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21/11/2013 TÜV SÜD 1

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An introduction to

Battery Testing and

Certification

Presented by:

Timothé Frealle Test Engineer

Matthew Larkin Battery Certification Services

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Contents

Introduction to Battery Testing and Certification

Battery testing

Battery safety

Support

Typical test plans

Directives and regulations

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Testing Services

TÜV SÜD Product

Service

Slide 3

13-11-29

Electrical Performance Testing

Environmental

Testing Abuse Testing UN 38.3

Performance tests

according to

different

standards (e.g.

IEC-61960) or

customer-specific

test protocols.

Environmental

tests according to

different

standards (e.g.

EN 62133), or

customer-specific

test protocols.

Abuse tests

according to

different

standards (e.g.

IEC-62660-2,

ISO-12405), or

customer-

specific test

protocols.

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Certification

Mark is a

combination of

performance,

safety and

abusive tests +

engineering

know-how.

Safety test

protocol

mandatory for

transport of

cells, batteries

and battery

packs.

Cell

Certification

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Safety Testing

• Mould stress (temperature)

• Continuous charge

• External Short-circuit

• Overcharge (time)

• Overcharge (voltage)

• Over discharge

• Drop test

• High temperature

Abuse Testing

• Crush tests

• Nail penetration

• Shock test

• Impact test

• Vibration test

• Immersion

• Fire

• Gas analysis

Safety and Abuse Testing

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Background: Electrochemical Window


Safety tests – How to be safe ?


- Temperature

- Charge

- Discharge

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Safety tests – The main risk

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Safety tests – Control the risk


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Safety tests – How avoid problems ?


Example overcharge test


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Abuse testing facilities


Battery Transport

• Essential to aid the transportation of Lithium metal or Lithium ion cells and batteries by land, sea & air.

• Required by such organisations as: IATA (International Air Transport Association)

IMO (International Maritime Organisation)

ADR (Road) & RID (Rail)

• Demonstrates your cell/pack is safe for transportation.

• Applies to both Primary & Secondary cells and batteries .

• Recommended to source cells already tested to UN Manual of Test to

minimise testing of your pack.

• Applicable to a variety of applications from coin cells to EV modules.

TRANSPORT OF DANGEROUS GOODS

UN Manual of Tests and Criteria - Section 38.3 Lithium Batteries ST/SG/AC.10/11/


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UN Manual of Test & Criteria

Test

• T1 Altitude Simulation

• T2 Thermal

• T3 Vibration

• T4 Shock

• T5 External Short Circuit

• T6 Impact

• T7 Overcharge

• T8 Forced Discharge

Cell

Battery Pack , Module, Battery Assemblies

T7 test only applies to secondary batteries.

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Performance Testing


Discharge performance at 20°C

IEC capacity

Discharge performance at -20°C

High rate discharge

Charge retention and recovery

Storage Endurance in

cycles

Internal resistance

Electrostatic resistance

+ specific test

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What’s a good battery ?


Adapted to an application

Lasting

Effective Reliable

Battery

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Parameters influencing the capacity/performance


• Electrochemical composition

• Battery size

• Battery’s internal resistance

• Temperature and relative humidity

• Frequency of use, usage pattern and ageing

• Battery discharge type (constant current/resistance/power)

• End-use application

o In the case of secondary batteries, their technology allows having low internal resistance,

leading to lower variation of the capacity depending on the end-use application: a single rated

capacity can be determined

o For general purpose primary batteries, the comparison of the performances of two distinct

batteries can therefore only be established regarding a specific end-use application that will

impose the discharging rate through its resistance

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Discharge performance


Discharge at different rate Rated capacity 6.6 Ah

Pulse test / difference

between chemistry

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Application testing


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Battery life


That batteries have a finite life is due to

occurrence of the unwanted chemical or

physical changes to, or the loss of, the active

materials of which they are made. Otherwise

they would last indefinitely. These changes

are usually irreversible and they affect the

electrical performance of the cell

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Storage performance


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Cell qualification Approach


Review qualification requirements

Construct qualification

test plan

Review and validation

Execute test plan

Confirm results and

submit report

Through review of

program

requirements and

what tests may be

required to ensure

compliance.

Test cell quantity

Testing resources

Schedule, test flow

Cell is qualified for

use in the

customer’s

application.

Present plan to

customer for

approval.

Revise as

necessary

Execute according

the customer test

plan.

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Qualification testing


Performances tests

Capacity Cell cycle life

Environmental

Temperature Humidity Shock

Safety

Overcharge Over-

discharge External short

circuit Heat to vent Drop test

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Comparatives tests


Example : Discharge performance at -20°C (mAh)

Cell A Cell B Cell C Cell D Cell E Cell F

For the cells in green, the results are superior than the minimum required.

For the cell in orange, the results are satisfactory but with restriction.

For the cells in red, the results are not satisfactory and would be not used for the application.

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Comparatives tests


0

1

2

3

4

5

6

7

8

9

10Capacity at +20°C

Capacity at -20°C

High rate discharge capacity

Charge retention

Charge recovery after storage

Endurance in cycles

Battery 1

Battery 2

Global comparaison between 2 batteries

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Battery testing info needed


Basic information needed to quote your test program:

- Nominal Voltage and Capacity (Ah) rating

- Maximum charging current and voltage

- Maximum discharge current and voltage

- Normal discharge current

- Cutoff voltage (voltage at which output is cut off or battery is considered)

- Cutoff voltage (voltage at which output is cut off or battery is considered "dead")

- Fully charged current/voltage (current and voltage points where battery is considered fully charged)

- Schematics of battery packs and protection circuitry (if applicable)

- For UL 2054 Limited Power Source test on Request only

- Existing certifications on cells or packs

- Chemistry used (MSDS, Shipping requirements)

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General Product Safety Directive (GPSD) 2001/95/EC


This directive covers all products not already covered by a specific EU Directive and applies to consumer

products. The LVD (Low Voltage Directive) is not applicable for the majority of consumer batteries as the

voltage is less than 75Vdc.

The purpose of the GPSD is to ensure that all products intended for or likely to be used by consumers

under normal or reasonably foreseeable conditions are safe.

This directive allows the national enforcement authority to take action in order to protect consumers from

unsafe products.

The common way to demonstrate compliance to the majority of the requirements is to assess the battery

against harmonised standards such as :

Consideration shall be given also to the end product safety standard if known.

Standard Title Chemistry

EN 62133 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

Lithium-ion

Nickel

EN 60086-4 Primary batteries - Part 4: Safety of lithium batteries Lithium

EN 60086-5

Safety of batteries with aqueous electrolyte Alkaline

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Batteries & Accumulators & Waste Batteries & Accumulators

2006/66/EC Overview

The “Battery Directive” can be broadly split into 2 UK Statutory Instruments:

The Waste Batteries and Accumulators Regulations S.I. 2009 No.890

Main objective relates to the collection, treatment and recycling of waste batteries.

The Batteries and Accumulators (placing on the market) (Amendment)

Regulations S.I 2012 No.1139 (S.I 2008 No.2164)

Main objective relates to material prohibition, labelling to aid recycling, capacity labelling,

placing on the market and removal of batteries.

“Battery Directive” applies to all batteries and accumulators regardless of shape, volume,

weight, material composition or use. Some exceptions exist such as batteries/

accumulators that's end use is for military or space applications.


The Batteries and Accumulators (placing on the market)

Regulations Overview

Came into effect 31st May 2012 (update) and applies to any person/company placing Batteries and products containing or incorporating such Batteries onto the EU market. The regulation is enforced by the National Measurements Office (NMO) on behalf of the Secretary of State for Business Innovation and Skills (BIS). Material Prohibitions Battery/Accumulator shall not exceed the below limits : Mercury - ≤ 0.0005% by weight of battery, for button cell ≤ 2% of weight. Cadmium - ≤ 0.002% by weight of portable battery. The Cadmium requirement does not apply for portable batteries intended for use in Emergency& alarm systems including lighting, medical equipment and cordless power Tools.


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Labelling to aid recycling

All batteries shall be labelled with the crossed out wheeled bin symbol.

Dimensions :

≥ 3% of area of the largest side of battery, with maximum size of 5 x 5cm.

≥ 1.5% of surface area for Cylindrical cells , with maximum size of 5 x 5cm.

If the symbol would be less than 0.5 x 0.5 cm the symbol can instead be located on the

packaging ≥ 1 x 1 cm.

The symbol shall be visible, legible and indelible.

Use of Mercury, Cadmium & Lead symbols The chemical symbol shall be placed below the wheeled bin symbol under the following circumstances :

The chemical symbol shall cover at least ¼ the size of the wheeled bin symbol.

Chemical Requirement

Mercury Hg ≥ 0.0005% by weight button cell only

Cadmium Cd ≥ 0.002% by weight

Lead Pb ≥ 0.004% by weight


Capacity labelling

The requirement to detail the capacity of the battery applies to portable rechargeable batteries and

Automotive batteries.

The requirement however does not apply to embedded batteries that are not user replaceable in end

application.

The below standards shall be used to determine the capacity of a battery:



Standard Chemistry

EN 61951-1 Nickel-Cadmium

EN 61951-2 Nickel-Metal Hydride

EN 60622 Nickel-Cadmium (Prismatic)

EN 61960 Lithium-ion

EN 61056-1 Lead Acid (portable)

EN 60095-1 Lead Acid (automotive)

EN 50342-1 Lead Acid (automotive)


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Capacity labelling The capacity shall be expressed in either mAh or Ah including if applicable cold cranking current. The size of the label shall be as follows :

If the Individual Batteries, accumulators or battery pack are small and cannot have labelling of this size , the packaging shall detail the capacity with a size of 5.0 x 12.0 mm.

Type of battery Location & Dimensions (height x length)

Individual Batteries & Accumulators On Battery: 1.0 x 5.0mm.

On Packaging Front: 5.0mm x 12.0mm

Battery Packs On Battery:

when the largest side is less than

70cm2 = 1.0 x 5.0mm.

when the largest side ≥ 70cm2 = 2.0 x 5.0mm.

Button Cell On Packaging front: 5.0 x 12.0mm

Automotive Batteries & Accumulators On Battery: ≥ 3% of area of largest side, up to 20 x

150mm

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Removal of batteries

The “Battery Directive” requires that battery powered appliances are not to be placed on the

market unless :

- The design allows end of life batteries to be readily removed from the appliance.

- Instructions showing how the battery can be removed safely and where appropriate details of the

type of battery shall be available to the end user.

This does not apply where for safety , performance , medical or data integrity reasons continuity

of power supply is necessary and permanent connection between battery and appliance is

required.

Consideration to end user safety shall also be given. Some product safety standards may

not allow access by end user only qualified personnel in this case the information shall be made

available to the recycling facility.

For embedded batteries the manufacturer shall ensure they have considered the lifetime of both

the battery and product.




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The Waste Batteries and Accumulators Regulations

Came into effect during 2009 – 2010 and applies to any person/company placing

Batteries and products containing or incorporating such Batteries onto the EU market

as well as battery distributors/retailers and waste battery collectors, recyclers and

Exporters.

The regulation is enforced by :

Agency Responsibility

BIS (Department for Business Innovation & Skills)

Waste Industrial and Automotive

Batteries

Environmental Agency (EA,SEPA,NEIA)

Waste Portable Batteries

VCA (Vehicle Certification Agency)

Distributors

Take-back of Waste Portable

Batteries



Slide 34 Introduction to Battery Testing and Certification 21/11/2013

Battery Categories

Portable :

• Sealed

• Can be hand carried by an average person without difficulty

• Does not meet the definition of the other categories

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Battery Categories

Industrial :

• Designed exclusively for industrial or professional uses

• Used as a power source for the propulsion in an electric vehicle including Hybrid

• Unsealed but is not an Automotive battery.

• Sealed but is not an Portable battery.

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Battery Categories

Automotive :

Battery solely used for the starting or ignition of a engine for a road going vehicles including

providing power for lighting.

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Who is a Producer ? “producer” means any company/person in the United Kingdom that, irrespective of the selling technique used, including by means of distance communication(website etc) places batteries including those incorporated into appliances or vehicles onto the market for the first time in the United Kingdom on a professional basis. Who is a Distributor ? “distributor” means that they provide batteries and accumulators on a professional basis to an end user You may be both a Producer and Distributor in which case you need to meet the obligations of both.



Portable Battery Producer Obligations “Small Producer” = ≤ 1 tonne of batteries (1,000 kg). Register on the NPWD(National Packaging Waste Database) Registration System. Pay annual charge typical £30 a year. Record the amount (weight) of batteries sold (UK) including chemistry. If you sell more than 1 tonne of batteries Register with a Battery Compliance Scheme (BCS) who will notify the environmental agency of your joining. Provide BCS with comprehensive details of your company. Provide quarterly data reports of the amount (weight) of batteries sold (UK) including Chemistry to BCS. Pay applicable fee to BCS for the service they provide you.


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Portable Battery Distributors Obligations

“Small Distributor” = ≤ 32 Kg

Record the amount (weight) of batteries sold (UK) including chemistry.

If you sell more than 32 Kg of batteries :

Must implement a take back scheme for waste (end of life) batteries.

The scheme must be free to the end user and accept all types of portable batteries not just

ones you sell.

Record the amount (weight) of batteries sold (UK) including chemistry and location of sale.

Arrange collection with a BCS.

Publicise / make available information to end users relating to cost of collection, treating and recycling

waste when selling new batteries to end users.

The requirement for a take back scheme is not required if you only sell equipment that contains batteries i.e you do

not sell batteries separately




Portable Battery Distributors Obligations

The weight limit, what does this mean in real terms?

Year Directive Target UK Actual

2012 25% 28.3%

2016 45% ??

Directive Targets for collection, treatment and recycling

National Packaging Waste Database Summary of Portable Batteries Data for the 2012 Compliance Period - as at 18 July 2013

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Industrial Battery Producer Obligations

Register company details with BIS.

Register on the NPWD (National Packaging Waste Database) Registration System. A BPRN (Battery Producer Registration Number) will be allocated to producer. Take Back & Collection (1) Provide free take back & collection on request if the end user is buying a replacement battery. (2) Provide free take back & collection on request if the end user cannot return the waste battery to there

original producer (supplier) if it is the same chemistry type as the Producer has placed on the market currently or in the last 3 years.

(3) Provide free take back & collection on request if the end user is unable for any reason to return the

waste battery to the producer under entitlement (1) & (2). Alternative commercial arrangements with end users is permitted relating to meeting of costs of collecting, treating and recycling waster industrial batteries but it is the responsibility of the Producer to meet the directive requirements.

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Industrial Battery Producer Obligations Publicise to Industrial Battery end users the take back scheme. Publicise chemistry of the batteries the producer has placed on the market currently and in the last 3 years. Compile yearly report s that are available to the Environmental Agency covering: • Amount and chemistry of batteries placed on the market. • Amount and chemistry of batteries received as part of the take back scheme .

• Amount and chemistry of batteries delivered to an approved Battery Treatment Operator for recycling

• Amount and chemistry of batteries delivered to an approved Battery Exporter for recycling outside the UK. • Records shall be kept for a minimum of 4 years.

When selling/supplying industrial batteries the producer must declare the BPRN number to their client. Illegal to dispose of waste Industrial Batteries in landfill or to incinerate them.

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TÜV SÜD Slide 43 Introduction to Battery Testing and Certification 21/11/2013

Automotive Battery Producer Obligations

Register company details with BIS.

Register on the NPWD (National Packaging Waste Database) Registration System. A BPRN (Battery Producer Registration Number) will be allocated to producer.

Collect waste Automotive Batteries from Final Holders free of charge, no requirement to collect from individual consumers. Publish waste battery collection to Final Holders. Compile yearly report s that are available to the BIS (Department for Business Innovation & Skills) covering: • Amount and chemistry of batteries placed on the market.

• Amount and chemistry of waste batteries collected.

• Amount and chemistry of batteries delivered to an approved Battery Treatment Operator for recycling or Battery Exporter for recycling outside the UK.

• Estimated tonnage of batteries that will be exported before use.

Illegal to dispose of waste Automotive Batteries in landfill or to incinerate them.


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Thank you for

listening!

For more information contact:

+44 (0)1489 558100

[email protected]

www.tuv-sud.co.uk

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Introduction to Battery Testing and Certification 21/11/2013

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