Performance Compliance Success

You Want to Do What to

My Battery?

Design for Global Regulatory Compliance of Batteries

Overview

• Scope of discussion

• Global battery standards

• Mechanical Concerns

• Electrical Concerns

• Upcoming Changes

Scope of Discussion

• What we are going to talk about: – Batteries for use with

portable devices – Rechargeable batteries

– NiCd, NiMH and Li Ion

batteries – How testing will be

performed

• What we are NOT going to talk about: – Large format batteries

– Primary batteries

– Specific product designs

– Why????

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

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

IEC 61960 Performance No

• UL requirements for cells and batteries – different standards

• Shipping regulations and testing requirements apply

• Compliance driven by end product needs

Basic Comparison of Standards

• Mechanical focus • Fresh non-faulted samples • Least stringent

IEC62133

• Mechanical focus • Cycled and fresh non-faulted samples • Sequential testing

UN 38.3

• Electrical focus • Li Ion cells cycled and fresh samples • Faulted samples • Testing below trip thresholds

UL 1642 and 2054

Most Stringent

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

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

Mechanical Concerns – Non-Similar Tests

Electrical Concerns – Similar Tests

IEC 62133 UN 38.3 Other Short Circuit • <0.1Ω

• 55±5°C and 20±5°C • Max temp -20% or

24hr

• <0.1Ω • 55±2°C • Max temp +1hr • 6hr observation

• Japan – prepare samples at upper and lower temperature

Overcharge Li Systems • Cell only • ≥ 10V • Irec • 2.5C5/Irec (hr) Nickel Systems • 2.5xIrec to 250%

• Pack only • Voltage varies • 2x Irec • 24hr

Forced Discharge (cell only)

• Reverse Polarity • It • 90 min

• Reverse Polarity • Imax • Irec/Imax (hr)

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

UL Electrical Tests

UL 2054

Short Circuit at Room Temp

Short Circuit at 55

Abnormal Charge

Abusive Overcharge

Forced Discharge

Limited Power Source

Component and Surface Temperature

Cell Voltage During Charge

UL 1642

Short Circuit at Room Temp

Short Circuit at 55

Abnormal Charge

Forced Discharge

Cell Cycling prior to testing

Single Fault Application – UL 2054

Not Allowable

• Devices Investigated for Purpose: • PTC • Fuse

Allowable

• Devices NOT Investigated for Purpose: • FET • Safety IC • Sense resistor

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.

Short Circuit at Room and 55°C

UL 2054

• 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

UL 1642

• Thermal link-CID-Fusible tabs – short across 80±20mΩ load

• Fuse-PTC – No Trip current

• Fully discharged or stable temperature

• No fire-No explosion

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

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

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

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

UL 2054

• Multiple methods • Charging and

discharging • Non-faulted samples • Temperatures < rated • Calculated max. temp. • Protective device cannot

terminate testing

Component and Surface Temperature

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

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.

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

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

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

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

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