Welcome to our webinar!

Rich Byczek, Intertek 12/9/2010

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Agenda

• Intertek Introduction: Who we are, what we do.

• Battery Standards Arena
• IEC 62133 adoption, transition
• Certification options for Lithium Batteries
• Transportation requirements for Lithium Batteries
• Battery Performance Validation
• Selecting the proper battery for your application

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Our industries

Supporting our customers in their global trade…..

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 Intertek’s Global Network

Strong growth market exposure Floated May 2002 – LSE: ITRK

FTSE 100, Support Services
EMEA Sector
Revenue split 29%

Americas
34% Asia Pacific
37%

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 Our Roots

• As one of Thomas Edison’s companies, we began testing light bulbs in 1896.

• Over 100 years later, we have built the largest network of product safety and
EMC laboratories.

1896 1925 1955 1965 1989 2004 2007

1961: SEMKO joins CB 1989: ETL OSHA

1925: SEMKO est Scheme: today’s largest issuer recognized NRTL 2006: ETL is the fastest
1896: Edison’s Testing 2004: Entela acquired
Growing certification
Bureau est; later as entrée into
1965: WH successfully challenges UL, Mark in North America
named ETL 1927: Chas Warnock 1992: Inchcape automotive
Co. founded CSA in Canada: sets precedent issues first ISO 9000
certificate

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Commercial & Electrical Services

Conformity Assessment Services

• Largest network of safety and EMC laboratories
• Fastest growing US certification mark
Performance & Benchmark Testing
• Widest range of performance testing capabilities in Industry
• Patented, proprietary processes (FMVT)
• World’s largest independent HVAC performance testing lab
Global approvals
• Market access to over 124 countries

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The Intertek Service Difference
We help you grow your business

The fastest, most responsive testing and certification services

• We work to your schedules and deadlines, not ours
• Shorter queue times, faster turnaround
• Promised completion times
Flexible, customized services
• Off-premise testing, witness testing, or “test at your desk” (web-camera-
monitoring solutions)
• MyTestCentral, on-line report management
World’s largest network of laboratories
• Testing where you need it, with over 60 locations globally
Efficient and cost-effective follow-up services program
• Less interruption to your business

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Local Capabilities Livonia, MI

BATTERY PERFORMANCE
- Over 500 small format test positions
- 28 Module positions (up to 80V, up to 600Amp)
- 8 pack position (up to 900V, up to 1000Amp)
- Temperature/Humidity Conditioning
- UN-DOT 38.3 testing: Altitude, Temp/Humidity, Vibration,
Shock.
- Abuse testing: Short, Over charge, Crush

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Local Capabilities Livonia, MI

EV COMPONENT TESTING
- Charge Stations
- Chargers
- Connectors
- Cordsets
- Service Disconnects
- BMS (Battery Management Systems)

AUTOMOTIVE COMPONENT PERFORMANCE (DV/PV)

ELECTRICAL PRODUCT SAFETY

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North American Certification Capabilities

IEC 62133: Cortland, New York (CBTL)

Detroit CBTL submission 2011

UL 2054: Detroit, MI and Cortland, NY

UL 1642: Detroit, MI and Cortland, NY

UN-DOT: Detroit, MI

Battery Performance: Detroit, MI

Battery Advisory Service: Detroit/ Cleveland

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BATTERY STANDARDS ARENA

What is
“THE STANDARD”
for Batteries?

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BATTERY STANDARDS ARENA

What is “THE STANDARD” for batteries?

- Depends on who you ask

- Depends on the type/ chemistry of battery
- Non-rechargeable (PRIMARY)
- Rechargeable (SECONDARY)
- Lithium / Lithium-ion is the focus of current standard
development.

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Why Lithium?

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Battery Chemistries: Why Lithium/ Li-ion?

NiMH
NICKEL
Pb/Ac METAL Li-Ion
LEAD ACID HYDRIDE LITHIUM ION

Nominal Voltage V 2 1.2 2-4

Specific energy Wh/kg 35 (80) 75 150 (240)

Energy density Wh/l 70 (115) 240 (300) 400 (450)

Specific Power W/kg 200 850 1500

Cycle life
(100% DOD) cycles 250 (800) 450 1000

Self discharge
(% per month at 20C) 2-8 10-30 2-10

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Battery Chemistries: Why Lithium/ Li-ion?

NiMH
NICKEL
Pb/Ac METAL Li-Ion
LEAD ACID HYDRIDE LITHIUM ION

Nominal Voltage V 2 1.2 2-4

Specific energy Wh/kg 35 (80) 75 150 (240)

Energy density Wh/l 70 (115) 240 (300) 400 (450)

Specific Power W/kg 200 850 1500

Cycle life
(100% DOD) cycles 250 (800) 450 1000

Self discharge
(% per month at 20C) 2-8 10-30 2-10

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BATTERY STANDARDS ARENA

US- Based Standards:

UL-1642: Lithium Batteries
- Focus on single-cells
- Used for evaluation of Lithium-Metal (PRIMARY)
- Used for evaluation of Lithium-Ion (SECONDARY)

UL-2054: Household and Commercial Batteries

- Focus on Portable Batteries
- Typically Battery Packs
- References UL 1642 for Lithium Cells

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BATTERY STANDARDS ARENA

US- Based Standards:

UL-1642: Lithium Batteries
- 4th edition, September 2005 (With Nov. 2009 updates)
- Several revisions currently in proposal
- Intention to harmonize with IEC 62133

UL-2054: Household and Commercial Batteries

- 2nd edition, October 2004 (With Nov. 2009 updates)
- Several revisions currently in proposal
- Intention to harmonize with IEC 62133

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BATTERY STANDARDS ARENA

IEC - Based Standards:

IEC-60086
- Primary Batteries (Non-rechargeable)
- Covers Performance and Safety

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BATTERY STANDARDS ARENA

IEC - Based Standards:

IEC-60086
- Primary Batteries (Non-rechargeable)
- Covers Performance and Safety

IEC-62133
- Secondary Batteries (Rechargeable)
- Focus on Lithium-ion Batteries
- First Edition, October 2002
- Second Edition in process, potential 2011 release

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BATTERY STANDARDS ARENA

Which of the
“THE STANDARD’s”
Does my product need?

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IEC 62133 ADOPTION, TRANSITION

BACKGROUND:
- For many years, IECEE (“CB SCHEME”), has accepted the
UL Standard as the basis for accepting batteries.
- Based on common usage of UL 1642/ 2054 for battery
packs.
- Proposal in place to fully accept IEC 62133 within IECEE, as
standard has been released since 2002.
- Proposal includes transition period.

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IEC 62133 ADOPTION, TRANSITION

Who is affected by this regulatory change?

Portable Battery
IEC 62133

Medical Devices Powertools Audio Video ICT Household App

IEC60601 IEC60745 IEC60065 IEC60950 IEC60335

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IEC 62133 ADOPTION, TRANSITION

• At the moment, IEC is working with product level groups to enforce the IEC62133
standard into the product level standard
• Some product level committees are making revision changes to their standard to
comply with battery requirement
• CMC accepted a firm and final enforcement date of May 1, 2011 for battery
standard IEC 62133, phasing out UL 1642 entirely, except for standards IEC
60950-1 and 60065, at the request of TC 108, responsible for those two
standards.

Example

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IEC 62133 ADOPTION, TRANSITION

TRANSITION TESTING:

- Assuming battery is already tested and

certified to UL-1642:
- “Delta” testing to be performed from May
2010. Transition:
Additional
Test to UL1642must
- From May 1, 2012, full testing to IEC be performed
to meet IEC62133
62133 required
- NOTE: IEC 62133 2nd edition is in revision. Full Implementation:
Release date may affect transition period. Test must be performed
according to IEC62133
Currently expecting release in 2011.

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IEC 62133 ADOPTION, TRANSITION

DELTA TESTING: Per May 2010 IECEE Decision, the following

additional clauses of IEC 62133 must be tested on UL-1642 tested
batteries. (16 clauses)
1.4 IEC - Parameters measurement tolerances:
Tolerances are provided for various test parameters.
2 IEC - General Safety Considerations:
Requirements intended to address safety during intended use and unintended use.
Cells and batteries
2.1 IEC - Insulation and Wiring:
Insulation resistance check between wiring and external battery pack case.
Insulated wiring shall be suitable for current voltage and temperature requirements
2.2 IEC - Venting: ·
A cell vent is required
2.4 IEC 62133 – Terminals Contacts:
terminal requirements such as polarity markings and construction to prevent
inadvertent short-circuiting, etc.

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IEC 62133 ADOPTION, TRANSITION

2.5 IEC – Assembly of Cells into Batteries:

Use of same cells with matched capacities from same manufacturer. When portions
of series connected cells are selectively discharged, separate circuitry shall be
utilized to prevent forced discharge.
2.6 IEC – Quality Plan:
Requires the manufacturer to have quality plan that defines procedures for the
inspection of materials, components, cells and batteries covering the process of
producing each type of cell or battery.
3 IEC – Type test conditions:
Batteries should be no more than three months old test ambient is 20+5C
Sample size is 5 samples for most of the tests.
4.2.1IEC – Continuous Low Rate Charging –
cell test
requires fully charged cells to be subjected to a low rate charge as specified by the
manufacturer for 28 days

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IEC 62133 ADOPTION, TRANSITION

4.2.3 IEC – Moulded case stress at high ambient temperature

Battery pack enclosure test
70 ± 2°C conditioning
7 hours, then return to ambient
4.3.3 IEC – Free Fall
Cell and Battery
Each sample dropped 3 times from 1.0 m height to concrete floor
4.3.6 IEC – Crushing of cells
• Cell test
• Cell crushed between two flat surfaces
• 13 kN 1 kN force
• force removed after obtaining 13 kN or voltagedrop of 1/3 of original
• prismatic and cylindrical tested
4.3.9 IEC - Overcharge for lithium systems
Charging for longer periods

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IEC 62133 ADOPTION, TRANSITION

5. Annex A and B
IEC - Information for Safety
Information for the safe use of batteries with guidance provided in IEC 61438 for
nickel batteries (not enforceable) and informative Annex A (equipment
manufacturers and battery assemblers) and informative Annex B (end users)
6.1 IEC – Cell Marking
Cells shall be marked per cell specification standards - (IEC 61960, IEC 61951-1, -
2, IEC 61436, IEC 61440, 60285
Cells used in pack need not be marked
6.2 IEC – Battery Marking
Batteries shall be marked per battery specification standards - (IEC 61960, IEC
61951-1, -2, IEC 61436, IEC 61440, 6028
Provided with appropriate caution statements

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CERTIFICATION OPTIONS

Options:

EXISTING BATTERIES WITH UL-1642 Certification:

- Delta testing (previous slides)
- Full IEC 62133 (1st edition) evaluation, with CB report

NEW BATTERIES:
- Full IEC 62133 Evaluation, with CB report
- UL-1642 + Delta test
- UL-1642 + UL-2054 + Delta Test (provides US listing to UL-2054)

NOTE: As UL-1642/2054 and IEC 62133 are not harmonized, separate samples should
be used for each standard in the above cases.

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CERTIFICATION OPTIONS :Urgency!

• European customers WILL require IEC62133.

Be first
• IEC62133 means higher quality – low risk.

Market your quality, market your compliance
• When implementation begins there will be waiting lines at the testing houses

Avoid long lead times and queue

Avoid disruption to your business
• UL1642 is being harmonized with IEC62133

Opens up 2 markets (US/EU)
• IEC62133 can be a way to source lower cost/high quality batteries.

Save money by requiring proper documentation

Validate the performance of your suppliers’ batteries

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TRANSPORTATION REQUIREMENTS

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TRANSPORTATION REQUIREMENTS

UN / USDOT Battery Designations for Lithium/ Li-Ion

Batteries
- Class 9 Material
- Present a hazard during transportation, but do not meet
the definition of any other hazard.

- UN3090: Lithium (Lithium Metal) Batteries

- UN3091: Lithium Batteries contained in equipment
- UN3480: Lithium-Ion Batteries
- UN3481: Lithium-Ion Batteries contained in equipment

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TRANSPORTATION REQUIREMENTS

According to DOT and FAA

- Since 1991:
- 44 “incidents” related to Lithium/ Lithium-ion batteries
- 23 of 44 in Cargo Aircraft
- 21 of 44 in Passenger Aircraft
- 1 in checked luggage
- 16 in passenger cabin/carry-on

- Total Battery incidents (all chemistries): 112

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TRANSPORTATION REQUIREMENTS

LATEST and GREATEST UN MANUAL:

Recommendations on the Transport of Dangerous Goods.
Manual of Tests and Criteria. 5th Revised Edition
(Issued December 2009)
Section 38.3 refers to “Lithium Battery Testing Requirements”

Per Federal register 49 CFR sections 171.7

- Currently references 4th Edition Revised
- 5th edition to be specifically required by January 2011

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TRANSPORTATION REQUIREMENTS

AKA:
- UN/DOT Testing
- 38.3 Tests
- T1 – T8 Testing
- UN ST/SG/AC.10/27/Rev. 4

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UN Manual of Tests and Criteria

Samples Needed: PRIMARY CELLS/ BATTERIES (5th edition)

UNDISCHARGED FULLY DISCHARGED TOTAL

PRIMARY 15 25 40
CELLS

PRIMARY 4 4 8
BATTERIES

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UN Manual of Tests and Criteria

Samples Needed: SECONDARY CELLS (5th edition)

Cylindrical Prismatic
(18650, Canister) (Pouch)

1st Cycle 1st Cycle FULLY 1st Cycle 50 Cycle FULLY TOTAL
CHARGED DISCHARGED 50% CHARGE DISCHARGED

Cylindrical 10 5 10 10 35
Cells

Prismatic 10 10 10 10 40
Cells

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UN Manual of Tests and Criteria

Samples Needed: SECONDARY BATTERIES (5th edition)

SMALL BATTERY: LARGE BATTERY:

Gross Mass up to 12 kg Gross Mass over 12 kg

1st Cycle 25 Cycle 50 Cycle TOTAL

CHARGED CHARGED CHARGED

Small 8 8 16
Batteries

Large 4 4 8
Batteries

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UN Manual of Tests and Criteria

Samples Needed: additional criteria

- Lithium Metal Primary Packs
- Up to 500g total Lithium content
- Cells/ Modules already tested
- 1 sample only:
- Tests 3,4,5 only

- Lithium Ion Rechargeable Packs

- Up to 6,200 Wh rating
- Cells/ Modules already tested
- 1 (or 2) sample(s) only, cycled 25 times, fully
charged
- Tests 3,4,5 and 7 only

- More than 500g Lithium or 6,200 Wh Rating

- No testing required if BMS in place
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UN Manual of Tests and Criteria

Tests T1 – T8
T1-T5 (Same Samples, Tested in Order, All Types)
T1: Altitude Simulation
T2: Thermal Test
T3: Vibration
T4: Shock
T5: External Short Circuit
T6: Impact (Cells Only)
T7: Overcharge (Rechargeable Batteries Only)
T8: Forced Discharge (Cells Only)

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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
"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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BATTERY PERFORMANCE TESTING

Does the data sheet describe the use –profile of your product??

Single Cell Primary Batteries: ANSI C18, IEC 60086: standardized

performance profiles.

Rechargeable: Data sheet verification

- capacity
- charge cycle life
- case temperature
- performance at non-standard temperatures (+37 C, for example)

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SELECTING THE PROPER BATTERY

Intertek’s Advisory Services Group: over 50 years experience.

- Test Plan Development

- SOR (Statement of Requirements) review
- Usage profile verification and development
- Paper Audit:
- How are you currently selecting your batteries?
- What parameters are important?
- How do you decipher the data provided?

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SELECTING THE PROPER BATTERY

Intertek’s Advisory Services Group: over 50 years experience.

- Factory Audits
- How reliable is the supplier’s manufacturing?
- Is ISO-9000 enough?
- Safety as well as performance concerns.

- Most known Lithium Battery incidents caused by internal

short circuit.
- Manufacturing controls
- Raw material supplier chain controls
- Lot Variability

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Intertek: Medical Device Services

Intertek is the Medical Device industry’s

premier resource for regulatory insight and
expert guidance on product testing, inspection
and certification.
Responsiveness to inquiries
Expertise in global requirements
Global network of accredited laboratories
Flexible to meet your needs and schedule

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Intertek: Medical Device Services

• FDA 3rd Party Reviews • Systems Certification

• Product Safety • EMC Testing
• CB Scheme • Performance Testing
• ETL (EU) • Environmental Services
• Satellite Data Acceptance • Analytical Services
Program

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 Thank You.
Rich Byczek,
Site Manager, Intertek Detroit
734-591-9161
rich.byczek@intertek.com

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