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Washington, Oct. 2nd 2013

Informal working group: Large Lithium batteries testing

RECHARGE & SAFT

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

Examples of “large batteries”

Stationary

Electro-Mobility

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Boundaries of an Industrial Battery for E-mobility

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Boundaries of an Industrial Battery for E-mobility

Cell Module stack

Inner jacket Inner jacket

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Boundaries of an Industrial Battery for E-mobility

Outer jacket

battery

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Stationary application: batteries sizes

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Boundaries of an Industrial Battery for Stationary

Cells modules cabinets

containerAssembly of cabinets

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Other types of industrial batteries

Aviation batteries,

Tram/ Railways batteries,

Others,…

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

What is the representative size of the battery for transport?Most batteries may be transported complete or in sub-parts:

For automotive:

• batteries can be transported complete (full battery pack)

• and/or in sub-parts: modules/stacks (i.e. when requested for maintenance, transfer between plants,…)

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For stationary industry:• Battery can be transported complete in containers (several number

of cabinets possible)

• And/or in cabinets (several number of module possible)

• And/or in modules (maintenance, pre-assembly, etc..)

For other applications: same modularity.

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What can be tested for safety during transport?

Batt type Very large assembly

Large Battery assembly

Battery assembly intermediate

Modules, stacks,

Cells

Automotive Battery pack: Truck and buses batteries may be too heavy

Battery pack: Can be tested

Can be tested according UN 38.3

Has to be tested according UN 38.3

Stationary Container: Too large and heavy for testing

Cabinets assembly: Too heavy for testing, too many configurations

Cabinet: Can be tested, however too many configurations

Can be tested according UN 38.3

Has to be tested according UN 38.3

Other applications

Marine: too large and heavy for testing

May be too heavy for testing

Aviation: can be tested according to UN 38.3

Can be tested according to UN 38.3

Has to be tested according to UN 38.3

6200 Wh limit?

12 kg limit?

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

Issues relative to 38.3.3 (f) and last § of 38.3.

Text of reference:

(f) When testing a battery assembly in which the aggregate lithium content of all anodes, when fully charged, is not more than 500g, or in case of a lithium battery, with a Watt-hour rating of not more than 6 200 Watt-hours, that is assembled from cells or batteries that have passed all applicable tests, one battery assembly at fully charged state shall be tested under tests 3, 4 and 5, and, in addition, test 7 in the case of a rechargeable battery assembly. For a rechargeable battery assembly, the assembly shall have been cycled at least 25 cycles.

When batteries that have passed all applicable tests are electrically connected to form a battery assembly in which the aggregate lithium content of all anodes, when fully charged, is more than 500g, or in case of a lithium battery, with a Watt-hour rating of more than 6 200 Watt-hours, that battery assembly does not need to be tested if it is equipped with a system capable of monitoring the battery assembly and preventing short circuits, or over discharge between batteries in the assembly and any overheat or overcharge of the battery assembly”

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Issues relative to 38.3.3 (f) and last § of 38.3.ISSUES:1- There is a need to define “battery assembly” for large batteries, which cannot be considered as a battery ( as stated in 38.3.2.2)

2- Transport safety protection is unevenly specified for Battery assemblies depending on their energy:-Over 6200 Wh, is specified a monitoring sytem (not active during transport), but no test.-Under 6200 Wh, a complementary test is specified, but no monitoring system.

3- Multiple batteries configurations may lead to several test for same type of battery using modules in series or in parallel: exemple: a cabinet of 6000 Wh with 6 modules of 1000 Wh/12V may need to be qualified 4 times depending on the serie/parallel configuration (6 S (72V), 2P 3S (36V), 3P 2s (24V), 6P (12V)), although it represents the same risk when not connected.

4- Significant cost and duration of cycling for large batteries assembly under 6200Wh, for a test duplicating the test already requested at battery level.

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

Proposals for change of 38.3.3 (f) and last § of 38.3.

* Option A: for reasons of clarity, the word « battery » could be replaced by « battery unit » or « battery-subassembly » in this text.

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

Proposal for the definition of the “battery assembly”

• Definition of the « battery assembly »

• Any set of “batteries”* and other components connected together for usage, mechanically assembled and/or contained in a single enclosure.

* Option A: definition of “battery-subassembly: a battery unit intended to be connected with other battery-subassemblies and/or other battery components to form a battery for purpose of usage

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Proposal for change of definition of “large batteries”

• Issues for T2 Thermal test, T4: Shock test

Example battery of 3 cells with a mass > 500g and the total mass of the battery < 12kg: it is a “small battery” assembled with “large cells”.

•Anomalies for T2 thermal test parameters between cells and batteries : time parameters for small batteries not adapted for large cells.

•Anomalies between the shock test parameters between cells and battery: acceleration for small batteries not adapted for large cells.

1. Proposal: complement in the definition of « large batteries »

« large battery means a lithium metal battery or lithium ion battery with a gross mass of more than 12kg. »

Any battery assembled with large cells shall be considered as a large battery for testing purpose.

When a large battery is assembled of small cells, these cells may be tested either as large cell or as small cells for the purpose of the qualification of the battery.

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Content:

1.Examples of large batteries.2.Batteries size and compatibility with tests.3.Issues relative to 38.3.3 (f) and last § of 38.3.4.Proposals for change of 38.3.3.5.Proposals for change of définition of « battery assembly » and « large battery » 6.Proposals for change of T.5 External short circuit

Proposal for change of the T.5: external short circuit.• Issue with T.5: Short circuit test.

• Tolerance for the temperature +55°C (+/-2°C) too tight

• Example: Thermal sensors at +/-2°C for temperature regulation• In several standards +/-4°C rather than +/-2°C• +/-2°C is a constraint for the test equipment

• Time of observation after the short-circuit implementation• Most of the large batteries are equipped with circuit breaker or

contactors system to protect the battery; if the system is effective, the battery will immediately open circuit and the short-circuit current is interrupted. Subsequent observation time of a battery in open circuit has no technical utility.

• Proposal: for §38.3.4.5.2 Test procedure.

• In the text, replace « 55±2°C » with « 55±4°C »

• At the end of §38.3.4.5.2 , add the text:

For large batteries, check the voltage when the short circuit condition is removed. If the battery is in open circuit, the further observation time can be reduced to one hour.

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