V).

IV. Routine Maintenance: From Manual Inspections to Predictive Management

Core Requirements:

1.Environmental Control:
○ Maintain battery room temperature at 22–25°C.
○  Record float current daily. If any individual battery (2V series) has a float voltage below 2.18V per cell, perform manual equalization charging:

       At 25°C: Charge at 2.30V per cell for 24 hours;

       Or at 25°C: Charge at 2.35V per cell for 12 hours.
○ If the battery still fails to recover after equalization, contact the manufacturer immediately.

2.Periodic Tests: Monthly cell voltage checks; annual capacity recovery tests.

3.Data Management: Compare operational data with baseline parameters; address anomalies promptly.

Intelligent Upgrades:

DFUN DFCS4200 Battery Monitoring System:
○ Real-time monitoring of cell voltage, internal resistance, temperature, SOC, SOH, and auto-balancing.
○ Predictive alerts for capacity decay or loose connections using 1.5B+ data models.
○ Full charge/discharge logs and historical data storage for compliance.

V. Industry Practices: Standards-Driven Efficiency

DFUN’s solutions comply with IEEE 1188, IEC 61000, and UN38.3 standards, applied in:

Power Industry: State Grid Chengdu Power Supply Company reduced annual labor costs by ¥1.2M and improved verification efficiency by 70%.

Petrochemicals: BASF Germany cut terminal corrosion failures by 60% across 3,000 battery rooms.

Telecom: 5G base stations using smart lithium batteries achieved 70% weight reduction and 3x backup capacity.

Conclusion: Intelligent O&M Simplifies Safety
Substation battery maintenance is critical for grid reliability. DFUN’s solutions—smart monitoring, lithium batteries, and remote verification—deliver:
☑ Zero Human Error: AI replaces manual checks and verification.
☑ 24/7 Protection: Multi-level alerts and real-time fault localization.
☑ Cost Efficiency: 40% lower O&M costs; 30% extended battery life.

Contact:+86-15919182362 | Website: www.dfuntech.com.cn