Transcript UL Test Comparison_Saft input on DO revised IEC 62660r

UN 38.3 Lithium Transport
Tests and Large Cell/Battery
Standards Comparison
Laurie Florence
UL LLC
[email protected]
UL and the UL logo are trademarks of UL LLC © 2013
UN T Tests Comparisons: General Info for Tables
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 - Lithiumbased 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
2
3
Comparison of UN Battery Tests
UN
IEC
62660
UL
2580
SAE
J2929
Altitude
RTCA
DO-311
DO-160
ISO
12405-3
IEC
62619
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
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.
4
5
UN T1 Test: Altitude Simulation
Standard
Cl
Test Name
Device
Tested
Parameters
Requirements
Comments
UN 38.3
38.3.4
.1
T.1 Altitude
Simulation
Cells or
Batteries
Fully charged
11.6 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 charged
11.6 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 test
Temperature: ambiant
9,12 kPa (reached in 14 min)
then maintained for 3 hours 2
times (6 hours in total)
NL, NF, NV,
ND, NR
No OCV
1 sample
There are
other types of
altitude tests in
D0311 and
D0160 not
reported here
UN T 2 Test: Thermal
Parameters
6
Standard
CL
Test
Name
Device
Tested
Requirements
Comments
UN
38.3
38.
3.4.
2
T2
Thermal
test
Cells and
Batteries
72 ± 2 °C for 12 h, -40  2C for 12 h
30 min interval between temps
10 cycles, 10 h at ambient
NL, NV, ND,NR, NF,
OCV ≤ 10%
Same 100%
SOC samples
from T1
UL
1642
18
Temperature
cycling
Cells
70 ±3°C for 4 h, 20  3C for 2 h,
-40 ±3°C for 4 h
30 min interval between temps
9 temp cycles, 24 h at ambient
NF, NE, NL, NR, NV
100%SOC, 5
fresh, 5 cycled
samples
IEC CD
626603
6.2.
2
Temperature
Cycling
Cells
-40C or Tmin for 1.5 h
85C or Tmax for 1.5 h
Transition to 25C between extreme temps
1 h transition time between 25C and extreme
temps
30 cycles from
NF, NE
1 sample
100% SOC BEV
80% SOC HEV
UL
2580
27
Thermal
cycling
Batteries
85  2C, -40  2C
15 min interval between temps
5 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 or
70 5C for ≥ 6 h, -40 5C for ≥ 6 h
15 min interval between temps
5 temp cycles, C/D cycle at end
NV, NF, NE, ≥100/V
OCV ≤ 10%,
No damage to HV
conduct.
1 sample
MOSOC
ISO
124053
7.2
Thermal
cycling
Batteries
60  2C for 6 h, -40  2C for 6 h
30 min interval between temps
5 temp cycles
NV, NF, NE, NL, NR,
≥100 /V.
1 sample 80%
SOC
RTCA
DO-311
3.5
Temperature
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 temps
3 temp cycles. C/D at end
NL, NF, NV, ND, NR
No OCV
Min value insulation
resistance 10M
1 sample
UN T3 Test: Vibration
7
Standard
C
L
Test
Name
Device
Tested
Parameters
Requirements
Comments
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
NL, NV, ND,NR, NF,
OCV ≤ 10%
Same
100% SOC
samples
from T2
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
626603
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 sample
100%SOC
BEV, 80%
SOC HV
UL
2580
23
Vibration
Endurance
Batteries
SAE J2380 Random vibration or
Vehicle specific profile
NV, NF, NE, NL, NR,
≥100/V. protectors
functional
1 sample at
MOSOC
SAE
J2929
4.
2.
2
Vibration
Batteries
UN T3; or
SAE J2380 Random Vibration; or
Vehicle specific profile
NV, NF, NE, ≥100/V
OCV ≤ 10%,
No damage to HV
conduct.
1 sample at
MOSOC
ISO
124053
6.
1
Vibration
Batteries
Random vibration of IEC 60068-2-64 and ISO 12405-1
or -2 with temperate variation; or
Vehicle specific profile; or UNECE R100-02
NV, NF, NE, NL, NR,
≥100/V.
1 sample at
50$ SOC
RTCA
DO311
3.
1
Vibration
Batteries
Random vibration of D0-160 §8.5.2
10 to 2000Hz (specific power spectral density curve),
0.5gn scan before and after, 3  directions 1 hour
duration each,
NL, NF, NV, ND, NR
No irregular V
Min value insulation
resistance 10M
1 sample
UN T4 Test: Mechanical Shock
Test
Name
Device
Tested
Parameters
8
Standard
CL
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 msecs
3 shocks in + and – direction,
3  direction for 18 total shocks
NL, NV, ND,NR, NF,
OCV ≤ 10%
Same 100%
SOC samples
from T3
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
Mechanical
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
NV, NF, NE, NL, NR,
≥100/V. protectors
functional
1 sample
MOSOC
SAE
J2929
4.5
Mechanical
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
NV, NF, NE, ≥100/V
OCV ≤ 10%,
No damage to HV
conduct.
1 sample
MOSOC
ISO
12405-3
6.2
Mechanical
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
Operational
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 sample
Other constant
acceleration
tests are not
reported here
UN T5 Test: External Short Circuit
Standard
CL
Test
Name
Device
Tested
UN
38.3
38.
3.4.
5
T5,External Short
Circuit
Cells &
Batteries
UL
1642
10
Short
Circuit
IEC
626603
6.3.
1
IEC
62619
Require
-ments
Comments
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
≤ 170C
Cells: 10
Batts: 2 cycle & 2
w/o cycle) 100%
SOC
Cells
55 ± 2 °C and 20  5C, Ext. resistance load of 80 ±20 m,
apply short until cell at 0.2 V and case temp  10C from
test ambient
NF, NE
5 fresh & 5
cycle/ temp
100% SOC
External
short
circuit
Cells
Ext resistance of ≤ 5 m, ESC applied for 10 mins
NE, NF
1 sample
100% SOC
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; or
SAE J2464 (External resistance of ≤5 m and <<DUT DC
impedance within 1 min and hold for 60 min. 1 h
observation).; or
ISO 12405-1, -2 (same as ISO 12405-3)
NF, NE,
NR, NC
1 sample
100% SOC
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 sample
100% SOC
Short
Circuit
Enabled
Protection
Batteries
Ext Resistance 2mΩ, 1 hour,
room temperature
Observation within 3 hours after test termination
NL, NF,
NE, no
fumes or
smokes
1 sample fully
charged
ISO
124053
RTCA
DO-311
2.3.
11
Parameters
9
UN T6 Test: Impact/Crush
Standard
CL
Test
Name
Device
Tested
UN
38.3
38.
3.4.
6
T6:
Impact/
Crush
Cells
UL
1642
14
Impact
UL
1642
15
IEC
62619
Parameters
10
Requirements
Comments
Impact test same as UL 1642
Crush 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 formats
Crush rate 1.5 cm/s
6 h observation period
ND, NF,
cell case ≤
170C
5 cells at 50% rated
Capaciity
Impact: applies to
cycl. cells > 20 mm
dia.
Crush: applies to
rest of cells
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% SOC
5 fresh and 5
cycled cells
Crush
Cells
Flat plate crush, Crush stopped when 13 ±1 kN
reached,
Crush all formats in one direction only
NF, NE
100% SOC
5 fresh and 5 cycled
cells
6.2.
2
Impact
Cells
Same as UL 1642
NF, NE
1 sample (2 for
prismatic)
IEC
626603
6.1.
3
Crush
Cells
Crushing mechanism 150 mm diameter:
• Bar: for cylindrical
• Sphere: for prismatic shaped
NF, NE
1 sample
100% SOC for BEV,
80% SOC for HEV
RTCA
DO311
N/A
Not applicable at
cell level
UN T7 Test: Overcharge
Test
Name
Device
Tested
Standard
CL
UN
38.3
38.
3.4.
7
T7:
Overcharge
Batteries
(with
protection)
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
7d
IEC
626603
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
DRAFT
Parameters
11
Requirements
Comments
2 fresh sample
and 2 cycled
25x,
100% SOC
12
UN T7 Test: Overcharge (continued)
Standard
CL
Test
Name
Device
Tested
Parameters
Requirements
Comments
ISO
124053
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 55C disconnect active controls
NE, NF, NL, NR,
≥100 Ω/V,
Overcharge
protection works
100% SOC
1 sample
RTCA
DO311
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
13
UN T8 Test: Forced Discharge
Standard
CL
Test
Name
Device
Tested
Parameters
Requirements
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 cells
10 cycled cells
50X
discharged
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