Voltage, load, internal resistance and capacity tests — in the order that finds the fault fastest.
Voltage and load testing
Resting voltage tells you state of charge; voltage under load tells you the truth about the pack.
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Internal resistance, capacity and diagnostics
Rising internal resistance is the earliest reliable signal that a pack is ageing.
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Maintenance & safety questions
The questions that come before an order.
How long should a lithium battery last?
A good LiFePO4 pack gives 4,000–6,000 cycles at 80% depth of discharge, which is eight to ten years of daily use. Heat, sitting at 100% and charging below freezing are what shorten it.
How do I test a battery?
Measure resting voltage first, then voltage under a known load, then internal resistance if you have the tool. A pack that holds voltage at rest but collapses under load has a bad cell group or a weak connection.
What maintenance does a lithium battery need?
Very little: keep terminals clean and tight, keep the enclosure ventilated, and review the BMS log periodically. There is no watering, no equalising and no acid to check.
Is a swollen battery dangerous?
Yes — stop using it and stop charging it. Swelling means gas inside the cell, and the pack should be replaced rather than investigated.
How should batteries be stored?
At around 50% state of charge, in a cool, dry place, disconnected from loads. Leaving a pack flat for months is what does the damage.
