IEC 63115-2:2021
(Main)Secondary cells and batteries containing alkaline or other non-acid electrolytes - Sealed nickel-metal hydride cells and batteries for use in industrial applications - Part 2: Safety
Secondary cells and batteries containing alkaline or other non-acid electrolytes - Sealed nickel-metal hydride cells and batteries for use in industrial applications - Part 2: Safety
IEC-63115-2:2021 specifies designations, tests and requirements for the safe operation of sealed nickel-metal hydride cells and batteries used in industrial applications excluding road vehicles.
Since this document covers batteries for various industrial applications, it includes those requirements which are common and minimum to the various applications.
Accumulateurs alcalins ou autres accumulateurs à électrolyte non acide - Accumulateurs étanches au nickel-métal hydrure destinés à l’utilisation dans les applications industrielles - Partie 2: Sécurité
L'IEC 63115-2:2021 précise les désignations, les essais et les exigences pour le fonctionnement en sécurité des accumulateurs étanches au nickel-métal hydrure destinés à une utilisation dans les applications industrielles, à l'exception des véhicules routiers.
Lorsqu'une Norme internationale IEC spécifiant des conditions d'essai et des exigences pour des éléments destinés à des applications particulières est en contradiction avec le présent document, la publication particulière est appliquée en priorité (par exemple, l'IEC 62675).
Le présent document inclut les exigences communes et minimales pour plusieurs applications dans la mesure où il traite des batteries destinées aux différentes applications industrielles.
General Information
Standards Content (Sample)
IEC 63115-2 ®
Edition 1.0 2021-01
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Sealed nickel-metal hydride cells and batteries for use in
industrial applications –
Part 2: Safety
Accumulateurs alcalins et autres accumulateurs à électrolyte non acide –
Accumulateurs étanches au nickel-métal hydrure destinés à l'utilisation dans
les applications industrielles –
Partie 2: Sécurité
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IEC 63115-2 ®
Edition 1.0 2021-01
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Sealed nickel-metal hydride cells and batteries for use in
industrial applications –
Part 2: Safety
Accumulateurs alcalins et autres accumulateurs à électrolyte non acide –
Accumulateurs étanches au nickel-métal hydrure destinés à l'utilisation dans
les applications industrielles –
Partie 2: Sécurité
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.220.30 ISBN 978-2-8322-9132-0
– 2 – IEC 63115-2:2021 © IEC 2021
CONTENTS
FOREWORD . 4
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 6
4 Parameter measurement tolerances . 9
5 General safety considerations . 10
5.1 General . 10
5.2 Insulation and wiring . 10
5.3 Venting . 10
5.4 Temperature, voltage and current management . 10
5.5 Terminal connectors . 11
5.6 Assembly of cells into batteries . 11
5.7 Quality plan . 11
5.8 Type test conditions . 11
5.9 Test items . 11
6 Specific requirements and tests . 12
6.1 General . 12
6.2 Preliminary preparation for test purposes . 13
6.3 Insulation . 13
6.4 Intended use . 13
6.4.1 Vibration . 13
6.4.2 Enclosure stress at high ambient temperature . 14
6.4.3 Temperature cycling . 14
6.5 Reasonably foreseeable misuse . 15
6.5.1 External short-circuit test . 15
6.5.2 Drop test . 15
6.5.3 Mechanical shock (crash hazard) . 16
6.5.4 Thermal abuse test . 16
6.5.5 Crush . 16
6.5.6 Low pressure . 17
6.5.7 Overcharge test . 17
6.5.8 Reverse charge test. 18
7 Battery system safety (considering functional safety) . 18
7.1 Battery management system (BMS) (or battery management unit) –
Requirements for the BMS . 18
7.2 Overheating control (battery system) . 19
8 EMC . 20
9 Information for safety . 20
10 Marking and designation . 20
Annex A (informative) Battery system safety (considering functional safety) – General
requirements . 21
Bibliography . 22
Figure 1 – Temperature profile for 6.4.3 – Temperature cycling test . 15
Figure 2 – Examples of BMS locations and battery system configurations . 19
Table 1 – Sample size for type tests . 12
Table 2 – Level of accessibility test . 13
Table 3 – Drop test conditions . 16
– 4 – IEC 63115-2:2021 © IEC 2021
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
SECONDARY CELLS AND BATTERIES CONTAINING
ALKALINE OR OTHER NON-ACID ELECTROLYTES –
SEALED NICKEL-METAL HYDRIDE CELLS AND BATTERIES
FOR USE IN INDUSTRIAL APPLICATIONS –
Part 2: Safety
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international
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rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 63115-2 has been prepared by subcommittee 21A: Secondary cells
and batteries containing alkaline or other non-acid electrolytes, of IEC technical committee 21:
Secondary cells and batteries.
The text of this International Standard is based on the following documents:
FDIS Report on voting
21A/735/FDIS 21A/743/RVD
Full information on the voting for the approval of this International Standard can be found in the
report on voting indicated in the above table.
This document has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 63115 series, published under the general title Secondary cells and
batteries containing alkaline or other non-acid electrolytes – Sealed nickel-metal hydride cells
and batteries for use in industrial applications, can be found on the IEC website.
The committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under "http://webstore.iec.ch" in the data related to
the specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
IMPORTANT – The 'colour inside' logo on the cover page of this publication indicates
that it contains colours which are considered to be useful for the correct understanding
of its contents. Users should therefore print this document using a colour printer.
– 6 – IEC 63115-2:2021 © IEC 2021
SECONDARY CELLS AND BATTERIES CONTAINING
ALKALINE OR OTHER NON-ACID ELECTROLYTES –
SEALED NICKEL-METAL HYDRIDE CELLS AND BATTERIES
FOR USE IN INDUSTRIAL APPLICATIONS –
Part 2: Safety
1 Scope
This document specifies designations, tests and requirements for the safe operation of sealed
nickel-metal hydride cells and batteries used in industrial applications excluding road vehicles.
When an IEC International Standard specifying test conditions and requirements for cells used
in special applications is in conflict with this document, the former takes precedence (e.g.
IEC 62675).
Since this document covers batteries for various industrial applications, it includes those
requirements which are common and minimum to the various applications.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any
amendments) applies.
IEC 60050-482, International Electrotechnical Vocabulary – Part 482: Primary and secondary
cells and batteries (available at www.electropedia.org)
IEC 63115-1:2020, Secondary cells and batteries containing alkaline or other non-acid
electrolytes – Sealed nickel-metal hydride cells and batteries for use in industrial applications
– Part 1: Performance
ISO/IEC Guide 51, Safety aspects – Guidelines for their inclusion in standards
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-482,
IEC 63115-1, ISO/IEC Guide 51, and the following apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
safety
freedom from unacceptable risk
[SOURCE: IEC 60050-903:2013, 903-01-19]
3.2
risk
combination of the probability of occurrence of harm and the severity of that harm
[SOURCE: IEC 60050-903:2013, 903-01-07, modified – The note has been omitted.]
3.3
harm
physical injury or damage to the health of people, or damage to property or the environment
[SOURCE: IEC 60050-351:2013, 351-57-02]
3.4
hazard
potential source of harm
[SOURCE: IEC 60050-351:2013, 351-57-01, modified – The note has been omitted.]
3.5
intended use
use of a product, process or service in accordance with the specifications, instructions and
information provided by the supplier
[SOURCE: IEC 60050-903:2013, 903-01-13, modified – The words "specifications" and
"instructions" have been added and "for use" omitted.]
3.6
reasonably foreseeable misuse
use of a product, process or service in a way not intended by the supplier, but which may result
from readily predictable human behaviour
[SOURCE: IEC 60050-903:2013, 903-01-14]
3.7
cell
sealed nickel-metal hydride cell
cell containing a nickel hydroxide compound for the positive electrode, a hydrogen absorbing
alloy for the negative electrode, and potassium hydroxide or other alkaline solution as
electrolyte, and not releasing either gas or liquid when operated within the limits specified by
the manufacturer
Note 1 to entry: A sealed cell may be equipped with a safety device to prevent a dangerously high internal pressure
and is designed to operate during its life in its original sealed state. See IEC 60050-482:2004, 482-05-17.
3.8
cell block
group of cells connected together in parallel configuration with or without protective devices
(e.g. fuse or PTC (positive temperature coefficient)) and monitoring circuitry
3.9
monobloc
battery with multiple separate but electrically connected cell compartments each of which is
designed to house an assembly of electrodes, electrolyte, terminals or interconnections and
possible separators
[SOURCE: IEC 60050-482:2004, 482-02-17, modified – "battery" has been omitted from the
term and the note to entry deleted.]
– 8 – IEC 63115-2:2021 © IEC 2021
3.10
module
group of cells connected together either in series and/or parallel configuration with or without
protective devices (e.g. fuse or PTC) and monitoring circuitry
3.11
battery pack
energy storage device comprised of one or more cells, monoblocs or modules electrically
connected
Note 1 to entry: A battery pack may have a monitoring circuitry which provides information (e.g. cell voltage) to a
battery system.
3.12
battery system
battery
system which comprises one or more cells, cell blocks, monoblocs, modules or battery packs
Note 1 to entry: The battery system has a battery management system to cut off current in case of overcharge,
overcurrent, overdischarge, or overheating.
Note 2 to entry: Overdischarge cut off is not mandatory if there is an agreement on this between the cell
manufacturer and the customer.
Note 3 to entry: The battery system may have cooling or heating units.
Note 4 to entry: The battery system may be enclosed in a battery box.
3.13
battery enclosure
enclosure
physical construction which separates the battery or battery system from its external
environment
3.14
battery management system
BMS
electronic system associated with a battery which has functions to cut off in case of overcharge,
overcurrent, overdischarge, and overheating
Note 1 to entry: The BMS monitors and/or manages its state, calculates secondary data, reports that data and/or
controls its environment to influence the battery's safety, performance and/or service life.
Note 2 to entry: The function of the BMS can be assigned to the battery pack or to equipment that uses the battery
(see Figure 2).
Note 3 to entry: The BMS can be divided and it can be found partially in the battery pack and partially on the
equipment that uses the battery (see Figure 2).
Note 4 to entry: The BMS is sometimes also referred to as a BMU (battery management unit).
3.15
final voltage
specified voltage of a battery at which the battery discharge is terminated
[SOURCE: IEC 60050-482:2004, 482-03-30, modified – The synonyms "end-of-discharge
voltage", "cut-off voltage" and "end-point voltage" have been omitted.]
3.16
nominal voltage
suitable approximate value of the voltage used to designate or identify the voltage of a cell or
battery
Note 1 to entry: The nominal voltage of a sealed nickel-metal hydride rechargeable single cell is 1,2 V.
Note 2 to entry: The nominal voltage of a battery of n series connected cells is equal to n times the nominal voltage
of a single cell.
[SOURCE: IEC 60050-482:2004, 482-03-31, modified – The words "the voltage of" have been
added; the notes to entry have been added and the reference to electrochemical systems has
been omitted.]
3.17
rated capacity
capacity value of a cell or battery determined under specified conditions and declared by the
manufacturer
Note 1 to entry: The rated capacity is the quantity of electricity in C Ah (ampere-hours) declared by the
manufacturer which a single cell can deliver when discharged at the reference test current of 0,2 I A to a specified
t
final voltage, after charging, storing and discharging under specified conditions.
[SOURCE: IEC 60050-482:2004, 482-03-15, modified – "cell" has been added to the definition,
along with a note to entry.]
3.18
explosion
failure that occurs when a cell, module, or monobloc container opens violently as a result of a
sudden increase of pressure and temperature in cell due to exothermic reaction and major
components are forcibly expelled
3.19
rupture
mechanical failure of a cell, monobloc or battery induced by an internal or external cause,
resulting in exposure or spillage but not ejection of materials
3.20
leakage
unplanned, visible escape of liquid electrolyte
[SOURCE: IEC 62133-1:2017, 3.9]
3.21
venting
release of excessive internal pressure from a cell, monobloc or battery in a manner intended
by design to preclude rupture or explosion
4 Parameter measurement tolerances
The overall accuracy of controlled or measured values, relative to the specified or actual values,
shall be within the following tolerances:
a) ± 1 % for voltage;
b) ± 1 % for current;
c) ± 1 % for capacity;
d) ± 2 °C for temperature;
e) ± 0,1 % for time;
f) ± 1 % for dimension.
These tolerances comprise the combined accuracy of the measuring instruments, the
measurement techniques used and all other sources of error in the test procedure.
The details of the instrumentation used shall be provided in each report of results.
– 10 – IEC 63115-2:2021 © IEC 2021
5 General safety considerations
5.1 General
The safety of sealed nickel-metal hydride cells or batteries requires the consideration of two
sets of applied conditions:
a) intended use;
b) reasonably foreseeable misuse.
The manufacturer can use "cell block(s) or monobloc(s)" instead of "cell(s)" for any test that
specifies "cell(s)". The manufacturer can use "battery pack" instead of "battery" as the test unit
in this document. The cell manufacturer shall clearly declare the test unit for each test.
Cells or batteries shall be so designed and constructed that they are safe under conditions of
both intended use and reasonably foreseeable misuse. It may also be expected that cells or
batteries subjected to intended use shall not only be safe but shall continue to be functional in
all respects.
It is expected that cells or batteries subjected to misuse may fail to function. However, even if
such a situation occurs, they shall not present any significant hazards.
Potential hazards which are the subject of this document are:
a) fire,
b) explosion,
c) electrical shock hazards,
d) venting (such as H gas),
e) rupture of the casing of a cell or battery with exposure of internal components,
f) leakage.
5.2 Insulation and wiring
The insulation resistance between the positive terminal and externally exposed electrically
active surfaces of the battery shall protect against shock hazard.
Internal wiring and insulation should be sufficient to withstand the maximum anticipated current,
voltage and temperature requirements. The orientation of wiring should be such that adequate
clearances and creepage distances are maintained between conductors as per the intended
application standard (or if unknown, as per IEC 60664-1). The mechanical integrity of internal
connections should be sufficient to accommodate conditions of reasonably foreseeable misuse
(i.e. solder alone is not considered a reliable means of connection). Adequate clearances and
creepage distances as noted above shall also be maintained on control boards and other areas
within the battery.
5.3 Venting
Battery cases and cells shall incorporate a pressure relief mechanism or shall be so constructed
that they will relieve excessive internal pressure at a value and rate that will preclude rupture,
explosion and self-ignition. If encapsulation is used to support cells within an outer case, the
type of encapsulating and the method of encapsulation shall neither cause the battery to
overheat during normal operation nor inhibit pressure relief.
5.4 Temperature, voltage and current management
The design of batteries shall be such that abnormal temperature-rise conditions are prevented.
Batteries shall be designed to be within temperature, voltage and current limits specified by the
cell manufacturer. Batteries shall be provided with specifications and charging instructions for
equipment manufacturers so that associated chargers are designed to maintain charging within
the temperature, voltage and current limits specified. Where necessary, applicable means can
be provided to limit current and temperature to safe levels during charge and discharge.
The battery manufacturer shall declare the cell design type as per IEC 63115-1:2020, Table 1.
5.5 Terminal connectors
The size and shape of the terminal connectors shall be such to ensure that they can carry the
maximum anticipated current. External terminal contact surfaces shall be formed from
conductive materials with good mechanical strength and corrosion resistance (see appropriate
corrosion tests, e.g. IEC 60068-2-60 and IEC 60068-2-11). Terminal connectors shall be
arranged so as to minimize the risk of short circuits. Terminal connectors shall be marked to
indicate polarity.
5.6 Assembly of cells into batteries
If there is more than one battery housed in a single battery enclosure, cells used in the assembly
of each battery shall be of the same design, be of the same chemistry and be from the same
manufacturer.
Manufacturers of cells shall specify current, voltage and temperature limits so that the battery
manufacturer and/or designer may ensure proper design and assembly.
Batteries that are designed for the selective discharge of a portion of their series connected
cells shall incorporate circuitry to prevent operation of cells outside the limits specified by the
cell manufacturer.
5.7 Quality plan
The manufacturer shall prepare and implement a quality plan that defines procedures for the
inspection of materials, components, cells and batteries and which covers the whole process of
producing each type of cell or battery. Manufacturers should understand their process
capabilities and should institute the necessary process controls as they relate to product safety.
5.8 Type test conditions
A battery system that is used outside of its operating region may exhibit hazards originating
from the cells or batteries. Such risks shall be taken into consideration in order to prepare a
safe test plan.
The test facility should have a sufficient structural integrity and a fire suppression system to
contain the conditions of overpressure and fire that may occur as a result of testing. The facility
should have a ventilation system to dilute gas which might be produced during the tests.
Consideration should be given to high voltage hazards when applicable.
5.9 Test items
Tests items are specified in Table 1, using cells or batteries that are not more than six months
old. Unless otherwise specified, tests are carried out in an ambient temperature of 20 °C ± 5 °C.
Test conditions are for type tests only and do not imply that intended use includes operation
under these conditions. Similarly, the limit of six months is introduced for consistency and does
not imply that cell and battery system safety is reduced after six months.
– 12 – IEC 63115-2:2021 © IEC 2021
Table 1 – Sample size for type tests
Test items Test unit (see 6.1)
Test Cell Battery
(see b) (see a and c)
6.4.1 Vibration R R
6.4.2 Enclosure stress at high ambient - R
temperature
6.4.3 Temperature cycling R -
6.5.1 External short-circuit test R R
6.5.2 Drop test R R
6.5.3 Mechanical shock (crash hazard) R R
6.5.4 Thermal abuse test R -
6.5.5 Crush R -
6.5.6 Low pressure R -
6.5.7 Overcharge test (see d) R R
6.5.8 Reverse charge test R -
"R" = required (minimum of 1)
"-" = unnecessary or not applicable
a The manufacturer can use "battery" instead of "cell" at any test that specifies "cell(s)" as the test unit in this
document if the test can be conducted for both battery and cell. The manufacturer clearly declares the test unit
for each test. If it is difficult to divide the small parts in the battery, the battery can be tested as a representative
of the cell. The manufacturer can add functions which are present in the final battery system to the tested unit.
The manufacturer shall clearly declare the tested unit.
b The manufacturer can use "cell block or monobloc" instead of "cell" at any test that specifies "cell(s)" as the
test unit in this document. The tested unit is declared clearly by the manufacturer.
c If a battery system is divided into smaller units the unit can be tested as a representative of the battery system.
The manufacturer can add functions which are present in the final battery system to the tested unit. The tested
unit is declared clearly by the manufacturer.
d The test is performed with those batteries that are provided with only a single control or protection for charging
voltage control.
6 Specific requirements and tests
6.1 General
If tests have already been performed on a battery, their results can be accepted as equivalent
for batteries of the same type.
An equivalent battery means that it is the same battery type.
The type of change that might be considered to differ from a tested type, such that it might lead
to failure of any of the test results, may include, but is not limited to:
1) a change in the material of the anode, the cathode, the separator or electrolyte;
2) a change of protective devices, including hardware and software;
3) a change of safety design in cells or batteries, such as a venting valve;
4) a change in the number of cells in the battery;
5) a change in the connecting mode of cells.
6.2 Preliminary preparation for test purposes
Prior to charging, the cells or batteries shall be fully discharged in an ambient temperature of
20 °C ± 5 °C, at a constant current of 0,2 I A, down to 1,0 V per cell.
t
Unless otherwise stated in this document, cells or batteries shall be fully charged in an ambient
temperature of 20 °C ± 5 °C, using the method as specified in IEC 63115-1:2020, 7.2 for the
cell design type as declared by the manufacturer.
Charge and discharge currents for the tests shall be based on the rated capacity, (C Ah).
These currents are expressed as multiples of I A, where I A = C Ah/1 h.
t t 5
6.3 Insulation
The insulation resistance between the positive terminal and externally exposed metal surfaces
of the battery excluding electrical contact surfaces shall be not less than 100 kΩ at 500 V DC
when measured 60 s after applying the voltage.
For evaluating limits for accessibility to electrically active surfaces, the applicable access probe
test as shown in Table 2 is conducted. Refer to IEC 61032 and IEC 60529 for details, including
type of access probe to use, and how to evaluate for the various IP levels noted in Table 2.
Table 2 – Level of accessibility test
IPXX Level of protection DC Voltage
1 Not > 50 mm, prevent access by hand < 60 V
2 Not > 12,5 mm, prevent access by finger > 60 V
3 Not > 2,5 mm, prevent access by screwdriver > 160 V
4 Not > 1 mm, prevent access by wire > 500 V
5 Dust protected
6 Dust tight
6.4 Intended use
6.4.1 Vibration
a) Purpose
Vibration encountered during transportation shall not cause leakage, fire or explosion.
b) Test
Fully charged cells or batteries according to 6.2 are firmly secured to the platform of the
vibration machine in such a manner as to faithfully transmit the vibration, without distorting
the cells. The vibration shall be a sinusoidal waveform with a logarithmic sweep between
7 Hz and 200 Hz and back to 7 Hz within 15 min. This cycle shall be repeated 12 times for
a total of 3 h for each of three mutually perpendicular mounting positions of the cell. One of
the directions of vibration shall be perpendicular to the terminal face.
A peak acceleration of 1 g is to be maintained from 7 Hz to 18 Hz. The amplitude is then
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maintained at 0,8 mm (1,6 mm total excursion) and the frequency increased until a peak
acceleration of 1,4 g occurs (at approximately 20 Hz). A peak acceleration of 1,4 g is then
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maintained until the frequency is increased to 200 Hz.
c) Requirements
No fire, no explosion, no leakage.
– 14 – IEC 63115-2:2021 © IEC 2021
6.4.2 Enclosure stress at high ambient temperature
a) Purpose
Internal components of batteries shall not be exposed during use at high temperature. This
requirement only applies to batteries within an enclosure.
b) Test
Fully charged batteries according to 6.2 are exposed to a moderately high temperature to
evaluate case integrity. The battery is placed in a circulating air convection oven at a
temperature of 70 °C ± 2 °C. The batteries remain in the oven for 7 h, after which they are
removed and allowed to return to room temperature.
c) Requirements
No physical distortion of the battery enclosure that compromises the designed safety
features specified by the manufacturer (such as Ingress Protection (IP) rating, fire barrier
rating, insulation resistance, etc.).
6.4.3 Temperature cycling
a) Purpose
Repeated exposure to high and low temperatures shall not cause leakage, fire or explosion.
b) Test
According to the following procedure and the profile shown in Figure 1. Cells which are fully
charged in accordance with 6.2 are subjected to temperature cycling (−20 °C, +70 °C), in
forced draught chambers, according to the following procedure:
Step 1: Place the cells in an ambient temperature of +70 °C ± 5 °C for 4 h.
Step 2: Change the ambient temperature to 20 °C ± 5 °C within 30 min and maintain at this
temperature for a minimum of 2 h.
Step 3: Change the ambient temperature to −20 °C ± 5 °C within 30 min and maintain at this
temperature for 4 h.
Step 4: Change the ambient temperature to 20 °C ± 5 °C within 30 min and maintain at this
temperature for a minimum of 2 h.
Step 5: Repeat steps 1 to 4 for a further four cycles. Transition from step 4 to step 1 within
30 min.
Step 6: After the fifth cycle, store the cells and conduct a visual check after a rest period of
at least 24 h.
This test can be performed in a single chamber whose temperature is changed or in three
separate chambers at three different test temperatures.
c) Requirements
No fire, no explosion, no leakage.
Figure 1 – Temperature profile for 6.4.3 – Temperature cycling test
6.5 Reasonably foreseeable misuse
6.5.1 External short-circuit test
a) Purpose
Short-circuit between the positive and negative terminals shall not cause fire or explosion.
b) Test
Each cell, fully charged according to the procedure set out in the second paragraph of 6.2
is stored in an ambient temperature of 20 °C ± 5 °C. While still in an ambient temperature
of 20 °C ± 5 °C, each cell or battery is then short-circuited by connecting the positive and
negative terminals with a total external resistance of 80 mΩ ± 20 mΩ. Alternatively, the total
external resistance obtained is determined by calculating the resistance of a 0,2 mΩ resistor
per cell (to be multiplied by the number of cells when series-connected cells are being
tested). The manufacturer shall clearly declare the value of the total external resistance in
this test. The cell or battery remains in testing for 24 h or until the case temperature of the
cell or battery declines by 20 % of the maximum temperature rise, whichever occurs sooner.
However, in case of rapid decline in the short-circuit current, the cell or battery should
remain in testing for an additional 1 h after the current reaches a low steady state condition
where, typically, the individual cell voltage (series cells only) of the cell or battery is below
0,8 V and has decreased by less than 0,1 V in a 30 min period.
c) Requirements
No explosion, no fire
6.5.2 Drop test
a) Purpose
Dropping the cell or battery shall not cause fire or explosion.
b) Test
Each fully charged cell or battery in accordance with 6.2 shall be discharged at a constant
current of 0,2 I A, to a state of charge for installation or maintenance which is specified by
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the manufacturer. Unless otherwise specified by the manufacturer, tests are carried out
without discharging after charging as per 6.2. The test unit is dropped once from a height
shown in Table 3 onto a flat concrete or metal floor. The test shall be performed with the
test unit as a whole dropped in the bottom down direction. The bottom surface of the test
unit is specified by the manufacturer. After the test, the test units shall be left to rest for a
minimum of 1 h, and then a visual inspection shall be performed.
– 16 – IEC 63115-2:2021 © IEC 2021
c) Requirements
No explosion, no fire.
Table 3 – Drop test conditions
Mass of the test unit Height of drop
Less than 50 kg 10,0 cm
50 kg or more but less than 100 kg 5,0 cm
100 kg or more 2,5 cm
In the case of a metal floor, appropriate measures should be taken to avoid external
short circuit of cell or battery with the floor.
6.5.3 Mechanical shock (crash hazard)
a) Purpose
Shocks encountered during handling or transportation shall not cause fire or explosion.
b) Test
Each cell or battery fully charged as per 6.2 is secured to the testing machine by means of
a rigid mount which supports all mounting surfaces of the cell or battery. The cell or battery
is subjected to a total of three shocks of equal magnitude. The shocks are applied in each
of three mutually perpendicular directions. At least one of them shall be perpendicular to a
flat face. For each shock the cell or battery is accelerated in such a manner that during the
(50 g ). Cells or batteries are
initial 3 ms the minimum average acceleration is 490 m/s
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tested in an ambient temperature of 20 °C ± 5 °C. After the test, the sample shall be left to
rest for a minimum of 1 h and then a visual inspection shall be performed.
Otherwise, for a cell or battery weighing over 100 kg, this test may not be required as per
the agreement between customer and manufacturer.
c) Requirements
No fire, no explosion.
6.5.4 Thermal abuse test
a) Purpose
An elevated temperature exposure shall not cause fire or explosion.
b) Test
Each fully charged cell or battery as per 6.2, stabilized in an ambient temperature of
20 °C ± 5 °C, is placed in a gravity or circulating air convection oven.
The oven temperature is raised at a rate of 5 °C/min ± 2 °C/min to a temperature that
depends on cell case material as follows:
1) Steel: 130 °C ± 5 °C,
2) Plastic: 85 °C ± 5 °C.
The cell or battery remains at this temperature for 30 min before the test is discontinued.
c) Requirements
No fire, no explosion.
6.5.5 Crush
a) Purpose
Severe crushing of a cell shall not cause fire or explosion.
b) Test
Each fully charged cell as per 6.2 is crushed between two flat surfaces. The force for the
crushing is applied by a device exerting a force of 13 kN ± 0,78 kN. The crushing is
performed in a manner that will cause the most adverse result. Once the maximum force
has been applied, or an abrupt voltage drop of one-third of the original voltage has been
obtained, the force is released.
A cylindrical or prismatic cell is crushed with its longitudinal axis parallel to the flat surfaces
of the crushing apparatu
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