ISO 12405-3:2014
(Main)Electrically propelled road vehicles — Test specification for lithium-ion traction battery packs and systems — Part 3: Safety performance requirements
Electrically propelled road vehicles — Test specification for lithium-ion traction battery packs and systems — Part 3: Safety performance requirements
ISO 12405-3:2014 specifies test procedures and provides acceptable safety requirements for voltage class B lithium-ion battery packs and systems, to be used as traction batteries in electrically propelled road vehicles. Traction battery packs and systems used for two-wheel or three-wheel vehicles are not covered by ISO 12405-3:2014. ISO 12405-3:2014 is related to the testing of safety performance of battery packs and systems for their intended use in a vehicle. ISO 12405-3:2014 is not intended to be applied for the evaluation of the safety of battery packs and systems during transport, storage, vehicle production, repair, and maintenance services.
Véhicules routiers à propulsion électrique — Spécifications d'essai pour packs et systèmes de batterie de traction aux ions lithium — Partie 3: Exigences de performance de sécurité
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INTERNATIONAL ISO
STANDARD 12405-3
First edition
2014-05-15
Electrically propelled road vehicles —
Test specification for lithium-ion
traction battery packs and systems —
Part 3:
Safety performance requirements
Véhicules routiers à propulsion électrique — Spécifications d’essai
pour packs et systèmes de batterie de traction aux ions lithium —
Partie 3: Exigences de performance de sécurité
Reference number
ISO 12405-3:2014(E)
©
ISO 2014
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ISO 12405-3:2014(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2014
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form
or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior
written permission. Permission can be requested from either ISO at the address below or ISO’s member body in the country of
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Tel. + 41 22 749 01 11
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Published in Switzerland
ii © ISO 2014 – All rights reserved
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ISO 12405-3:2014(E)
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Symbols and abbreviated terms . 4
5 General requirements . 5
5.1 General conditions . 5
5.2 Test sequence plan . 6
5.3 Preparation of the DUT for testing. 6
5.4 Pre-conditioning cycles . 7
5.5 General safety requirements . 7
6 Mechanical tests . 7
6.1 Vibration . 7
6.2 Mechanical shock . 8
7 Climatic tests . 8
7.1 Dewing (temperature change) . 8
7.2 Thermal shock cycling . 9
8 Simulated vehicle accidents . 9
8.1 Inertial load at vehicle crash . 9
8.2 Contact force at vehicle crash .11
8.3 Water immersion .14
8.4 Exposure to fire .14
9 Electrical tests .16
9.1 Short circuit .16
10 System functionality tests .16
10.1 Overcharge protection .16
10.2 Overdischarge protection .17
10.3 Loss of thermal control/cooling .17
Annex A (informative) Battery systems and related parts .19
Annex B (informative) Description of the screen referenced in 8.4 Exposure to fire .23
Bibliography .24
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ISO 12405-3:2014(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www.iso.org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the meaning of ISO specific terms and expressions related to conformity
assessment, as well as information about ISO’s adherence to the WTO principles in the Technical Barriers
to Trade (TBT) see the following URL: Foreword - Supplementary information
The committee responsible for this document is ISO/TC 22, Road vehicles, Subcommittee SC 21,
Electrically propelled road vehicles.
ISO 12405 consists of the following parts, under the general title Electrically propelled road vehicles —
Test specification for lithium-ion traction battery packs and systems:
— Part 1: High-power applications
— Part 2: High-energy applications
— Part 3: Safety performance requirements
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ISO 12405-3:2014(E)
Introduction
Lithium-ion battery systems are efficient rechargeable energy storage systems for electrically propelled
road vehicles. The requirements for lithium-ion battery systems to be used as power source for the
propulsion of electric road vehicles are significantly different to those batteries used for consumer
electronics or for stationary applications.
Lithium-ion batteries can store electricity at relatively high-energy density compared to other battery
chemistries currently available. Under current state of art, most lithium-ion batteries use organic
electrolytes which are classified as Class 3 “flammable liquid” under the “UN Recommendations on
the Transport of Dangerous Goods — Model Regulations”. Therefore, mitigating potential hazards
associated with fire or explosion of lithium-ion batteries is considered an important issue.
This part of ISO 12405 provides specific test procedures and related requirements to ensure an
appropriate and acceptable level of safety of lithium-ion battery systems specifically developed for
propulsion of road vehicles.
© ISO 2014 – All rights reserved v
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INTERNATIONAL STANDARD ISO 12405-3:2014(E)
Electrically propelled road vehicles — Test specification
for lithium-ion traction battery packs and systems —
Part 3:
Safety performance requirements
1 Scope
This part of ISO 12405 specifies test procedures and provides acceptable safety requirements for voltage
class B lithium-ion battery packs and systems, to be used as traction batteries in electrically propelled
road vehicles. Traction battery packs and systems used for two-wheel or three-wheel vehicles are not
covered by this part of ISO 12405. This part of ISO 12405 is related to the testing of safety performance
of battery packs and systems for their intended use in a vehicle. This part of ISO 12405 is not intended
to be applied for the evaluation of the safety of battery packs and systems during transport, storage,
vehicle production, repair, and maintenance services.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
ISO 6469-1, Electrically propelled road vehicles — Safety specifications — Part 1: On-board rechargeable
energy storage system (RESS)
ISO 6469-3, Electrically propelled road vehicles — Safety specifications — Part 3: Protection of persons
against electric shock
ISO/TR 8713, Electrically propelled road vehicles — Vocabulary
ISO 12405-1:2011, Electrically propelled road vehicles — Test specification for lithium-ion traction battery
packs and systems — Part 1: High-power applications
ISO 12405-2:2012, Electrically propelled road vehicles — Test specification for lithium-ion traction battery
packs and systems — Part 2: High-energy applications
ISO 20653, Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against
foreign objects, water and access
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO/TR 8713 and the following
apply.
3.1
battery control unit
BCU
electronic device that controls, manages, detects, or calculates electric and thermal functions of the
battery system that provides communication between the battery system and other vehicle controllers
Note 1 to entry: See also Annex A for further explanation.
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ISO 12405-3:2014(E)
3.2
battery pack
energy storage device that includes cells or cell assemblies normally connected with cell electronics,
voltage class B circuit, and overcurrent shut-off device, including electrical interconnections and
interfaces for external systems
Note 1 to entry: For further explanation, see A.2.
Note 2 to entry: Examples of external systems are cooling, voltage class B, auxiliary voltage class A, and
communication.
3.3
battery pack subsystem
representative portion of the battery pack
3.4
battery system
energy storage device that includes cells or cell assemblies or battery pack(s), as well as electrical
circuits and electronics
Note 1 to entry: For further explanation, see A.3.1 and A.3.2. Battery system components can also be distributed
in different devices within the vehicle.
Note 2 to entry: Examples of electronics are the BCU and contactors.
3.5
bus
vehicles designed and constructed for the carriage of passengers, comprising more than eight seats in
addition to the driver’s seat, and having a maximum mass exceeding 5 t
3.6
capacity
total number of ampere-hours that can be withdrawn from a fully charged battery under specified
conditions
3.7
cell electronics
electronic device that collects and possibly monitors thermal or electric data of cells or cell assemblies
and contains electronics for cell balancing, if necessary
Note 1 to entry: The cell electronics can include a cell controller. The functionality of cell balancing can be
controlled by the cell electronics or it can be controlled by the BCU.
3.8
customer
party that is interested in using the battery pack or system and, therefore, orders or performs the test
EXAMPLE A vehicle manufacturer.
3.9
device under test
DUT
in this part of ISO 12405, a battery pack or battery system
3.10
explosion
sudden release of energy sufficient to cause pressure waves and/or projectiles that can cause structural
and/or physical damage to the surroundings of the DUT
Note 1 to entry: The kinetic energy of flying debris from the battery pack or system can be sufficient to cause
damage to the surroundings of the DUT as well.
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ISO 12405-3:2014(E)
3.11
fire
continuous emission of flames from a DUT (approximately more than 1 s)
Note 1 to entry: Sparks and arcing are not considered as flames.
3.12
heavy-duty truck
vehicle designed and constructed for the carriage of goods and having a maximum mass exceeding 12 t
3.13
high-energy application
characteristic of device or application for which the numerical ratio between maximum allowed electric
power output (power in W) and electric energy output (energy in Wh) at a 1 C discharge rate at RT for a
battery pack or system is typically lower than 10
Note 1 to entry: Typically, high-energy battery packs and systems are designed for applications in BEVs.
3.14
high-power application
characteristic of device or application for which the numerical ratio between maximum allowed electric
power output (power in W) and electric energy output (energy in Wh) at a 1 C discharge rate at RT for a
battery pack or system is typically equal to or higher than 10
Note 1 to entry: Typically, high-power battery packs and systems are designed for application in HEVs and FCVs.
3.15
isolation resistance
resistance between live parts of the voltage class B electric circuit and the electric chassis, as well as the
voltage class A system
3.16
leakage
escape of liquid or gas from a DUT except for venting
3.17
maximum working voltage
highest value of a.c. voltage (rms) or of d.c. voltage, which can occur in an electrical system under any
normal operating conditions according to the battery manufacturer’s specifications, disregarding
transients
3.18
medium-duty truck
vehicle designed and constructed for the carriage of goods and having a maximum mass exceeding 3,5 t
but not exceeding 12 t
3.19
midi bus
vehicle designed and constructed for the carriage of passengers, comprising more than eight seats in
addition to the driver’s seat, and having a maximum mass not exceeding 5 t
3.20
rated capacity
supplier’s specification of the total number of ampere-hours that can be withdrawn from a fully charged
battery pack or system for a specified set of test conditions such as discharge rate, temperature,
discharge cut-off voltage, etc.
3.21
room temperature
RT
temperature of (25 ± 2) °C
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ISO 12405-3:2014(E)
3.22
rupture
loss of mechanical integrity of the enclosure of the DUT resulting in openings that do not fulfil protection
degree IPXXB according to ISO 20653
Note 1 to entry: The kinetic energy of released material is not sufficient to cause structural and/or physical
damage to the surrounding of the DUT.
3.23
state of charge
SOC
available capacity in a battery pack or system expressed as a percentage of rated capacity
3.24
supplier
party that provides battery systems and packs
EXAMPLE A battery manufacturer.
3.25
venting
release of excessive pressure from a DUT intended by design to preclude rupture or explosion
3.26
voltage class A
classification of an electric component or circuit with a maximum working voltage of ≤30 V a.c. (rms) or
≤60 V d.c., respectively
Note 1 to entry: See ISO 6469-3.
3.27
voltage class B
classification of an electric component or circuit with a maximum voltage of (>30 and ≤1 000) V a.c.
(rms) or (>60 and ≤1 500) V d.c., respectively
Note 1 to entry: See ISO 6469-3.
4 Symbols and abbreviated terms
a.c. alternating current
BCU battery control unit
BEV battery electric vehicle
d.c. direct current
DUT device under test
FCV fuel cell vehicle
HEV hybrid electric vehicle
RESS rechargeable energy storage system
RT room temperature [(25 ± 2) °C]
SOC state of charge
UNECE United Nations Economic Commission for Europe
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ISO 12405-3:2014(E)
5 General requirements
5.1 General conditions
A battery pack or system to be tested according to this part of ISO 12405 shall fulfil the following
requirements.
— Electrical safety design shall be approved according to the requirements given in ISO 6469-1 and
ISO 6469-3.
— The necessary documentation for operation and needed interface parts for connection to the test
equipment (i.e. connectors, plugs including cooling) shall be delivered together with the DUT.
— A battery system shall enable the specified tests, e.g. by specified test modes implemented in the
BCU, and shall be able to communicate with the test bench via common communication buses.
— The DUT can also be equipped with additional sensors, wires, and support jig, which are necessary
to conduct the specific test or to obtain the required data for such a test. Such additional devices
shall not influence the result with respect to the intended purpose of the test.
If not otherwise specified, the tests described apply to battery packs and systems.
The battery pack subsystem as a DUT shall comprise all parts specified by the customer (e.g. including
mechanical and electrical connecting points for mechanical test).
The status of the DUT, e.g. new product, tested, or used, shall be agreed upon between the customer and
the supplier before testing. The history of the DUT shall be documented.
When reference to ISO 12405-1 and ISO 12405-2 is made, only the test procedure in the corresponding
clause shall apply. In this case, the test procedures and pre-conditions (e.g. temperatures, SOC) shall be
selected according to the battery packs or systems application. For high-power applications, refer to
ISO 12405-1, and for high-energy applications, refer to ISO 12405-2.
If not otherwise specified, the following conditions shall apply.
— The test temperature shall be RT.
— Before each test, the DUT shall be equilibrated at the test temperature. The thermal equilibration
is reached, if during a period of 1 h without active cooling the deviations between test temperature
and temperature of all cell temperature measuring points are lower than ±2 K.
— Before each test, the SOC of the DUT shall be set to a value agreed upon between the customer and
the supplier but at least 50 % SOC for high-power applications. For high-energy applications, the
SOC shall be set to maximum SOC at normal operation.
— Each charge and each SOC change shall be followed by a rest period of 30 min.
— The conduction of component-based testing or vehicle-based testing is optional. The selection of
either of the described options shall be according to the agreement between the customer and the
supplier.
The accuracy of external measurement equipment shall be at least within the following tolerances:
— voltage: ±0,5 %;
— current: ±0,5 %;
— temperature: ±1 K.
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ISO 12405-3:2014(E)
The overall accuracy of externally controlled or measured values, relative to the specified or actual
values, shall be at least within the following tolerances:
— voltage: ±1 %;
— current: ±1 %;
— temperature: ±2 K;
— time: ±0,1 %;
— mass: ±0,1 %;
— dimensions: ±0,1 %.
All values (time, temperature, current, and voltage) shall be noted at least every 5 % of the estimated
discharge and charge time, except if it is noted otherwise in the individual test procedure.
If any test in this part of ISO 12405 is performed on the vehicle, the same test on battery pack or system
level is not necessary.
5.2 Test sequence plan
5.2.1 General
The test sequence for an individual battery pack or system or a battery pack subsystem shall be based
on the agreement between the customer and the supplier.
The re-use of the battery system and/or components in multiple tests is acceptable based on the
agreement between the customer and the supplier.
5.3 Preparation of the DUT for testing
5.3.1 Preparation of battery pack
If not otherwise specified, the battery pack shall be connected with voltage class B and voltage class A
connections to the test bench equipment. Contactors, available voltage, current, and temperature data
shall be controlled according to the supplier’s requirements and according to the given test specification
by the test bench equipment. The passive overcurrent protection shall be maintained by the test bench
equipment, if necessary via disconnection of the battery pack main contactors. The cooling device can
be connected to the test bench equipment and operated according to the supplier’s requirements.
5.3.2 Preparation of battery system
If not otherwise specified, the battery system shall be connected with voltage class B, voltage class
A, and cooling system and BCU to the test bench equipment. The battery system shall be controlled
by the BCU. The test bench equipment shall follow the operational limits provided by the BCU via
bus communication. The test bench equipment shall maintain the on/off requirements for the main
contactors and the voltage, current, and temperature profiles according to the requested requirements
of the given test procedure. The battery system cooling device and the corresponding cooling loop at the
test bench equipment shall be operational according to the given test specifications and the controls by
the BCU. The BCU shall enable the test bench equipment to perform the requested test procedure within
the battery system operational limits. If necessary, the BCU program shall be adapted by the supplier for
the requested test procedure. The active and passive overcurrent protection device shall be operational
by the battery system. Active overcurrent protection shall be maintained by the test bench equipment,
too, if necessary, via request of disconnection of the battery system main contactors.
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ISO 12405-3:2014(E)
5.4 Pre-conditioning cycles
5.4.1 DUT
If not otherwise specified, this test applies to each subsequent test of battery packs and systems.
5.4.2 Purpose
The DUT shall be conditioned by performing some electrical cycles, before starting the real testing
sequence, in order to ensure an adequate stabilization of the battery pack or system performance.
5.4.3 Test procedure
The test procedure for pre-conditioning cycles shall apply according to 6.1.2 of ISO 12405-1:2011 or
ISO 12405-2:2012, as appropriate for the DUT.
The battery pack or system shall be considered as pre-conditioned if the discharge capacity during two
consecutive discharges does not change by a value greater than 3 % of the rated capacity. The pre-
conditioning cycles are not necessary if the requirement is already fulfilled by an equivalent procedure.
5.5 General safety requirements
The following requirements are standard requirements, which apply when cited.
During the test and for a 1 h post-test observation period, the DUT shall not exhibit evidence of leakage,
rupture, fire, or explosion. The evidence of leakage shall be verified by visual inspection without
disassembling any part of the DUT.
The DUT shall maintain an isolation resistance of at least 100 Ω/V, if not containing a.c., or 500 Ω/V,
if containing a.c. When the DUT is integrated in a whole electric circuit, a higher resistance value for
the DUT might be necessary. After the post-test observation period, the isolation resistance shall be
measured in accordance with ISO 6469-1 without climatic pre-conditioning and conditioning.
NOTE DUT in this part of ISO 12405 is equivalent to RESS in ISO 6469-1.
6 Mechanical tests
6.1 Vibration
6.1.1 Purpose
The purpose of this test is to verify the safety performance of the DUT under a mechanical load due to
vibration, which a battery system will likely experience during the normal operation of a vehicle.
6.1.2 Test procedure
Choose one of the following two options:
1) vibration according to 8.3.2.1 of ISO 12405-1:2011 or ISO 12405-2:2012, as appropriate for the DUT;
2) vibration profile as given by the customer, specifically applicable to the vehicle(s) in which the
battery will be used.
NOTE 1 A vibration profile determined by the customer is an option described in ISO 12405-1 or ISO 12405-2.
NOTE 2 A vibration profile is given in UN ECE R100–02.
In case of liquid- or refrigerant-cooled battery systems, the DUT shall be filled with the specified
coolant. The connection to an external cooling circuit shall be maintained according to the battery
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ISO 12405-3:2014(E)
manufacturer’s specifications or the connecting ports shall be sealed to retain the coolant inside the
piping within the DUT.
NOTE 3 This test can be performed using a battery pack subsystem (see 5.1).
6.1.3 Requirements
Requirements as given in 5.5 shall apply.
6.2 Mechanical shock
6.2.1 Purpose
The purpose of this test is to verify the safety performance of the DUT under a mechanical load due
to mechanical shock, which a battery system will likely experience during the normal operation of a
vehicle.
NOTE Mechanical shock considers driving operations, such as deceleration in sudden braking situations or
driving over road bumps or pot holes. It does not include a vehicle crash scenario.
6.2.2 Test procedure
Choose one of the following two options:
1) mechanical shock according to 8.4.2. of ISO 12405-1:2011 or ISO 12405-2:2012, as appropriate for
the DUT;
2) mechanical shock profile as given by the customer, specifically applicable to the vehicle(s) in which
the battery will be used.
NOTE 1 A mechanical shock profile determined by the customer is an option described in ISO 12405-1 or
ISO 12405-2.
NOTE 2 If the DUT is tested with a fixture according to the vehicle application, a lower acceleration value can
apply.
NOTE 3 This test can be performed using a battery pack subsystem (see 5.1).
NOTE 4 A shock profile is given in UN ECE R100–02.
6.2.3 Requirements
Requirements as given in 5.5 shall apply.
7 Climatic tests
7.1 Dewing
...
DRAFT INTERNATIONAL STANDARD ISO/DIS 12405-3
ISO/TC 22/SC 21 Secretariat: DIN
Voting begins on Voting terminates on
2013-03-22 2013-06-22
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION
Electrically propelled road vehicles — Test specification for
Lithium-ion traction battery packs and systems —
Part 3:
Safety performance requirements
ICS 43.120
To expedite distribution, this document is circulated as received from the committee
secretariat. ISO Central Secretariat work of editing and text composition will be undertaken at
publication stage.
Pour accélérer la distribution, le présent document est distribué tel qu'il est parvenu du
secrétariat du comité. Le travail de rédaction et de composition de texte sera effectué au
Secrétariat central de l'ISO au stade de publication.
THIS DOCUMENT IS A DRAFT CIRCULATED FOR COMMENT AND APPROVAL. IT IS THEREFORE SUBJECT TO CHANGE AND MAY NOT BE
REFERRED TO AS AN INTERNATIONAL STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS BEING ACCEPTABLE FOR INDUSTRIAL, TECHNOLOGICAL, COMMERCIAL AND USER PURPOSES, DRAFT
INTERNATIONAL STANDARDS MAY ON OCCASION HAVE TO BE CONSIDERED IN THE LIGHT OF THEIR POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN NATIONAL REGULATIONS.
RECIPIENTS OF THIS DRAFT ARE INVITED TO SUBMIT, WITH THEIR COMMENTS, NOTIFICATION OF ANY RELEVANT PATENT RIGHTS OF WHICH
THEY ARE AWARE AND TO PROVIDE SUPPORTING DOCUMENTATION.
© International Organization for Standardization, 2013
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ISO/DIS 12405-3
Copyright notice
This ISO document is a Draft International Standard and is copyright-protected by ISO. Except as permitted
under the applicable laws of the user’s country, neither this ISO draft nor any extract from it may be
reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic,
photocopying, recording or otherwise, without prior written permission being secured.
Requests for permission to reproduce should be addressed to either ISO at the address below or ISO’s
member body in the country of the requester.
ISO copyright office
Case postale 56 • CH-1211 Geneva 20
Tel. + 41 22 749 01 11
Fax + 41 22 749 09 47
E-mail copyright@iso.org
Web www.iso.org
Reproduction may be subject to royalty payments or a licensing agreement.
Violators may be prosecuted.
ii © ISO 2013 – All rights reserved
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ISO/DIS 12405-3
Contents Page
Foreword . iv
Introduction . v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Symbols and abbreviated terms . 4
5 General requirements . 4
5.1 General conditions . 4
5.2 Test sequence plan . 6
5.3 Pre-conditioning . 6
5.4 General safety requirements . 6
6 Mechanical tests . 7
6.1 Vibration . 7
6.2 Mechanical shock . 7
7 Climatic tests . 8
7.1 Dewing . 8
7.2 Thermal cycling . 8
8 Simulated vehicle accidents . 9
8.1 Inertial load at vehicle crash . 9
8.2 Contact force at vehicle crash . 11
8.3 Water immersion . 12
8.4 Exposure to fire . 12
9 Electrical tests . 14
9.1 Short circuit . 14
10 System functionality tests . 15
10.1 Overcharge protection . 15
10.2 Overdischarge protection . 15
10.3 Loss of thermal control/cooling . 16
Annex A (informative) Battery Systems and related parts . 17
Annex B (informative) To chapter 9.4. Exposure to fire – Description of the screen . 20
Bibliography . 21
© ISO 2012 – All rights reserved iii
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ISO/DIS 12405-3
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 12405-3 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 21,
Electrically propelled road vehicles.
ISO 12405 consists of the following parts, under the general title Electrically propelled road vehicles — Test
specification for lithium-ion battery packs and systems:
Part 1: High power application
Part 2: High energy application
Part 3: Safety performance requirements
iv © ISO 2012 – All rights reserved
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ISO/DIS 12405-3
Introduction
Lithium-ion battery systems are efficient rechargeable energy storage systems for electrically propelled road
vehicles. The requirements for lithium-ion battery systems to be used as power source for the propulsion of
electric road vehicles are significantly different to those batteries used for consumer electronics or for
stationary applications.
Lithium-Ion batteries may store electricity at relatively high energy density com-pared to other battery
chemistries currently available. Under current state of art, most lithium-ion batteries use organic electrolytes
which are classified as Class 3 "flammable liquid" under "UN Recommendations on the Transport of
Dangerous Goods – Model Regulations". Therefore, mitigating potential hazards associated with fire or
explosion of lithium-ion batteries is considered an important issue.
This International Standard provides specific test procedures and related requirements to ensure an
appropriate and acceptable level of safety of lithium-ion battery systems specifically developed for propulsion
of road vehicles.
© ISO 2012 – All rights reserved v
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DRAFT INTERNATIONAL STANDARD ISO/DIS 12405-3
Electrically propelled road vehicles — Test specification for
lithium-ion battery packs and systems — Part 3: Safety
performance requirements
1 Scope
This International Standard specifies test procedures and provides acceptable safety requirements for voltage
class B lithium-ion battery packs and systems, to be used as traction batteries in electrically propelled road
vehicles. Traction battery packs and systems used for two-wheel or three-wheel vehicles are not covered by
this standard. This International Standard is related to the testing of safety performance of battery packs and
systems for their intended use in a vehicle. This International Standard is not intended to be applied for the
evaluation of the safety of battery packs and systems during transport, storage, vehicle production, repair and
maintenance services.
2 Normative references
The following referenced documents are indispensable for the application 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.
ISO 6469-1, Electrically propelled road vehicles – Safety specifications — Part 1: On-board rechargeable
energy storage system (RESS)
ISO DIS 6469, Electrically propelled road vehicles – Safety specifications — Part 4: Post crash electrical
safety requirements
ISO/TR 8713, Electrically Propelled Road vehicles -- Vocabulary
ISO 12405-1:2011, Electrically propelled road vehicles – Test specification for lithium-ion traction battery
packs and systems — Part 1: High-power applications
ISO 12405-2:2012, Electrically propelled road vehicles — Test specification for lithium-ion traction battery
packs and systems —Part 2: High-energy applications
ISO 20653, Road vehicles -- Degrees of protection (IP-Code) -- Protection of electrical equipment against
foreign objects, water and access
3 Terms and definitions
For the purposes of this document, the following terms and definitions and the definitions given in ISO/TR
8713 apply.
3.1
battery control unit
BCU
electronic device that controls or manages or detects or calculates electric and thermal functions of the battery
systems and other vehicle controllers
NOTE See also Annex A for further explanation.
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3.2
battery pack
energy storage device that includes cells or cell assemblies normally connected with cell electronics, voltage
class B circuit and overcurrent shut-off device, including electrical interconnections, interfaces for external
systems
NOTE 1 For further explanation, see A.2.
NOTE 2 Examples of external systems are cooling, voltage class B, auxiliary voltage class A and communication.
3.3
battery system
energy storage device that includes cells or cell assemblies or battery pack(s) as well as electrical circuits and
electronics
NOTE 1 For further explanation, see A.3.1 and A.3.2. Battery system components can also be distributed in different
devices within the vehicle.
NOTE 2 Examples of electronics are the BCU and contactors.
3.4
capacity
total number of ampere-hours that can be withdrawn from a fully charged battery under specified conditions
3.5
cell electronics
electronic device that collects and possibly monitors thermal or electric data of cells or cell assemblies and
contains electronics for cell balancing, if necessary
NOTE The cell electronics may include a cell controller. The functionality of cell balancing may be controlled by the
cell electronics or it may be controlled by the BCU.
3.6
customer
party that is interested in using the battery pack or system and, therefore, orders or performs the test
EXAMPLE A vehicle manufacturer.
3.7
device under test
DUT
within this part of ISO 12405 a battery pack or battery system
3.8
explosion
sudden release of energy sufficient to cause pressure waves and/or projectiles that may cause structural
and/or physical damage to the surrounding of the DUT
NOTE The kinetic energy of flying debris from the battery back or system may be sufficient to cause damage to the
surrounding of the DUT as well.
3.9
fire
continuous emission of flames from a DUT (approximately more than one second)
NOTE Sparks and arcing are not considered as flames.
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3.10
high energy application
characteristic of device or application, for which the numerical ratio between maximum allowed electric power
output (power in W) and electric energy output (energy in Wh) at a 1 C discharge rate at RT for a battery pack
or system is typically lower than 10
NOTE Typically high energy battery packs and systems are designed for applications in BEVs.
3.11
high power application
characteristic of device or application, for which by the numerical ratio between maximum allowed electric
power output (power in W) and electric energy output (energy in Wh) at a 1 C discharge rate at RT for a
battery pack or system is typically equal or higher than 10
NOTE Typically high power battery packs and systems are designed for application in HEVs and FCVs.
3.12
isolation resistance
resistance between live parts of voltage class B electric circuit and the electric chassis as well as the voltage
class A system
3.13
leakage
escape of liquid or gas from a DUT except for venting
3.14
maximum working voltage
highest value of a.c. voltage (rms) or of d.c. voltage which may occur in an electrical system under any normal
operating conditions according to the battery manufacturer's specifications, disregarding transients
3.15
rated capacity
suppliers specification of the total number of ampere-hours that can be withdrawn from a fully charged battery
pack or system for a specified set of test conditions such as discharge rate, temperature, discharge cut-off
voltage, etc.
3.16
room temperature
RT
temperature of (25 ± 2)°C
3.17
rupture
loss of mechanical integrity of the enclosure of the battery pack or system resulting in openings not fulfilling
protection degree IPXXB according to ISO 20653
NOTE The kinetic energy of released material is not sufficient to cause structural and/or physical damage to the
surrounding of the DUT.
3.18
state of charge
SOC
available capacity in a battery pack or system expressed as a percentage of rated capacity
3.19
supplier
party that provides battery systems and packs
EXAMPLE A battery manufacturer.
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3.20
venting
release of excessive pressure from a DUT intended by design to preclude rupture or explosion
3.21
voltage class A
classification of an electric component or circuit with a maximum working voltage of ≤ 30 V a.c. or ≤ 60 V d.c.,
respectively
NOTE For more details, see ISO 6469-3.
3.22
voltage class B
classification of an electric component or circuit with a maximum voltage of (> 30 and ≤ 1000) V a.c. or
(> 60 and ≤ 1500) V d.c., respectively
NOTE For more details, see ISO 6469-3.
4 Symbols and abbreviated terms
a.c. alternating current
BCU battery control unit
BEV battery electric vehicle
d.c. direct current
DUT device under test
FCV fuel cell vehicle
HEV hybrid electric vehicle
RT room temperature (25 ± 2) °C
SOC state of charge
UNECE United Nations Economic Commission for Europe
5 General requirements
5.1 General conditions
A battery pack or system to be tested according to this standard shall fulfil the following requirements:
The necessary documentation for operation and needed interface parts for connection to the test
equipment (i.e. connectors, plugs including cooling) shall be delivered together with the DUT.
A battery system shall enable the specified tests, e.g. by specified test modes implemented in the
BCU, and shall be able to communicate with the test bench via common communication buses.
The DUT may also be equipped with additional sensors, wires, support jig which are necessary to
conduct the specific test or to obtain the required data for such test. Such additional devices shall
not influence the result with respect to the intended purpose of the test.
If not otherwise specified, the tests described apply to battery packs and systems.
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The battery pack subsystem as a DUT shall comprise all parts specified by the customer (e.g. including
mechanical and electrical connecting points for mechanical test).
The status of the DUT, e.g. new product, tested or used, shall be agreed upon between customer and supplier
before testing. The history of the DUT shall be documented.
When reference to ISO 12405-1 and ISO 12405-2 is made only the test procedure in the corresponding
clause shall apply. In this case the test procedures and pre-conditions (e.g. temperatures, SOC) shall be
selected according to the battery packs or systems application. For high-power applications refer to ISO
12405-1 and for high-energy applications refer to ISO 12405-2.
If not otherwise specified, the test temperature shall be RT.
If not otherwise specified, before each test the DUT shall be equilibrated at the test temperature. The thermal
equilibration is reached, if during a period of 1 h without active cooling the deviations between test
temperature and temperature of all cell temperature measuring points are lower than ± 2 K.
If not otherwise specified, before each test the DUT shall be set to a value agreed upon between customer
and supplier but at least 50 % SOC for high-power applications. If not otherwise specified, before each test
the DUT shall be set to maximum SOC at normal operation for high-energy applications.
If not otherwise specified, each charge and each SOC change shall be followed by a rest period of 30 min.
If not otherwise specified, all battery system electronic control units have to be connected and in operation or
"off" state, as recommended by the battery manufacturer during testing.
If not specified otherwise in the corresponding test procedure, the conduction of component based testing or
vehicle based testing is optional. The selection of either of the described options shall be up to the agreement
between customer and supplier.
The accuracy of external measurement equipment shall be at least within the following tolerances:
voltage ± 0,5 %
current ± 0,5 %
temperature ± 1 K
The overall accuracy of externally controlled or measured values, relative to the specified or actual values,
shall be at least within the following tolerances:
voltage ± 1 %
current ± 1 %
temperature ± 2 K
time ± 0,1 %
mass ± 0,1 %
dimensions ± 0,1 %
All values (time, temperature, current and voltage) shall be noted at least every 5 % of the estimated
discharge and charge time, except if it is noted otherwise in the individual test procedure.
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If any test in this standard is performed on vehicle, the same test on battery pack or system level is not
necessary.
5.2 Test sequence plan
The test sequence for an individual battery pack or system, or a battery pack subsystem shall be based on
agreement between the customer and the supplier.
The re-use of the battery system and/or components in multiple tests is acceptable based on the agreement
between customer and supplier.
5.2.1 Preparation of battery pack
If not otherwise specified, the battery pack shall be connected with voltage class B and voltage class A
connections to the test bench equipment. Contactors, available voltage, current and temperature data shall be
controlled according to the suppliers requirements and according to the given test specification by the test
bench equipment. The passive overcurrent protection shall be maintained by the test bench equipment, if
necessary via disconnection of the battery pack main contactors. The cooling device may be connected to the
test bench equipment and operated according to the suppliers requirements.
5.2.2 Preparation of battery system
If not otherwise specified, the battery system shall be connected with voltage class B, voltage class A and
cooling system and BCU to the test bench equipment. The battery system shall be controlled by the BCU. The
test bench equipment shall follow the operational limits provided by the BCU via bus communication. The test
bench equipment shall maintain the on/off requirements for the main contactors and the voltage, current and
temperature profiles according to the requested requirements of the given test procedure. The battery system
cooling device and the corresponding cooling loop at the test bench equipment shall be operational according
to the given test specifications and the controls by the BCU. The BCU shall enable the test bench equipment
to perform the requested test procedure within the battery system operational limits. If necessary, the BCU
program shall be adapted by the supplier for the requested test procedure. The active and passive overcurrent
protection device shall be operational by the battery system. Active overcurrent protection shall be maintained
by the test bench equipment, too, if necessary via request of disconnection of the battery system main
contactors.
5.3 Pre-conditioning
5.3.1 DUT
If not otherwise specified, this test applies to each subsequent test of battery packs and systems.
5.3.2 Purpose
The DUT shall be conditioned by performing some electrical cycles, before starting the real testing sequence,
in order to ensure an adequate stabilisation of the battery pack or system performance.
5.3.3 Test procedure
Pre-conditioning cycles according to clause 6.1 of ISO 12405-1 or ISO 12405-2 as appropriate for the DUT.
The battery pack or system shall be considered as pre-conditioned if the discharge capacity during two
consecutive discharges does not change by a value greater than 3 % of the rated capacity. The
preconditioning is not necessary if the requirement is already fulfilled by an equivalent procedure.
5.4 General safety requirements
The following requirements are standard requirements, which apply when cited.
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During the test and for a 1 hour post-test observation period, the DUT shall exhibit no evidence of leakage or
rupture, fire, or explosion. The DUT shall maintain an isolation resistance of at least 100 Ω/V, if not containing
a.c., or 500 Ω/V, if containing a.c. When the DUT is integrated in a whole electric circuit, a higher resistance
value for the DUT may be necessary. After the post-test observation period an isolation measurement shall be
done in accordance with ISO 6469-1 without climatic preconditioning and conditioning.
NOTE: DUT in this standard is equivalent to RESS in ISO 6469-1.
The evidence of leakage shall be verified by visual inspection without disassembling any part of the DUT.
6 Mechanical tests
6.1 Vibration
6.1.1 Purpose
The purpose of this test is to verify the safety performance of the battery packs and systems under a
mechanical load due to vibration which the battery system will likely experience during the normal operation of
the vehicle.
6.1.2 Test procedure
Choose one of the two options:
(1) Vibration according to clause 8.3.2.1 of ISO 12405-1 or ISO 12405-2.
(2) Vibration profile as given by the customer, specifically applicable to the vehicle(s) in which the battery
will be used.
NOTE 1 A vibration profile determined by the customer is an option described in ISO 12405-1 or -2.
NOTE 2 A vibration profile is given in UNECE R100-02.
In case of liquid or refrigerant-cooled battery systems, the DUT shall be filled with the specified coolant. The
connection to an external cooling circuit shall be maintained according to the manufacturer’s specifications or
the connecting ports shall be sealed to retain the coolant inside the piping within the battery pack.
NOTE 3 This test may be performed using a battery pack subsystem, see 5.1.
6.1.3 Requirements
Requirements as given in clause 5.4 shall apply.
6.2 Mechanical shock
6.2.1 Purpose
The purpose of this test is to verify the safety performance of the battery system under a mechanical load due
to mechanical shock which the battery system will likely experience during the normal operation of the vehicle.
Note: Mechanical shock considers driving operations such as deceleration in sudden braking situations, handling
shocks during shipping and driving over road bumps or pot holes. It does not include a vehicle crash scenario.
6.2.2 Test procedure
Choose one of the two options:
(1) Mechanical shock according to clause 8.4.2. of ISO 12405-1 or ISO 12405-2.
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(2) Mechanical shock profile as given by the customer, specifically applicable to the vehicle(s) in which
the battery will be used.
NOTE 1 A mechanical shock profile determined by the customer is an option described in ISO 12405-1 or -2.
NOTE 2 If the DUT is tested with a fixture according to the vehicle application, a lower acceleration value may apply.
NOTE 3 This test may be performed using a battery pack subsystem, see 5.1.
6.2.3 Requirements
Requirements as given in clause 5.5 shall apply.
7 Climatic tests
7.1 Dewing
7.1.1 Purpose
Simulates a climatic load which causes dewing derived from vehicle operation which battery packs and
systems will likely experience during service life.
7.1.2 Test procedure
According to clause 8.1.2 of ISO 12405-1 or ISO 12405-2.
7.1.3 Requirements
Requirements as given in clause 5.4 shall apply.
7.2 Thermal cycling
7.2.1 Purpose
The purpose of this test is to verify the ability of battery packs and systems to withstand sudden changes in
ambient temperature. The test simulates rapid temperature changes which battery packs and systems would
likely experience during service life.
7.2.2 Test procedure
The DUT shall undergo a specified number of temperature cycles, which start at ambient temperature
followed by high and low temperature cycling in accordance with clause 8.2.2 of ISO 12405-1 or ISO 12405-2.
If the DUT utilizes liquid cooling, the coolant shall be present as for normal operation but all thermal control
shall be non-operational.
NOTE: The following test parameters may be chosen:
maximum ambient temperature: 60°C ± 2K
time at temperature extremes: 6h.
7.2.3 Requirements
Requirements as given in clause 5.4 shall apply.
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8 Simulated vehicle accidents
8.1 Inertial load at vehicle crash
8.1.1 Purpose
The purpose of this test is to verify the safety performance of battery packs and systems under inertial loads
caused by acceleration which may occur at a vehicle crash.
8.1.2 Test procedure
Testing shall be conducted at least once in the same direction of th
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