Presentation from 2013 30th International Battery Symposium by Cindy Millsaps related to designing for compliance with various portable battery standards.

1. You Want to Do What to
My Battery?
Design for Global Regulatory
Compliance of Batteries
Performance Compliance Success

2. Overview
• Scope of discussion
• Global battery standards
• Mechanical Concerns
• Electrical Concerns
• Upcoming Changes

3. Scope of Discussion
• What we are going to talk
about:
• What we are NOT going
to talk about:
– Batteries for use with
portable devices
– Rechargeable batteries
– Large format batteries
– NiCd, NiMH and Li Ion
batteries
– How testing will be
performed
– Specific product designs
– Primary batteries
– Why????

4. Nickel Based Battery Standards
Standard
Performance or Safety
Required
UL 2054
Safety
Maybe
IEC 62133
Safety
Yes
IEC 61951-1
NiCd Performance
No
IEC 61951-2
NiMH Performance
No
• UL 2054 – Nickel cells and batteries
• No transportation testing requirements
• Compliance driven by end product needs

5. Lithium Ion Battery Standards
Standard
Performance or Safety
Required
UL 1642 – Cells only
Safety
Maybe
UL 2054 – Batteries only
Safety
Maybe
IEC 62133
Safety
Yes
UN Manual of Tests and
Criteria (UN 38.3)
Safety
Yes
Performance
No
IEC 61960
• UL requirements for cells and batteries – different standards
• Shipping regulations and testing requirements apply
• Compliance driven by end product needs

6. Basic Comparison of Standards
IEC62133
UN 38.3
Most
Stringent
• Mechanical focus
• Fresh non-faulted samples
• Least stringent
• Mechanical focus
• Cycled and fresh non-faulted samples
• Sequential testing
UL 1642 and
2054
• Electrical focus
• Li Ion cells cycled and fresh samples
• Faulted samples
• Testing below trip thresholds

7. Mechanical Concerns – Similar testing
UL
UN
IEC
Mechanical Shock
(Shock)
Cell only
3 shocks (1 per plane)
18 shocks (3 per face)
Different pulse definition
Mass/Voltage loss
3 shocks (1 per plane)
Heating (Thermal
Abuse)
Cell Only
130°C for 10min
Not Required
Cell Only
130°C for 10min
Temperature Cycling
(Thermal Test)
10 cycles
+70 to -20
Cell only
10 cycled
+75 to -40
Mass/Voltage loss
5 cycles
+75 to -20
Altitude Simulation
(Low Pressure)
Cell only
≥6hr
≤11.6kPa
Cell and Pack
≥6hr
≤11.6kPa
Mass/voltage loss
Cell only test
≥6hr
≤11.6kPa
Crush (Crushing of
cells)
13kN
Reach limit – stop
13kN
Reach limit or 50% deformation or
100mV drop*
13kN
Reach limit or abrupt voltage
drop
Impact
9.1kg mass
61cm drop
15.8mm bar
9.1kg mass
61cm drop
15.8mm bar
>20mm dia. cylindrical cells*
Not Required
Mold stress
Min. 70°C for 7 hr
Fully discharged
Not required
70°C for 7hr
Fully charged

8. Mechanical Concerns – Non-Similar Tests
Drop
Vibration
250N Force
Projectile
• UL - Conditioning of samples prior to
drop
• UL – Drop with cold samples
• Japan – Drop with host from various
heights
• UL and IEC only
• UN Manual – 3hr/plane
• Stringent profile
• UN – voltage drop pass/fail criteria
•
•
•
•
250N force
5 sec
All faces
UL only – Battery Only
• Fire exposure test
• Set cell over burner until it explodes
or burns out
• Cannot penetrate wire mesh screen
2ft by 1ft
• UL only – Cell Only

9. Electrical Concerns – Similar Tests
IEC 62133
Short Circuit
UN 38.3
Other
• <0.1Ω
• 55±5°C and 20±5°C
• Max temp -20% or
24hr
• <0.1Ω
• 55±2°C
• Max temp +1hr
• Japan – prepare
samples at upper
and lower
temperature
• 6hr observation
Overcharge
Forced
Discharge
(cell only)
Li Systems
• Cell only
• ≥ 10V
• Irec
• 2.5C5/Irec (hr)
Nickel Systems
• 2.5xIrec to 250%
• Reverse Polarity
• It
• 90 min
•
•
•
•
Pack only
Voltage varies
2x Irec
24hr
• Reverse Polarity
• Imax
• Irec/Imax (hr)

10. IEC 62133 Specific Electrical Tests
Cell Protection Against
High Charging Rate
• 3x Irec
• Recommended Charge
Voltage
• To fully charged or until
safety activates
• Cell only
Incorrect Installation of a
Cell (Nickel Systems Only)
• 5 fully charged cells
• 1 installed reversed in
series
• Short with 1Ω resistor
• Vent opens or temp
stabilizes
• Cell only

11. UL Electrical Tests
UL 2054
Short Circuit at Room Temp
UL 1642
Short Circuit at Room Temp
Short Circuit at 55
Abnormal Charge
Short Circuit at 55
Abusive Overcharge
Abnormal Charge
Forced Discharge
Limited Power Source
Forced Discharge
Component and Surface Temperature
Cell Voltage During Charge
Cell Cycling prior to testing

12. Single Fault Application – UL 2054
Not
Allowable
• Devices Investigated for Purpose:
• PTC
• Fuse
Allowable
• Devices NOT Investigated for
Purpose:
• FET
• Safety IC
• Sense resistor

13. Protective Devices – Trip/No Trip
• Performed on faulted and non-faulted samples
• Performed at temperature for testing (55°C short circuit)
Start at max
rated – hold
for 2 min.
Increase by
5% - hold for
2 min
Repeat until
protector
trips in
<2min
Note:
Secondary trip and no trip value needed for component and surface temperature testing.

14. Short Circuit at Room and 55°C
UL 2054
UL 1642
• RT – Bare wire Short –
no fault – 1 sample
• Single Fault
• No Trip current
• Fully discharged or stable
temperature
• No Fire-No explosion-no
excessive cell temp
• Thermal link-CID-Fusible
tabs – short across
80±20mΩ load
• Fuse-PTC – No Trip
current
• Fully discharged or stable
temperature
• No fire-No explosion

15. Abnormal Charge
UL 2054
• Max. specified charge
voltage
• 3X max. charger current or
no trip current
• Fully charged plus 7hr
and/or 10 cycles of
resettable device
• Single fault
• No fire-no explosion-no
chemical leaks
UL 1642
• Max. specified charge
voltage or lower value
• Thermal link or CID - 3X, 2X
and 1.5X max. specified
charge current
• PTC – cycle 10x, or fully
charged (min. 7 hr)
• Fuse – no trip current
• Fully charged plus 7hr
• No fire-no explosion

16. Abusive Overcharge
UL 2054
• NO upper voltage limit – min. 6V/cell Lithium ion, and 3V/cell
Nickel)
• 10xC5 and 5xC5
• Single faulted sample
• Termination criteria
• Non-resettable protective device activates or
• Resettable device cycles 10x, or
• Temperature stable
• Sample explodes or catches fire
• No fire-No explosion

17. Forced Discharge
UL 2054
• Discharge one cell or one
string of series connected
parallel strings
• Short across a 80±20mΩ load
• Single fault
• Termination criteria
• Fully discharged or
• Thermal stability or
• Fire or explosion
• No fire-no explosion-no
spillage of liquid
UL 1642
• Discharge one cell or one
string of series connected
parallel strings
• CID-thermal link-fusible tabs Short across a 80±20mΩ load
• PTC-fuse – no trip current
• Termination criteria
• Fully discharged or
• Thermal stability or
• Fire or explosion

18. Limited Power Source
• Based on 60950 LPS test
• Test method depends on type of protection circuit utilized:
– Output inherently limited (without assistance of protective device,
limiting impedances or regulating network)
– Impedance limited
– Regulating network or IC current limiter (normal and single fault)
– Overcurrent protective device (Fuse)
• Must limit current and power to below noted levels within 5
or 60s

19. Component and Surface Temperature
UL 2054
• Multiple methods
• Charging and
discharging
• Non-faulted samples
• Temperatures < rated
• Calculated max. temp.
• Protective device cannot
terminate testing
Charging Test Method:
• CC/CV – 3x current or
• No trip value **
• Maximum normal
charge current
Discharging Test Method:
• No trip value **
• Maximum normal load
• Max. VA with voltage
>2V

20. Lithium Ion Systems - Cell Voltage
• Concurrent with Component Temperature Test
• Monitor voltage of each cell or cell string
• Verify value does not exceed cell manufacturer
maximum recommended.

21. Re-use of Samples
Minimum samples required:
• UL 2054
– 35-45 batteries
– 70 cells
• UL 1642
– 75-150
• UN
– 16 batteries
– 35-40 cells
• IEC 62133 1st Ed. (2nd Ed.)
– 32-37 (21-37) batteries
– 75-85 (50-85) cells
Reuse:
• UL
– Verify function-document
– No required sequence
– 11 batteries
• UN
– Verify function
– T1-T5 cycled to T7
– 4 batteries
• IEC 62133
– Depends – not specifically
addressed

22. Re-use of Data
Similar testing, but not Identical
•
•
•
•
Sequential testing
Cycled testing
Samples sizes
Faulted and non-faulted
Testing in UN-UL-IEC standards are all different

23. Changes
UN 5th Revised Edition – Amendment 1
– Effective January 1, 2013 –December 31, 2014
• Exception - Manufactured prior to January 1, 2014 and of a design that was
tested to the 5th Revised Edition may continue to be trasported.
– First update since 2003
Changes include:
• Impact – only required for cylindrical cells >20mm dia.
• Added Crush test for prismatic, pouch, coin/button and cylindrical <20mm dia.
• Single cell battery is a cell – T7 only
• Clarified cells and batteries must be tested
• Component cells must complete T8 (FD)
• Cells defined by mass (not Wh or lithium metal – same as battery)
• Removed mass loss – updated leakage definition - widened limits

24. Upcoming Changes
• IEC 62133 2nd Edition
– Released 12-2012 – 3 year implementation period
– Nickel testing remains the same
– Li Ion Batteries
• Removed redundant testing from UN manual (vibration, shock, temp cycling) –
added requirement to meet UN Manual
• Added conditioning at high and low temp prior to Short Circuit at 55°C
• Removed Short Circuit at RT
• Added requirement to meet UN Manual
– Li Ion Cells
• Low rate charge to Continuous Charge – 7 days
• Removed redundant testing from UN Manual (vibration, shock, temp cycling, low
pressure) – added requirement to meet UN Manual
• Added conditioning requirements to Short Circuit, Thermal Abuse, Crush
• Added Forced Internal Short Circuit test

25. Contact Information
Energy Assurance LLC
5202 Belle Wood Court, Suite 106
Buford, GA 30518
• www.Energy-Assurance.com
• Cindy Millsaps
• CindyMillsaps@Energy-Assurance.com
• 404-954-2054