How to Choose Batteries for Industrial Instruments?

When selecting batteries for industrial instruments, the core consideration isn’t “how big to buy,” but rather: how long they will operate stably and predictably under harsh conditions, while also meeting certification requirements and being easy to maintain. Below, I present a systematic, actionable “industrial instrument battery selection framework” based on project-based selection principles, interspersed with references to official materials from several major manufacturers.

Clarify five critical questions—don’t start by looking at battery models

 When conducting custom battery training for OEM equipment, TEFOO-ENERGY begins by posing these questions:

 These questions apply equally to industrial instruments. You must first define:

 Functional Positioning

• Primary power source (e.g., handheld meters, wireless sensors, field sampling terminals)
• Backup/standby power (e.g., SRAM/RTC backup for industrial controllers, meter/NVRAM retention, etc.)

 Application Mode

• Intermittent operation, primarily standby (meters/meter reading/telemetry)
• Continuous high load (field gateways, edge computing, motor drives)

 Operating Environment

• Temperature Range (-40 to 85°C? Or only 0 to 40°C)
• Vibration, shock, humidity, explosion-proof requirements (mining/petrochemical/railway)

 Lifetime Specifications

• Design life: 3 years? 5 years? 10 years?
• Is battery replacement permitted, or is a “maintenance-free lifespan” required?

 Compliance and certification

• Required certifications: UL, IEC 60086/62133, UN 38.3, medical/explosion-proof, etc.

 The answers to these questions will essentially determine your choice:
 Primary lithium / Rechargeable lithium / NiMH / Industrial alkaline / Modules & Packs.

Primary Lithium vs. Lithium-ion vs. NiMH vs. Industrial Alkaline

 Primary Lithium: Ultra-long lifespan + Wide temperature range

 Panasonic’s “Primary Lithium Batteries” documentation emphasizes: Primary lithium batteries offer diverse options, serving as primary power for small devices or long-life backup power, featuring high energy density and a wide temperature range.

 Typical applications:

• Smart water/gas/electricity meters
• Remote pressure/flow/temperature-humidity data loggers
• Data loggers, RTC/NVRAM backup
• Instruments requiring 5–20 years of maintenance-free operation

 Advantages:

• High energy density, low leakage current, minimal self-discharge
• Operates from -40°C to 85°C or wider (depending on model)
• Storage/operating life exceeding 10 years achievable

 Disadvantages:

• Non-rechargeable; reverse charging must be strictly prohibited
• Limited high-current output capability (depending on specific system)

 Panasonic specifically emphasizes in its industrial device manual: When using disposable lithium batteries, connect a reverse-charge diode and current-limiting resistor in series to prevent dangerous equipment malfunctions caused by accidental charging.

 Suitable industrial instruments:

• Meter reading/telemetry terminals (transmitting data every few years)
• Single-use sensor nodes that are difficult to maintain after deployment

 Lithium-ion batteries (Li-ion / Li-Polymer): Rechargeable, high energy density

 Panasonic’s Li-ion product line description: Li-ion batteries feature high energy density, lightweight construction, and extended cycle life, widely used in power tools, energy storage, and electrified industrial equipment. TEFOO-ENERGY also offers standard and customized Li-ion battery packs utilizing Panasonic cells for industrial equipment and medical device power supplies, providing one-stop services from design to mass production.

 Advantages:

• Rechargeable, ideal for portable/mobile instruments requiring frequent use
• High cell voltage (3.6/3.7 V) facilitates multi-series battery pack assembly
• High energy density with significant overall volume and weight advantages
• Cycle life ranging from hundreds to thousands of cycles (depending on rate and temperature)

 Disadvantages:

• Requires BMS (protection, state-of-charge measurement, balancing)
• Stricter safety and transportation regulations (e.g., UN 38.3)
• Lower temperature discharge performance compared to primary lithium batteries

 Suitable industrial instruments:

• Portable industrial analyzers, handheld oscilloscopes/multimeters
• Industrial tablets, warehouse handheld terminals, inspection robots
• Various mobile devices requiring frequent charge/discharge cycles

 NiMH (Nickel-Metal Hydride): Safe, mature, suitable for button/small power sources

 NiMH rechargeable button cells are highly mature in terms of safety, environmental friendliness, and reliability, making them suitable for safety-sensitive applications in medical, industrial, and other fields.

 Advantages:

• High safety profile with a relatively “mild” chemical system
• Rechargeable with relatively low cost
• Easier to meet certification requirements in certain environments (e.g., medical)

 Disadvantages:

• Lower energy density compared to lithium-ion
• Slightly higher self-discharge rate compared to primary lithium and high-quality lithium-ion batteries

 Suitable industrial instruments:

• Small portable devices with moderate endurance requirements
• Applications with additional safety and environmental requirements

 Alkaline Industrial Batteries

 A series of alkaline batteries specifically designed for professional/industrial applications, emphasizing “professional-grade power” and “worry-free use.”

 Advantages:

• Low cost, standard sizes (AA, AAA, C, D, etc.)
• Plug-and-play functionality with established supply channels
• High cost-effectiveness for light-duty, non-critical equipment

 Disadvantages:

• Higher self-discharge than primary lithium batteries, shorter lifespan
• Average performance in high-temperature, high-humidity, or heavy-load environments

 Suitable industrial instruments:

• Simple gauges where on-site charging is inconvenient but batteries can be replaced periodically
• Devices requiring 1–2 years of service life in relatively mild environments

 Selecting models from the “battery library”: Capacity isn’t the only factor

 Manufacturers like Panasonic, VARTA, TEFOO-ENERGY, and GP offer industrial/primary lithium product lines and selection guides where models can be filtered by “application + requirements.”

 First, select by application and voltage

• Voltage requirements: Single-cell 3 V / 3.6 V? Or 12 V / 24 V battery packs?
• Current demand: Continuous tens of microamperes + occasional hundreds of mA pulses? Or sustained output of several amperes?
• Package constraints: Volume, thickness, button cell/cylindrical/flat pouch type?

 Panasonic’s primary lithium battery data clearly differentiates between “button cell / cylindrical / wound” structures based on energy density and pulse capability—a common reference for industrial instrument selection.

Next, consider capacity, pulse capability, and temperature range

 Typical datasheets provide:

• Nominal voltage, nominal capacity (mAh / Ah)
• Maximum continuous discharge current, maximum pulse current
• Recommended operating temperature range
• Internal resistance (sometimes indirectly provided)

 For example, the datasheet for a primary lithium coin cell like the Panasonic BR1225 will specify:

• Nominal voltage 3 V
• Nominal capacity: 48 mAh
• Standard continuous current: 0.03 mA
• Operating temperature: -30 to 85 °C

 Your task is to map the instrument load (average current + pulse current) to these parameters while ensuring sufficient margin.

 Estimating lifespan: Calculate “Ah/year”

 For typical industrial instruments (e.g., weather station sensors, electricity meters), primary batteries are generally selected based on “annual average consumption”:

1. Calculate the average daily current:

• Standby current (uA level)
• Sampling/processing current
• Communication peak current (GPRS/LoRa/NB-IoT, etc.)

2. Convert to annual mAh consumption, then multiply by the target lifespan (e.g., 10 years) to obtain the total power requirement.
3. Account for self-discharge and temperature effects by applying a safety factor of 1.2–1.5.

 Many industrial battery manufacturers (e.g., Large Battery) have dedicated articles emphasizing that “selecting batteries for precision instruments requires consideration of stability, lifespan, and safety.” They stress the importance of calculating based on load curves, temperature, and lifespan, rather than relying solely on nominal capacity.

 “Hidden Metrics” Essential for Industrial Applications

 Long-Term Stability & Self-Discharge

 For instruments requiring 10 years of maintenance-free operation, self-discharge is a critical factor. Some primary lithium series achieve annual self-discharge rates as low as 1%, a feature prominently highlighted in product manuals from manufacturers like Panasonic and Saft.

 Key selection criteria include:

• Capacity retention curve after 10 years of storage
• Capacity retention rate after high-temperature storage/operation

 Temperature & Thermal Response

 Industrial equipment frequently operates within a temperature range of -40°C to 85°C or higher. GlobalSpec’s overview of industrial battery applications notes that these batteries are commonly used in forklifts, oil/gas, solar energy, and similar scenarios, requiring both deep discharge capability and thermal performance.

 Under extreme temperatures, it is essential to examine:

• Discharge curve at specified temperatures (voltage retention)
• Capacity derating at low temperatures and internal resistance changes

 Safety & Compliance

 VARTA, Panasonic, and Tefoo-Energy all emphasize various certifications across their industrial/medical/energy storage product lines: UL, IEC, UN 38.3, and even medical/explosion-proof certifications.

 For industrial instruments, pay particular attention to:

• Whether the battery has the certifications required for the target market
• Does the shipping method meet air/sea transport standards for batteries?
• Is it convenient for the entire device to pass IEC/UL/explosion-proof certification?

 Maintainability and product line continuity

 Is this a one-time product or a long-term product line? For industrial instruments, it is crucial to consider:

• Is the battery model stably supplied by major manufacturers, or is there a risk of discontinuation?
• Are dimensions and interfaces standardized (ensuring future replacement availability)?
• Is field replacement convenient (tray/battery compartment design)?

 When should you use a “battery pack/module” instead of bare cells?

 When your instrument meets any of the following conditions, consider manufacturer-provided module/pack solutions directly:

• High operating voltage (12 V / 24 V / 48 V)
• High power output with stringent safety requirements (robotic arms, small AGVs, compact electric equipment)
• Requires Battery Management System (BMS), energy meter, communication interfaces (CAN, SMBus, etc.)

 Panasonic and TEFOO-ENERGY both offer specialized battery packs and modules for industrial applications, providing ready-to-use safety designs and certification support.

 For industrial equipment manufacturers, the benefits include:

• Minimized safety and design pitfalls (short circuits, overcharging, thermal runaway)
• Easier overall product certification
• Simplified supply chain and after-sales management

 A simple “decision tree” for practical implementation

 Follow this approach to quickly narrow down types before specifying models:

 Does it require charging?

• Yes → Li-ion / NiMH / Industrial battery pack
• No or not allowed → Primary lithium / Industrial alkaline

 Target lifespan & maintenance requirements?

• Requires ≥10 years maintenance-free, low power consumption → Primary lithium (BR/CR series, etc.)
• 3–5 years, periodic maintenance permitted → Industrial alkaline / NiMH / Small Li-ion

 Ambient Temperature and Operating Conditions?

• -40 to 85°C, outdoor → Primary lithium (wide-temperature series)
• Indoor, 0–40°C → Li-ion/NiMH preferred

 Load power and pulse current?

• Only uA–mA level + occasional tens of mA → Button/small cylindrical primary lithium
• Requires A-grade pulse or continuous current → Li-ion 18650/21700/Pack

 Certification and safety?

• Medical, explosion-proof, rail transit, etc. → Prioritize major manufacturers’ industrial/medical series + pre-certified packs
• General industrial applications → Ensure at least mainstream IEC/UL/UN certifications

Before final selection, follow these steps:

 Based on official data and experience, follow these steps in actual projects:

1. Calculate annual Wh demand and total lifetime Wh using a simplified load model (average current/power), allowing a 20–50% margin.
2. Select the chemical system (primary lithium / Li-ion / NiMH / alkaline) based on voltage, lifespan, environment, and maintenance strategy.
3. Screen candidate models in the industrial battery/design libraries of official websites like Panasonic, TEFOO-ENERGY, Saft, GP, etc. (consider voltage, capacity, temperature, discharge curve).
4. Conduct physical prototype testing on 2–3 candidate solutions:

• Discharge curves at different temperatures
• Endurance under real-world load (including communication/pulse)
• Accelerated aging/cycle testing

5. Ensure the final BOM locks in at least two compatible suppliers to mitigate single-source risk.

 If you wish, you may share general details about your “specific industrial instrument” with TEFOO-ENERGY (e.g., handheld/fixed? Voltage, average and peak current, expected lifespan, ambient temperature, rechargeability). TEFOO-ENERGY’s technical experts will tailor the perfect lithium-ion battery solution for your company!