Secondary lithium batteries for LEV (Light Electric Vehicle) applications - Part 1: General safety requirements and test methods

This standard specifies test methods and requirements for secondary lithium batteries and its interface with an appropriate charging system for the safe use in EPACs.
This standard does not apply to performance and functional characteristics of batteries.
This standard refers to the UN Recommendations on the Transport of Dangerous Goods - Manual of Tests and Criteria: Section 38.3 which are performed independently from this testing program. Test reports issued by an ILAC, APLAC or similar accredited party are acceptable for the Battery complying with all aspects of Section 38.3 of Manual of Tests and Criteria of UN Recommendations on the Transport of Dangerous Goods for this test option.
This standard treats electric chargers only as far as it defines requirements for the interface between pack and charger which influence the safety of Li-battery-packs while being charged.
This standard does not cover batteries for electric vehicles covered by ISO 6469 and ISO 18246.
For cells: Relevant international standard IEC 62133, IEC 61960; IEC 62660.
This standard does not apply to:
-   lithium cells;
-   batteries other than lithium ion types;
-   primary Batteries(including lithium types);
-   lithium Battery Packs with a total weight exceeding 12 kg (UNT 38.3);
-   batteries covered by ISO 12405 and ISO 18243.

Sekundärbatterien für LEV - Anwendungen (Light Electric Vehicle) - Teil 1: Allgemeine Sicherheitsanforderungen und Prüfverfahren

Diese Europäische Norm legt Prüfverfahren fest und enthält anerkannte Sicherheitsanforderungen für ent-nehmbare Lithium-Ionen-Batterie-(Packs und)Systeme der Spannungsklasse A und Spannungsklasse B zur Verwendung als Traktionsbatterien von oder für elektrisch angetriebene(n) Straßenfahrzeuge(n). Diese Europäische Norm bezieht sich auf die Prüfung der Leistungssicherheit von Batteriepacks und  systemen bei deren bestimmungsgemäßer Verwendung in einem Fahrzeug.
Diese Europäische Norm ist nicht zur Anwendung für die Bewertung der Sicherheit der Lagerung eines Batteriepacks/ systems, Fahrzeugherstellung, Reparatur und Wartungsarbeiten vorgesehen.
Leichte Elektrofahrzeuge schließen alle zwei- und dreirädrigen Elektrofahrzeuge der Kategorie L1 bis einschließlich L7 entsprechend der Definition nach ECE/TR ANS-WP29-78r2e ein sowie alle elektrisch angetriebenen oder unterstützen Fahrräder, einschließlich Plug-in-Hybridelektrofahrzeugen (PHEV), welche ihre Energie vollständig oder teilweise aus On-Board-wiederaufladbaren Energiespeichersystemen (RESS) beziehen.
Diese Europäische Norm ermöglicht das Festlegen eines zugeordneten Prüfplans für ein einzelnes Batterie-pack/ system im Rahmen einer Vereinbarung zwischen dem Kunden und dem Lieferanten. Erforderlichenfalls dürfen die maßgebenden Prüfverfahren und/oder Prüfbedingungen für Lithium-Ionen-Batteriepacks und  systeme aus den Standard-Prüfungen nach dieser Norm gewählt werden, um einen zugeordneten Prüfplan zu erstellen.
Diese Europäische Norm gilt für alle Batteriesysteme, die für die Anwendung gemeinsam mit den in der Normenreihe IEC/TS 61851 3 beschriebenen Produkten oder Systemen vorgesehen sind.
ANMERKUNG   Prüfung auf Zellenebene ist in der Normenreihe IEC 62660 festgelegt.
Diese Europäische Norm gilt nicht für:
-   Lithiumzellen;
-   andere Batterien als Lithium-Ionen-Batterien;
-   Primärbatterien (einschließlich Lithium-Batterien);
-   Batterien, welche durch die Normenreihe ISO 12405 abgedeckt sind.

Batteries d'accumulateurs au lithium pour applications liées aux véhicules électriques légers (VEL) - Partie 1: Exigences générales de sécurité et méthodes d'essai

La présente norme spécifie les exigences et les méthodes d'essai relatives aux batteries d'accumulateurs au lithium, ainsi que leur interface avec un système de charge adéquat pour la sécurité d'utilisation dans des EPAC (Electronically Power Assisted Cycle).
La présente norme ne s'applique pas aux caractéristiques de performance ni aux caractéristiques fonctionnelles des batteries.
La présente norme fait référence au Manuel d'épreuves et de critères des Recommandations des Nations unies relatives au transport des marchandises dangereuses: Section 38.3, qui est élaboré indépendamment de ce programme d'essai. Les rapports d'essai délivrés par une organisation de coopération internationale pour l'agrément des laboratoires d'essais (ILAC, International Laboratory Accreditation Cooperation), une organisation de coopération Asie-Pacifique pour l'agrément des laboratoires d'essais (APLAC, Asia Pacific Laboratory Accreditation Cooperation) ou une entité accréditée similaire sont acceptables pour les batteries satisfaisant à tous les aspects de la Section 38.3 du Manuel d'épreuves et de critères des Recommandations des Nations unies relatives au transport des marchandises dangereuses pour cette option d'essai.
La présente norme s'intéresse aux chargeurs électriques dans la mesure où elle se limite à définir les exigences relatives à l'interface entre le bloc et le chargeur, qui influencent la sécurité des blocs de batteries au lithium pendant le processus de charge.
La présente norme ne couvre pas les batteries destinées aux véhicules électriques couverts par l'ISO 6469 et l'ISO 18246.
Pour les éléments, les normes internationales applicables sont l'IEC 62133, l'IEC 61960 et l'IEC 62660.
La présente norme ne s'applique pas aux:
-   éléments au lithium;
-   batteries autres que celles au lithium-ion;
-   batteries principales (y compris celles au lithium);
-   blocs de batteries au lithium présentant un poids total supérieur à 12 kg (section 38.3 du Manuel d'épreuves et de critères des Recommandations des Nations unies relatives au transport des marchandises dangereuses);
-   batteries couvertes par l'ISO 12405 et l'ISO 18243.

Sekundarne litijeve baterije za lahka električna vozila - 1. del: Splošne varnostne zahteve in preskusne metode

Ta standard določa preskusne metode in zahteve za sekundarne litijeve baterije ter vmesnik z ustreznim sistemom polnjenja za varno uporabo v kolesih s pomožnim električnim pogonom in pedali (EPAC).
Ta standard se ne uporablja za zmogljivost in funkcijske značilnosti baterij.
Ta standard se sklicuje na priporočila Združenih narodov o prevozu nevarnega blaga – Priročnik za preskuse in merila: razdelek 38.3, ki se izvajajo neodvisno od tega preskusnega programa. Poročila o preskusih, ki jih izda ILAC, APLAC ali podobna akreditirana organizacija, so sprejemljiva za baterije, ki so skladne z vsemi vidiki razdelka 38.3 v Priročniku za preskuse in merila priporočil Združenih narodov o prevozu nevarnega blaga.
Električni polnilniki so v tem standardu obravnavani le v okviru določitve zahtev za vmesnik med baterijskim paketom in polnilnikom, ki vplivajo na varnost litij-ionskega baterijskega paketa med polnjenjem.
Ta standard ne zajema baterij za električna vozila, ki so obravnavane v standardih ISO 6469 in ISO 18246.
Za člene: ustrezni mednarodni standard IEC 62133, IEC 61960; IEC 62660.
Ta standard se ne uporablja za:
– litijeve člene;
– baterije, ki niso litij-ionske;
– primarne baterije (vključno z litijevimi);
– litijeve baterijske pakete, katerih skupna teža je večja od 12 kg (UNT 38.3);
– baterije, ki so obravnavane v standardih ISO 12405 in ISO 18243.

General Information

Status
Published
Public Enquiry End Date
31-Jul-2014
Publication Date
22-Aug-2016
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
19-Aug-2016
Due Date
24-Oct-2016
Completion Date
23-Aug-2016

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Sekundärbatterien für LEV - Anwendungen (Light Electric Vehicle) - Teil 1: Allgemeine Sicherheitsanforderungen und PrüfverfahrenBatteries d'accumulateurs au lithium pour applications liées aux véhicules électriques légers (VEL) - Partie 1: Exigences générales de sécurité et méthodes d'essaiSecondary lithium batteries for LEV (Light Electric Vehicle) applications - Part 1: General safety requirements and test methods43.120Electric road vehicles29.220.30EDWHULMHAlkaline secondary cells and batteriesICS:Ta slovenski standard je istoveten z:EN 50604-1:2016SIST EN 50604-1:2016en01-september-2016SIST EN 50604-1:2016SLOVENSKI
STANDARD



SIST EN 50604-1:2016



EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 50604-1
August 2016 ICS 29.220.30 English Version
Secondary lithium batteries for light EV (electric vehicle) applications - Part 1: General safety requirements and test methods
Batteries d'accumulateurs au lithium pour applications liées aux véhicules électriques légers - Partie 1 : Exigences générales de sécurité et méthodes d'essai
Lithium-Sekundärbatterien für Anwendungen in leichten Elektrofahrzeugen - Teil 1: Allgemeine Sicherheitsanforderungen und Prüfverfahren This European Standard was approved by CENELEC on 2016-07-04. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions. CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung CEN-CENELEC Management Centre: Avenue Marnix 17,
B-1000 Brussels © 2016 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Ref. No. EN 50604-1:2016 ESIST EN 50604-1:2016



EN 50604-1:2016 (E) Contents Page European foreword .5 Introduction .6 1 Scope .7 2 Normative references .7 3 Terms and definitions .8 4 Symbols and abbreviated terms . 13 5 General requirements. 14 5.1 General. 14 5.2 Test sequence plan . 15 5.3 Preparation of the DUT for testing . 15 5.4 Pre-conditioning cycles . 15 5.5 General safety requirements . 15 6 Mechanical tests . 19 7 Climatic tests . 21 7.1 Dewing (temperature change) . 21 7.2 Thermal shock cycling . 21 8 Simulated vehicle accidents . 21 8.1 Inertial load at vehicle crash . 21 8.2 Contact force at vehicle crash . 21 8.3 Water immersion . 22 8.4 Exposure to fire . 22 9 Electrical tests . 23 10 System functionality tests . 25 Annex AA (informative)
Battery Systems and related parts . 26 AA.1 General. 26 AA.2 Battery pack . 26 AA.3 Battery system . 27 AA.3.1 Battery system with integrated BCU/BMS . 27 AA.3.2 Battery system with external BCU/BMS . 28 Annex BB (normative)
General marking requirements . 29 BB.1 Marking and instructions . 29 BB.1.1 Removable (RESS) battery systems (packs) marking . 29 BB.1.2 Graphical symbols . 30 BB.2 Instructions . 30 BB.3 Instructions for built-in battery system . 32 BB.4 Language . 32 BB.5 Label test . 32 BB.6 Markings . 33 SIST EN 50604-1:2016



EN 50604-1:2016 (E) Annex CC (normative)
Test stamp for crush test . 34 Annex DD (normative)
Test probe . 35 Annex EE (informative)
Packaging and transportation for not tested battery samples . 36 EE.1 Information regarding packaging and transportation . 36 EE.1.1 Sample classification . 36 EE.1.2 Labelling . 36 EE.1.3 Packaging . 36 EE.1.4 Transport or shipper’s declaration . 36 EE.1.5 List of content of package . 36 EE.2 Documents . 36 EE.2.1 Form with data regarding the properties of substances of cells. 36 EE.2.2 Handling instructions and guidelines for cells and battery packs . 36 EE.2.3 Operation manual of battery packs, chargers (VCUs), PCB or BMS . 37 EE.2.4 Certificates for components and subsystems . 37 EE.2.5 Quality examination report of samples . 37 EE.2.6 Overview about provided samples and their respective cycle history . 37 EE.3 Additional information . 37 EE.3.1 Instructions on bypassing protective devices . 37 EE.3.2 Other information . 37 Annex FF (informative)
Transport regulations . 38 FF.1 Regulatory information . 38 FF.2 UN-Numbers . 38 FF.3 Transport information . 38 FF.4 UN Recommendations on the Transport of Dangerous Goods . 39 FF.5 UN Recommendations on the Transport of Dangerous Goods – Manual of Test and Criteria . 40 FF.6 Overview about UN-T Tests T.1 - T.8 lithium, lithium ion and lithium polymer cells and batteries . 40 FF.6.1 Test T.1: Altitude simulation . 40 FF.6.2 Test T.2: Thermal test . 40 FF.6.3 Test T.3: Vibration . 41 FF.6.4 Test T.4: Shock . 41 FF.6.5 Test T.5: External Short Circuit . 41 FF.6.6 Test T.6: Impact . 41 FF.6.7 Test T.7: Overcharge . 42 FF.6.8 Test T.8: Forced Discharge. 42 Annex GG (normative)
Test sequences and number of samples . 43 Bibliography . 44
SIST EN 50604-1:2016



EN 50604-1:2016 (E) Figure AA.1 — Typical configuration of a battery pack . 26 Figure AA.2 — Typical configuration of a battery system with integrated BCU/BMS. 27 Figure AA.3 — Typical configuration of a battery system with external BCU . 28 Figure DD.1 — Test probe “test finger” . 35
Table 1 — Battery system requirements . 16 Table BB.1 — Graphical symbols . 30 Table FF.1 — Comparison of test items . 40 Table GG.1 — Number of samples required . 43
SIST EN 50604-1:2016



EN 50604-1:2016 (E) European foreword This document (EN 50604-1:2016) has been prepared by CLC/TC 21X “Secondary cells and batteries”. The following dates are fixed: • latest date by which the existence of this document has to be announced at national level (doa) 2017–01–04 • latest date by which this document has to be implemented at national level by publication of an identical national standard or by endorsement (dop) 2017–07–04 • latest date by which the national standards conflicting with this document have to be withdrawn (dow) 2019–07–04 The goal of this standard is to increase safety of battery packs/ systems which contain lithium battery technologies in combination with their voltage converter unit for use in light electric vehicles. Part 1 sets definitions, safety issues and test procedures. This standard was designed to assess aspects on battery pack/system level. This standard covers the Principal Elements of the Safety Objectives for Electrical Equipment Designed for Use within Certain Voltage Limits (LVD - 2006/95/EC). This standard covers the Principal Elements of the Safety Objectives for battery packs/systems Designed for Use by Light EVs (Directive 2002/24/EC, Regulation (EU) 168/2013). Light EV includes all electrically propelled two, three and four wheeled vehicles of category L1 up to Category L7 according to the definition of ECE/TR ANS-WP29-78r2e and all electrically propelled or assisted cycles including plug-in hybrid road vehicles (PHEV), that derive all or part of their energy from on-board rechargeable energy storage systems (RESS). This standard covers issues mentioned in EU Mandate M/468 and M/533. This part is to be used in conjunction with the appropriate part of the ISO 12405- series. NOTE The following print types are used: – requirements: in roman type; – test specifications: in italic type; – notes: in small roman type. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CENELEC shall not be held responsible for identifying any or all such patent rights. SIST EN 50604-1:2016



EN 50604-1:2016 (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 may 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 “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. EN 50604-1 will be read in conjunction with ISO 12405-3. The clauses of the particular requirements in EN 50604-1 supplement or modify the corresponding clauses in ISO 12405-3. Where the text indicates an “addition” to or a “replacement” of the relevant requirement, test specification or explanation of ISO 12405-3, these changes are made to the relevant text of ISO 12405-3, which then becomes part of the standard. Where no change is necessary, the words “This (sub)clause of ISO 12405-3:2014 is applicable” are used. Test items were selected to simulate conditions likely to occur during handling (e.g. removal or replacement) or during operation. They cover conditions of normal operation, rough handling and as well likely conditions of misuse or negligent handling. For electric vehicles operating under extreme conditions (e.g. off-road, extreme climate, etc.) additional requirements may be necessary which are not covered by this standard. Additional requirements might also apply to battery system after the integration into the vehicle resulting from national or regional regulations and are not dealt within this standard. Same applies to hazards from electric shock. This European 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. This standard refers to the UN Recommendations on the Transport of Dangerous Goods – Manual of Tests and Criteria: Section 38.3 which are performed independently from this testing program. Test reports issued by an ILAC, APLAC or similar accredited party are acceptable for the battery system complying with all aspects of Section 38.3 of Manual of Tests and Criteria of UN Recommendations on the Transport of Dangerous Goods for this test option. SIST EN 50604-1:2016



EN 50604-1:2016 (E) 1 Scope This European Standard specifies test procedures and provides acceptable safety requirements for voltage class A and voltage class B removable lithium-ion battery (packs and) systems, to be used as traction batteries of or for electrically propelled road vehicles. This European Standard is related to the testing of safety performance of battery packs and systems for their intended use for a vehicle. This European Standard is not intended to be applied for the evaluation of the safety of battery packs/systems storage, vehicle production, repair and maintenance services. Light EV includes all electrically propelled two, three and four wheeled vehicles of category L1 up to Category L7 according to the definition of ECE/TR ANS-WP29-78r2e and all electrically propelled or assisted cycles including plug-in hybrid road vehicles (PHEV), that derive all or part of their energy from on-board rechargeable energy storage systems (RESS). This European Standard enables setting up a dedicated test plan for an individual battery pack/system subject to an agreement between customer and supplier. If required, the relevant test procedures and/or test conditions of lithium-ion battery packs and systems may be selected from the standard tests provided in this standard to configure a dedicated test plan. This European Standard applies to all battery systems intended to be used in conjunction with products or systems described in the IEC/TS 61851-3 series. NOTE
Testing on cell level is specified in the IEC 62660 series. This European Standard does not apply to: – lithium cells; – batteries other than lithium ion types; – primary Batteries(including lithium types); – batteries covered by the ISO 12405- series. 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 12405-3:2014, Electrically propelled road vehicles — Test specification for lithium-ion traction battery packs and systems — Part 3: Safety performance requirements This clause of ISO 12405-3:2014 is applicable except as follows: Additions: EN 60068-2-47, Environmental testing — Part 2-47: Test — Mounting of specimens for vibration, impact and similar dynamic tests (IEC 60068-2-47) EN 60335-2-29, Household and similar electrical appliances — Safety — Part 2-29: Particular requirements for battery chargers (IEC 60335-2-29) EN ISO 14021, Environmental labels and declarations — Self-declared environmental claims (Type II environmental labelling) (ISO 14021) EN ISO 4892-2, Plastics — Methods of exposure to laboratory light sources — Part 2: Xenon-arc lamps (ISO 4892-2) SIST EN 50604-1:2016



EN 50604-1:2016 (E) EN ISO 7010:2012, Graphical symbols - Safety colours and safety signs - Registered safety signs (ISO 7010:2011) EN ISO 13849 (all parts), Safety of machinery — Safety-related parts of control systems (ISO 13849, all parts) IEC 60335-1, Household and similar electrical appliances — Safety — Part 1: General requirements IEC 60417:2002, Graphical symbols for use on equipment — 12-month subscription to online database comprising all graphical symbols published in IEC 60417 IEC/TS 60479-2:2007, Effects of current on human beings and livestock — Part 2: Special aspects IEC 61140, Protection against electric shock — Common aspects for installation and equipment IEC 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-related systems IEC/TS 61851-3-1:20161), Electric Vehicles conductive power supply system — Part 3-1: General Requirements for Light Electric Vehicles (LEV) AC and DC conductive power supply systems IEC/TS 61851-32), Electric Vehicles conductive power supply system IEC/TS 62196-43), Plugs, socket-outlets, and vehicle couplers — Conductive charging of electric vehicles — Part 4: Dimensional compatibility and interchangeability requirements for a.c., d.c. and a.c./ d.c. vehicle couplers for Class II or Class III light electric vehicles (LEV) IEC 62660 (all parts), Secondary lithium-ion cells for the propulsion of electric road vehicles 3 Terms and definitions For the purposes of this document, the terms and definitions given in ISO/TR 8713 and ISO 12405-3 and the following apply. Addition: 3.1 battery control unit BCU electronic device that controls, manages, detects or calculates electric and thermal functions of the battery system and that provides communication between the battery system and other vehicle controllers Note 1 to entry: See also Annex AA for further explanation. [SOURCE: ISO 12405-3:2014, 3.1] ————————— 1) Under consideration. 2) Under consideration. 3)
Under consideration. SIST EN 50604-1:2016



EN 50604-1:2016 (E) 3.2 battery pack energy storage device that includes cells or cell assemblies normally connected with cell electronics, voltage class A or B circuit and overcurrent shut-off device, including electrical interconnections, interfaces for external systems Note 1 to entry: For further explanation, see AA.2. Note 2 to entry: Examples of external systems are cooling, voltage class B, auxiliary voltage class A and communication. [SOURCE: ISO 12405-3:2014, 3.2, modified — The original definition mentioned voltage class B circuit only.] 3.3 battery pack subsystem representative portion of the battery pack [SOURCE: ISO 12405-3:2014, 3.3] 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 Annex AA. 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. [SOURCE: ISO 12405-3:2014, 3.4, modified — The former cross-reference to “A.3.1 and A.3.2” has been updated as “Annex AA” here.] 3.5 battery management system BMS local energy management system (EMS Unit) for the battery system, protecting the battery system from damage, monitoring and increasing the lifetime, and maintaining the functional state Note 1 to entry: BMS and BCU according to the ISO 12405- series do not have the same functions. [SOURCE: IEC/TS 61851-3-4] 3.6 capacity total number of ampere-hours and/or watt-hours that can be withdrawn from a fully charged battery under specified conditions [SOURCE: ISO 12405-3:2014, 3.6, modified — “And/or watt-hours” has been added in the present definition.] 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 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. [SOURCE: ISO 12405-3:2014, 3.7, modified — The verb “may” is used three times in the present definition instead of “can” in the original one.] SIST EN 50604-1:2016



EN 50604-1:2016 (E) 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. [SOURCE: ISO 12405-3:2014, 3.8] 3.9 device under test DUT battery pack or battery system, within EN 50604-1 [SOURCE: ISO 12405-3:2014, 3.9, modified — The definition was updated so as to mention “within EN 50604-1” instead of “in this part of ISO 12405” in the original one.] 3.10 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 1 to entry: The kinetic energy of flying debris from the battery pack or system may be sufficient to cause damage to the surrounding of the DUT as well. [SOURCE: ISO 12405-3:2014, 3.10, modified — The verb “may” is used in the Note 1 to entry instead of “can” in the NOTE in the original definition.] 3.11 fire continuous emission of flames from a DUT (approximately more than one second) Note 1 to entry:
Sparks and arcing are not considered as flames. Note 2 to entry:
Smoke is not considered as fire. [SOURCE: ISO 12405-3:2014, 3.11, modified — Note 2 to entry was added.] 3.12 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 less than 10 C Note 1 to entry: Typically high-energy battery packs and systems are designed for applications in BEVs. [SOURCE: ISO 12405-3:2014, 3.13, modified — “Typically lower than 10” was replaced with “typically less than 10 C” in the present definition.] 3.13 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 or greater than 10 C Note 1 to entry: Typically high-power battery packs and systems are designed for application in HEVs and FCVs. [SOURCE: ISO 12405-3:2014, 3.14, modified — “Or higher than 10” was replaced with “or greater than 10 C” in the present definition.] SIST EN 50604-1:2016



EN 50604-1:2016 (E) 3.14 isolation resistance resistance between live parts of voltage class B electric circuit and the electric chassis as well as the voltage class A system [SOURCE: ISO 12405-3:2014, 3.15] 3.15 leakage escape of liquid or gas from a DUT except for venting [SOURCE: ISO 12405-3:2014, 3.16] 3.16 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 supplier’s specifications, disregarding transients [SOURCE: ISO 12405-3:2014, 3.17, modified — “According to the battery manufacturer's specifications” was replaced with “according to the supplier’s specifications” in the present definition.] 3.17 rated capacity supplier's specification of the total number of ampere-hours and/or watt-hour 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 [SOURCE: ISO 12405-3:2014, 3.20, modified — “And/or watt-hour” was added into the present definition.] 3.18 removable RESS (battery system/pack) RESS that can be moved /removed from an EV by hand (portable RESS) or with the assistance of an installation/device (mobile RESS) [SOURCE: IEC/TS 61851-3-4] 3.19 portable RESS (battery system/pack) RESS that may be moved /removed from an EV while in operation, having a mass less than 12 kg [SOURCE: IEC/TS 61851-3 series, modified — “Equipment” was replaced with “RESS”.] 3.20 mobi
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SLOVENSKI STANDARD
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01-julij-2014
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Secondary lithium batteries for LEV (Light Electric Vehicle) applications - Part 1: General
safety requirements and test methods
Sekundärbatterien für LEV - Anwendungen (Light Electric Vehicle) - Teil 1: Allgemeine
Sicherheitsanforderungen und Prüfverfahren
Batteries d'accumulateurs au lithium pour applications liées aux véhicules électriques
légers (VEL) - Partie 1: Exigences générales de sécurité et méthodes d'essai
Ta slovenski standard je istoveten z: prEN 50604-1:2014
ICS:
29.220.30 $ONDOQLVHNXQGDUQLþOHQLLQ Alkaline secondary cells and
EDWHULMH batteries
oSIST prEN 50604-1:2014 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN 50604-1:2014

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oSIST prEN 50604-1:2014

EUROPEAN STANDARD DRAFT
prEN 50604-1
NORME EUROPÉENNE

EUROPÄISCHE NORM

May 2014
ICS 29.220.30
English Version
Secondary lithium batteries for LEV (Light Electric Vehicle)
applications - Part 1: General safety requirements and test
methods
Batteries d'accumulateurs au lithium pour applications liées Sekundärbatterien für LEV - Anwendungen (Light Electric
aux véhicules électriques légers (VEL) - Partie 1: Exigences Vehicle) - Teil 1: Allgemeine Sicherheitsanforderungen und
générales de sécurité et méthodes d'essai Prüfverfahren
This draft European Standard is submitted to CENELEC members for enquiry.
Deadline for CENELEC: 2014-10-03.

It has been drawn up by CLC/TC 21X.

If this draft becomes a European Standard, CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CENELEC in three official versions (English, French, German).
A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to
the CEN-CENELEC Management Centre has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic,
Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and the United Kingdom.

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.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.



European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2014 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Project: 24438 Ref. No. prEN 50604-1:2014 E

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1 Contents
2 Page
3 Foreword. 4
4 Introduction . 5
5 1 General . 6
6 1.1 Scope . 6
7 1.2 General explanation . 6
8 1.3 Subsystem requirements . 7
9 2 Normative references . 7
10 3 Terms and definitions . 8
11 3.1 Batteries . 8
12 3.2 Others . 10
13 4 Safety considerations . 11
14 4.1 Special considerations . 11
15 4.2 Precautions when conducting tests. 11
16 4.3 Evaluation of protective devices and electronic circuits . 11
17 4.4 Thermoplastic materials exposed to sunlight . 11
18 4.5 Design variations requiring additional testing . 12
19 4.6 Batteries providing protection against ingress of foreign objects and water . 12
20 5 Test setup . 12
21 5.1 Test equipment . 12
22 5.2 General conditions for tests . 13
23 5.3 Sample preparation . 13
24 5.4 Test sequence and number of samples . 14
25 6 Type tests . 16
26 6.1 Electrical tests . 16
27 6.2 Mechanical tests. 17
28 6.3 Environmental tests . 18
29 7 Compliance criteria. 18
30 Annex A (informative) Transport regulations . 21
31 Annex B (normative) Environmental Management System Evaluation . 25
32 Annex C (normative) General marking requirements . 26
33 Annex D (normative) Test stamp for crush test . 27
34 Annex E (normative) Test probe . 28
35 Annex F (informative) Information to be provided by manufacturers . 29
36 Annex G (informative) Miscellaneous . 31
37 Annex H (informative) Changes in this edition . 36
38 Bibliography . 38
39

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40 Figures
41
Figure 1 – Battery packs system and subsystems . 5
42 Figure D.1 . 27
43 Figure D.2 . 27
44 Figure D.3 . 27
45 Figure D.4 . 27
46 Figure E.1 – Test probe (“test finger”) . 28
47
48 Tables
49
Table 1 – subsystem requirements red in Part 2. 7
50 Table 2 – Number of samples required . 14
51 Table 3 – Test sequences . 15
52 Table 4 – Summary of type tests and requirements . 19
53 Table G.1 – Comparison of test items . 31
54
55

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56 Foreword
57 This document [prEN 50604-1:2014] has been prepared by CLC/TC 21X "Secondary cells and batteries".
58 This document is currently submitted to the Enquiry.

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59 Introduction
60 The goal of EN 50604 is to increase safety of battery packs (EPAC) which contain lithium battery techno-
61 logies in combination with their chargers for use in light electric vehicles.
62 Part 1 sets definitions, safety issues and test procedures.
63 Part 2 sets construction rules.
64 EN 50604 was designed to assess aspects on battery pack level. The battery pack and its charger can be
65 described as system comprising of following subsystems:
66

cell
Control electronic and
Part 1 Part 2, …
protective devices
 enclosure Interface to
  charger or other
  subsystems
67 Figure 1 – Battery packs system and subsystems
68 The requirements to be met by subsystems are detailed in other parts of EN 50604.

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69 1 General
70 1.1 Scope
71 This standard specifies test methods and requirements for secondary lithium batteries and its interface with
72 an appropriate charging system for the safe use in EPACs.
73 This standard does not apply to performance and functional characteristics of batteries.
74 This standard refers to the UN Recommendations on the Transport of Dangerous Goods – Manual of Tests
75 and Criteria: Section 38.3 which are performed independently from this testing program. Test reports issued
76 by an ILAC, APLAC or similar accredited party are acceptable for the Battery complying with all aspects of
77 Section 38.3 of Manual of Tests and Criteria of UN Recommendations on the Transport of Dangerous Goods
78 for this test option.
79 This standard treats electric chargers only as far as it defines requirements for the interface between pack
80 and charger which influence the safety of Li-battery-packs while being charged.
81 This standard does not cover batteries for electric vehicles covered by ISO 6469 and ISO 18246.
82 For cells: Relevant international standard IEC 62133, IEC 61960; IEC 62660.
83 This standard does not apply to:
84 – lithium cells;
85 – batteries other than lithium ion types;
86 – primary Batteries(including lithium types);
87 – lithium Battery Packs with a total weight exceeding 12 kg (UNT 38.3);
88 – batteries covered by ISO 12405 and ISO 18243.
89 1.2 General explanation
90 Test items were selected to simulate conditions likely to occur during the transport of batteries (either
91 transported separately or when installed into the electric vehicle ), during the handling (e. g. removal or
92 replacement) or during the operation. They cover conditions of normal operation, rough handling and as well
93 likely conditions of misuse or negligent handling. For electric vehicles operating under extreme conditions
94 (e. g. off-road, extreme climate etc.) additional requirements may be necessary which are not covered by this
95 standard.
96 Additional requirements might also apply to battery system after the integration into the vehicle resulting from
97 national or regional regulations and are not dealt within this standard. Same applies to hazards from electric
98 shock.

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99 1.3 Subsystem requirements
100 Table 1 – subsystem requirements red in Part 2
Subsystem Requirement

a
Protective devices
Corresponding IEC component standards , or
a
– Other component standards ensuring corresponding safety levels
– Controlling of charging/discharging process avoiding
overcharge/overdischarge, of internal shortcircuits, respecting
temperature limits detection
– The device may be integrated in charger or battery pack
Enclosure Mechanical strength to withstand stress caused by normal use and rough
handling
– Sufficiently resistant to degradation caused by sunlight radiation
– Reducing the possibility of ignition and spread of flame
– Providing suitable insulation characteristics
– The housing of the battery pack has to be constructed in a way that it
cannot be opened without the use of tools and any opening from not
authorized people should be easily detectible e. g. by a broken seal to
be defined by the manufacturer.
Charger – IEC 61851 series, or
– IEC 60335-1 and IEC 60335-2-29, or
– Other product standards ensuring corresponding safety levels, and
– IEC 60529 IP codes according to the designed use
– – Charger and battery pack form a functional unit
– Charger and battery are constructed in a way that they can undoubtedly
identify each other before any energy transfer.

For the connection of the battery pack to the supply equipment no plug

or socket shall be used with which a direct connection to any

unintended power source e. g. a household AC-net can be realized

(IEC/TR 683; IEC 60906-1; IEC 60320; IEC 60884; IEC 60309;

EN 50075)
Battery Pack
– The terminals have to be protected against accidental short circuit
a
Valid component certificate must be available.
101 NOTE Test reports issued by an ILAC, APLAC or similar accredited party are acceptable.
102 2 Normative references
103 The following documents, in whole or in part, are normatively referenced in this document and are
104 indispensable for its application. For dated references, only the edition cited applies. For undated references,
105 the latest edition of the referenced document (including any amendments) applies.
106 IEC 60335-1:2006 (4.2 ed.), Household and similar electrical appliances – Safety – Part 1: General
107 requirements
108 IEC 60335-2-29:2010 (4.2 ed.), Household and similar electrical appliances – Safety – Part 2-29: Particular
109 requirements for battery chargers
110 IEC 60529:2001 (2.1 ed.), Degrees of protection provided by enclosures (IP code)
st
111 IEC 61851-1:2001 (1 ed.), Electric vehicle conductive charging system – Part 1: General requirements

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112 IEC 61851-21:2001 (1 ed.), Electric vehicle conductive charging system – Part 21: Electric vehicle
113 requirements for conductive connection to an a.c./d.c. supply
st
114 IEC 61851-22:2001 (1 ed.), Electric vehicle conductive charging system – Part 22: AC electric vehicle
115 charging station
st
116 IEC 61960:2003 (1 ed.), Secondary cells and batteries containing alkaline or other non-acid electrolytes –
117 Secondary lithium cells and batteries for portable applications
st
118 IEC 62133:2002 (1 ed.), Secondary cells and batteries containing alkaline or other non-acid electrolytes –
119 Safety requirements for portable sealed secondary cells, and for batteries made from them, for use in
120 portable applications
nd
121 ed.), Plastics – Methods of exposure to laboratory light sources – Part 2: Xenon-arc
ISO 4892-2:2006 (2
122 lamps
123 3 Terms and definitions
124 For the purposes of this document, the following terms and definitions apply.
125 3.1 Batteries
126 3.1.1
127 active protective device
128 devices integral to the battery pack or the charger requiring active external controls, that are intended for
129 protection from or mitigation of abusive, out-of range conditions experienced by the cell or battery. The active
130 device cuts the connection to the charger or to a consumer (e. g. a motor) if the controls detect a situation
131 under which the battery could be damaged or become dangerous
132 EXAMPLES MOSFET, integrated circuits, microcontroller.
133 3.1.2
134 ambient temperature
135 temperature of the medium in the immediate vicinity of the battery
136 3.1.3
137 battery assembly
138 connection of two or more batteries in series or parallel.
139 Note 1 to entry: Such assemblies are not covered by the manual.
140 Note 2 to entry: Such assemblies must contain protective devices and/or electronic circuits.
141 3.1.4
142 battery cell
143 cell
144 single encased electrochemical unit (one positive and one negative electrode), which exhibits a voltage
145 difference across its two terminals
146 3.1.5
147 battery pack
148 battery
149 two or more cells that are electrically connected by permanent means. It may include housing, terminals,
150 electronic circuits, sensors, markings and protective devices. If the cells are integrated in a frame of the LEV,
151 this frame means the housing of the cells
152 3.1.6
153 cycle
154 one sequence of fully charging and fully discharging a rechargeable battery within the limits specified by the
155 manufacturer

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156 3.1.7
157 enclosure
158 cabinet, box or container providing protection for the parts building the battery
159 Note 1 to entry: Specific requirements applying to enclosures are detailed in 3.4 and 5.2.
160 3.1.8
161 first cycle
162 initial cycle following the completion of all manufacturing processes
163 3.1.9
164 fresh battery
165 battery after the completion of all manufacturing processes, ready for use
166 3.1.10
167 fully charged
168 rechargeable battery, which has been electrically charged to its rated electrical capacity, as specified by the
169 manufacturer
170 3.1.11
171 fully discharged
172 rechargeable battery, which has been electrically discharged to its cut-off voltage as specified by the
173 manufacturer
174 3.1.12
175 lithium ion battery
176 rechargeable electrochemical battery in which the positive and negative electrodes are both intercalation
177 compounds (intercalated lithium exists in an ionic form in the lattice of the electrode material) constructed
178 with no metallic lithium in either electrode. A lithium polymer battery that uses lithium ion chemistries, as
179 described herein, is regulated as a lithium ion battery.
180 3.1.13
181 passive protective device
182 devices that do not require active external control for operation and which are either integral or external to
183 the cell
184 EXAMPLES Over-current fuse links, circuit breaker, thermal releases.
185 Note 1 to entry: Protective devices, which were not tested according to the relevant component standard, are not
186 considered as protective device.
187 Note 2 to entry: Semiconductor devices with no interface for external control can be permitted if they are subject to
188 testing according to the relevant component standard, e.g. IEC 61643-321:2001 for avalanche breakdown diodes.
189 3.1.14
190 prismatic battery
191 battery whose ends are similar, equal and parallel rectilinear figures, and whose sides are parallelograms
192 3.1.15
193 protective device
194 either an active protective device or passive protective device
195 3.1.16
196 rated capacity
197 capacity, in ampere-hours, of a battery as measured by subjecting it to a load specified by IEC 61960, 7.2.1,
198 temperature and voltage cut-off point as specified by the manufacturer
199 3.1.17
200 rechargeable or secondary battery
201 batteries or cells that can be repeatedly electrically charged and discharged

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202 3.1.18
203 short circuit
204 direct low resistance connection between positive and negative terminals of a battery that provides a virtual
205 zero resistance path for current flow
206 3.1.19
207 swapable batteries
208 lithium battery with a gross mass of not exceeding 12 kg intended to be easily removable by the end-user
209 3.1.20
210 built-in batteries
211 lithium battery fixed, installed and connected to the vehicle. Only meant to be removed by authorised
212 persons
213 3.1.21
214 subsystem
215 major portion or module that comprises the overall system
216 3.1.22
217 type
218 particular electrochemical system and physical design of a battery
219 3.1.23
220 watt-hour rating
221 unit of energy, which is calculated by multiplying the discharge current with the time integral of the voltage
222 curve of a battery.
223 Energy, in watt-hours of a battery as measured by subjecting it to a load specified by IEC 61960, 7.2.1,
224 temperature and voltage cut-off point as specified by the manufacturer.
225 Note 1 to entry: See ISO/CD 18243.
226 3.2 Others
227 3.2.1
228 fault condition
229 equipment operated not in accordance with the manufacturer’s specification and accompanying documents
230 and markings. Conditions can occur as result of negligent use (foreseeable misuse), accident, failure of
231 components or materials or other situations
232 3.2.2
233 normal condition
234 equipment operated in accordance with the manufacturer’s specification and accompanying documents and
235 markings
236 3.2.3
237 single fault
238 single failure of any protection means integral to the battery/charger design. When the application of a single
239 fault condition is required by tests of this manual, the equipment, circuit diagrams, and component specifi-
240 cations are to be examined to determine those fault conditions that are likely to occur. Consideration shall be
241 taken for any active protective devices and passive protective devices, which could be either electrical
242 protection means or mechanical protection means
243 Note 1 to entry: Examples of single faults include but are not limited to:
244 a) short circuits and open circuits of semiconductor devices and capacitors;
245 b) faults causing continuous dissipation in resistors designed for intermittent dissipation;
246 c) internal faults in integrated circuits causing excessive dissipation;
247 d) any mechanical conducting part to bridge or open the circuits.

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248 Note 2 to entry: Single faults can be the result of misuse of the battery or the partial or complete loss of function of
249 components.
250 3.2.4
251 steady state condition
252 state reached when the temperature rise of the several parts of the battery does not vary by more than a
253 gradient of 2 K per hour
254 Note 1 to entry: Steady state condition may be determined from the time-temperature rise plot when the straight lines
255 between points at the beginning and end of two successive reasonable intervals each have a gradient of less than 2 K
256 per hour.
257 4 Safety considerations
258 4.1 Special considerations
259 All tests, which could be negatively influenced by integration of the battery into the vehicle (e. g. installation
260 into the frame), shall be tested with the battery integrated into the vehicle. Such tests can be conducted on
261 specially prepared samples (e. g. parts of frames of vehicle) provided that the results are representative for
262 the results of testing the assembled product (battery installed).
263 4.2 Precautions when conducting tests
264 Some of the tests specified can be hazardous to the persons carrying them out; all appropriate measures to
265 protect personnel and affected environment from possible chemical, burn or explosion hazards should be
266 taken.
267 NOTE More details are provided in G.2.
268 4.3 Evaluation of protective devices and electronic circuits
269 Evaluation option 1: Active protective devices bypassed
270 Protective devices which have not been tested according to or do not comply with the functional safety
271 standard IEC 61508 or DIN/EN 13849 (Performance Level C).
272 NOTE 1 On request of the applicant also passive protective devices which comply with the functional safety standard
273 can be bypassed in addition. This condition shall be stated in the corresponding test report.
274 NOTE 2 For affected test items refer to 6.1.1.1, 6.1.2.1 and 6.1.4.
275 Evaluation option 2: All protective circuits operating
276 Protective devices which are considered to be reliable according to the functional safety standard of
277 IEC 61508 or DIN/EN 13849 (Performance Level C).
278 NOTE 3 single fault tests are conducted for components and assembly – refer to 3.3.
279 Test can be performed either under evaluation option 1 or 2.
280 4.4 Thermoplastic materials exposed to sunlight
281 All non-metallic materials exposed to UV radiation (sunlight) shall be tested according to ISO 4892-2
282 condition A. The test has to be performed without cells in the housing, but the temperature inside the
283 housing must be recorded.
284 NOTE Examples of materials that could be affected: thermoplastic enclosure materials, wire and cable insulation,
285 thermoplastic parts of connectors.

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286 4.5 Design variations requiring additional testing
287 In addition to UNT 38.3 batteries are considered to be different from a tested type if the following applies:
288 – A change that would affect the safety of the battery pack. It is the responsibility of the pack manufacturer
289 to make this statement
290 In such a case such a battery type shall be subject to all tests.
291 4.6 Batteries providing protection against ingress of foreign objects and water
292 Enclosures of batteries or parts of it that are not enclosed during normal use shall comply with IP54 of
293 IEC 60529 or better.
294 NOTE If enclosed after installation into the vehicle the degree of protection provided by the vehicle should be IP54 of
295 IEC 60529, or whatever is required in relevant national or regional regulations.
296 5 Test setup
297 5.1 Test equipment
298 5.1.1 Parameter measurement tolerances
299 Measurement values taken during tests shall be obtained with instruments with accuracies within following
300 limits, if not otherwise specified for specific test items:
301 – Capacity: ± 1 %
302 – Current: ± 1 %
303 – Force: ± 6 %
304 – Linear dimension: ± 0.01 mm (up to 25 mm) or ± 0.5 % (above 25 mm)
305 – Mass: ± 1 %
306 – Resistance: ± 5 %
307 – Temperature: ± 2 K (thermocouple not included)
308 – Time: ± 0.1 %
309 – Voltage: ± 1 %
310 NOTE ISO/IEC 17025 provides rules for the estimation of measurement uncertainty for testing laboratories.
311 The details of the instrumentation used for testing shall be provided in the test report.
312 5.1.2 Temperature measurements
313 The temperature on the surface of the battery casings shall be monitored during the tests described in 6.1.1,
314 6.1.2, 6.1.3, 6.1.4 and 6.2.1. The thermocouples used for te
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