ISO 19453-6:2020

INTERNATIONAL ISO
STANDARD 19453-6
First edition
2020-07
Road vehicles — Environmental
conditions and testing for electrical
and electronic equipment for
drive system of electric propulsion
vehicles —
Part 6:
Traction battery packs and systems
Véhicules routiers — Spécifications d'environnement et essais
de l'équipement électrique et électronique pour les véhicules à
propulsion électrique —
Partie 6: Packs et systèmes de batterie de traction
Reference number
ISO 19453-6:2020(E)
©
ISO 2020

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ISO 19453-6:2020(E)

COPYRIGHT PROTECTED DOCUMENT
© ISO 2020
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
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Published in Switzerland
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ISO 19453-6:2020(E)

Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Symbols and abbreviated terms . 3
4.1 Symbols . 3
4.2 Abbreviated terms . 4
5 Operating modes . 4
5.1 General . 4
5.2 Operating mode 5 . 5
5.3 Operating mode 6 . 5
5.4 Operating mode 7 . 6
6 Functional status classification . 6
7 Functional status checks . 6
7.1 Electrical requirements check . 6
7.1.1 General. 6
7.1.2 Equipotential bonding . 6
7.1.3 Insulation resistance . 7
7.1.4 Withstand voltage test . 7
7.2 Mechanical requirements check . 7
7.2.1 Technical tightness check of battery pack or system enclosure . 7
7.2.2 Leak tightness check of internal temperature control system . 7
8 Tests and requirements . 8
8.1 Mechanical categories of battery packs or systems . 8
8.1.1 Category 1 . 8
8.1.2 Category 2 . 9
8.1.3 Category 3 . 9
8.2 Pre-conditioning . 9
8.2.1 General. 9
8.2.2 Thermo-mechanical pre-conditioning .10
8.3 Thermal cycling tests .10
8.3.1 General.10
8.3.2 Thermal cycling for DUT without internal temperature control system .10
8.3.3 Thermal cycling for DUT with internal temperature control system .12
8.3.4 Thermal cycling with electric operation .14
8.4 Structural durability and strength tests .16
8.4.1 General.16
8.4.2 Fixture .16
8.4.3 Pre-conditioning for mechanical tests .17
8.4.4 Durability test .17
8.4.5 Mechanical shock .24
8.4.6 Requirements .25
8.5 Water protection .25
8.5.1 Test .25
8.5.2 Requirements .25
8.6 Dust protection .26
8.6.1 Test .26
8.6.2 Requirements .26
8.7 Humid heat condensation test .26
8.7.1 Purpose .26
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ISO 19453-6:2020(E)

8.7.2 Test .26
8.7.3 Requirements .28
8.8 Damp heat, steady state test.28
8.8.1 Purpose .28
8.8.2 Test .28
8.8.3 Requirement .29
8.9 Corrosion .29
8.9.1 General.29
8.9.2 Mixed gas corrosion .29
8.9.3 Salt-spray test for external mounting location .30
8.9.4 Salt corrosion test for internal mounting location .31
8.10 Chemical resistance .34
Annex A (informative) Example of leak tightness check .35
Annex B (informative) Test concept for additional mechanical loads on a battery pack or
system .36
Annex C (informative) Example of electrical and thermal profile for the mechanical
durability test .39
Annex D (informative) Example of electrical profile for heat dissipation.41
Annex E (informative) Example of acceptance criterion for corrosion infiltration .42
Bibliography .44
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ISO 19453-6:2020(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso .org/
iso/ foreword .html.
This document was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 32,
Electrical and electronic components and general system aspects.
A list of all parts in the ISO 19453 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
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ISO 19453-6:2020(E)

Introduction
For over fifty years, traction batteries for electric vehicles have been developed to achieve high energy
density and high power output. Specifically, lead-acid battery, Ni-Cd battery and Ni-MH battery
with aqueous electrolyte were most applied to electric vehicles in the early days. Thermal activated
batteries, such as molten salt batteries like sodium sulphur battery and Zebra battery were also
examined. Lithium ion battery penetrated the consumer market in portable battery application from
1991. Currently, it is the most promising candidate of traction battery for electric vehicles. ISO 6469-1
specifies safety requirement of RESS (Rechargeable Energy Storage System) and the ISO 12405
series has been published to specify performance and reliability tests. This document focuses on
environmental and endurance tests of lithium ion battery systems.
The ISO 19453 series specifies the test conditions on environment and reliability for electrical and
electric equipment for the drive system of electric propulsion vehicles. The battery pack or system is the
electric system which charges and discharges electricity through the converter. The test condition for
mechanical load in ISO 19453-3 is too severe to apply to the battery pack or system from the standpoint
of frequency range and amplitude of vibration in the test input spectrum. The test conditions for
climatic load in ISO 19453-4 is also excessive to apply to the battery pack or system, because lithium ion
battery pack is designed to control temperature within adequate operational range. That is the reason
why appropriate conditions for the lithium ion battery are specified in this document.
The purpose of this document is to assist its user in systematically defining and/or applying a set of
internationally accepted environmental conditions, tests and operating requirements, which are based
on the anticipated actual environment in which the equipment will be operated and exposed to during
its life cycle. This document has been developed based on fundamental investigations and vehicle
measurements on voltage class A and B battery pack/system. The following environmental factors have
been considered in the development of the ISO 19453 series.
— World geography and climate
Electric propulsion vehicles are operated in nearly all terrestrial regions of the earth. Significant
variation in environmental conditions due to climatic environment, including diurnal and seasonal
cycles, can therefore be expected. Consideration has been given to worldwide ranges in the
temperature, humidity, precipitation and atmospheric conditions including dust, pollution and altitude.
— Type of electric propulsion vehicle
Operating environment in an electric propulsion vehicle can depend on its electric powertrain
architecture as well as its mass, size, supply voltage and so on. Consideration has been given to typical
types of series production electric propulsion vehicle architectures such as hybrid electric vehicles,
battery electric vehicles, range extender hybrid electric vehicles and fuel cell vehicles, but not including
equipment specific for fuel cell system.
— Vehicle use conditions and operating modes
Environmental conditions in and on the vehicle vary significantly with vehicle use (e.g. driving,
charging during parking, etc.). Operating modes, such as starting, driving, braking, stopping and so
on, have been considered, in particular, for traction battery system.
— Battery durability
For battery system, it is necessary to be resistant to environmental conditions experienced during
manufacture, shipping, handling, storage, vehicle assembly, vehicle usage and vehicle maintenance
and repair.
— Component mass and volume
The mass of battery pack is generally in the range of around 20 kg up to 60 kg for HEV, 80 kg to 150 kg for
PHEV, more than 200 kg for BEV (weight assumptions from year 2020). The battery pack has generally
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ISO 19453-6:2020(E)

a large volume and thermal capacity. It is necessary not only to prepare a large chamber but it will also
take a long time to keep the thermal equivalent when performing a thermal shock test.
— Mounting location in the vehicle
HEV battery packs are generally installed inside the vehicle, PHEV battery packs are installed both
outside and inside, and BEV battery packs are generally installed outside. The environmental condition
such as water splashing, dust, salt spray, humidity or corrosion for battery packs installed outside
vehicle interior is more severe than for battery packs installed inside. In this document, test conditions
are specified according to mounting location.
a) Applicability to manufacturers’ responsibility
Due to technology limitations or variations in vehicle design, the vehicle manufacturer may be required
to place a component in a location where it cannot withstand the environmental conditions described
in the ISO 19453 series. Under these circumstances, it is the responsibility of the vehicle manufacturer
to provide the necessary environmental protection.
b) Applicability to wiring harnesses, cables and electrical connectors
Although some environmental conditions and tests in the ISO 19453 series may be relevant to vehicle
wiring harnesses, cables and connectors, its scope is not sufficient to be used as a complete standard.
It is therefore not recommended that the ISO 19453 series is directly applied to such devices and
equipment.
c) Applicability to parts or assemblies inside equipment
The ISO 19453 series describes environmental conditions and tests to be applied to electrical and
electronic equipment directly mounted in or on the vehicle. It is not intended for direct application to
parts or assemblies that are part of the equipment. For example, the ISO 19453 series should not be
directly applied to integrated circuits (ICs) and discrete components, electrical connectors, printed
circuit boards (PCBs), gauges, etc. that are attached in or on the equipment. Electrical, mechanical,
climatic and chemical loads for such parts and assemblies can be quite different from those described
in the ISO 19453 series. Therefore, for those sub-components applying test conditions of the ISO 16750
series can be considered as a reference.
On the other hand, it is desirable to use the ISO 19453 series to help derive environmental conditions
and test requirements for parts and assemblies that are intended for use in road vehicle equipment.
d) Applicability relative to system integration and validation
The user of the ISO 19453 series is cautioned to understand that its scope is limited to conditions and
testing at the equipment level and therefore does not represent all conditions and testing necessary
for complete verification and validation of the vehicle system, for example cold water shock tests
were omitted from this document. Environmental and reliability testing of equipment parts and
vehicle systems may be required. For example, the ISO 19453 series does not necessarily ensure that
environmental and reliability requirements for solder joints, solderless connections, integrated circuits
and so on are met. Such items are assured at the part, material or assembly level. Additionally, vehicle
and system level testing might be required to validate the equipment in the vehicle application.
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INTERNATIONAL STANDARD ISO 19453-6:2020(E)
Road vehicles — Environmental conditions and testing for
electrical and electronic equipment for drive system of
electric propulsion vehicles —
Part 6:
Traction battery packs and systems
1 Scope
This document specifies requirements for lithium-ion traction battery packs or systems used in
battery electric, hybrid electric and fuel cell electric road vehicles. This document describes the most
relevant environmental stresses and specifies tests and test boundary conditions. This document
establishes a classification of battery packs or systems and defines different stress levels for testing
when a classification is applicable and required. The objective of this document is to specify standard
test procedures and conditions to enable the observation of the reliability of the lithium-ion traction
battery in the vehicle.
This document specifies tests for a battery pack or system of voltage class A and B.
This document provides the necessary information to set up a dedicated test plan for a battery pack
or system subject to agreement between the customer and supplier. If required, the relevant test
procedures and/or test conditions can also be selected from this document.
NOTE This document only covers requirements and test conditions for a traction battery pack or system
used in passenger cars.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
ISO 6469-3, Electrically propelled road vehicles — Safety specifications — Part 3: Electrical safety
ISO 6469-3:2018/Amd 1, Electrically propelled road vehicles — Safety specifications — Part 3: Electrical
safety — Amendment 1: Withstand voltage test for electric power sources
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests
ISO 19453-1, Road vehicles — Environmental conditions and testing for electrical and electronic equipment
for drive system of electric propulsion vehicles — Part 1: General
ISO 19453-4, Road vehicles — Environmental conditions and testing for electrical and electronic equipment
for drive system of electric propulsion vehicles — Part 4: Climatic loads
ISO 19453-5, Road vehicles — Environmental conditions and testing for electrical and electronic equipment
for drive system of electric propulsion vehicles — Part 5: Chemical loads
ISO 20653, Road vehicles — Degrees of protection (IP code) — Protection of electrical equipment against
foreign objects, water and access
IEC 60068-2-14, Environmental testing — Part 2-14: Tests — Test N: Change of temperature
IEC 60068-2-27, Environmental testing — Part 2-27: Tests — Test Ea and guidance: Shock
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ISO 19453-6:2020(E)

IEC 60068-2-38, Environmental testing — Part 2-38: Tests — Test Z/AD: Composite temperature/humidity
cyclic test
IEC 60068-2-60, Environmental testing — Part 2-60: Tests — Test Ke: Flowing mixed gas corrosion test
IEC 60068-2-64, Environmental testing — Part 2-64: Tests — Test Fh: Vibration, broad-band random and
guidance
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 19453-1, ISO 20653 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
3.1
BMS
battery management system
electronic system that controls, manages, detects or calculates electric and thermal functions of the
battery pack or system and that provides communication between the battery pack or system and
other vehicle controllers
3.2
electric chassis
conductive parts of a vehicle that are electrically connected and whose potential is taken as reference
3.3
ITCS
internal temperature control system
internal thermal management system of a battery pack or system that can heat or cool the battery pack
or system to a target temperature determined by the BMS (3.1)
EXAMPLE Liquid based heating/cooling system.
3.4
main contactor
electronic or mechanic switching/disconnect device for the battery pack or system main power supply
live part (3.5)
3.5
main power supply live part
conductor or conductive part intended to be energized in normal use, but by convention not the electric
chassis (3.2) or the class A auxiliary voltage supply
3.6
MAST
multiaxial simulation table
multiaxial system to induce vibrations or shocks in all three axial dimensions to the DUT
3.7
PSD
power spectral density
measure of signal's power content versus frequency
Note 1 to entry: A PSD is typically used to characterize broadband random signals. The amplitude of the PSD is
normalized by the spectral resolution employed to digitize the signal.
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ISO 19453-6:2020(E)

3.8
rated capacity
total number of ampere-hours that can be withdrawn from a fully charged battery pack or system
under test conditions defined by the battery pack or system manufact
...