ISO 6469-1:2019
(Main)Electrically propelled road vehicles — Safety specifications — Part 1: Rechargeable energy storage system (RESS)
Electrically propelled road vehicles — Safety specifications — Part 1: Rechargeable energy storage system (RESS)
This document specifies safety requirements for rechargeable energy storage systems (RESS) of electrically propelled road vehicles for the protection of persons. It does not provide the comprehensive safety information for the manufacturing, maintenance and repair personnel. NOTE 1 Requirements for motorcycles and mopeds are specified in ISO 13063 and ISO 18243. NOTE 2 Additional safety requirements can apply for RESS that can be recharged by means different from supplying electric energy (e.g. redox flow battery).
Véhicules routiers électriques — Spécifications de sécurité — Partie 1: Système de stockage d'énergie rechargeable (RESS)
General Information
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Standards Content (Sample)
INTERNATIONAL ISO
STANDARD 6469-1
Third edition
2019-04
Electrically propelled road vehicles —
Safety specifications —
Part 1:
Rechargeable energy storage system
(RESS)
Véhicules routiers électriques — Spécifications de sécurité —
Partie 1: Système de stockage d'énergie rechargeable (RESS)
Reference number
ISO 6469-1:2019(E)
©
ISO 2019
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ISO 6469-1:2019(E)
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ISO 6469-1:2019(E)
Contents Page
Foreword .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 General requirements . 4
4.1 General electrical requirements . 4
4.2 General safety requirements . 5
5 Technical requirements . 5
5.1 Mechanical requirements . 5
5.2 Climatic requirements . 5
5.2.1 Thermal shock cycling . 5
5.3 Simulated vehicle accident requirements . 5
5.3.1 Vehicle crash . 5
5.3.2 Immersion into water . 6
5.3.3 Exposure to fire . 6
5.4 Electrical requirements . 7
5.4.1 Isolation resistance . 7
5.4.2 Clearance and creepage distance . 7
5.4.3 Short-circuit protection . 8
5.5 Functional requirements . 8
5.5.1 General. 8
5.5.2 Overcharge protection . 8
5.5.3 Overdischarge protection . 8
5.5.4 Protection against internal overheating . 8
5.6 Requirements for the emission of hazardous gases and other hazardous substances . 9
6 Test procedures . 9
6.1 General test conditions . 9
6.1.1 Test types and post-test observation . 9
6.1.2 Test parameters . 9
6.1.3 DUT requirements and preparation of the DUT for testing .10
6.1.4 Preconditioning of the DUT .10
6.1.5 Standard cycle (SC) .11
6.1.6 Testing of general safety requirements .11
6.2 Mechanical test .12
6.2.1 General.12
6.2.2 Vibration .12
6.2.3 Mechanical shock .14
6.3 Climatic test .15
6.3.1 Thermal shock cycling .15
6.4 Simulated vehicle accident tests .15
6.4.1 Vehicle crash .15
6.4.2 Immersion into water .18
6.4.3 Exposure to fire .19
6.5 Electrical test .20
6.5.1 Short circuit .20
6.6 Functional tests .21
6.6.1 General procedures .21
6.6.2 Overcharge protection .21
6.6.3 Overdischarge protection .21
6.6.4 Protection against internal overheating .22
Annex A (informative) Damage calculation .23
Annex B (informative) Example of the OEM specific test .24
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ISO 6469-1:2019(E)
Annex C (informative) Description of the screen .25
Bibliography .26
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ISO 6469-1:2019(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. 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. 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 of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso
.org/iso/foreword .html.
This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 37,
Electrically propelled vehicles.
This third edition cancels and replaces the second edition (ISO 6469-1:2009) and ISO 12405-3:2014,
which have been technically revised.
The main changes compared to ISO 6469-1:2009 and ISO 12405-3:2014 are as follows:
— test descriptions and requirements were reworked to include specific characteristics for lithium-
ion based battery systems;
— document was reworked to become a general safety standard for all RESS types; and
— almost all test procedures and descriptions as given in the previous versions of both documents
have been adapted to the latest technical developments.
A list of all parts in the ISO 6469 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
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INTERNATIONAL STANDARD ISO 6469-1:2019(E)
Electrically propelled road vehicles — Safety
specifications —
Part 1:
Rechargeable energy storage system (RESS)
1 Scope
This document specifies safety requirements for rechargeable energy storage systems (RESS) of
electrically propelled road vehicles for the protection of persons.
It does not provide the comprehensive safety information for the manufacturing, maintenance and
repair personnel.
NOTE 1 Requirements for motorcycles and mopeds are specified in ISO 13063 and ISO 18243.
NOTE 2 Additional safety requirements can apply for RESS that can be recharged by means different from
supplying electric energy (e.g. redox flow battery).
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.
ISO 6469-3, Electrically propelled road vehicles — Safety specifications — Part 3: Electrical safety
ISO 20653, Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against
foreign objects, water and access
IEC 60068-2-27, Environmental testing - Part 2-27: Tests — Test Ea and guidance: Shock
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
3.1
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 exceeding 5 t
3.2
capacity
total number of ampere-hours that can be withdrawn from a fully charged RESS (3.22) under specified
operating
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ISO 6469-1:2019(E)
3.3
clearance
shortest distance in air between two conductive parts (3.4)
[SOURCE: IEC 60664-1:2007, 3.2]
3.4
conductive part
part which can carry electric current
[SOURCE: IEC 60050-195:1998, 195-01-06]
3.5
creepage distance
shortest distance along a surface of a solid insulating material between two conductive parts (3.4)
[SOURCE: IEC 60050-151:2001/AMD1: 2013, 151-15-50]
3.6
customer
party that is interested in using the RESS (3.22) or RESS subsystem (3.24) and therefore, orders or
performs the test
EXAMPLE Vehicle manufacturers.
[SOURCE: ISO PAS 19295:2016, modified — “voltage class B component or system” replaced by “RESS or
RESS subsystems and therefore, orders or performs the test”, EXAMPLE added]
3.7
electric chassis
conductive parts (3.4) of a vehicle that are electrically connected and whose potential is taken as
reference
[SOURCE: ISO 6469-3:2018, 3.12]
3.8
electric drive
combination of an electric traction motor, power electronics and their associated controls for the
conversion of electric to mechanical power and vice versa
[SOURCE: ISO 6469-3:2018, 3.13]
3.9
electrically propelled vehicle
vehicle with one or more electric drive(s) (3.8) for vehicle propulsion
[SOURCE: ISO 6469-3:2018, 3.15]
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 surrounding area
3.11
flammable electrolyte
electrolyte having a flash point of not more than 93 °C
Note 1 to entry: The determination of flash point is based on ISO 2592.
3.12
heavy-duty truck
vehicle designed and constructed for the carriage of goods and having a maximum mass exceeding 12 t
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ISO 6469-1:2019(E)
3.13
isolation resistance
insulation resistance
resistance between live parts (3.16) of an electric circuit and the electric chassis (3.7) as well as other
electric circuits which are insulated from this electric circuit
[SOURCE: ISO 6469-3:2018, 3.23]
3.14
isolation resistance monitoring system
system that periodically or continuously monitors the isolation resistance (3.13) between live parts
(3.16) and the electric chassis (3.7)
[SOURCE: ISO 6469-3:2018, 3.24]
3.15
leakage
escape of liquid or gas except for venting (3.28)
3.16
live part
conductor or conductive part (3.4) intended to be energized in normal use, but by convention, not the
electric chassis (3.7)
[SOURCE: IEC 60050-195:1998, 195-02-19, modified — “including a neutral conductor” and Note 1 to
entry deleted and "a PEN conductor or PEM conductor or PEL conductor" replaced by "the electric
chassis"]
3.17
maximum operating temperature
highest value of the temperature at which the systems/components can be operated continuously
3.18
maximum working voltage
highest value of AC voltage (rms) or of DC voltage that can occur under any normal operating conditions
according to the manufacturer's specifications, disregarding transients and ripple
[SOURCE: ISO 6469-3:2018, 3.26]
3.19
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
3.20
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
3.21
overcurrent protection
protection intended to operate when the current is in excess of a predetermined value
[SOURCE: IEC 60050-195:1998, 448-14-26]
3.22
rechargeable energy storage system
RESS
rechargeable system that stores energy for delivery of electric energy for the electric drive (3.8)
EXAMPLE Battery, capacitor, flywheel.
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ISO 6469-1:2019(E)
3.23
RESS control unit
electronic device that controls functions of the RESS (3.22) and that provides communication between
the RESS (3.22) and other vehicle controllers
EXAMPLE Battery control unit.
3.24
RESS subsystem
any assembly of RESS (3.22) components which stores energy
3.25
rupture
loss of mechanical integrity of an enclosure resulting in openings not fulfilling protection degree IPXXB
according to ISO 20653
Note 1 to entry: Predetermined openings for venting are not considered as rupture.
3.26
state of charge
SOC
available capacity (3.2) of an RESS (3.22) or RESS subsystem (3.24) expressed as a percentage of rated
capacity (3.2)
3.27
supplier
party that provides RESS (3.22) or RESS subsystem (3.24)
EXAMPLE RESS manufacturers.
[SOURCE: ISO PAS 19295:2016, modified — “voltage class B component or system” replaced by “RESS or
RESS subsystems”, EXAMPLE added]
3.28
venting
release of excessive pressure intended by design
3.29
voltage class
classification of an electric component or circuit according to its maximum working voltage (3.18)
Note 1 to entry: The classification to the voltage classes A, B and B2 is according to ISO 6469-3:2018
[SOURCE: ISO 6469-3:2018, 3.35, modified — Note 1 to entry added.]
3.30
water depth
w
water depth level a vehicle is designed for operation according to the vehicle manufacturer’s
specification
Note 1 to entry: The vehicle manufacturer may consider the local environmental conditions where the vehicle is
placed on the market.
4 General requirements
4.1 General electrical requirements
If not otherwise specified in this document, the voltage class B RESS shall fulfil the electrical safety
requirements in accordance with ISO 6469-3. These electrical safety requirements may be fulfilled for
an RESS on the component or vehicle level.
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ISO 6469-1:2019(E)
The voltage class B RESS or the voltage class B RESS subsystem shall be marked in accordance with
ISO 6469-3.
NOTE For marking requirements for a voltage class A RESS or RESS subsystem when integrated into a
voltage class B circuit see ISO 6469-3.
4.2 General safety requirements
The following requirements are general safety requirements, which apply when cited.
— The RESS shall not exhibit any evidence of leakage.
— The RESS shall not exhibit continuous emission of flames for more than 1 s or explosion.
— The RESS shall not exhibit any evidence of rupture.
— The voltage class B2 RESS shall maintain an isolation resistance according to 5.4.1.
Compliance shall be tested in accordance with 6.1.6.
5 Technical requirements
5.1 Mechanical requirements
The RESS shall provide the safety performance as specified below under mechanical loads due to
vibration and mechanical shock, which an RESS will likely experience during the normal operation of a
vehicle over its lifetime.
The general safety requirements in accordance with 4.2 shall be fulfilled.
Compliance shall be tested in accordance with 6.2.
5.2 Climatic requirements
5.2.1 Thermal shock cycling
The RESS shall provide the safety performance as specified below under a climatic load due to rapid
temperature changes, which an RESS will likely experience during the normal operation of a vehicle.
The general safety requirements in accordance with 4.2 shall be fulfilled.
Compliance shall be tested in accordance with 6.3.1.
5.3 Simulated vehicle accident requirements
5.3.1 Vehicle crash
The RESS shall provide the safety performance at a vehicle crash, which shall comply with 5.3.1.1 and
5.3.1.2. Testing shall be performed at vehicle level or RESS level.
5.3.1.1 Inertial load at a vehicle crash
The RESS shall provide the safety performance under inertial loads caused by an acceleration which
can occur at a vehicle crash. The general safety requirements in accordance with 4.2 shall be fulfilled.
Compliance shall be tested in accordance with 6.4.1.1.2 or 6.4.1.2.
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ISO 6469-1:2019(E)
5.3.1.2 Contact force at a vehicle crash
The RESS shall provide the safety performance under contact forces which can occur at a vehicle crash.
The general safety requirements in accordance with 4.2 shall be fulfilled.
For an RESS intended to be installed in vehicles with a gross mass exceeding 3,5 t, the requirements are
deemed to be fulfilled, if the RESS is intended to be installed at a position higher than 700 mm above
the ground (distance between the ground and the bottom surface of the RESS).
For an RESS intended to be installed in vehicles with a gross mass exceeding 7,5 t the requirements
are deemed to be fulfilled, if the RESS is intended to be installed within a longitudinal chassis frame
structure of the vehicle.
Compliance shall be tested in accordance with 6.4.1.1.3 or 6.4.1.2.
5.3.2 Immersion into water
The RESS shall provide the safety performance as specified below when it is exposed to water due to
water immersion.
NOTE This requirement does not cover incidents in which the primary hazard for persons is caused by the
presence of water, e.g. high flooding, flooded underground parking, flooded underpass.
The requirement is fulfilled if the RESS or RESS subsystem meets one of the following conditions:
— The RESS or RESS subsystem shall be tested in accordance with 6.4.2. During the test and during
the post-test observation period of 2 h, the RESS or RESS subsystem shall not exhibit any evidence
of continuous emission of flames for more than 1 s, or explosion.
— The RESS or RESS subsystem including all connectors, air ducts and connections for cooling attached
is water protected. It shall be tested in accordance with IPX7 in ISO 20653 and no occurrence of
water is allowed inside the RESS or RESS subsystem after the exposure to water. The test may be
conducted with only the housing of an RESS or RESS subsystem and all connectors, air ducts and
connections for cooling attached.
Minimal appearance of water due to the condensation of air humidity is possible and not considered as
an occurrence of water. In case of doubt the test may be performed with coloured water.
5.3.3 Exposure to fire
This sub-clause applies to the RESS using flammable electrolyte only.
The RESS shall provide the safety performance as specified below when it is exposed to fire from
outside of the vehicle. A thermal load can occur due to a fuel fire underneath the vehicle. Such a fire
can be caused by fire from ignited spilled fuel either from the vehicle itself or a nearby vehicle. The
intention is to provide time for the driver, passengers, and bystanders to evacuate.
During the test and during the specific post-test observation period for the exposure to fire, the RESS
shall not exhibit any evidence of explosion.
Compliance shall be tested in accordance with 6.4.3.
The requirement is deemed to be fulfilled when the RESS is intended to be installed in the vehicle
and mounted at a position higher than 1,5 m above the ground (distance between the ground and the
bottom surface of the RESS subsystem).
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ISO 6469-1:2019(E)
5.4 Electrical requirements
5.4.1 Isolation resistance
For a voltage class B2 RESS its isolation resistance divided by its maximum working voltage shall be at
least as follows:
— 100 Ω/V, if the RESS contains DC circuits only;
— 100 Ω/V, if the RESS contains AC circuits and additional AC protection in accordance with ISO 6469-3;
— 500 Ω/V, if the RESS contains AC circuits without additional AC protection in accordance with
ISO 6469-3.
When the RESS is installed in a vehicle and conductively connected to a voltage class B2 electric circuit,
a higher resistance value for the RESS is necessary to meet the requirements in ISO 6469-3.
NOTE For the isolation resistance required on a voltage class A or B1 RESS conductively connected to a
voltage class B2 electric circuit see ISO 6469-3.
Compliance shall be tested according to the relevant test given in ISO 6469-3.
5.4.2 Clearance and creepage distance
For an open-type voltage class B RESS or RESS subsystem, where electrolyte leakage can occur, the
following requirements shall apply:
NOTE An open-type lead acid battery is an example of an open-type voltage class B RESS.
The creepage distance between voltage class B terminals shall be as follows:
d ≥ 0,25U + 5
where
d is the creepage distance in millimetres (mm);
U is the maximum working voltage of the RESS in volts (V).
The creepage distance between voltage class B live parts and the electric chassis shall be as follows:
d ≥ 0,125U + 5
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ISO 6469-1:2019(E)
where
d is the creepage distance in millimetres (mm);
U is the maximum working voltage of the RESS in volts (V).
The clearance between voltage class B terminals shall be at least 2,5 mm.
5.4.3 Short-circuit protection
The RESS shall have a short-circuit protection and provide its safety performance in case of an external
short-circuit as specified below when the RESS is operational (e.g. the contactor is closed). The
requirements in a) or b) provide short-circuit protection.
a) The cross-sectional area of the live conductors of the RESS have a short-circuit current withstand
2
rating (I t) according to the maximum short-circuit current of the RESS.
b) An overcurrent protection for the live conductors of an RESS according to their cross-sectional
area is provided. The overcurrent protection is capable to interrupt a short-circuit current.
NOTE Short circuit is a specific case of overcurrent.
...
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