UN 38.3 Lithium Transport Tests and Large Cell/Battery Standards Comparison

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UN 38.3 Lithium Transport Tests and Large Cell/Battery Standards ComparisonLaurie Florence

UL LLC

[email protected]

UN Manual of Tests and Criteria, Section 38.3 - For dangerous goods classification of lithium metal and lithium ion cells and batteries

IEC 62619 - Safety requirements for large format secondary lithium cells and batteries for use in industrial applications

IEC 62660-3 - Secondary lithium-ion cells for the propulsion of electric road vehicles - Part 3: Safety requirements of cells and modules

SAE J2929 - Electric and Hybrid Vehicle Propulsion Battery System Safety Standard - Lithium-based Rechargeable Cells

UL 2580 - Batteries for Use in Electric Vehicles

ISO 12405-3 - Electrically propelled road vehicles - Test specification for Lithium-ion traction battery packs and systems -- Part 3: Safety performance requirements

RTCA DO-311 - Minimum Operational Performance Standards for rechargeable lithium battery systems to be used as permanently installed power sources on aircraft.

RTCA DO-160 – Environmental Conditions and Test Procedures for Airbone equipments

2UN T Tests Comparisons: General Info for Tables

Comparison of UN Battery Tests

UN IEC 62660

UL2580

SAEJ2929

RTCADO-311 DO-160

ISO12405-3

IEC 62619

Altitude Y

Thermal Y Y Y Y Y

Vibration Y Y Y Y Y

Shock Y Y Y Y Y

Sh. Circuit Y Y Y Y Y

O-Charge Y Y Y Y Y Y

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UN T Tests Comparisons: General Info for Tables

Results Key: NL – no leakage, NF – no fire, NC – no combustible mixtures, NV – no venting, NE – no explosion, ND – no disassembly (same as NE), NR – no rupture of case/enclosure, ≥ 100/V – minimum isolation resistance value, OCV ≤ 10% - change in open circuit voltage

IEC 62660-3 and IEC 62619 are draft standards and may be subject to change before publication. Information represents current draft status.

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UN T1 Test: Altitude Simulation

Standard Cl Test Name Device Tested

Parameters Require-ments

Comments

UN 38.3 38.3.4.1

T.1 Altitude Simulation

Cells or Batteries

Fully charged11.6 kPa or less for 6 hours

NL, NV, ND,NR, NF, OCV ≤ 10%

10 fresh cells,2 fresh bat & 2 cycled bat (25 cycl)

UL 1642 19 Low Pressure (Altitude Simulation)

Cells Fully charged11.6 kPa or less for 6 hours

NL, NV, ND,NR, NF

5 fresh 5 cycled (new designs)

RTCA DO-311

3.4.1 Steady state altitude

Batteries Fully charged (according to manufacturer design), then discharged and charged during the testTemperature: ambiant9,12 kPa (reached in 14 min) then maintained for 3 hours 2 times (6 hours in total)

NL, NF, NV, ND, NRNo OCV

1 sample

There are other types of altitude tests in D0311 and D0160 not reported here

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UN T 2 Test: Thermal

Stan-dard

CL Test Name

Device Tested

Parameters Requirements Comments

UN 38.3

38.3.4.2

T2 Thermal test

Cells and Batteries

72 ± 2 °C for 12 h, -40 2C for 12 h30 min interval between temps10 cycles, 10 h at ambient


Same 100% SOC samples from T1

UL 1642

18 Temper-ature cycling

Cells 70 ±3°C for 4 h, 20 3C for 2 h, -40 ±3°C for 4 h30 min interval between temps9 temp cycles, 24 h at ambient

NF, NE, NL, NR, NV 100%SOC, 5 fresh, 5 cycled samples

IEC CD 62660-3

6.2.2

Temper-ature Cycling

Cells -40C or Tmin for 1.5 h85C or Tmax for 1.5 hTransition to 25C between extreme temps1 h transition time between 25C and extreme temps30 cycles from

NF, NE 1 sample100% SOC BEV 80% SOC HEV

UL 2580

27 Thermal cycling

Batteries 85 2C, -40 2C15 min interval between temps5 temp cycles, C/D cycle at end

NV, NF, NE, NL, NR, ≥100/V. protectors functional

1 sample MOSOC Cells: 1642

SAE J2929

4.2.3

Thermal Shock Cycling

Batteries UN T2 or70 5C for ≥ 6 h, -40 5C for ≥ 6 h15 min interval between temps5 temp cycles, C/D cycle at end

NV, NF, NE, ≥100/VOCV ≤ 10%,No damage to HV conduct.

1 sample MOSOC

ISO 12405-3

7.2 Thermal cycling

Batteries 60 2C for 6 h, -40 2C for 6 h30 min interval between temps5 temp cycles

NV, NF, NE, NL, NR, ≥100 /V.

1 sample 80% SOC

RTCA DO-311

3.5 Temper-ature shock

Batteries 85°C ± 2°C for 4.25 h ± 0.25 h; -55°C ±2°C. 4.25 h +/- 0.25 h.85°C ±2°C. 4.25 h +/- 0.25 h.5min interval between temps3 temp cycles. C/D at end

NL, NF, NV, ND, NRNo OCV Min value insulation resistance 10M

1 sample

6

UN T3 Test: VibrationStan-dard

CL

Test Name

Device Tested

Parameters Requirements Com-ments

UN 38.3

38.3.4.2

T3 Vibration

Cells and Batteries

Sinusoidal Waveform , Log sweep 7 Hz 200 Hz 7 Hz in 15 min., 12 times, 3 directions:•7 18 Hz., peak accel of 1 gn,• 0.8 mm amp maint. , •18 200 Hz, peak accel. of 2 gn



UL 1642

16 Vibration Cells Simple harmonic vibration, 0.8 mm amp. Frequency varied at 1 Hz/min,From 10 – 55 Hz within 90-100 min.3 direction

NF, NE, NL, NR, NV 5 sample 100% SOC

IEC 62660-3

6.1.1

Vibration Cells IEC 60068-2-64 random vibration, 8 h vibration for each plane of cell,rms accel. is 27.8 m/s2, 10 Hz to 2000 Hz frequency, PSD range is 20 – 0.14 (m/s2)2/Hz

NF, NE 1 sample100%SOC BEV, 80% SOC HV

UL 2580

23 Vibration Endur-ance

Batteries SAE J2380 Random vibration orVehicle specific profile


1 sample at MOSOC

SAE J2929

4.2.2

Vibration Batteries UN T3; orSAE J2380 Random Vibration; or Vehicle specific profile


1 sample at MOSOC

ISO 12405-3

6.1

Vibration Batteries Random vibration of IEC 60068-2-64 and ISO 12405-1 or -2 with temperate variation; orVehicle specific profile; or UNECE R100-02

NV, NF, NE, NL, NR, ≥100/V.

1 sample at 50$ SOC

RTCA DO-311

3.1

Vibration Batteries Random vibration of D0-160 §8.5.210 to 2000Hz (specific power spectral density curve), 0.5gn scan before and after, 3 directions 1 hour duration each,

NL, NF, NV, ND, NRNo irregular V Min value insulation resistance 10M

1 sample

7

UN T4 Test: Mechanical ShockStan-dard

CL Test Name

Device Tested

Parameters Requirements Comments

UN 38.3 38.3.4.4

T4 Shock

Cells and Batteries

Large cell and Batt: half-sine shock, peak accel. of 50 gn, pulse duration of 11 msecs3 shocks in + and – direction, 3 direction for 18 total shocks



UL 1642 15 Shock Cells first 3 msec . 75 g ave. accel.125 - 175 gn peak accel.3 shocks in 3 direction for 18 total shocks

NL, NV, NE, NR, NF 5 sample fresh and 5 samples cycled 100% SOC

IEC 62660-3

6.1.2

Mech-anical Shock

Cells Half-sine, 500 m/sec2, accel., 6 ms duration, 10 shocks/direction, 6 spatial directions applied

NE, NF 1 sample, 100% SOC BEV, 80% SOC HEV

UL 2580 24 Shock Batteries Half-sine, 25 gn peak accel., 15 ms pulse dur., 3 shocks in 3 directions for 18 total


1 sample MOSOC

SAE J2929

4.5 Mechan-ical Shock

Batteries • UN T4 shock test, or • Half-sine, 25 gn peak accel., 15 ms pulse

dur.,1 repetition in + and - directions of vehicle longit.

and later. axes for total 4 separate shocks


1 sample MOSOC

ISO 12405-3

6.2 Mechan-ical shock

Batteries Half-sine, 500 m/sec2, accel., 6 ms duration, 10 shocks/direction, 6 spatial directions applied

NV, NF, NE, NL, NR, ≥100/V.

1 sample

RTCA DO-311

3.3 Opera-tional shock and crash safety

Batteries Saw tooth pulse, acceleration 6 and 20 gn, 11 ms pulse duration, 3 shocks in + and – direction, 3 direction

No damage or leakage (NL, NF, NV, NE, ND, NR)

1 sampleOther constant acceleration tests are not reported here

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UN T5 Test: External Short Circuit

Stan-dard

CL Test Name

Device Tested


Comments

UN 38.3

38.3.4.5

T5,Exter-nal Short Circuit

Cells & Batteries

55 ± 2 °C, ext. resist. 0.1 ohm, continue short until temp reaches 55C and 1 h elapse, 6 h observation

NF, ND, case temp ≤ 170C

Cells: 10 Batts: 2 cycle & 2 w/o cycle) 100% SOC

UL 1642

10 Short Circuit

Cells 55 ± 2 °C and 20 5C, Ext. resistance load of 80 ±20 m, apply short until cell at 0.2 V and case temp 10C from test ambient

NF, NE 5 fresh & 5 cycle/ temp100% SOC

IEC 62660-3

6.3.1

External short circuit

Cells Ext resistance of ≤ 5 m, ESC applied for 10 mins NE, NF 1 sample100% SOC

IEC 62619

8.2.1

External short circuit

Cells Ext. resistance of 30+/-10 mΩ, 6 h or case temp declines by 20 % of max temp rise,

NE, NF 1 sample cell, 100% SOC

UL 2580, 1973

14, Short Circuit

Batteries Ext. resistance ≤ 20 m, single fault condition in discharge circuit, repeat at output 15% below protection operating current, until @ 0 SOC and temps near ambient

NC, NF, NE, NL, NR, NV ≥100/V

1 sample MOSOC

SAE J2929

4.8 Electrical Short circuit

Batteries UN T5; orSAE J2464 (External resistance of ≤5 m and <<DUT DC impedance within 1 min and hold for 60 min. 1 h observation).; orISO 12405-1, -2 (same as ISO 12405-3)

NF, NE, NR, NC

1 sample100% SOC

ISO 12405-3

Short Circuit

Batteries Ext Resistance of 20 +0/-10 mΩ applied < 1 min and held for 10 min, 2 h observation

NE, NF, NL, NR, ≥100 Ω/V,

1 sample100% SOC

RTCA DO-311

2.3.11

Short Circuit Enabled Protection

Batteries Ext Resistance 2mΩ, 1 hour, room temperatureObservation within 3 hours after test termination

NL, NF, NE, no fumes or smokes

1 sample fully charged

9

UN T6 Test: Impact/Crush

Stan-dard

CL Test Name

Device Tested


Comments

UN 38.3

38.3.4.6

T6: Impact/ Crush

Cells Impact test same as UL 1642Crush test same as UL 1642 except crush stopped:

• 13 kN ± 0.78 kN reached; or• ≥100 mV OCV drop; or• ≥ 50% deformation from original

Crush in 1 direction for all formatsCrush rate 1.5 cm/s 6 h observation period

ND, NF, cell case ≤ 170C

5 cells at 50% rated CapaciityImpact: applies to cycl. cells > 20 mm dia.Crush: applies to rest of cells

UL 1642

14 Impact Cells A 9.1 ±0.46-kg weight is dropped from a height of 610 ±25 mm onto a 15.8 mm diameter steel bar laying across center cell, Prismatic impacted in 2 directions, other formats only impacted 1 direction

NF, NE 100% SOC5 fresh and 5 cycled cells

UL 1642

15 Crush Cells Flat plate crush, Crush stopped when 13 ±1 kN reached, Crush all formats in one direction only

NF, NE 100% SOC5 fresh and 5 cycled cells

IEC 62619

6.2.2

Impact Cells Same as UL 1642 NF, NE 1 sample (2 for prismatic)

IEC 62660-3

6.1.3

Crush Cells Crushing mechanism 150 mm diameter:• Bar: for cylindrical• Sphere: for prismatic shaped

NF, NE 1 sample100% SOC for BEV, 80% SOC for HEV

RTCA DO-311

N/A Not applicable at cell level

10

UN T7 Test: Overcharge

Stan-dard

CL Test Name

Device Tested


Comments

UN 38.3

38.3.4.7

T7: Overcharge

Batteries (with protec-tion)

CC max with supply volt:• 2 x max charge voltage of battery or 22V• 1.2 x max charge voltage of battery

24 h charge, 7 d observation

NF, ND for 7 d

2 fresh sample and 2 cycled 25x,100% SOC

IEC 62660-3DRAFT

6.3.2

Overcharge Cells Continue charging the cell beyond the 100 % SOC with 1 It for BEV application and 5 It for HEV.The voltage of cell reaches 120% of the maximum voltage, or the cell reaches 130 % SOC equivalent.

NF, NE

IEC 62619

9.2.2

Overcharge control of voltage

Batteries charged at the maximum current of the recommended charger with voltage of supply set to exceed upper limit charging voltage by 10% for each cell in battery.

NF, NE, BMU control auto dis. to prevent hazard

1 sample discharged

IEC 62619

9.2.3

Overcharge control of current

Batteries charged at a current exceeding the maximum charging current by 20%.

NF, NE, BMU prevent Ich > Imax charge

1 sample discharged

UL 2580, 1973

13 Overcharge Batteries Charge at max rate with single fault condition in charging circuit, push charging to 110% max charge voltage.

NE, NF, NR, NC, NV, NL ≥100/V

1 sample discharged

SAE J2929

4.9 Single Point Overcharge Protection System Failure

Batteries Charge at max rate, continue charging until the charge device voltage is reached or the connection interface disconnects battery from charge device, active charge control disabled during test

NE, NF, NR, NC 1 sample discharged

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UN T7 Test: Overcharge (continued)

Stan-dard

CL Test Name

Device Tested


Comments

ISO 12405-3

10.1

Overcharge protection

Batteries Charge at 2C or 5C, power supply 20% above VCmax, continue charging until: Interrupt by auto disconnect, or 130% SOC reached or cell temps reach 55C disconnect active controls

NE, NF, NL, NR, ≥100 Ω/V,Overcharge protection works

100% SOC1 sample

RTCA DO-311

2.3.18

Overcharge Protection Enabled

Batteries Constant voltage, 1.5 maximum battery voltage, current 8 times nominal current, 1 hour maintain of power source + 3 hours of observation

NL, NF, NE, no fumes or smokes

1 sample fully charged

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UN T8 Test: Forced Discharge

Stan-dard

CL Test Name

Device Tested


Comments

UN 38.3 38.3.4.8

T8: Forced discharge

Cells discharge at 1 It A for a test period of 90min NF, ND 10 fresh cells10 cycled cells 50Xdischarged

IEC 62619

8.2.6 Forced discharge

Cells Same as UN 38.3 T8 NF, NE 1 sample,discharged

IEC 62660-3

6.3.3.1

Forced discharge

Cells discontinued when voltage of cell ≤ 25 % of nominal voltage specified by the mfg, or cell is discharged for 30 min.

NF, NE 1 sample discharged

RTCA DO-311

N/A Not applicable at cell level

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Documents

UN 38.3 Lithium Transport Tests and Large Cell/Battery Standards Comparison