IEC 62485-3:2010

IEC 62485-3


®

Edition 1.0 2010-08



INTERNATIONAL



STANDARD



NORME
INTERNATIONALE


Safety requirements for secondary batteries and battery installations –
Part 3: Traction batteries

Exigences de sécurité pour les batteries d’accumulateurs et les installations
de batteries –
Partie 3: Batteries de traction


IEC 62485-3:2010

---------------------- Page: 1 ----------------------
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IEC 62485-3


®

Edition 1.0 2010-08



INTERNATIONAL



STANDARD



NORME
INTERNATIONALE


Safety requirements for secondary batteries and battery installations –
Part 3: Traction batteries

Exigences de sécurité pour les batteries d’accumulateurs et les installations
de batteries –
Partie 3: Batteries de traction


INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
S
CODE PRIX
ICS 29.220.20; 29.220.30; 43.040.10 ISBN 978-2-88910-997-5
® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale

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– 2 – 62485-3 © IEC:2010


CONTENTS


FOREWORD.4

1 Scope.6


2 Normative references.6

3 Terms and definitions .6

4 Protection against electric shock by the battery and charger.8

4.1 General .8

4.2 Protection against both direct and indirect contact.9

4.3 Protection against direct and indirect contact when discharging the traction
battery on the vehicle (battery disconnected from charger/mains).9
4.4 Protection against direct and indirect contact when charging the traction
battery.10
5 Prevention of short circuits and protection from other effects of electric current .10
5.1 Cables and cell connectors .10
5.2 Protective measures during maintenance.10
5.3 Battery insulation .11
5.3.1 General .11
6 Provisions against explosion hazards by ventilation.11
6.1 Gas generation.11
6.2 Ventilation requirements .12
6.2.1 General .12
6.2.2 Standard formula .12
6.2.3 Special formula.13
6.2.4 Unconventional chargers.14
6.2.5 Multiple charging.14
6.3 Natural ventilation.14
6.4 Forced ventilation .15
6.5 Close vicinity to the battery .15
6.6 Ventilation of battery compartment.15
7 Provisions against electrolyte hazard .15
7.1 Electrolyte and water .15
7.2 Protective clothing .15
7.3 Accidental contact, "first aid".15
7.3.1 General .15

7.3.2 Eye contact.16
7.3.3 Skin contact.16
7.4 Battery accessories and maintenance tools.16
8 Battery containers and enclosures .16
9 Accommodation for charging/maintenance .16
10 Battery peripheral equipment/accessories .17
10.1 Battery monitoring system.17
10.2 Central water filling system .17
10.2.1 General .17
10.2.2 Safety aspects .18
10.3 Central degassing systems .18
10.4 Thermal management systems .18
10.5 Electrolyte agitation system .18
10.6 Catalyst vent plugs .19

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62485-3 © IEC:2010 – 3 –


10.7 Connectors (plugs/sockets).19

11 Identification labels, warning notices and instructions for use, installation and

maintenance.19

11.1 Warning labels .19


11.2 Identification label.19

11.3 Instructions.20

11.4 Other labels.20

12 Transportation, storage, disposal and environmental aspects .20

12.1 Packing and transport.20

12.2 Disassembly, disposal, and recycling of batteries .20

13 Inspection and monitoring .20
Bibliography .22

Table 1 – Gas producing current I respectively typical end of charge current in A per
gas
100 Ah rated capacity, when charging with IU or IUI-chargers.13

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– 4 – 62485-3 © IEC:2010


INTERNATIONAL ELECTROTECHNICAL COMMISSION

_____________



SAFETY REQUIREMENTS FOR SECONDARY BATTERIES

AND BATTERY INSTALLATIONS –



Part 3: Traction batteries





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
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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 62485-3 has been prepared by IEC technical committee 21:
Secondary cells and batteries.
The text of this standard is based on the following documents:
FDIS Report on voting
21/712/FDIS 21/719/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.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts of the IEC 62485 series can be found, under the general title Safety
requirements for secondary batteries and battery installations, on the IEC website.

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62485-3 © IEC:2010 – 5 –


The committee has decided that the contents of this publication will remain unchanged until the

stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data related to

the specific publication. At this date, the publication will be


• reconfirmed,

• withdrawn,

• replaced by a revised edition, or

• amended.

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– 6 – 62485-3 © IEC:2010


SAFETY REQUIREMENTS FOR SECONDARY BATTERIES

AND BATTERY INSTALLATIONS –



Part 3: Traction batteries








1 Scope


This part of the IEC 62485 applies to secondary batteries and battery installations used for
electric vehicles, e.g. in electric industrial trucks (including lift trucks, tow trucks, cleaning
machines, automatic guided vehicles), in battery powered locomotives, in electric vehicles (e.g.
goods vehicles, golf carts, bicycles, wheelchairs), and does not cover the design of such
vehicles.
This International Standard covers lead dioxide-lead (lead-acid), nickel oxide-cadmium, nickel-
oxide-metal hydride and other alkaline secondary batteries. Safety aspects of secondary lithium
batteries in such applications will be covered in their own appropriate standards.
The nominal voltages are limited to 1 000 V AC and 1 500 V DC respectively and describe the
principal measures for protection against hazards generally from electricity, gas emission and
electrolyte.
It provides requirements on safety aspects associated with the installation, use, inspection,
maintenance and disposal of batteries.
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 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock

IEC 60900, Live working – Hand tools for use up to 1 000 V a.c. and 1 500 V d.c.
IEC 61140, Protection against electric shock – Common aspects for installation and equipment
ISO 3864 (all parts), Graphical symbols – Safety colours and safety signs
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
(secondary) cell
(rechargeable) cell
single cell
assembly of electrodes and electrolyte which constitutes the basic unit of a secondary battery

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62485-3 © IEC:2010 – 7 –


NOTE This assembly is contained in an individual case and closed by a cover.


3.2

lead dioxide-lead (acid) battery
secondary battery with an aqueous electrolyte based on dilute sulphuric acid, a positive
electrode of lead dioxide and a negative electrode of lead


3.3
nickel oxide-cadmium battery
secondary battery with an alkaline electrolyte, a positive electrode containing nickel oxide and

a negative electrode of cadmium


3.4
vented (secondary) cell
a secondary cell having a cover provided with an opening through which gaseous products may
escape
3.5
valve regulated (secondary) cell
secondary cell which is closed under normal conditions but has an arrangement which allows
the escape of gas if the internal pressure exceeds a predetermined value. The cell cannot
normally receive addition to the electrolyte
3.6
gas-tight sealed (secondary) cell
secondary cell which remains closed and does not release either gas or liquid when operated
within the limits of charge and temperature specified by the manufacturer. The cell may be
equipped with a safety device to prevent dangerously high internal pressure
NOTE The cell does not require addition to the electrolyte and is designed to operate during its life in its original
sealed state.
3.7
secondary battery
two or more secondary cells connected together and used as a source of electrical energy
3.8
traction battery
secondary battery which is designed to provide the propulsion energy for electric vehicles
3.9
monobloc battery

battery with multiple separate but electrically connected cell compartments each of which is
designed to house an assembly of electrodes, electrolyte, terminals and interconnections and
possible separator
NOTE The cells in a monobloc battery can be connected in series or parallel.
3.10
electrolyte
liquid or solid substance containing mobile ions which render it ionically conductive
NOTE The electrolyte may be a liquid, solid or a gel.
3.11
gassing
gas emission
evolution of gas resulting from the electrolysis of water in the electrolyte of the cell

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– 8 – 62485-3 © IEC:2010


3.12

charge

charging (of a battery)

operation during which a secondary cell or battery is supplied with electrical energy from an

external circuit which results in chemical changes within a cell and thus storage of energy as

chemical energy occurs


3.13

equalisation charge

extended charge which ensures complete charging of all cells in a battery


3.14
opportunity charging
use of free time during a work period to top up the charge and thus extend the work period of a
battery whilst avoiding excessive discharge
3.15
overcharge
overcharging (of a cell or battery)
continued charging after the full charge of a cell or battery
NOTE Overcharge is also the act of charging beyond a certain limit specified by the manufacturer.
3.16
discharge
discharging (of a battery)
operation during which a battery delivers, to an external circuit and under specified conditions,
electrical energy produced in the cells
3.17
(battery) peripheral equipment
equipment installed on the battery, which supports or monitors the operation of the battery, e.g.
central water filling system, electrolyte agitation system, battery monitoring system, central de-
gassing system, battery connectors (plugs and sockets), thermal management system, etc
3.18
charging room
room or closed area intended specifically for recharging batteries. The room may also be used
for battery maintenance
3.19
charging area

open area designated and made suitable for recharging batteries. The area may also be used
for battery maintenance
4 Protection against electric shock by the battery and charger
4.1 General
Measures shall be taken on traction batteries and in traction battery charging installations for
protection against either direct contact or indirect contact, or against both direct and indirect
contact.
These measures are described in detail in IEC 60364-4-41 and IEC 61140. The following
clauses and the resulting amendments describe the typical measures to be taken for traction
battery installations.

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62485-3 © IEC:2010 – 9 –


The appropriate equipment standard IEC 61140 applies to batteries and direct current

distribution circuits located inside equipment.


4.2 Protection against both direct and indirect contact


On batteries and in battery charging installations protection against direct contact with live

parts shall be ensured in accordance with IEC 60364-4-41.


The following protective measures against direct contact apply:

– “protection by insulation of live parts”;

– “protection by barriers or enclosures”;
– “protection by obstacles”;
– “protection by placing out of reach”.
The following protective measures against indirect contact apply:
– “protection by automatic disconnection or signalling”;
– “protection by protective insulation”;
– “protection by earth-free local equipotential bonding”;
– “protection by electrical separation”.
4.3 Protection against direct and indirect contact when discharging the traction
battery on the vehicle (battery disconnected from charger/mains)
4.3.1 For batteries having a nominal voltage up to and including 60 V DC, protection against
electric shock caused by direct contact is not formally required, as long as the whole
installation corresponds to the conditions for safety extra low voltage (SELV) and protective
extra low voltage (PELV).
NOTE The nominal voltage of a lead dioxide - lead cell (lead acid) is 2,0 V, that of a nickel oxide – cadmium or
nickel oxide - metal hydride cell is 1,2 V. When these cells are boost charged, their voltage may reach 2,7 V in lead
acid or 1,6 V in nickel oxide based systems.
However, for other reasons, e.g. short circuits, mechanical damage etc., all batteries in
electrical vehicles shall be protected against direct contact of live parts, even if the battery
nominal voltage is 60 V DC or less.
4.3.2 For batteries having a nominal voltage above 60 V DC and up to and including 120 V DC,
protection against electric shock caused by direct contact is required.
NOTE Batteries with nominal voltage up to and including 120 V DC are regarded as safe power sources for SELV-

systems (safety extra low voltage) or PELV-systems (protective extra low voltage), see IEC 60364-4-41,411.1.
The following protective measures apply:
– “protection by insulation of live parts”;
– “protection by barriers or enclosures”;
– “protection by obstacles”;
– “protection by placing out of reach”.
If the protection against direct contact of live parts is ensured only by obstacles or placing out
of reach, access to the battery accommodation shall be restricted to trained and authorized
personnel only, and the battery accommodation shall be marked by appropriate warning labels
(see Clause 11).
For batteries having a nominal voltage exceeding 120 V DC, protective measures against both
direct and indirect contact are required.

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– 10 – 62485-3 © IEC:2010


Battery compartments with batteries having a nominal voltage exceeding 120 V DC shall be

locked and have restricted access for trained and authorized personnel only and shall be

marked by appropriate warning labels (see Clause 11).


For batteries with a nominal voltage exceeding 120 V DC, the following protective measures

against indirect contact apply:


– “protection by electrical insulation of live parts”;

– “protection by earth-free equipotential local bonding”;

– “protection by automatic disconnection or signalling”.


4.4 Protection against direct and indirect contact when charging the traction battery
When battery chargers with safe galvanic separation from the feeding mains are used
according to IEC 61140, the protective measures SELV or PELV shall be applied. If the
nominal voltage of the battery does not exceed 60 V DC protection against direct contact is not
formally required, as long as the total installation corresponds to conditions of SELV or PELV.
When the battery charger does not comply with these requirements, then the protective
measures against direct and indirect contact shall be applied according to IEC 60364-4-41.
However, for other reasons, e.g. short circuits, mechanical damage etc., all batteries in
electrical vehicles shall be protected against direct contact of live parts, even if the battery
nominal voltage is 60 V DC or less.
5 Prevention of short circuits and protection from other effects of electric
current
5.1 Cables and cell connectors
Cables and cell connectors shall be insulated to prevent short circuits.
If protection against short circuits cannot be provided by over-current protection devices for
battery-specific reasons, then the connecting cables between charger, respective battery fuse,
and battery, and between battery and vehicle shall be protected against short circuits and earth
fault.
The cables shall meet the requirements of IEC 60204-1.
When a trailing cable is used, the protection against short circuits shall be improved by the use
of single core cable according to IEC 60204-1. However, where the battery nominal voltage is

less than or equal to 120 V DC, a trailing cable of grade H01ND2, for higher flexibility, can be
used.
The battery terminal cables shall be fixed in a manner that prevents tensile and torsional strain
on the battery terminals.
Insulation shall be resistant to the effects of ambient influences such as temperature,
electrolyte, water, dust, commonly occurring chemicals, gasses, steam and mechanical stress.
5.2 Protective measures during maintenance
When working on live equipment, appropriate procedures shall be implemented so to reduce
the risk of injury and only insulated tools according to IEC 609
...