EN 60896-21:2004

SLOVENSKI STANDARD
01-maj-2004
1DGRPHãþD
SIST EN 60896-2:1997
Stationary lead-acid batteries - Part 21: Valve regulated types - Methods of test
Stationary lead-acid batteries -- Part 21: Valve regulated types - Methods of test
Ortsfeste Blei-Akkumulatoren -- Teil 21: Verschlossene Bauarten - Prüfverfahren
Batteries stationnaires au plomb -- Partie 21: Types étanches à soupapes - Méthodes
d'essais
Ta slovenski standard je istoveten z: EN 60896-21:2004
ICS:
29.220.20 .LVOLQVNLVHNXQGDUQLþOHQLLQ Acid secondary cells and
EDWHULMH batteries
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD EN 60896-21
NORME EUROPÉENNE
EUROPÄISCHE NORM March 2004
ICS 29.220.20 Supersedes EN 60896-2:1996

English version
Stationary lead-acid batteries
Part 21: Valve regulated types –
Methods of test
(IEC 60896-21:2004)
Batteries stationnaires au plomb Ortsfeste Blei-Akkumulatoren
Partie 21: Types étanches à soupapes - Teil 21: Verschlossene Bauarten -
Méthodes d'essais Prüfverfahren
(CEI 60896-21:2004) (IEC 60896-21:2004)

This European Standard was approved by CENELEC on 2004-03-01. CENELEC members are bound to
comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and
notified to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden,
Switzerland and United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2004 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. EN 60896-21:2004 E
Foreword
The text of document 21/594/FDIS, future edition 1 of IEC 60896-21, prepared by IEC TC 21,
Secondary cells and batteries, was submitted to the IEC-CENELEC parallel vote and was approved by
CENELEC as EN 60896-21 on 2004-03-01.
This European Standard supersedes EN 60896-2:1996.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2004-12-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2007-03-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 60896-21:2004 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 60050-826 NOTE Harmonized as HD 384.2 S1:1986 (not modified).
IEC 60095 NOTE Harmonized in EN 60095 series (partly modified).
IEC 61056 NOTE Harmonized in EN 61056 series (not modified).
IEC 61427 NOTE Harmonized as EN 61427:2001 (not modified).
ISO 9000 NOTE Harmonized as EN ISO 9000:2000 (not modified).
ISO 9001 NOTE Harmonized as EN ISO 9001:1994 (not modified).
ISO 9001 NOTE Harmonized as EN ISO 9001:2000 (not modified).
__________
- 3 - EN 60896-21:2004
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant
EN/HD applies.
Publication Year Title EN/HD Year
IEC 60068-2-32 1975 Basic environmental testing procedures
Part 2: Tests - Test Ed: Free fall
(Procedure 1)
+ A2 1990 HD 323.2.32 S2 1991

1) 2)
IEC 60695-11-10 - Fire hazard testing EN 60695-11-10 1999
Part 11-10: Test flames - 50 W
horizontal and vertical flame test
methods
1) 2)
IEC 60707 - Flammability of solid non-metallic EN 60707 1999
materials when exposed to flame
sources - List of test methods

IEC 60896-22 2004 Stationary lead-acid batteries EN 60896-22
Part 22: Valve regulated types –
Requirements
IEC 60950-1 2001 Information technology equipment - EN 60950-1 2001
(mod) Safety
Part 1: General requirements
IEC 61430 1997 Secondary cells and batteries - Test - -
methods for checking the performance
of devices designed for reducing
explosion hazards - Lead-acid starter
batteries
ISO 1043-1 2001 Plastics - Symbols and abbreviated - -
terms
Part 1: Basic polymers and their special
characteristics
1)
Undated reference.
2)
Valid edition at date of issue.

NORME CEI
INTERNATIONALE IEC
60896-21
INTERNATIONAL
Première édition
STANDARD
First edition
2004-02
Batteries stationnaires au plomb –
Partie 21:
Types étanches à soupapes –
Méthodes d'essai
Stationary lead-acid batteries –
Part 21:
Valve regulated types –
Methods of test
 IEC 2004 Droits de reproduction réservés  Copyright - all rights reserved
Aucune partie de cette publication ne peut être reproduite ni No part of this publication may be reproduced or utilized in any
utilisée sous quelque forme que ce soit et par aucun procédé, form or by any means, electronic or mechanical, including
y compris la photocopie et les photocopying and microfilm, without permission in writing from
électronique ou mécanique,
microfilms, sans l'accord écrit de l'éditeur. the publisher.
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Telephone: +41 22 919 02 11 Telefax: +41 22 919 03 00 E-mail: inmail@iec.ch  Web: www.iec.ch
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PRICE CODE
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International Electrotechnical Commission
МеждународнаяЭлектротехническаяКомиссия
Pour prix, voir catalogue en vigueur
For price, see current catalogue

60896-21  IEC:2004 – 3 –
CONTENTS
FOREWORD.5
1 Scope.9
2 Normative references .9
3 Definitions .11
4 Functional characteristics .21
5 Test set-up .25
6 Test methods.33
Bibliography.79
Figure 1 – Suggested layout for the test.33
Figure 2 – Typical test circuit .41
Figure 3 – Test fixture (IEC 61430) .43
Figure 4 – Orientation of the cell or monobloc battery in the test.45
Figure 5 – Suggested test circuit (fuse protected d.c. source) for the evaluation of
ground short propensity .45
Figure 6 – U-shaped tubing for the detection of gas flow through the valve .51
Figure 7 – Top view of the arrangement for monobloc batteries and single cells .69
Figure 8 – Top view of the arrangement for front-access monobloc batteries .71
Figure 9 – Impact locations.77
Figure 10 – Configuration for the shortest edge drop test.77
Figure 11 – Configuration for the corner drop test.77
Table 1 – Safe operation characteristics .23
Table 2 – Performance characteristics .23
Table 3 – Durability characteristics .25
Table 4 – Safe operation characteristics .31
Table 5 – Performance characteristics .31
Table 6 – Durability characteristics .31
Table 7 – Spark test according to IEC 61430 (for a venting system only) .43
Table 8 – Final voltage de-rating factor in commissioning or acceptance test.55
Table 9 – List of results of float service with daily discharges .59
Table 10 – Summary of results of float service with daily discharges .61
Table 11 – Data report .73

60896-21  IEC:2004 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
STATIONARY LEAD-ACID BATTERIES –
Part 21: Valve regulated types –
Methods of test
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with an IEC Publication.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60896-21 has been prepared by IEC technical committee 21:
Secondary cells and batteries.
This standard cancels and replaces IEC 60896-2 published in 1995.
The text of this standard is based on the following documents:
FDIS Report on voting
21/594/FDIS 21/600/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.

60896-21  IEC:2004 – 7 –
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
This standard constitutes Part 21 of the IEC 60896 series, published under the general title
Stationary lead-acid batteries. At the time of the publication of this part, the following parts
had already been published or were in the process of being published:
Part 11: Vented types – General requirements and methods of tests
1)
Part 21: Valve regulated types – Methods of test
Part 22: Valve regulated types – Requirements
The committee has decided that the contents of this publication will remain unchanged until
2011. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition or
• amended.
———————
This standard replaces IEC 60896-2:1995, Stationary lead-acid batteries – General requirements and methods
of test – Part 2: Valve regulated types.

60896-21  IEC:2004 – 9 –
STATIONARY LEAD-ACID BATTERIES –
Part 21: Valve regulated types –
Methods of test
1 Scope
This part of IEC 60896 applies to all stationary lead-acid cells and monobloc batteries of the
valve regulated type for float charge applications, (i.e. permanently connected to a load and
to a d.c. power supply), in a static location (i.e. not generally intended to be moved from place
to place) and incorporated into stationary equipment or installed in battery rooms for use in
telecom, uninterruptible power supply (UPS), utility switching, emergency power or similar
applications.
The objective of this part of IEC 60896 is to specify the methods of test for all types and
construction of valve regulated stationary lead acid cells and monobloc batteries used in
standby power applications.
This part of IEC 60896 does not apply to lead-acid cells and monobloc batteries used for
vehicle engine starting applications (IEC 60095 series), solar photovoltaic energy systems
(IEC 61427), or general purpose applications (IEC 61056 series).
2 Normative references
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest edition
of the referenced document (including any amendments) applies.
IEC 60068-2-32:1975, Basic environmental testing procedures – Part 2: Test; Test Ed: Free fall
Amendment 2 (1990)
IEC 60695-11-10, Fire hazard testing – Part 11-10 Test flames – 50 W horizontal and vertical
flame test methods
IEC 60707, Flammability of solid non-metallic materials when exposed to flame sources – List
of test methods
IEC 60896-22:2004, Stationary lead acid batteries – Part 22: Valve regulated types –
Requirements
IEC 60950-1:2001, Information technology equipment – Safety – Part 1: General requirements

60896-21  IEC:2004 – 11 –
IEC 61430:1997, Secondary cells and batteries – Test methods for checking the performance
of devices designed for reducing explosion hazards – Lead-acid starter batteries
ISO 1043-1, Plastics – Symbols and abbreviated terms – Part 1: Basic polymers and their
special characteristics
3 Definitions
For the purpose of this part of IEC 60896, the following definitions apply:
3.1
accuracy (of a measuring instrument)
quality which characterizes the ability of a measuring instrument to provide an indicated value
close to a true value of the measurand
[IEV 311-06-08]
NOTE Accuracy is all the better when the indicated value is closer to the corresponding true value.
3.2
accuracy class
category of measuring instruments, all of which are intended to comply with a set of
specifications regarding uncertainty
[IEV 311-06-09]
3.3
ambient temperature
temperature of the medium in the immediate vicinity of a cell or battery
[IEV 486-03-12]
3.4
ampere-hour
quantity of electricity or a capacity of a battery obtained by integrating the discharge current
in ampere with respect to time in hours.
NOTE One ampere-hour equals 3 600 coulombs.
3.5
secondary battery
two or more secondary cells connected together and used as a source of electrical energy
[IEV 486-01-03]
3.6
monobloc battery
secondary battery in which the plate packs are fitted in a multi-compartment container
[IEV 486-01-17]
3.7
floating battery
secondary battery whose terminals are permanently connected to a source of constant
voltage sufficient to maintain the battery approximately fully charged, intended to supply a
circuit, if the normal supply is temporarily interrupted
[IEV 486-04-10]
60896-21  IEC:2004 – 13 –
3.8
battery capacity
quantity of electricity or electrical charge, which a fully charged battery can deliver under
specified conditions
[IEV 486-03-01]
NOTE The SI unit for electric charge is the coulomb (1 C = 1 A.s) but in practice, battery capacity is expressed in
ampere-hours (Ah).
3.9
charge
operation during which a secondary battery receives from an external circuit electrical energy,
which is converted into chemical energy
[IEV 486-01-11]
NOTE A charge is defined by its maximum voltage, current and duration.
3.10
full charge
state where all the available active material of a secondary cell or battery has been
reconverted to its fully charged status
[IEV 486-03-37]
3.11
overcharge
continued charging after the full charge of a secondary cell or battery
[IEV 486-03-35]
3.12
cell
assembly of electrodes and electrolyte, which constitutes the basic unit of a secondary battery
[IEV 486-01-02]
3.13
electrochemical cell
electrochemical system capable of storing in chemical form the electric energy received and
which can give it back by reconversion, i.e. a secondary cell
[IEV 486-01-01, modified]
3.14
secondary cell
assembly of electrodes and electrolyte which constitutes the basic unit of a secondary battery
[IEV 486-01-02]
3.15
valve regulated cell
secondary cell which is closed under normal conditions but which has an arrangement which
allows the escape of gas if the internal pressure exceeds a predetermined value. The cell
cannot normally receive the addition of electrolyte
[IEV 486-01-20]
60896-21  IEC:2004 – 15 –
NOTE Such cells have an immobilized electrolyte to prevent spillage and allow for oxygen recombination on the
negative electrode.
3.16
actual capacity
C
a
quantity of electricity delivered by a cell or battery, determined experimentally with a
discharge at a specified rate to a specified end-voltage and at a specified temperature
NOTE This value is usually expressed in ampere-hours (Ah).
3.17
nominal capacity
C
n
suitable approximate quantity of electricity used to identify the capacity of a cell or battery
NOTE This value is usually expressed in ampere-hours (Ah).
[IEV 486-03-021]
3.18
rated capacity
C
rt
quantity of electricity, declared by the manufacturer, which a cell or battery can deliver under
specified conditions after a full charge
NOTE This value is usually expressed in ampere-hours (Ah).
[IEV 486-03-22]
3.19
shipping capacity
C
sh
quantity of electricity, declared by the manufacturer, which a cell or battery can deliver, at the
time of shipment, under specified conditions of charge.
NOTE 1 This value is usually expressed in ampere-hours (Ah).
NOTE 2 In the present standard this value is assumed to be at least 0,95 C .
rt
3.20
durability
ability of an item (battery) to perform a required function under given conditions of use and
maintenance, until a limiting state is reached
NOTE A limiting state of an item (battery) may be characterized by the end of the useful life, unsuitability for any
economic or technological reasons or other relevant factors.
[IEV 191-02-02]
3.21
electrolyte
solid or liquid phase containing mobile ions that render the phase electrically conducting
[IEV 486-02-19]
60896-21  IEC:2004 – 17 –
3.22
stationary equipment
either fixed equipment or equipment not provided with a carrying handle and having such a
mass that it cannot easily be moved
[IEV 826-07-06]
3.23
failure
termination of the ability of an item (battery) to perform the required function
[IEV 603-035-06]
3.24
lead-acid battery
secondary battery in which the electrodes are made mainly from lead and the electrolyte is a
sulphuric acid solution
[IEV 486-01-04]
3.25
design life
expected period of useful life of a battery according to components, design and application
3.26
service life
period of useful life of a battery under specified conditions
[IEV 486-03-23]
3.27
useful life
under given conditions, the time interval beginning at a certain instant of time, and ending
when the failure intensity becomes unacceptable or when the item (battery) is considered un-
repairable as a result of a fault
[IEV 191-10-06]
3.28
performance
characteristics defining the ability of a battery to achieve its intended functions
[IEV 311-06-11]
3.29
product range
range of products, i.e. cells or monobloc batteries, over which specified design features,
materials, manufacturing processes, and quality systems (e.g. ISO 9000) of manufacturing
locations are identical
NOTE This definition guides the selection of the units to be tested in the framework of this standard.

60896-21  IEC:2004 – 19 –
3.30
accelerated test
test in which the applied stress level is chosen to exceed that stated in the reference
conditions in order to shorten the time duration required to observe the stress response of the
item (battery), or to magnify the response in a given time duration
NOTE To be valid, an accelerated test shall not alter (or conceal) the basic fault modes and failure mechanisms,
or their relative prevalence.
[IEV 191-14-07]
3.31
acceptance test
contractual test to prove to the customer that the device (battery) meets certain conditions of
its specification
[IEV 151-16-23]
3.32
commissioning test
tests applied on a device (battery) carried out on site to prove the correctness of installation
and operation
[IEV 151-15-24]
3.33
compliance test
test used to show whether or not a characteristic or property of an item (battery) complies
with the stated requirements.
[IEV 191-14-02]
3.34
endurance test
test carried out over a time interval to investigate how properties of an item (battery) are
affected by the application of stated stresses and by their time duration or repeated
application
[IEV 151-16-22]
3.35
laboratory test
compliance test made under prescribed and controlled conditions, which may or may not
simulate field conditions
[IEV191-14-04]
3.36
life test
test to ascertain the probable life, under specified conditions, of a component or a device
(battery)
[IEV 151-16-21]
NOTE In VRLA batteries it is customary to assume that for every 10 K rise in service temperature above the
reference temperature (20 °C – 25 °C) a halving of the life in a life test is observed. (For a test temperature up to
60 °C)
60896-21  IEC:2004 – 21 –
3.37
performance test
test carried out to determine the characteristics of a machine (battery) and to show that the
machine (battery) achieves its intended function
3.38
type test
conformity test made on one or more items representative of the production
[IEV 151-16-16]
3.39
thermal runaway
critical condition arising during constant voltage charge in which the current and the
temperature of the battery produce a cumulative mutually reinforcing effect which further
increases them and can lead to the destruction of the battery
[IEV 486-03-34]
3.40
boost voltage
U
boost
voltage specified by the manufacturer for charging at an elevated voltage so as to accelerate
charge, mildly overcharge or to equalized the state of charge of cells and monobloc batteries
3.41
final voltage
U
final
specified voltage at which a discharge of a battery is considered finished.
[IEV 486-03-04]
NOTE This voltage relates to the demand of the exterior circuit, the discharge rate and temperature.
3.42
float voltage
U
flo
constant charge voltage specified by the manufacturer for a floating battery
4 Functional characteristics
4.1 Overview
In this part of IEC 60896 the following characteristics are deemed essential to
comprehensively define the ability of stationary lead-acid batteries of the valve regulated type
to perform their intended function as a reliable source of emergency power.
This part of IEC 60896 is a collection of test methods used to define specified characteristics.
The applicability of a test method and the relevant requirements for each application are
specified in IEC 60896-22.
The characteristics are grouped into safe operation, performance and durability properties.

60896-21  IEC:2004 – 23 –
4.2 Safe operation characteristics
These tests (see Table 1) verify essential safe operation properties of stationary lead-acid
batteries of the valve regulated type.
Table 1 – Safe operation characteristics
Test clause Measures Purpose
6.1 Gas emission To determine the emitted gas volume
6.2 High current tolerance To verify the adequacy of current conduction
cross- sections
6.3 Short circuit current and d.c. internal To provide data for the sizing of fuses in the
resistance exterior circuit
6.4 Protection against internal ignition from To evaluate the adequacy of protective features
external spark sources
6.5 Protection against ground short propensity To evaluate the adequacy of design features
6.6 Content and durability of required markings To evaluate the quality of the markings and the
content of the information
6.7 Material identification To ensure the presence of material identification
markings
6.8 Valve operation To ensure the correct opening of safety valves
6.9 Flammability rating of materials To verify the fire hazard class of battery materials
6.10 Intercell connector performance To verify the maximum surface temperatures of
the connectors during high rate discharges
4.3 Performance characteristics
These tests (see Table 2) describe essential performance properties of stationary lead-acid
batteries of the valve regulated type.
Table 2 – Performance characteristics
Test Clause Measures Purpose
6.11 Discharge capacity To verify the available capacities at selected
discharge rates or discharge durations.
6.12 Charge retention during storage To provide storage duration data
6.13 Float service with daily discharges To determine cyclic performance under float
charge conditions
6.14 Recharge behaviour To determine the recovery of capacity or
autonomy time after a power outage
4.4 Durability characteristics
These tests (see Table 3) describe essential durability properties of stationary lead-acid
batteries of the valve regulated type. It must be noted that certain conditions of test are
abusive and severely detrimental to battery life and safe operation. Operating batteries at
these conditions is not recommended and predictions of operational life under these
conditions are difficult.
60896-21  IEC:2004 – 25 –
Table 3 – Durability characteristics
Test Clause Measures Purpose
6.15 Service life at an operating temperature of To determine the operational life at elevated
40 °C temperatures
6.16 Impact of a stress temperature of 55 °C or To determine the influence of high stress
60 °C temperatures on cell or monobloc battery life
6.17 Abusive over-discharge To determine the expected behaviour when
excessive capacity is discharged
6.18 Thermal runaway sensitivity To determine the expected times to establish a
condition of escalating current and temperature
6.19 Low temperature sensitivity To determine the sensitivity toward damage
induced by electrolyte freezing
6.20 Dimensional stability at elevated internal To determine the propensity of the cell or
pressure and temperature monobloc battery to be deformed by internal
pressure and at elevated temperature
6.21 Stability against mechanical abuse of units To determine the propensity of the cell or
during installation monobloc battery to fracture or leak when
dropped.
4.5 Test result requirements
The test results required to verify the characteristics defined in 6.1 to 6.21, are stated and
maintained in the separate standard IEC 60896-22.
A stationary lead-acid battery of the VRLA type covered by this present standard will be thus
considered as “Tested according to IEC 60896-21 and compliant with defined requirements of
IEC 60896-22.”
The results of the test for the safe operation characteristics will be reported on a “pass” or
“report/state the value” basis.
The requirements for performance and/or drability characteristics, defined in IEC 60896-22,
will depend not only on the general category of intended use of the stationary lead-acid
battery (telecom, uninterruptible power supply (UPS), utility switching, emergency power or
similar applications)) but also on the particular environmental and operational condition within
each application.
5 Test set-up
5.1 Accuracy of measuring instruments
5.1.1 Voltage measurements
The instruments used shall be of an accuracy class 0,5 or better where required. The
resistance of the voltmeters shall be at least 10 000 Ω/V.
5.1.2 Current measurements
The instruments used shall be of an accuracy class 0,5 or better where required.

60896-21  IEC:2004 – 27 –
5.1.3 Temperature measurement
The instruments used shall have a resolution of 1 K. The absolute accuracy of the instruments
shall be 1 K or better where required.
NOTE As the electrolyte temperature cannot be measured directly in valve regulated cells and monobloc
batteries, an alternative measuring point is chosen for giving a temperature reading as close as possible to that of
the electrolyte. The preferred point of measurement is either the negative terminal or the cell wall in direct contact
of the plates.
5.1.4 Time measurements
The time measurements shall have of an accuracy of ±1 % or better where required.
5.1.5 Length measurements
The instruments used shall have an accuracy of ±0,1 % or better where required.
5.1.6 Weight measurements
The instruments used shall have an accuracy of ±1 % or better where required.
5.1.7 Gas volume measurements
The instruments used shall have an accuracy of ±5 % or better where required.
5.1.8 Gas pressure measurements
The instruments used shall have an accuracy of ±10 % or better where required.
5.2 Selection of test units
The units to be used for type testing according to this part of IEC 60896 shall be selected in
accordance with the procedures as follows:
a) Step 1: The product range(s) in a manufacturer’s stationary lead-acid batteries, valve
regulated types product portfolio shall be clearly and unequivocally defined by using the
description as specified in 3.29.
b) Step 2: From within this product range a representative cell or monobloc battery model
shall be selected such that this model has the most critical features regarding the outcome
of the greatest number of tests.
The same model within a product range shall then be subjected to all tests to qualify the
entire product range. Exception shall be made for the test of 6.2, where the unit with the
highest current per terminal, and the test of 6.3, where information for each cell and
monobloc battery of the product range shall be reported.
The documents reporting the test result shall mention the manufacturing location of the
tested cells and monobloc batteries.
c) Step 3: The model thus defined shall be declared as the representative of the concerned
product range
60896-21  IEC:2004 – 29 –
d) Step 4: The test units (identical samples of the representative model) shall be produced in
accordance with the manufacturer’s standard quality procedures and marked with “60896-
21 Test unit” and a unique “identification number” with indelible, handwritten and
distinctive numbers of at least 30mm height on the unit cover. Component samples shall
be also identified with such marking as clearly as possible taking in consideration their
physical dimension and the eventual interference with test procedures.
e) Step 5: The date of production (in MM.YYYY) of the test units shall be reported in the
relevant test documentation.
f) Step 6: The selected test units shall not be stored for more than three months after
electrolyte filling and the eventual storage conditions shall be exclusively those specified
in the technical documentation of the product range and reported in the relevant test
documentation.
g) Step 7: The test units shall not be subjected to exceptional conditioning or commissioning
treatments beyond or above that specified in the relevant technical documentation of the
product range. These treatments shall be reported in the relevant test documentation.
Such non-authorized exceptional conditioning treatments are, for example, repetitive
charge/discharge cycling, high temperature storage and similar procedures.
When a manufacturer’s normal practice is to dispatch units with an actual capacity C of
a
less than 0,95 C , then it is acceptable that the units are treated per a documented
rt
procedure so as to bring them up to an actual capacity C of at least 0,95 C or C as
a rt rt
required prior to the test start. These treatments shall be reported in relevant test
documentations and shall be uniform throughout all the tests.
NOTE In certain tests, the results could be slightly different if the units have a capacity of only 0,95 C instead
rt
of C
rt.
5.3 General test features and rules
5.3.1 The test units shall not undergo any maintenance operations such as water or
electrolyte additions or withdrawals during the entire duration of a test.
5.3.2 The test units shall be tested in the position specified by the manufacturer in the
relevant technical documentation of the product range except for those cases in which a
particular position is specified in the test clause. The position used in any given test shall be
reported in the relevant test documentation.
5.3.3 The test units shall always be tested fully charged with the method and duration of
charge being exclusively that specified by the manufacturer in the relevant technical
documentation of the product range except for those cases in which a particular method or
duration is specified in the test subclause. The charge methods and duration used in each
test shall be reported in the relevant test documentation.
5.3.4 Whenever there is a significant change in a specified design feature, material,
manufacturing process, relevant quality inspection and test procedures of the manufacturing
location(s) of a product range, the relevant type test(s) shall be repeated to ensure that the
affected product range continues to be in compliance with the defined Safe operation,
Performance and Durability requirements for the intended application.
5.3.5 Each test and test set-up shall be documented with photographs that give a clear
image of the test units and their identification numbers.

60896-21  IEC:2004 – 31 –
5.4 Number of test units
5.4.1 The number of units to be tested is summarized below (see Tables 4, 5 and 6).
Table 4 – Safe operation characteristics
Test Clause Measures Number of test units
6.1 Gas emission 6 cells or 3 monobloc batteries
6.2 High current tolerance 3 cells or 3 monobloc batteries
6.3 Short circuit current and d.c. internal resistance 3 cells or 3 monobloc batteries
6.4 Protection against internal ignition from external 3 valve assemblies
spark sources
6.5 Protection against ground short propensity 1 cell or 1 monobloc battery
6.6 Content and durability of required markings 3 samples
6.7 Material identification 1 cover or 1 case sample
6.8 Valve operations 3 cells or 3 monobloc batteries
6.9 Flammability rating of materials 1 sample per material
6.10 Intercell connector performance 6 cells or 6 monobloc batteries
Table 5 – Performance characteristics
Test Clause Measures Number of test units
6.11 Discharge capacity 5 x 6 cells or 5 x 6 monobloc batteries
6.12 Charge retention during storage 6 cells or 6 monobloc batteries
6.13 Float service with daily discharges 6 cells or 3 monobloc batteries
6.14 Recharge behaviour 3 cells or 3 monobloc batteries
Table 6 – Durability characteristics
Test Clause Measures Number of test units
6.15 Service life at an operating temperature of 40 °C 3 cells or 3 monobloc batteries
6.16 Impact of a stress temperature of 55 °C or 60 °C 3 cells or 3 monobloc batteries
6.17 Abusive over-discharge 4+3 cells or 4+3 monobloc batteries
6.18 Thermal runaway sensitivity 6 cells or 6 monobloc batteries
6.19 Low temperature sensitivity 3 cells or 3 monobloc batteries
6.20 Dimensional stability at elevated internal 1 cell or 1 monobloc battery
pressure and temperature
6.21 Stability against mechanical abuse of units 2 cells or 2 monobloc batteries
during installation
60896-21  IEC:2004 – 33 –
5.5 Suggested test sequence
Multiple tests on the same units are allowed. However, the test sequence should be planned
carefully to ensure that the execution of one test does not disturb or unduly influence the
outcome of a subsequent test or cause hidden safety problems. In some cases, a test clause
may proscribe a sequence of tests. Separate units may be used for each test unless
otherwise specified. The manufacturer makes the final decision on the test sequence. The
adopted test sequence shall be recorded in the relevant test documentation.
5.6 Customer test
5.6.1 The test units and test to be used for acceptance or commissioning tests shall be
selected and defined by a joint agreement between the battery supplier and battery user.
For an acceptance or commissioning capacity test, a discharge at the 3 h rate to a final
voltage of 1,70 Vpc or as agreed upon between battery supplier and battery user, shall be
selected.
6 Test methods
6.1 Gas emission
6.1.1 The test shall be carried out with six cells or three monobloc batteries.
6.1.2 The test units shall be selected and prepared according to 5.2.
6.1.3 The test units shall be tested connected in series and maintained during the test
between 20 °C and 25 °C (temperature of test unit). The units shall be fitted with an individual
or common gas collection device so that the emitted gas can be collected from all cells over
several days and its volume determined with the required accuracy.
6.1.4 The gas collection shall be carried out, for example, with a volumetric measurement or
gas collection device similar to that shown in Figure 1. Careful attention shall be paid to
ensure leak-free gas transport from the test units to the collection device during long
unattended operation. The maximum hydrostatic head (as given by the difference in collection
vessel immersion depth and water level) shall be not more than 20 mm.
X
Distance between the maximum
water level and the underside of
the collection vessel shall be
20 mm max.
Test unit
IEC  016/04
Figure 1 – Suggested layout for the test

60896-21  IEC:2004 – 35 –
6.1.5 The test units shall have, before starting the test, an actual capacity C of at least C
a rt
(3 h rate – U 1,70 Vpc at the selected reference temperature), be fully charged and then
final
float charged, in a series string, for 72 h ± 0,1 h with the manufacturer’s specified float
voltage of n × U ± 0,01 Vpc. This voltage shall be recorded and reported. All units shall be
flo
checked for absence of leaks before commencing the test.
6.1.6 After 72 h ± 0,1 h of float charge, the gas collection shall commence and the collection
of gas be continued for four periods each of 168 h ± 0,1 h duration.
6.1.7 The cumulative total gas volume (V in ml) collected over each of the four periods of
a
168 h ± 0,1 h shall be recorded together with the ambient temperature T (in K) and the
a
ambient pressure P (in kPa) at which each determination of the gas volumes was made.
a
6.1.8 The corrected volume of gas V emitted at the reference temperature of 293 K (20 °C)
n
or 298 K (25 °C) and the reference pressure of 101,3 kPa, shall be calculated by the formula
(ignoring correction for water vapour pressure)
V ×T P
a r a
V = × in ml
n
T P
a r
where
V is the cumulative total gas collected of all cells in ml;
a
T is the reference temperature in K (at 293 K or 298 K);
r
T is the ambient temperature (in K) = 273 + T (in °C);
a a
P is the ambient atmospheric pressure in kPa;
a
P is the reference pressure of 101,3 kPa.
r
6.1.9 The normalized gas emission G per cell at float charge voltage conditions shall be
e
calculated for each of the four 168 h ± 0,1 h periods with the formula below:
G = V / (n × 168 × C ) in ml per cell, hour and Ah (rated C
e n rt 3)
where
V is the total corrected gas volume emitted per test unit in ml
n
n is the number of cells from which the gas was collected in the collection vessel
168 is the number of hours during which the gas was collected
C is the rated C capacity in Ah of the test units from which the gas was collected.
rt 3
The normalized gas emission G per cell at float charge voltage conditions during each of the
e
four periods of 168 h ± 0,1 h of the test shall be reported.
6.1.10 The charge voltage of the same test unit string shall then be increased to
n × 2,40 Vp
...