UN 38.

3 Lithium Transport
Tests and Large Cell/Battery
Standards Comparison
Laurie Florence
UL LLC
laurie.b.florence@ul.com

UL and the UL logo are trademarks of UL LLC 2013

 UN T Tests Comparisons: General Info for Tables 2

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
 3

Comparison of UN Battery Tests

UN IEC UL SAE RTCA ISO IEC

62660 2580 J2929 DO-311 12405-3 62619
DO-160
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
 4

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.
 5
UN T1 Test: Altitude Simulation

Standard Cl Test Name Device Parameters Require- Comments

Tested ments
UN 38.3 38.3.4 T.1 Altitude Cells or Fully charged NL, NV, 10 fresh cells,
.1 Simulation Batteries 11.6 kPa or less for 6 hours ND,NR, NF, 2 fresh bat & 2
OCV 10% cycled bat (25
cycl)

UL 1642 19 Low Pressure Cells Fully charged NL, NV, 5 fresh

(Altitude 11.6 kPa or less for 6 hours ND,NR, NF 5 cycled (new
Simulation) designs)

RTCA 3.4.1 Steady state Batteries Fully charged (according to NL, NF, NV, 1 sample
DO-311 altitude manufacturer design), then ND, NR
discharged and charged during No OCV There are
the test other types of
Temperature: ambiant altitude tests in
9,12 kPa (reached in 14 min) D0311 and
then maintained for 3 hours 2 D0160 not
times (6 hours in total) reported here
 UN T 2 Test: Thermal 6

Stan- CL Test Device Parameters Requirements Comments

dard Name Tested
UN 38. T2 Cells and 72 2 C for 12 h, -40 2C for 12 h NL, NV, ND,NR, NF, Same 100%
38.3 3.4. Thermal Batteries 30 min interval between temps OCV 10% SOC samples
2 test 10 cycles, 10 h at ambient from T1

UL 18 Temper- Cells 70 3C for 4 h, 20 3C for 2 h, NF, NE, NL, NR, NV 100%SOC, 5

1642 ature -40 3C for 4 h fresh, 5 cycled
cycling 30 min interval between temps samples
9 temp cycles, 24 h at ambient
IEC CD 6.2. Temper- Cells -40C or Tmin for 1.5 h NF, NE 1 sample
62660- 2 ature 85C or Tmax for 1.5 h 100% SOC BEV
3 Cycling Transition to 25C between extreme temps 80% SOC HEV
1 h transition time between 25C and extreme
temps
30 cycles from
UL 27 Thermal Batteries 85 2C, -40 2C NV, NF, NE, NL, NR, 1 sample
2580 cycling 15 min interval between temps 100/V. protectors MOSOC
5 temp cycles, C/D cycle at end functional Cells: 1642
SAE 4.2. Thermal Batteries UN T2 or NV, NF, NE, 100/V 1 sample
J2929 3 Shock 70 5C for 6 h, -40 5C for 6 h OCV 10%, MOSOC
Cycling 15 min interval between temps No damage to HV
5 temp cycles, C/D cycle at end conduct.
ISO 7.2 Thermal Batteries 60 2C for 6 h, -40 2C for 6 h NV, NF, NE, NL, NR, 1 sample 80%
12405- cycling 30 min interval between temps 100 /V. SOC
3 5 temp cycles
RTCA 3.5 Temper- Batteries 85C 2C for 4.25 h 0.25 h; NL, NF, NV, ND, NR 1 sample
DO-311 ature -55C 2C. 4.25 h +/- 0.25 h. No OCV
shock 85C 2C. 4.25 h +/- 0.25 h. Min value insulation
5min interval between temps resistance 10M
3 temp cycles. C/D at end
 UN T3 Test: Vibration 7

Stan- C Test Device Parameters Requirements Com-

dard L Name Tested ments
UN 38 T3 Cells and Sinusoidal Waveform , Log sweep 7 Hz 200 Hz 7 NL, NV, ND,NR, NF, Same
38.3 .3. Vibration Batteries Hz in 15 min., 12 times, 3 directions: OCV 10% 100% SOC
4. 7 18 Hz., peak accel of 1 gn, samples
2 0.8 mm amp maint. , from T2
18 200 Hz, peak accel. of 2 gn

UL 16 Vibration Cells Simple harmonic vibration, 0.8 mm amp. Frequency NF, NE, NL, NR, NV 5 sample
1642 varied at 1 Hz/min, 100% SOC
From 10 55 Hz within 90-100 min.
3 direction
IEC 6. Vibration Cells IEC 60068-2-64 random vibration, 8 h vibration for NF, NE 1 sample
62660- 1. each plane of cell, 100%SOC
3 1 rms accel. is 27.8 m/s2, 10 Hz to 2000 Hz frequency, BEV, 80%
PSD range is 20 0.14 (m/s2)2/Hz SOC HV

UL 23 Vibration Batteries SAE J2380 Random vibration or NV, NF, NE, NL, NR, 1 sample at
2580 Endur- Vehicle specific profile 100/V. protectors MOSOC
ance functional

SAE 4. Vibration Batteries UN T3; or NV, NF, NE, 100/V 1 sample at

J2929 2. SAE J2380 Random Vibration; or OCV 10%, MOSOC
2 Vehicle specific profile No damage to HV
conduct.
ISO 6. Vibration Batteries Random vibration of IEC 60068-2-64 and ISO 12405-1 NV, NF, NE, NL, NR, 1 sample at
12405- 1 or -2 with temperate variation; or 100/V. 50$ SOC
3 Vehicle specific profile; or UNECE R100-02
RTCA 3. Vibration Batteries Random vibration of D0-160 8.5.2 NL, NF, NV, ND, NR 1 sample
DO- 1 10 to 2000Hz (specific power spectral density curve), No irregular V
311 0.5gn scan before and after, 3 directions 1 hour Min value insulation
duration each, resistance 10M
 UN T4 Test: Mechanical Shock 8

Stan- CL Test Device Parameters Requirements Comments

dard Name Tested
UN 38.3 38. T4 Cells and Large cell and Batt: half-sine shock, peak accel. NL, NV, ND,NR, NF, Same 100%
3.4. Shock Batteries of 50 gn, pulse duration of 11 msecs OCV 10% SOC samples
4 3 shocks in + and direction, from T3
3 direction for 18 total shocks

UL 1642 15 Shock Cells first 3 msec . 75 g ave. accel. NL, NV, NE, NR, NF 5 sample
125 - 175 gn peak accel. fresh and 5
3 shocks in 3 direction for 18 total shocks samples
cycled
100% SOC
IEC 6.1. Mech- Cells Half-sine, 500 m/sec2, accel., 6 ms duration, 10 NE, NF 1 sample,
62660-3 2 anical shocks/direction, 6 spatial directions applied 100% SOC
Shock BEV, 80%
SOC HEV
UL 2580 24 Shock Batteries Half-sine, 25 gn peak accel., 15 ms pulse dur., 3 NV, NF, NE, NL, NR, 1 sample
shocks in 3 directions for 18 total 100/V. protectors MOSOC
functional
SAE 4.5 Mechan- Batteries UN T4 shock test, or NV, NF, NE, 100/V 1 sample
J2929 ical Half-sine, 25 gn peak accel., 15 ms pulse OCV 10%, MOSOC
Shock dur., No damage to HV
1 repetition in + and - directions of vehicle longit. conduct.
and later. axes for total 4 separate shocks
ISO 6.2 Mechan- Batteries Half-sine, 500 m/sec2, accel., 6 ms duration, 10 NV, NF, NE, NL, NR, 1 sample
12405-3 ical shocks/direction, 6 spatial directions applied 100/V.
shock
RTCA 3.3 Opera- Batteries Saw tooth pulse, acceleration 6 and 20 gn, 11 ms No damage or leakage 1 sample
DO-311 tional pulse duration, 3 shocks in + and direction, 3 (NL, NF, NV, NE, ND, Other constant
shock direction NR) acceleration
and tests are not
crash reported here
safety
 UN T5 Test: External Short Circuit 9

Stan- CL Test Device Parameters Require Comments

dard Name Tested -ments
UN 38. T5,Exter- Cells & 55 2 C, ext. resist. 0.1 ohm, continue short until temp NF, ND, Cells: 10
38.3 3.4. nal Short Batteries reaches 55C and 1 h elapse, 6 h observation case temp Batts: 2 cycle & 2
5 Circuit 170C w/o cycle) 100%
SOC
UL 10 Short Cells 55 2 C and 20 5C, Ext. resistance load of 80 20 m, NF, NE 5 fresh & 5
1642 Circuit apply short until cell at 0.2 V and case temp 10C from cycle/ temp
test ambient 100% SOC
IEC 6.3. External Cells Ext resistance of 5 m, ESC applied for 10 mins NE, NF 1 sample
62660- 1 short 100% SOC
3 circuit
IEC 8.2. External Cells Ext. resistance of 30+/-10 m, 6 h or case temp declines NE, NF 1 sample cell,
62619 1 short by 20 % of max temp rise, 100% SOC
circuit
UL 14, Short Batteries Ext. resistance 20 m, single fault condition in discharge NC, NF, 1 sample
2580, Circuit circuit, repeat at output 15% below protection operating NE, NL, MOSOC
1973 current, until @ 0 SOC and temps near ambient NR, NV
100/V
SAE 4.8 Electrical Batteries UN T5; or NF, NE, 1 sample
J2929 Short SAE J2464 (External resistance of 5 m and <<DUT DC NR, NC 100% SOC
circuit impedance within 1 min and hold for 60 min. 1 h
observation).; or
ISO 12405-1, -2 (same as ISO 12405-3)
ISO Short Batteries Ext Resistance of 20 +0/-10 m applied < 1 min and held NE, NF, 1 sample
12405- Circuit for 10 min, 2 h observation NL, NR, 100% SOC
3 100 /V,
RTCA 2.3. Short Batteries Ext Resistance 2m, 1 hour, NL, NF, 1 sample fully
DO-311 11 Circuit room temperature NE, no charged
Enabled Observation within 3 hours after test termination fumes or
Protection smokes
 UN T6 Test: Impact/Crush 10

Stan- CL Test Device Parameters Require- Comments

dard Name Tested ments

UN 38. T6: Cells Impact test same as UL 1642 ND, NF, 5 cells at 50% rated
38.3 3.4. Impact/ Crush test same as UL 1642 except crush cell case Capaciity
6 Crush stopped: 170C Impact: applies to
13 kN 0.78 kN reached; or cycl. cells > 20 mm
100 mV OCV drop; or dia.
50% deformation from original Crush: applies to
Crush in 1 direction for all formats rest of cells
Crush rate 1.5 cm/s
6 h observation period
UL 14 Impact Cells A 9.1 0.46-kg weight is dropped from a height NF, NE 100% SOC
1642 of 610 25 mm onto a 15.8 mm diameter steel 5 fresh and 5
bar laying across center cell, cycled cells
Prismatic impacted in 2 directions, other formats
only impacted 1 direction
UL 15 Crush Cells Flat plate crush, Crush stopped when 13 1 kN NF, NE 100% SOC
1642 reached, 5 fresh and 5 cycled
Crush all formats in one direction only cells
IEC 6.2. Impact Cells Same as UL 1642 NF, NE 1 sample (2 for
62619 2 prismatic)
IEC 6.1. Crush Cells Crushing mechanism 150 mm diameter: NF, NE 1 sample
62660- 3 Bar: for cylindrical 100% SOC for BEV,
3 Sphere: for prismatic shaped 80% SOC for HEV
RTCA N/A Not applicable at
DO- cell level
311
 UN T7 Test: Overcharge 11

Stan- CL Test Device Parameters Require- Comments

dard Name Tested ments

UN 38. T7: Batteries CC max with supply volt: NF, ND for 2 fresh sample
38.3 3.4. Overcharge (with 2 x max charge voltage of battery or 22V 7d and 2 cycled
7 protec- 1.2 x max charge voltage of battery 25x,
tion) 24 h charge, 7 d observation 100% SOC

IEC 6.3. Overcharge Cells Continue charging the cell beyond the 100 % NF, NE
62660- 2 SOC with 1 It for BEV application and 5 It for
3 HEV.The voltage of cell reaches 120% of the
DRAFT maximum voltage, or the cell reaches 130 %
SOC equivalent.
IEC 9.2. Overcharge Batteries charged at the maximum current of the NF, NE, BMU 1 sample
62619 2 control of recommended charger with voltage of supply set control auto dis. discharged
voltage to exceed upper limit charging voltage by 10% to prevent
for each cell in battery. hazard

IEC 9.2. Overcharge Batteries charged at a current exceeding the maximum NF, NE, BMU 1 sample
62619 3 control of charging current by 20%. prevent Ich > discharged
current Imax charge
UL 13 Overcharge Batteries Charge at max rate with single fault condition in NE, NF, NR, NC, 1 sample
2580, charging circuit, push charging to 110% max NV, NL 100/V discharged
1973 charge voltage.

SAE 4.9 Single Point Batteries Charge at max rate, continue charging until the NE, NF, NR, NC 1 sample
J2929 Overcharge charge device voltage is reached or the discharged
Protection connection interface disconnects battery from
System charge device, active charge control disabled
Failure during test
 12
UN T7 Test: Overcharge (continued)

Stan- CL Test Device Parameters Require- Comments

dard Name Tested ments

ISO 10. Overcharge Batteries Charge at 2C or 5C, power supply 20% above NE, NF, NL, NR, 100% SOC
12405- 1 protection VCmax, continue charging until: Interrupt by 100 /V, 1 sample
3 auto disconnect, or 130% SOC reached or cell Overcharge
temps reach 55C disconnect active controls protection works

RTCA 2.3. Overcharge Batteries Constant voltage, 1.5 maximum battery voltage, NL, NF, NE, no 1 sample fully
DO- 18 Protection current 8 times nominal current, 1 hour maintain fumes or smokes charged
311 Enabled of power source + 3 hours of observation
 13
UN T8 Test: Forced Discharge

Stan- CL Test Device Parameters Require- Comments

dard Name Tested ments
UN 38.3 38.3. T8: Cells discharge at 1 It A for a test period of 90min NF, ND 10 fresh cells
4.8 Forced 10 cycled cells
discharge 50X
discharged
IEC 8.2.6 Forced Cells Same as UN 38.3 T8 NF, NE 1 sample,
62619 discharge discharged
IEC 6.3.3 Forced Cells discontinued when voltage of cell 25 % of NF, NE 1 sample
62660-3 .1 discharge nominal voltage specified by the mfg, or cell is discharged
discharged for 30 min.
RTCA N/A Not applicable
DO-311 at cell level