Secondary lithium batteries for light EV (electric vehicle) applications - Part 1: General safety requirements and test methods

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.

Lithium-Sekundärbatterien für Anwendungen in leichten Elektrofahrzeugen - Teil 1: Allgemeine Sicherheitsanforderungen und Prüfverfahren

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

La présente Norme européenne spécifie des procédures d'essai et fournit des exigences de sécurité acceptables pour (les blocs et) les systèmes de batteries d'accumulateurs au lithium-ion amovibles de tension de classe A et de tension de classe B qui doivent être utilisés comme batteries de traction ou pour les véhicules routiers à propulsion électrique. La présente Norme européenne concerne l'essai des performances de sécurité des systèmes et des blocs de batteries pour leur utilisation prévue dans un véhicule. La présente Norme européenne n'est pas destinée à être appliquée pour l'évaluation de la sécurité du stockage des systèmes/blocs de batteries, de la production des véhicules, de leur réparation et des services de maintenance. Les véhicules électriques légers incluent tous les véhicules à propulsion électrique, de la catégorie L1 à la catégorie L7, conformes à la définition de l'ECE-TRANS-WP29-78r6e, ainsi que tous les cycles à propulsion ou à assistance électrique, notamment les véhicules routiers hybrides rechargeables (PHEV - plug-in hybrid road vehicle) qui reçoivent tout ou partie de leur énergie de systèmes de stockage de l'énergie rechargeables embarqués (RESS - rechargeable energy storage system). La présente Norme européenne permet de configurer un plan d'essai dédié pour un bloc/système de batteries particulier soumis à un accord entre le client et le fournisseur. Si cela est exigé, les procédures d'essai adéquates et/ou les conditions d'essai des systèmes et des blocs de batteries d'accumulateurs au lithium-ion peuvent être choisies parmi les essais normaux fournis dans la présente Norme pour configurer un plan d'essai dédié. NOTE 1 Les essais au niveau des éléments sont spécifiés dans la série IEC 62660. Le présent document s’applique également aux: - blocs/systèmes de batteries intégrés dans les véhicules électriques (VE); NOTE 2 L’Annexe HH informative donne des informations sur les essais possibles avec d’autres compositions chimiques. La présente Norme européenne ne s'applique pas aux: - éléments individuels; - systèmes de batteries non amovibles; - piles (y compris celles au lithium); - batteries couvertes par la série ISO 12405.

Sekundarne litijeve baterije za lahka električna vozila - 1. del: Splošne varnostne zahteve in preskusne metode - Dopolnilo A1

General Information

Status
Published
Publication Date
01-Sep-2021
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
27-Jul-2021
Due Date
01-Oct-2021
Completion Date
02-Sep-2021

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SLOVENSKI STANDARD
SIST EN 50604-1:2016/A1:2021
01-oktober-2021

Sekundarne litijeve baterije za lahka električna vozila - 1. del: Splošne varnostne

zahteve in preskusne metode - Dopolnilo A1

Secondary lithium batteries for light EV (electric vehicle) applications - Part 1: General

safety requirements and test methods

Lithium-Sekundärbatterien für Anwendungen in leichten Elektrofahrzeugen - Teil 1:

Allgemeine Sicherheitsanforderungen und Prüfverfahren

Batteries d'accumulateurs au lithium pour applications liées aux véhicules électriques

légers - Partie 1 : Exigences générales de sécurité et méthodes d'essai
Ta slovenski standard je istoveten z: EN 50604-1:2016/A1:2021
ICS:
29.220.30 Alkalni sekundarni členi in Alkaline secondary cells and
baterije batteries
43.120 Električna cestna vozila Electric road vehicles
SIST EN 50604-1:2016/A1:2021 en

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN 50604-1:2016/A1:2021
---------------------- Page: 2 ----------------------
SIST EN 50604-1:2016/A1:2021
EUROPEAN STANDARD EN 50604-1:2016/A1
NORME EUROPÉENNE
EUROPÄISCHE NORM
July 2021
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 Lithium-Sekundärbatterien für Anwendungen in leichten

aux véhicules électriques légers - Partie 1 : Exigences Elektrofahrzeugen - Teil 1: Allgemeine

générales de sécurité et méthodes d'essai Sicherheitsanforderungen und Prüfverfahren

This amendment A1 modifies the European Standard EN 50604-1:2016; it was approved by CENELEC on 2021-06-21. CENELEC

members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this amendment 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 amendment 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, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the

Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia, 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: Rue de la Science 23, B-1040 Brussels

© 2021 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.

Ref. No. EN 50604-1:2016/A1:2021 E
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Contents Page

European foreword ...................................................................................................................................5

Introduction ...............................................................................................................................................6

1 Modification to Clause 1, “Scope” ....................................................................................................7

2 Modification to Clause 2, “Normative references” ............................................................................7

3 Modification to Clause 3, “Terms and definitions” ............................................................................8

4 Modification to subclause 5.2, “Test sequence plan” .................................................................... 10

5 Modification to subclause 5.101, “Battery pack/system requirements” ......................................... 10

6 Deletion of subclause 5.102, “Thermoplastic materials exposed to sunlight” ............................... 13

7 Modification to subclause 5.103, “Safety considerations” ............................................................. 13

8 Modification to subclause 5.104, “Evaluation of protective devices and electronic circuits” ......... 14

9 Modification to subclause 5.105, “Voltage classes” ...................................................................... 15

10 Modification to subclause 5.106, “Battery management system” ................................................. 15

11 Modification to subclause 5.107, “Charging/discharging” ............................................................. 15

12 Modification to subclause 5.109, “Test result fire” ........................................................................ 15

13 Modification to subclause 5.110, “Test result leakage” ................................................................. 16

14 Addition of a new subclause, “Flammability of non-metallic materials” ........................................ 16

15 Modification to subclause 6.101.2, “Test procedure” .................................................................... 16

16 Modification to subclause 6.101.3, “Requirements” ...................................................................... 16

17 Modification to subclause 6.104, “Thermoplastic materials exposed to sunlight” ......................... 16

18 Modification to subclause 8.101, “Crush test” ............................................................................... 17

19 Modification to subclause 8.3.101, “Purpose” ............................................................................... 17

20 Modification to subclause 8.103.2, “Test procedure” .................................................................... 17

21 Modification to subclause 8.103.3, “Requirements” ...................................................................... 18

22 Modification to subclause 9.1.101, “Test procedure” .................................................................... 18

23 Modifications to subclause 9.101, “Touch current” ....................................................................... 18

24 Modification to subclause 10.1, “Overcharge protection” .............................................................. 18

25 Modification to subclause 10.2, “Over-discharge protection” ........................................................ 19

26 Modification to subclause 10.3, “Loss of thermal control/cooling” ................................................ 19

27 Modification to Clause 10, “System functionality tests” ................................................................. 19

28 Modification to subclause BB.1.1, “Removable (RESS) battery systems (packs) marking” ......... 20

29 Modification to Table BB.1, “Graphical symbols” .......................................................................... 21

30 Modification to subclause BB.2, “Instructions” .............................................................................. 21

31 Modifications to Annex FF, “Transport regulations” ...................................................................... 22

32 Modification of Annex GG, “Test sequences and number of samples” ........................................ 22

33 Addition of Annex HH, “Comparison Table for chemistries others than Li-ion” ............................ 23

34 Modification to the Bibliography .................................................................................................... 26

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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
European foreword

This document (EN 50604-1:2016/A1:2021) has been prepared by CLC/TC 21X “Secondary cells and

batteries”.
The following dates are fixed:
• latest date by which the existence of this (doa) 2021-12-21
document has to be announced at national
level
• latest date by which this document has to be (dop) 2022-06-21
implemented at national level by publication of
an identical national standard or by
endorsement
• latest date by which the national standards (dow) 2024-06-21
conflicting with this document have to be
withdrawn

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.

This part is read in conjunction with the appropriate part of the withdrawn ISO 12405-1, ISO 12405-2

and ISO 12405-3 and novel ISO 6469-1:2019. Remark: the 1 Ed of EN 50604-1 is referencing to

ISO 12405-3.
NOTE 1 The following print types are used:
— requirements: in roman type;
— test specifications: in italic type;
— notes: in small roman type.

This document has been prepared under a mandate given to CENELEC by the European Commission

and the European Free Trade Association.

Any feedback and questions on this document should be directed to the users’ national committee. A

complete listing of these bodies can be found on the CENELEC website.
---------------------- Page: 5 ----------------------
SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (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 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 are considered as an important issue.

The EN 50604-1 series is read in conjunction with ISO 12405-3:2014 (withdrawn) and ISO 6469-1:2019

(for this amendment). The clauses of the particular requirements in EN 50604-1 supplement or modify

the corresponding clauses in ISO 12405-3:2014 (withdrawn) and ISO 6469-1:2019 (for this

amendment). Where the text indicates an “addition” to or a “replacement” of the relevant requirement,

test specification or explanation of ISO 12405-3:2014 (withdrawn) and ISO 6469-1:2019 (for this

amendment), these changes are made to the relevant text of ISO 12405-3:2014 (withdrawn) and

ISO 6469-1:2019 (for this amendment), which then becomes part of the standard. Where no change is

necessary, the words “This 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 could be necessary which are

not covered by this document.

NOTE Additional requirements might also apply to battery system after the integration into the vehicle resulting

from national or regional regulations and are not dealt with in this document. Same applies to hazards from electric

shock.

This document provides specific test procedures and related requirements to ensure an appropriate and

acceptable level of safety of lithium-ion (Li-ion) battery systems specifically developed for propulsion of

road vehicles. Propositions for other chemistries are given in informative Annex HH.

This document indicates references 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. Test reports issued and

verified by in house testing according to UN 38.3 are also accepted.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
1 Modification to Clause 1, “Scope”
Replace the 3rd paragraph by the following:

“Light EV includes all electrically propelled vehicles of category L1 up to category L7 according to the

definition of ECE-TRANS-WP29-78r6e 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).“
Delete the 5th paragraph.
Add after NOTE and renumber it NOTE 1:
“This document also applies to:
— built-in battery packs/systems in EVs.

NOTE 2 Informative Annex HH gives information on possible tests for other chemistries.“

Replace the first and second point of the last paragraph by:
— individual cells;
— non-removable battery systems;“
2 Modification to Clause 2, “Normative references”
Add the following new references:

EN IEC 60812:2018, Failure modes and effects analysis (FMEA and FMECA) (IEC 60812:2018)

EN 60529:1991 , Degrees of protection provided by enclosures (IP Code)

EN 61000-6-7:2015, Electromagnetic compatibility (EMC) - Part 6-7: Generic standards - Immunity

requirements for equipment intended to perform functions in a safety-related system (functional safety)

in industrial locations (IEC 61000-6-7:2014)

EN 61326-3-1:2017, Electrical equipment for measurement, control and laboratory use - EMC

requirements - Part 3-1: Immunity requirements for safety-related systems and for equipment intended

to perform safety-related functions (functional safety) - General industrial applications (IEC 61326-3-

1:2017)

EN 61508 (series), Functional safety of electrical/electronic/programmable electronic safety-related

systems (IEC 61508 series)

EN 62133-2, Secondary cells and batteries containing alkaline or other non-acid electrolytes - Safety

requirements for portable sealed secondary cells, and for batteries made from them, for use in portable

applications - Part 2: Lithium systems (IEC 62133-2:2017)
—————————

As impacted by EN 60529:1991/A1:2000, EN 60529:1991/A2:2013, EN 60529:1991/A2:2013/AC:2019-02,

EN 60529:1991/AC:2016-12, and EN 60529:1991/corrigendum May 1993.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
EN ISO 178:2010 , Plastics – Determination of flexural properties (ISO 178:2010)

EN ISO 179 (series), Plastics – Determination of Charpy impact properties (ISO 179 series)

EN ISO 2409:2013 , Paints and varnishes – Cross-cut test (ISO 2409:2013)

EN ISO 4892-2:2013, Plastics - Methods of exposure to laboratory light sources - Part 2: Xenon-arc

lamps (ISO 4892-2:2013)

EN ISO 13849 (all parts), Safety of machinery – Safety-related parts of control systems

ISO 6469-1:2019, Electrically propelled road vehicles — Safety specifications — Part 1: Rechargeable

energy storage system (RESS)

IEC 60695-11-10, Fire hazard testing - Part 11-10: Test flames - 50 W horizontal and vertical flame test

methods

SAE J 1739:2009, Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential

Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA)"

3 Modification to Clause 3, “Terms and definitions”
Replace term entry 3.5 by:
3.5
battery management system
BMS

local energy management system 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 do not have the same functions.
[SOURCE: IEC/TS 61851-3-4]“
Add note to entry to 3.14:

Note 1 to entry: In the context of this document, “electric chassis” can be replaced by “enclosure”."

Add the following figure at the end of 3.18:
—————————
A newer edition exists: EN ISO 178:2019.
A newer edition exists: EN ISO 2409:2020.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Key
3 DC/DC converter for removable battery systems
4 Removable battery system
6 RESS inlet
9* A/B coupler (optional)
17 Gateway
40 Manufacturer specific communication circuit
42 Protective device(s) (active and/or passive)
43 Battery Management System
44 Battery Pack
45 Sensing and balancing electronics/equipment
46 Cells
47 Cell block
S2 Switch
Figure 1 — Example of a removable battery system”
Replace the term entry of 3.31:
3.31
active protective device

device integral to the battery pack requiring active control, that is intended for protection from or

mitigation of abusive, out of range conditions experienced by the cell or battery

EXAMPLE MOSFET.

Note 1 to entry: The active protective device disconnects source or sink if the BMS detects parameters outside

of the normal operating conditions.”
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Add new term entries:
3.33
local energy management system
local EMS

active device’s internal system that protects the energy buffer, source or load from damage, monitors

and increases the lifetime of the buffer, source or load, maintains the buffer, and source or load in a

functional state
[SOURCE: IEC/TS 61851-3-4]
3.34
A/B coupler
means enabling the connection and disconnection of RESS to an EV
[SOURCE: IEC/TS 61851-3-1]
3.35
RESS coupler
means enabling the connection of RESS to an EV or a DRI EV supply equipment
[SOURCE: IEC PAS 62840-3]
3.36
keyed connector

part of coupler with a unique mechanical profile which can only be mated with each other in a

particular orientation and which does not allow mating with the counterpart with a different design

EXAMPLE 1 Hollow plugs of simple shape, where sockets-outlet compensate the variations of hollow plugs with

a slightly different inner and/or outer diameter of the plug.

EXAMPLE 2 Plugs for applications or charging systems that do not meet the electrical requirements of the

specific interface. “
4 Modification to subclause 5.2, “Test sequence plan”
Delete the 2 paragraph.
“Addition”:
Add the following paragraph at the end of the subclause:
“For details on test sequences and numbers of samples, see Annex GG, Table GG.1.
NOTE EMC could be subject to further tests.”
5 Modification to subclause 5.101, “Battery pack/system requirements”
Replace Table 1 by:
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Table 1 — Battery system requirements
Subsystem Requirement

cell Battery packs/systems shall contain only Li-ion cells which comply with the UN

Recommendations on the Transport of Dangerous Goods - Manual of Tests and
Criteria: Section 38.3, and with one of the following:
— relevant Li-ion battery cell standard EN 62660-3; or
— relevant Li-ion battery cell standard EN 62133-2.
Compliance is checked by a valid certificate.

NOTE Battery packs/systems containing cells with other chemistries are shown in Annex HH.

BMS The BMS shall be an integral part of the removable battery system. The BMS shall

provide (see 3.5 and 5.106):
— controlling of charging/discharging process;
— active or passive protective devices (see 5.104);
— protective devices as part of BMS (see 5.104):
— avoiding overcharge/overdischarge,
— detection of internal short-circuits,
— respecting temperature limits at least one temperature sensor which measures
the temperature of the interior of the battery pack/system as close as possible
to the most critical spot according to the design,
— compatibility check between battery system and connected equipment.
Manufacturer specific solutions:
— Clear assignment of connected equipment with keyed connectors, which ensures

to operate the battery within its voltage- and current specifications during charging

and discharging and which prevents reverse polarity connections. Standard
connectors (e.g. EN 60320 series) shall not be used.
— compatibility check provided by manufacturer including the following minimum
information / parameters:
— device type;
— supported functionality;
— device manufacturer or responsible vendor;
— software version;
— hardware version;
— minimum voltage;
— maximum voltage;
— max. continuous input current;
— max. continuous output current;
— complete documentation of the compatibility check.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Subsystem Requirement
Compliance is checked by inspection.
Interoperable solution using CANopen communication as described in
CLC/prTS 61851-3-4 or any other communication solution proved to be equally
suitable:
— compatibility check according to IEC/TS 61851-3-4:— , 8.2.3.4;
— communication over gateway to CLC/prTS 61851-3 (series) products (optional).

NOTE The term BMS is used to designate equipment intimately linked to the battery

pack/system that provides all the relevant safety and control functions needed for a removable

battery system.

Enclosure of Enclosure of removable battery packs/systems shall provide at least:

removable
— mechanical strength to withstand stress caused by normal use and rough
battery
handling, see Clause 6;
systems

— sufficiently resistant to degradation caused by sunlight radiation, see 6.104;

— reducing the possibility of ignition and spread of flame, see 8.4;

— providing suitable insulation characteristics, at least basic insulation according to

IEC 60664-1:2007, 5.3.3.2;
— protection against ingress of foreign objects and water: IP54, according to
IEC 60529:1989+A1:1999+A2:2013;

— the battery pack/system housing constructed in a way that it cannot be opened

without the use of tools and any opening shall be easily detectable by a broken
seal.
Assembled Manufacturer specific solution shall provide the following:
removable
— for RESS connector or RESS inlet, standard plug and standard socket-outlets
battery
and connectors (e.g. IEC 60320 series) shall not be used;
system
— the RESS connector shall prevent reverse polarity connections;
— the RESS connector shall not have a simple shape, which cannot grant a
sufficiently unique mechanical profile (see NOTE 1);

— an internal switch in the DC power circuit of the battery pack/system, controlled

by the BMS, able to interrupt all power flow and ensure safety. The switch shall only

be closed after a successful compatibility check;

— a compatibility check between battery system and EV supply equipment shall be

performed based on at least two of the following:
— mechanical;
— electrical (e.g. additional contacts or voltages);
— electronical;
— communication means.

Bijective recognition of both sides is requirement for successful compatibility check.

Compliance is checked by inspection, testing and design review.
—————————
Under preparation. Stage at the time of publication: IEC/TS 61851-3-4:2021.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Subsystem Requirement
Interoperable solution using CANopen communication as described in
IEC/TS 61851-3-4:— :
— RESS connector and RESS inlet shall be in accordance with
IEC/TS 62196-4:— , IEC/TS 61851-3 (all parts) or IEC 62840 (all parts);

— battery pack/system according to this interoperable solution are intended to be

connected only to DRI EV supply equipment according to IEC 60335-2-29:2016:
fulfilling the additional requirements of IEC/TS 61851-3-2:— ;

— an internal switch in the DC power circuit of the battery pack/system shall allow

to disconnect the battery system from the RESS coupler or A/B coupler.
Compliance is checked by inspection.
6 Deletion of subclause 5.102, “Thermoplastic materials exposed to sunlight”
Delete subclause 5.102 and renumber the following subclauses.
7 Modification to subclause 5.103, “Safety considerations”
Replace the title of subclause 5.103 by:
“5.103 Battery pack/system safety considerations”
Replace the entire text of subclause 5.103.1 by:
“5.103.1 General

All tests, which could be influenced by integration of the battery pack/system into the vehicle (e.g.

installation into the frame), shall be carried out with the battery pack/system integrated into the vehicle.

Such tests can be conducted on specially prepared samples (e.g. parts of frames of vehicle) provided

that the results are representative for the results of testing the assembled product (battery pack/system

installed).
Removable RESS can be tested without the vehicle or parts of it.

In a battery system consisting of two or more battery packs, each battery pack shall be isolated from

each other battery pack by thermal isolation, protective barrier, or protective separation, or a stable gap

from other battery packs and the enclosure.
NOTE This isolation can be an integral part of the battery pack.

Wire ways shall be smooth and free from sharp edges, and internal wiring shall be routed, supported,

clamped or secured in a manner that reduces the likelihood of excessive strain on wire and on terminal

connections.

Holes through which insulated wires pass shall have smooth well-rounded surfaces or be provided with

bushings.

Wire insulation shall be sufficient to withstand the maximum anticipated voltage, current, temperature,

altitude, humidity requirements and mechanical stress.

In connections by soldered terminations, the conductor shall be held in position additionally to the

soldering to maintain it in position.

Connection to the cells shall be made according to the specification of the cell manufacturer in a manner

that does not result in damage to the cells.
—————————
Under preparation. Stage at the time of publication: IEC/TS 62196-4:2021.
Under preparation. Stage at the time of publication: IEC/TS 61851-3-2:2021.
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SIST EN 50604-1:2016/A1:2021
EN 50604-1:2016/A1:2021 (E)
Compliance is checked by design review or inspection.

The enclosure of a removable battery pack/system shall provide at least IP54 according to

EN 60529:1991.

A crush test is not required if the battery system in the EV is secured by double mechanical protection

(e.g. latch and mechanical cover).Compliance shall be verified by inspection of a test report.

Only for battery systems permanently fixed to vehicles with maximum speed more than 45 km/h, crash

tests which may replace a crush test are defined by the countries where the vehicles are released.

It is strongly recommended to extend the post-test observation period for destructive tests to 24h.“

8 Modification to subclause 5.104, “Evaluation of protective devices and
electronic circuits”
Replace subclause and title of 5.104 by:
“5.104 Options for tests for evaluation of protective devices
5.104.1 General

The evaluation of active or passive protective devices including electronics and software depends on

the design. The functionality of the active or passive protective devices shall be designed and tested

according to option 1, option 2 or option 3.

NOTE The active or passive protective devices can be divided, and they can be found partially in the battery

pack or in the battery system. See Figure 1.

Some of the tests described in Clauses 8, 9 and 10 give the possibility to the manufacturer to select one

of the following options, that describe different ways of testing hardware and/or software, for the testing

procedure:
— option 1 (5.104.2);
— option 2 (5.104.3);
— option 3 (5.104.4);
5.104.2 Evaluation option 1

All active protective devices are bypassed unless they comply with the functional safety standard as

described in option 2. These active protective devices may also be bypassed at the demand of the

manufacturer. This condition shall be stated in the corresponding test report.
5.104.3 Evaluation option 2
All protective devices are operating.

All protective devices shall be proven to be reliable according to the EN 61508 (series) or

EN ISO 13849 (all parts) performance level c.
Compliance is given by evaluation of evidence.
5.104.4 Evaluation Option 3

Active protective devices in operation with all single faults injected and tested separately.

If protective devices which are not proven to reach performance level c according to the

EN ISO 13849 (all parts) or EN 61508 (series) are used, a design review (e.g. FMEA according to

EN IEC 60812:2018 or SAE J 1739:2009) shall be performed to identify failure modes taking in

consideration also EMC conditions according to EN 61000-6-7:2015 or EN 61326-3-1:2017. All single

faults which could influence the test result according to the design review shall be separately injected

during the tests and separately tested for each fault injection.

Each protective device shall be rendered inoperative separately (common causes) e.g.:

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SIST EN 506
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