Regulation No. 100-02

Name:Regulation No. 100-02
Description:Approval of Vehicles with Electric Power Train.
Official Title:Uniform Provisions Concerning the Approval of Vehicles with Regard to Specific Requirements for the Electric Power Train.
Country:ECE - United Nations
Date of Issue:2013-08-12
Amendment Level:02 Series, Supplement 3
Number of Pages:85
Vehicle Types:Bus, Car, Component, Heavy Truck, Light Truck
Subject Categories:Electrical and Electronic, Miscellaneous
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Keywords:

test, reess, vehicle, voltage, annex, approval, hydrogen, regulation, manufacturer, paragraph, temperature, electrical, tested-device, type, resistance, enclosure, isolation, charge, high, part, system, protection, accordance, circuit, parts, means, charging, measured, normal, conditions, period, conducted, measurement, power, figure, technical, chamber, electric, requirements, emission, maximum, tests, chassis, volume, connected, procedure, service, end, vehicles, force

Text Extract:

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E/ECE/324
) Rev.2/Add.99/Rev.2/Amend.3
E/ECE/TRANS/505 )
July 11, 2016
STATUS OF UNITED NATIONS REGULATION
ECE 100-02
UNIFORM PROVISIONS CONCERNING THE APPROVAL OF:
VEHICLES WITH REGARD TO SPECIFIC
REQUIREMENTS FOR THE ELECTRIC POWER TRAIN
Incorporating:
Supplement 1 to the 01 series of amendments
Date of Entry into Force: 26.07.12
Supplement 2 to the 01 series of amendments
Date of Entry into Force: 15.07.13
02 series of amendments to the Regulation
Date of Entry into Force: 15.07.13
Supplement 1 to the 02 series of amendments
Date of Entry into Force: 10.06.14
Supplement 2 to the 02 series of amendments
Date of Entry into Force: 29.01.16
Supplement 3 to the 02 series of amendments
Date of Entry into Force: 18.06.16

REGULATION
1. Scope
2. Definitions
REGULATION No. 100-02
UNIFORM PROVISIONS CONCERNING THE APPROVAL OF VEHICLES WITH
REGARD TO SPECIFIC REQUIREMENTS FOR THE ELECTRIC POWER TRAIN
3. Application for Approval
4. Approval
CONTENTS
5. Part I: Requirements of a Vehicle with Regard to its Electrical Safety
6. Part II: Requirements of a Rechargeable Electrical Energy Storage System (REESS) with Regard
to Safety
7. Modifications and Extension of the Type Approval
8. Conformity of Production
9. Penalties for Non-conformity of Production
10. Production Definitively Discontinued
11. Names and Addresses of Technical Services Responsible for Conducting Approval Tests and of
Type Approval Authorities
12. Transitional Provisions
ANNEXES
Annex 1
Annex 1
Annex 2
Annex 3
− Part 1 – Communication concerning the approval or extension or refusal or withdrawal of
approval or production definitively discontinued of a vehicle type with regard to its electrical
safety pursuant to Regulation No. 100
− Part 2 – Communication concerning the approval or extension or refusal or withdrawal of
approval or production definitively discontinued of a REESS type as component/separate
technical unit pursuant to Regulation No. 100
− Arrangements of the approval marks
− Protection against direct contacts of parts under voltage
Annex 4A − Isolation resistance measurement method for vehicle based tests
Annex 4B − Isolation resistance measurements method for component based tests of a REESS

1. SCOPE
1.1 Part I:
1.2 Part II:
Safety requirements with respect to the electric power train of road vehicles of Categories M
and N , with a maximum design speed exceeding 25km/h, equipped with one or more
traction motor(s) operated by electric power and not permanently connected to the grid, as
well as their high voltage components and systems which are galvanically connected to the
high voltage bus of the electric power train.
Part I of this regulation does not cover post-crash safety requirements of road vehicles
Safety requirements with respect to the Rechargeable Electrical Energy Storage System
(REESS), of road vehicles of Categories M and N equipped with one or more traction
motors operated by electric power and not permanently connected to the grid.
Part II of this Regulation does not apply to REESS(s) whose primary use is to supply power
for starting the engine and/or lighting and/or other vehicle auxiliaries systems.
2. DEFINITIONS
For the purpose of this Regulation the following definitions apply:
2.1 "Active driving possible mode" means the vehicle mode when application of pressure to
the accelerator pedal (or activation of an equivalent control) or release of the brake system
will cause the electric power train to move the vehicle.
2.2. "Barrier" means the part providing protection against direct contact to the live parts from
any direction of access.
2.3. "Cell" means a single encased electrochemical unit containing one positive and one
negative electrode which exhibits a voltage differential across its two terminals.
2.4 "Conductive connection" means the connection using connectors to an external power
supply when the rechargeable electrical energy storage system (REESS) is charged.
2.5. "Coupling system for charging the Rechargeable Electrical Energy Storage System
(REESS)" means the electrical circuit used for charging the REESS from an external
electric power supply including the vehicle inlet.
2.6. "C Rate" of "n C" is defined as the constant current of the tested-device, which takes
1/n hours to charge or discharge the tested-device between 0% of the state of charge
and 100% of the state of charge.
2.7. "Direct contact" means the contact of persons with live parts.
2.8. "Electrical chassis" means a set made of conductive parts electrically linked together,
whose potential is taken as reference.

2.23. "Luggage compartment" means the space in the vehicle for luggage accommodation,
bounded by the roof, hood, floor, side walls, as well as by the barrier and enclosure
provided for protecting the occupants from direct contact with live parts, being separated
from the passenger compartment by the front bulkhead or the rear bulk head.
2.24. "Manufacturer" means the person or body who is responsible to the approval authority for
all aspects of the type approval process and for ensuring conformity of production. It is not
essential that the person or body be directly involved in all stages of the construction of the
vehicle, system or component which is the subject of the approval process.
2.25. "On-board isolation resistance monitoring system" means the device which monitors
the isolation resistance between the high voltage buses and the electrical chassis.
2.26. "Open type traction battery" means a liquid type battery requiring refilling with water and
generating hydrogen gas released to the atmosphere.
2.27. "Passenger compartment" means the space for occupant accommodation, bounded by
the roof, floor, side walls, doors, window glass, front bulkhead and rear bulkhead, or rear
gate, as well as by the barriers and enclosures provided for protecting the occupants from
direct contact with live parts.
2.28. "Protection degree" means the protection provided by a barrier/enclosure related to the
contact with live parts by a test probe, such as a test finger (IPXXB) or a test wire (IPXXD),
as defined in Annex 3.
2.29. "Rechargeable Electrical Energy Storage System (REESS)" means the rechargeable
electrical energy storage system that provides electric energy for electric propulsion. The
REESS may include subsystem(s) together with the necessary ancillary systems for
physical support, thermal management, electronic control and enclosures.
2.30. "Rupture" means opening(s) through the casing of any functional cell assembly created or
enlarged by an event, large enough for a 12mm diameter test finger (IPXXB) to penetrate
and make contact with live parts (see Annex 3).
2.31. "Service disconnect" means the device for deactivation of the electrical circuit when
conducting checks and services of the REESS, fuel cell stack, etc.
2.32. "State of Charge (SOC)" means the available electrical charge in a tested device
expressed as a percentage of its rated capacity.
2.33. "Solid insulator" means the insulating coating of wiring harnesses provided in order to
cover and protect the live parts against direct contact from any direction of access; covers
for insulating the live parts of connectors, and varnish or paint for the purpose of insulation.
2.34. "Subsystem" means any functional assembly of REESS components.
2.35. "Tested-device" means either the complete REESS or the subsystem of a REESS that is
subjected to the tests prescribed by this Regulation.

3.1.3. A vehicle representative of the vehicle type to be approved shall be submitted to the
Technical Service responsible for conducting the approval tests and, if applicable, at the
manufacturer's discretion with the agreement of the Technical Service, either additional
vehicle(s), or those parts of the vehicle regarded by the Technical Service as essential for
the test(s) referred to in the Paragraph 6. of this Regulation.
3.2. Part II:
Approval of a Rechargeable Electrical Energy Storage System (REESS)
3.2.1. The application for approval of a type of REESS or separate technical unit with regard to the
safety requirements of the REESS shall be submitted by the REESS manufacturer or by his
duly accredited representative.
3.2.2. It shall be accompanied by the under-mentioned documents in triplicate and comply with the
following particulars:
3.2.2.1. Detailed description of the type of REESS or separate technical unit as regards the safety of
the REESS.
3.2.3. A component(s) representative of the type of REESS to be approved plus, at the
manufacturer's discretion, and with the agreement of the Technical Service, those parts of
the vehicle regarded by the Technical Service as essential for the test, shall be submitted to
the Technical Service responsible for conducting the approval tests.
3.3. The Type Approval Authority shall verify the existence of satisfactory arrangements for
ensuring effective control of the conformity of production before type approval is granted.
4. APPROVAL
4.1. If the type submitted for approval pursuant to this Regulation meets the requirements of the
relevant parts of this Regulation, approval of that type shall be granted.
4.2. An approval number shall be assigned to each type approved. Its first two digits (at
present 02 for the Regulation in its form) shall indicate the series of amendments
incorporating the most recent major technical amendments made to the Regulation at the
time of issue of the approval. The same Contracting Party shall not assign the same number
to another vehicle type.
4.3. Notice of approval or of refusal or of extension or withdrawal of approval or production
definitively discontinued of a vehicle type pursuant to this Regulation shall be communicated
to the Parties to the Agreement applying this Regulation, by means of a form conforming to
the model in Annex 1, Part 1 or 2 as appropriate to this Regulation.

5.1.1. Protection Against Direct Contact
Protection against direct contact with live parts is also required for vehicles equipped with
any REESS type approved under Part II of this Regulation.
Live parts shall be protected against direct contact and shall comply with
Paragraphs 5.1.1.1. and 5.1.1.2. Barriers, enclosures, solid insulators and connectors shall
not be able to be opened, separated, disassembled or removed without the use of tools.
However, connectors (including the vehicle inlet) are allowed to be separated without the
use of tools, if they meet one or more of the following requirements:
(a)
(b)
(c)
(d)
They comply with Paragraphs 5.1.1.1. and 5.1.1.2. when separated, or
They are located underneath the floor and are provided with a locking mechanism, or
They are provided with a locking mechanism. Other components, not being part of the
connector, shall be removable only with the use of tools in order to be able to
separate the connector, or
The voltage of the live parts becomes equal or below 60V DC or equal or below
30V AC (rms) within 1s after the connector is separated.
5.1.1.1. For protection of live parts inside the passenger compartment or luggage compartment, the
protection degree IPXXD shall be provided.
5.1.1.2. For protection of live parts in areas other than the passenger compartment or luggage
compartment, the protection degree IPXXB shall be satisfied.
5.1.1.3. Service Disconnect
5.1.1.4. Marking
For a service disconnect which can be opened, disassembled or removed without tools, it is
acceptable if protection degree IPXXB is satisfied under a condition where it is opened,
disassembled or removed without tools.
5.1.1.4.1. In the case of a REESS having high voltage capability the symbol shown in Figure 1 shall
appear on or near the REESS. The symbol background shall be yellow, the bordering and
the arrow shall be black.
Figure 1
Marking of High Voltage Equipment

5.1.3.2. Electric Power Train Consisting of Combined dc- and ac-Buses
If ac high voltage buses and dc high voltage buses are galvanically connected isolation
resistance between the high voltage bus and the electrical chassis shall have a minimum
value of 500Ω/V of the working voltage. However, if all ac high voltage buses are protected
by one of the 2 following measures, isolation resistance between the high voltage bus and
the electrical chassis shall have a minimum value of 100Ω/V of the working voltage:
(a)
(b)
Double or more layers of solid insulators, barriers or enclosures that meet the
requirement in Paragraph 5.1.1. independently, for example wiring harness;
Mechanically robust protections that have sufficient durability over vehicle service life
such as motor housings, electronic converter cases or connectors;
The isolation resistance between the high voltage bus and the electrical chassis may be
demonstrated by calculation, measurement or a combination of both.
The measurement shall be conducted according to Annex 4A "Isolation resistance
measurement method for vehicle based tests".
5.1.3.3. Fuel Cell Vehicles
If the minimum isolation resistance requirement cannot be maintained over time, then
protection shall be achieved by any of the following:
(a)
(b)
Double or more layers of solid insulators, barriers or enclosures that meet the
requirement in Paragraph 5.1.1. independently;
On-board isolation resistance monitoring system together with a warning to the driver
if the isolation resistance drops below the minimum required value. The isolation
resistance between the high voltage bus of the coupling system for charging the
REESS, which is not energised besides during charging the REESS, and the
electrical chassis need not be monitored. The function of the on-board isolation
resistance monitoring system shall be confirmed as described in Annex 5.
5.1.3.4. Isolation Resistance Requirement for the Coupling System for Charging the REESS
For the vehicle inlet intended to be conductively connected to the grounded external ac
power supply and the electrical circuit that is galvanically connected to the vehicle inlet
during charging of the REESS, the isolation resistance between the high voltage bus and
the electrical chassis shall be at least 1MΩ when the charger coupler is disconnected.
During the measurement, the traction battery may be disconnected.

5.4.4. During a charge carried out by a charger presenting a failure (conditions given in Annex 7),
hydrogen emissions shall be below 42g. Furthermore the charger shall limit this possible
failure to 30min.
5.4.5. All the operations linked to the REESS charging shall be controlled automatically, included
the stop for charging.
5.4.6. It shall not be possible to take a manual control of the charging phases.
5.4.7. Normal operations of connection and disconnection to the mains or power cuts shall not
affect the control system of the charging phases.
5.4.8. Important charging failures shall be permanently indicated. An important failure is a failure
that can lead to a malfunction of the charger during charging later on.
5.4.9. The manufacturer has to indicate in the owner's manual, the conformity of the vehicle to
these requirements.
5.4.10. The approval granted to a vehicle type relative to hydrogen emissions can be extended to
different vehicle types belonging to the same family, in accordance with the definition of the
family given in Annex 7, Appendix 2.
6. PART II: REQUIREMENTS OF A RECHARGEABLE ELECTRICAL ENERGY STORAGE
SYSTEM (REESS) WITH REGARD TO ITS SAFETY
6.1. General
6.2. Vibration
The procedures prescribed in Annex 8 of this Regulation shall be applied.
6.2.1. The test shall be conducted in accordance with Annex 8A to this Regulation.
6.2.2. Acceptance Criteria
6.2.2.1. During the test, there shall be no evidence of:
(a)
(b)
(c)
(d)
Electrolyte leakage;
Rupture (applicable to high voltage REESS(s) only);
Fire;
Explosion.
Evidence of electrolyte leakage shall be verified by visual inspection without disassembling
any part of the tested-device.
6.2.2.2. For a high voltage REESS, the isolation resistance measured after the test in accordance
with Annex 4B to this Regulation shall not be less than 100Ω/V.

6.4.1.3. Acceptance Criteria
During the test there shall be no evidence of:
(a)
(b)
Fire;
Explosion;
(c1) Electrolyte leakage if tested according to Paragraph 6.4.1.1.:
(i)
(ii)
For a period from the impact until 30min after the impact there shall be no
electrolyte spillage from the REESS into the passenger compartment;
No more than 7% by volume of the REESS electrolyte capacity shall spill from
the REESS to the outside of the passenger compartment (for open type
traction batteries a limitation to a maximum of 5l also applies);
(c2) Electrolyte leakage if tested according to Paragraph 6.4.1.2.
After the vehicle based test (Paragraph 6.4.1.1.), a REESS which is located inside the
passenger compartment shall remain in the installed location and the REESS components
shall remain inside REESS boundaries. No part of any REESS that is located outside the
passenger compartment shall enter the passenger compartment during or after the impact
test procedures. After the component based test (Paragraph 6.4.1.2.) the tested-device shall
be retained by its mounting and its components shall remain inside its boundaries.
For a high voltage REESS the isolation resistance of the tested-device shall ensure at
least 100Ω/V for the whole REESS measured after the test in accordance with Annex 4A or
Annex 4B to this Regulation, or the protection degree IPXXB shall be fulfilled for the testeddevice.
For a REESS tested in accordance with Paragraph 6.4.1.2., the evidence of electrolyte
leakage shall be verified by visual inspection without disassembling any part of the testeddevice.
To confirm compliance to (c1) of Paragraph 6.4.1.3. an appropriate coating shall, if
necessary, be applied to the physical protection (casing) in order to confirm if there is any
electrolyte leakage from the REESS resulting from the impact test. Unless the manufacturer
provides a means to differentiate between the leakage of different liquids, all liquid leakage
shall be considered as the electrolyte.
6.4.2. Mechanical Integrity
This test applies only to a REESS intended for installation in vehicles of Categories M and
N .
At the manufacturer’s choice, the test may be performed as, either:
(a)
(b)
Vehicle based tests in accordance with Paragraph 6.4.2.1. of this Regulation, or
Component based tests in accordance with Paragraph 6.4.2.2. of this Regulation.

6.4.2.2. Component Based Test
The test shall be conducted in accordance with Annex 8D to this Regulation. REESS
approved according to this Paragraph shall be mounted in a position which is between the
two planes; (a) a vertical plane perpendicular to the centre line of the vehicle
located 420mm rearward from the front edge of the vehicle, and (b) a vertical plane
perpendicular to the centre line of the vehicle located 300mm forward from the rear edge of
the vehicle.
The mounting restrictions shall be documented in Annex 6 - Part 2.
The crush force specified in Paragraph 3.2.1. of Annex 8D may be replaced with the value
declared by the manufacturer, where the crush force shall be documented in Annex 6,
Part 2 as a mounting restriction. In this case, the vehicle manufacturer who uses such
REESS shall demonstrate, during the process of approval for Part I of this Regulation, that
the contact force to the REESS will not exceed the figure declared by the REESS
manufacturer. Such force shall be determined by the vehicle manufacturer using the data
obtained from either actual crash test or its simulation as specified in Annex 3 of
Regulations Nos. 12 or 94 in the direction of travel and according to Annex 4 to Regulation
No. 95 in the direction horizontally perpendicular to the direction of travel. These forces shall
be agreed by the manufacturer together with the Technical Service.
The manufacturers may, in agreement with the Technical Services, use forces derived from
the data obtained from alternative crash test procedures, but these forces shall be equal to
or greater than the forces that would result from using data in accordance with the
regulations specified above.

6.5.2. Component Based Test
The test shall be conducted in accordance with Annex 8E Paragraph 3.2.2. of this
Regulation.
6.5.3. Acceptance Criteria
6.5.3.1. During the test, the tested-device shall exhibit no evidence of explosion.
6.6. External Short Circuit Protection
6.6.1. The test shall be conducted in accordance with Annex 8F of this Regulation.
6.6.2. Acceptance Criteria;
6.6.2.1. During the test there shall be no evidence of:
(a)
(b)
(c)
(d)
Electrolyte leakage;
Rupture (applicable to high voltage REESS(s) only);
Fire;
Explosion.
Evidence of electrolyte leakage shall be verified by visual inspection without disassembling
any part of the tested-device.
6.6.2.2. For a high voltage REESS, the isolation resistance measured after the test in accordance
with Annex 4B to this Regulation shall not be less than 100Ω/V.
6.7. Overcharge Protection
6.7.1. The test shall be conducted in accordance with Annex 8G to this Regulation.
6.7.2. Acceptance Criteria
6.7.2.1. During the test there shall be no evidence of:
(a)
(b)
(c)
(d)
Electrolyte leakage;
Rupture (applicable to high voltage REESS(s) only);
Fire;
Explosion.
Evidence of electrolyte leakage shall be verified by visual inspection without disassembling
any part of the tested-device.
6.7.2.2. For a high voltage REESS, the isolation resistance measured after the test in accordance
with Annex 4B to this Regulation shall not be less than 100Ω/V.

6.10. Emission
Possible emission of gases caused by the energy conversion process during normal use
shall be considered.
6.10.1. Open type traction batteries shall meet the requirements of Paragraph 5.4. of this
Regulation with regard to hydrogen emissions.
Systems with a closed chemical process shall be considered as emission-free under normal
operation (e.g. lithium-ion battery). The closed chemical process shall be described and
documented by the battery manufacturer in Annex 6 - Part 2.
Other technologies shall be evaluated by the manufacturer and the Technical Service
regarding any possible emissions under normal operation.
6.10.2. Acceptance Criteria
For hydrogen emissions see Paragraph 5.4. of this Regulation.
For emission free systems with closed chemical process no verification is necessary.
7. MODIFICATIONS AND EXTENSION OF THE TYPE APPROVAL
7.1. Every modification of the vehicle or REESS type with regard to this Regulation shall be
notified to the Type Approval Authority which approved the vehicle or REESS type. The
Authority may then either:
7.1.1. Consider that the modifications made are unlikely to have an appreciable adverse effect and
that in any case the vehicle or the REESS still complies with the requirements, or
7.1.2. Require a further test report from the Technical Service responsible for conducting the tests.
7.2. Confirmation or refusal of approval, specifying the alteration, shall be communicated by the
procedure specified in Paragraph 4.3. above to the Parties to the Agreement applying this
Regulation.
7.3. The Type Approval Authority issuing the extension of approval shall assign a series number
to each communication form drawn up for such an extension and inform thereof the other
Parties to the 1958 Agreement applying the Regulation by means of a communication form
conforming to the model in Annex 1 (Part 1 or Part 2) to this Regulation.
8. CONFORMITY OF PRODUCTION
8.1. Vehicles or REESS approved under this Regulation shall be so manufactured as to conform
to the type approved by meeting the requirements of the relevant part(s) of this Regulation.
8.2. In order to verify that the requirements of Paragraph 8.1. are met, appropriate production
checks shall be carried out.
8.3. The holder of the approval shall, in particular:
8.3.1. Ensure the existence of procedures for the effective quality control of vehicles or REESS;

10. PRODUCTION DEFINITIVELY DISCONTINUED
If the holder of the approval completely ceases to manufacture a vehicle/REESS type
approved in accordance with this Regulation, he shall so inform the Authority which granted
the approval. Upon receiving the relevant communication, that Authority shall inform thereof
the other Contracting Parties to the 1958 Agreement applying this Regulation by means of a
communication form conforming to the model in Annex 1 (Part 1 or Part 2) to this
Regulation.
11. NAMES AND ADDRESSES OF TECHNICAL SERVICES RESPONSIBLE FOR
CONDUCTING APPROVAL TESTS AND OF TYPE APPROVAL AUTHORITIES
The Contracting Parties to the 1958 Agreement applying this Regulation shall communicate
to the United Nations Secretariat the names and addresses of the Technical Services
responsible for conducting approval tests and the Type Approval Authorities which grant
approval and to which forms certifying approval or extension or refusal or withdrawal of
approval or production definitively discontinued, issued in other countries are to be sent.
12. TRANSITIONAL PROVISIONS
12.1. As from the official date of entry into force of the 02 series of amendments, no Contracting
Party applying this Regulation shall refuse to grant approval under this Regulation as
amended by the 02 series of amendments.
12.2. As from (36) months after the date of entry into force of the 02 series of amendments,
Contracting Parties applying this Regulation shall grant approvals only if the vehicle type to
be approved meets the requirements of this Regulation as amended by the 02 series of
amendments.
12.3. Contracting Parties applying this Regulation shall continue to grant approvals to those types
of vehicles which comply with the requirements of this Regulation as amended by the
preceding series of amendments during the (36) months' period which follows the date of
entry into force of the 02 series of amendments.
12.4. Contracting Parties applying this Regulation shall not refuse to grant extensions of approval
to the preceding series of amendments to this Regulation.
12.5. Notwithstanding the transitional provisions above, Contracting Parties whose application of
this Regulation comes into force after the date of entry into force of the most recent series of
amendments are not obliged to accept approvals which were granted in accordance with
any of the preceding series of amendments to this Regulation.

8.
Technical service responsible for conducting approval tests: .........................................................
........................................................................................................................................................
9.
Date of report issued by that service: .............................................................................................
10.
Number of report issued by that service: ........................................................................................
11.
Location of the approval mark: ........................................................................................................
12.
Reason(s) for extension of approval (if applicable)
:.....................................................................
13.
Approval granted/extended/refused/withdrawn
:..........................................................................
14.
Place: ..............................................................................................................................................
15.
Date: ................................................................................................................................................
16.
Signature: ........................................................................................................................................
17.
The documents filed with the request for approval or extension may be obtained on request.

14.
Place: ..............................................................................................................................................
15.
Date: ................................................................................................................................................
16.
Signature: ........................................................................................................................................
17.
The documents filed with the request for approval or extension may be obtained on request.

Model B
(See Paragraph 4.5. of this Regulation)
a = 8mm min.
The above approval mark affixed to a vehicle shows that the road vehicle concerned has been approved
in the Netherlands (E4) pursuant to Regulations Nos. 100 and 42 . The approval number indicates that,
at the dates when the respective approvals were granted, Regulation No. 100 was amended by the 02
series of amendments and Regulation No. 42 was still in its original form.

Table 1
Access Probes for the Tests for Protection of Persons Against Access to Hazardous Parts

ANNEX 4A
ISOLATION RESISTANCE MEASUREMENT METHOD FOR VEHICLE BASED TESTS
1. GENERAL
The isolation resistance for each high voltage bus of the vehicle shall be measured or shall
be determined by calculation using measurement values from each part or component unit
of a high voltage bus (hereinafter referred to as the "divided measurement").
2. MEASUREMENT METHOD
The isolation resistance measurement shall be conducted by selecting an appropriate
measurement method from among those listed in Paragraphs 2.1. through 2.2. of this
annex, depending on the electrical charge of the live parts or the isolation resistance, etc.
The range of the electrical circuit to be measured shall be clarified in advance, using
electrical circuit diagrams, etc.
Moreover, modification necessary for measuring the isolation resistance may be carried out,
such as removal of the cover in order to reach the live parts, drawing of measurement lines,
change in software, etc.
In cases where the measured values are not stable due to the operation of the on-board
isolation resistance monitoring system, etc., necessary modification for conducting the
measurement may be carried out, such as stopping of the operation of the device
concerned or removing it. Furthermore, when the device is removed, it shall be proven,
using drawings, etc., that it will not change the isolation resistance between the live parts
and the electrical chassis.
Utmost care shall be exercised as to short circuit, electric shock, etc., for this confirmation
might require direct operations of the high-voltage circuit.
2.1. Measurement method using voltage from off-vehicle sources
2.1.1. Measurement Instrument
An isolation resistance test instrument capable of applying a dc voltage higher than the
working voltage of the high voltage bus shall be used.
2.1.2. Measurement Method
An insulator resistance test instrument shall be connected between the live parts and the
electrical chassis. Then, the isolation resistance shall be measured by applying a dc voltage
at least half of the working voltage of the high voltage bus.
If the system has several voltage ranges (e.g. because of boost converter) in galvanically
connected circuit and some of the components cannot withstand the working voltage of the
entire circuit, the isolation resistance between those components and the electrical chassis
can be measured separately by applying at least half of their own working voltage with those
component disconnected.

2.2.3.3. Third Step
2.2.3.4. Fourth Step
Measure and record the voltage (V2) between the positive side of the high voltage bus and
the electrical chassis (see Figure 1).
If V1 is greater than or equal to V2, insert a standard known resistance (Ro) between the
negative side of the high voltage bus and the electrical chassis. With Ro installed, measure
the voltage (V1’) between the negative side of the high voltage bus and the electrical
chassis (see Figure 2).
Calculate the electrical isolation (Ri) according to the following formula:
Ri = Ro*(Vb/V1’ – Vb/V1) or Ri = Ro*Vb*(1/V1’ – 1/V1)
Figure 2
Measurement of V1’
If V2 is greater than V1, insert a standard known resistance (Ro) between the positive side
of the high voltage bus and the electrical chassis. With Ro installed, measure the
voltage (V2’) between the positive side of the high voltage bus and the electrical chassis
(see Figure 3). Calculate the electrical isolation (Ri) according to the formula shown. Divide
this electrical isolation value (in Ω) by the nominal operating voltage of the high voltage bus
(in V).
Calculate the electrical isolation (Ri) according to the following formula:
Ri = Ro*(Vb/V2’ – Vb/V2) or Ri = Ro*Vb*(1/V2’ – 1/V2)

ANNEX 4B
ISOLATION RESISTANCE MEASUREMENT METHOD FOR
COMPONENT BASED TESTS OF A REESS
1. MEASUREMENT METHOD
The isolation resistance measurement shall be conducted by selecting an appropriate
measurement method from among those listed in Paragraphs 1.1. through 1.2. of this
annex, depending on the electrical charge of the live parts or the isolation resistance, etc.
If the operating voltage of the tested-device (Vb, Figure 1) cannot be measured (e.g. due to
disconnection of the electric circuit caused by main contactors or fuse operation) the test
may be performed with a modified test device to allow measurement of the internal voltages
(upstream the main contactors).
These modifications shall not influence the test results.
The range of the electrical circuit to be measured shall be clarified in advance, using
electrical circuit diagrams, etc. If the high voltage buses are galvanically isolated from each
other, isolation resistance shall be measured for each electrical circuit.
Moreover, modification necessary for measuring the isolation resistance may be carried out,
such as removal of the cover in order to reach the live parts, drawing of measurement lines,
change in software, etc.
In cases where the measured values are not stable due to the operation of the isolation
resistance monitoring system, etc., necessary modification for conducting the measurement
may be carried out, such as stopping the operation of the device concerned or removing it.
Furthermore, when the device is removed, it shall be proven, using drawings, etc., that it will
not change the isolation resistance between the live parts and the ground connection
designated by the manufacturer as a point to be connected to the electrical chassis when
installed on the vehicle.
Utmost care shall be exercised as to short circuit, electric shock, etc., for this confirmation
might require direct operations of the high-voltage circuit.
1.1. Measurement Method using Voltage from External Sources
1.1.1. Measurement Instrument
An isolation resistance test instrument capable of applying a dc voltage higher than the
nominal voltage of the tested-device shall be used.
1.1.2. Measurement Method
An insulation resistance test instrument shall be connected between the live parts and the
ground connection. Then, the isolation resistance shall be measured.
If the system has several voltage ranges (eg. because of boost converter) in a galvanically
connected circuit and some of the components cannot withstand the working voltage of the
entire circuit, the isolation resistance between those components and the ground connection

1.2.3.4. Fourth Step
If V1 is greater than or equal to V2, insert a standard known resistance (Ro) between the
negative pole of the tested-device and the ground connection. With Ro installed, measure
the voltage (V1’) between the negative pole of the tested-device and the ground connection
(see Figure 2).
Calculate the electrical isolation (Ri) according to the following formula:
Ri = Ro*(Vb/V1’ – Vb/V1) or Ri = Ro*Vb*(1/V1’ – 1/V1)
Figure 2
If V2 is greater than V1, insert a standard known resistance (Ro) between the positive pole
of the tested-device and the ground connection. With Ro installed, measure the voltage
(V2’) between the positive pole of the tested-device and the ground connection
(see Figure 3).
Calculate the electrical isolation (Ri) according to the following formula:
Ri = Ro*(Vb/V2’ – Vb/V2) or Ri = Ro*Vb*(1/V2’ – 1/V2)

ANNEX 5
CONFIRMATION METHOD FOR FUNCTION OF ON-BOARD
ISOLATION RESISTANCE MONITORING SYSTEM
The function of the on-board isolation resistance monitoring system shall be confirmed by the following
method:
Insert a resistor that does not cause the isolation resistance between the terminal being monitored and
the electrical chassis to drop below the minimum required isolation resistance value. The warning shall
be activated.

3.3.4.
Casing (construction, materials and physical dimensions): ............................................................
3.4.
Electrical Specification
3.4.1.
Nominal voltage (V):........................................................................................................................
3.4.2.
Working voltage (V):........................................................................................................................
3.4.3.
Capacity (Ab):..................................................................................................................................
3.4.3.
Maximum current (A):......................................................................................................................
3.5.
Gas combination rate (in %):...........................................................................................................
3.6.
Description or drawing (s) or picture(s) of the installation of the REESS in the vehicle: ................
3.6.1.
Physical support: .............................................................................................................................
3.7.
Type of thermal management: ........................................................................................................
3.8.
Electronic control: ............................................................................................................................
4.
FUEL CELL (IF ANY):
4.1.
Trade name and mark of the fuel cell: ............................................................................................
........................................................................................................................................................
4.2
Types of fuel cell: ............................................................................................................................
4.3.
Nominal voltage (V):........................................................................................................................
4.4.
Number of cells: ..............................................................................................................................
4.5.
Type of cooling system (if any): ......................................................................................................
4.6.
Max Power (kW):.............................................................................................................................
5.
FUSE AND/OR CIRCUIT BREAKER:
5.1.
Type: ...............................................................................................................................................
5.2.
Diagram showing the functional range: ...........................................................................................
6.
POWER WIRING HARNESS:
6.1.
Type: ...............................................................................................................................................
7.
PROTECTION AGAINST ELECTRIC SHOCK:
7.1.
Description of the protection concept: .............................................................................................

ANNEX 6 – PART 2
ESSENTIAL CHARACTERISTICS OF REESS
1.
REESS
1.1.
Trade name and mark of the REESS: ............................................................................................
1.2.
Indication of all types of cells: .........................................................................................................
1.2.1.
The cell chemistry: ..........................................................................................................................
1.2.2.
Physical dimensions: .......................................................................................................................
1.2.3.
Capacity of the cell (Ah): .................................................................................................................
1.3.
DESCRIPTION OR DRAWING(S) OR PICTURE(S) OF THE REESS EXPLAINING
1.3.1.
Structure: .........................................................................................................................................
1.3.2.
Configuration (number of cells, mode of connection, etc.): ............................................................
1.3.3.
Dimensions: .....................................................................................................................................
1.3.4.
Casing (construction, materials and physical dimensions): ............................................................
1.4.
ELECTRICAL SPECIFICATION
1.4.1.
Nominal voltage (V):........................................................................................................................
1.4.2.
Working voltage (V):........................................................................................................................
1.4.3.
Capacity (Ah):..................................................................................................................................
1.4.4.
Maximum current (A):......................................................................................................................
1.5.
Gas combination rate (in %):...........................................................................................................
1.6.
Description or drawing(s) or picture(s) of the installation of the REESS in the vehicle: .................
1.6.1.
Physical support: .............................................................................................................................
1.7.
Type of thermal management: ........................................................................................................
1.8.
Electronic control: ............................................................................................................................
1.9.
Category of vehicles on which the REESS can be installed: ..........................................................

1. INTRODUCTION
ANNEX 7
DETERMINATION OF HYDROGEN EMISSIONS DURING
THE CHARGE PROCEDURES OF THE TRACTION BATTERY
This Annex describes the procedure for the determination of hydrogen emissions during the
charge procedures of the REESS of all road vehicles, according to Paragraph 5.4. of this
Regulation.
2. DESCRIPTION OF TEST
The hydrogen emission test (Figure 7.1 of the present annex) is conducted in order to
determine hydrogen emissions during the charge procedures of the REESS with the
charger. The test consists in the following steps:
(a)
(b)
(c)
(d)
Vehicle/REESS preparation;
Discharge of the REESS;
Determination of hydrogen emissions during a normal charge;
Determination of hydrogen emissions during a charge carried out with the charger
failure.
3. TESTS
3.1. Vehicle Based Test
3.1.1. The vehicle shall be in good mechanical condition and have been driven at least 300 km
during seven days before the test. The vehicle shall be equipped with the REESS subject to
the test of hydrogen emissions, over this period.
3.1.2. If the REESS is used at a temperature above the ambient temperature, the operator shall
follow the manufacturer's procedure in order to keep the REESS temperature in normal
functioning range.
The manufacturer's representative shall be able to certify that the temperature conditioning
system of the REESS is neither damaged nor presenting a capacity defect.
3.2. Component Based Test
3.2.1. The REESS shall be in good mechanical condition and have been subject to minimum
of 5 standard cycles (as specified in Annex 8, Appendix 1).
3.2.2. If the REESS is used at a temperature above the ambient temperature, the operator shall
follow the manufacturer's procedure in order to keep the REESS temperature in its normal
functioning range.
The manufacturer's representative shall be able to certify that the temperature conditioning
system of the REESS is neither damaged nor presenting a capacity defect.

4. TEST EQUIPMENT FOR HYDROGEN EMISSION TEST
4.1. Chassis Dynamometer
The chassis dynamometer shall meet the requirements of the 06 series of amendments to
Regulation No 83.
4.2 Hydrogen Emission Measurement Enclosure.
The hydrogen emission measurement enclosure shall be a gas-tight measuring chamber
able to contain the vehicle/REESS under test. The vehicle/REESS shall be accessible from
all sides and the enclosure when sealed shall be gastight in accordance with Appendix 1 to
this annex. The inner surface of the enclosure shall be impermeable and non-reactive to
hydrogen. The temperature conditioning system shall be capable of controlling the internal
enclosure air temperature to follow the prescribed temperature throughout the test, with an
average tolerance of ±2K over the duration of the test.
To accommodate the volume changes due to enclosure hydrogen emissions, either a
variable-volume or another test equipment may be used. The variable-volume enclosure
expands and contracts in response to the hydrogen emissions in the enclosure. Two
potential means of accommodating the internal volume changes are movable panels, or a
bellows design, in which impermeable bags inside the enclosure expand and contract in
response to internal pressure changes by exchanging air from outside the enclosure. Any
design for volume accommodation shall maintain the integrity of the enclosure as specified
in Appendix 1 to this annex.
Any method of volume accommodation shall limit the differential between the enclosure
internal pressure and the barometric pressure to a maximum value of ±5hPa.
The enclosure shall be capable of latching to a fixed volume. A variable volume enclosure
shall be capable of accommodating a change from its "nominal volume" (see Annex 7,
Appendix 1, Paragraph 2.1.1.), taking into account hydrogen emissions during testing.
4.3. Analytical Systems
4.3.1. Hydrogen Analyser
4.3.1.1. The atmosphere within the chamber is monitored using a hydrogen analyser
(electrochemical detector type) or a chromatograph with thermal conductivity detection.
Sample gas shall be drawn from the mid-point of one side-wall or roof of the chamber and
any bypass flow shall be returned to the enclosure, preferably to a point immediately
downstream of the mixing fan.
4.3.1.2. The hydrogen analyser shall have a response time to 90% of final reading of less than 10s.
Its stability shall be better than 2% of full scale at zero and at 80% ± 20% of full scale, over
a 15min period for all operational ranges.
4.3.1.3. The repeatability of the analyser expressed as one standard deviation shall be better than
1% of full scale, at zero and at 80% ± 20% of full scale on all ranges used.
4.3.1.4. The operational ranges of the analyser shall be chosen to give best resolution over the
measurement, calibration and leak checking procedures.

4.7. Fans
4.8. Gases
The chamber shall be equipped with one or more fans or blowers with a possible flow of
0.1 to 0.5m /s in order to thoroughly mix the atmosphere in the enclosure. It shall be
possible to reach a homogeneous temperature and hydrogen concentration in the chamber
during measurements. The vehicle in the enclosure shall not be subjected to a direct stream
of air from the fans or blowers.
4.8.1. The following pure gases shall be available for calibration and operation:
(a) Purified synthetic air (purity <1ppm C1 equivalent; <1ppm CO; <400ppm CO ;
<0.1ppm NO); oxygen content between 18 and 21% by volume,
(b)
Hydrogen (H ), 99.5% minimum purity.
4.8.2. Calibration and span gases shall contain mixtures of hydrogen (H ) and purified synthetic
air. The real concentrations of a calibration gas shall be within ±2% of the nominal values.
The accuracy of the diluted gases obtained when using a gas divider shall be within ±2% of
the nominal value. The concentrations specified in Appendix 1 may also be obtained by a
gas divider using synthetic air as the dilution gas.
5. TEST PROCEDURE
The test consists in the five following steps:
(a)
(b)
(c)
(d)
(e)
Vehicle/REESS preparation;
Discharge of the REESS;
Determination of hydrogen emissions during a normal charge;
Discharge of the traction battery;
Determination of hydrogen emissions during a charge carried out with the charger
failure.
If the vehicle/REESS has to be moved between two steps, it shall be pushed to the following
test area.
5.1. Vehicle Based Test
5.1.1. Vehicle Preparation
The ageing of REESS shall be checked, proving that the vehicle has performed at least
300km during seven days before the test. During this period, the vehicle shall be equipped
with the traction battery submitted to the hydrogen emission test. If this cannot be
demonstrated then the following procedure will be applied.

5.1.4. Hydrogen Emission Test During a Normal Charge
5.1.4.1. Before the completion of the soak period, the measuring chamber shall be purged for
several minutes until a stable hydrogen background is obtained.
The enclosure mixing fan(s) shall also be turned on at this time.
5.1.4.2. The hydrogen analyser shall be zeroed and spanned immediately prior to the test.
5.1.4.3. At the end of the soak, the test vehicle, with the engine shut off and the test vehicle windows
and luggage compartment opened shall be moved into the measuring chamber.
5.1.4.4. The vehicle shall be connected to the mains. The REESS is charged according to normal
charge procedure as specified in Paragraph 5.1.4.7. below.
5.1.4.5. The enclosure doors are closed and sealed gas-tight within 2min from electrical interlock of
the normal charge step.
5.1.4.6. The start of a normal charge for hydrogen emission test period begins when the chamber is
sealed. The hydrogen concentration, temperature and barometric pressure are measured to
give the initial readings C , T and P for the normal charge test.
These figures are used in the hydrogen emission calculation (Paragraph 6. of this annex).
The ambient enclosure temperature T shall not be less than 291K and no more than 295K
during the normal charge period.
5.1.4.7. Procedure of Normal Charge
The normal charge is carried out with the charger and consists of the following steps:
(a) Charging at constant power during t ;
(b)
Over-charging at constant current during t . Over-charging intensity is specified by
manufacturer and corresponds to the one used during equalisation charging.
The end of REESS charge criteria corresponds to an automatic stop given by the charger to
a charging time of t + t . This charging time will be limited to t + 5 h, even if a clear
indication is given to the driver by the standard instrumentation that the battery is not yet
fully charged.
5.1.4.8. The hydrogen analyser shall be zeroed and spanned immediately before the end of the test.
5.1.4.9. The end of the emission sampling period occurs t + t or t + 5h after the beginning of the
initial sampling, as specified in Paragraph 5.1.4.6. of this annex. The different times elapsed
are recorded. The hydrogen concentration, temperature and barometric pressure are
measured to give the final readings C , T and P for the normal charge test, used for the
calculation in Paragraph 6. of this annex.
5.1.5. Hydrogen Emission Test with the Charger Failure
5.1.5.1. Within seven days maximum after having completed the prior test, the procedure starts with
the discharge of the REESS of the vehicle according to Paragraph 5.1.2. of this annex.

5.2.2. Discharge of the REESS
5.2.3. Soak
The REESS is discharged at 70% ± 5% of the nominal power of the system.
Stopping the discharge occurs when minimum SOC as specified by the manufacturer is
reached.
Within 15min of the end of the REESS discharge operation specified in Paragraph 5.2.2.
above, and before the start of the hydrogen emission test, the REESS shall be soaked at
293K ± 2K for a minimum period of 12h and a maximum of period of 36h.
5.2.4. Hydrogen Emission Test During a Normal Charge
5.2.4.1. Before the completion of the REESS's soak period, the measuring chamber shall be purged
for several minutes until a stable hydrogen background is obtained. The enclosure mixing
fan(s) shall also be turned on at this time.
5.2.4.2. The hydrogen analyser shall be zeroed and spanned immediately prior to the test.
5.2.4.3. At the end of the soak period, the REESS shall be moved into the measuring chamber.
5.2.4.4. The REESS shall be charged in accordance with the normal charge procedure as specified
in Paragraph 5.2.4.7. below.
5.2.4.5. The chamber shall be closed and sealed gas-tight within 2min of the electrical interlock of
the normal charge step.
5.2.4.6. The start of a normal charge for hydrogen emission test period shall begin when the
chamber is sealed. The hydrogen concentration, temperature and barometric pressure are
measured to give the initial readings C , T and P for the normal charge test.
These figures are used in the hydrogen emission calculation (Paragraph 6. of this annex).
The ambient enclosure temperature T shall not be less than 291K and no more than 295K
during the normal charge period.
5.2.4.7. Procedure of Normal Charge
The normal charge is carried out with a suitable charger and consists of the following steps:
(a) Charging at constant power during t ;
(a)
Over-charging at constant current during t . Over-charging intensity is specified by
manufacturer and corresponding to that used during equalisation charging.
The end of REESS charge criteria corresponds to an automatic stop given by the charger to
a charging time of t + t . This charging time will be limited to t + 5h, even if a clear
indication is given by a suitable instrumentation that the REESS is not yet fully charged.

5.2.5.11. The end of test period occurs t' + 30min after the beginning of the initial sampling, as
specified in Paragraph 5.2.5.8. above. The times elapsed are recorded. The hydrogen
concentration, temperature and barometric pressure are measured to give the final readings
C , T and P for the charging failure test, used for the calculation in Paragraph 6. below.
6. CALCULATION
The hydrogen emission tests described in Paragraph 5. above allow the calculation of the
hydrogen emissions from the normal charge and charging failure phases. Hydrogen
emissions from each of these phases are calculated using the initial and final hydrogen
concentrations, temperatures and pressures in the enclosure, together with the net
enclosure volume.
The formula below is used:
M
= k × V × 10

⎜ (1+
× ⎜


V
V
) × C
T
× P
C


× P

T ⎟

Where:
M = hydrogen mass, in grams
C = measured hydrogen concentration in the enclosure, in ppm volume
V = net enclosure volume in cubic metres (m ) corrected for the volume of the vehicle,
with the windows and the luggage compartment open. If the volume of the vehicle
is not determined a volume of 1.42m is subtracted.
V = compensation volume in m³, at the test temperature and pressure
T = ambient chamber temperature, in K
P = absolute enclosure pressure, in kPa
K = 2.42
Where:
i
f
is the initial reading
is the final reading
6.1. Results of Test
The hydrogen mass emissions for the REESS are:
MN = hydrogen mass emission for normal charge test, in grams
MD = hydrogen mass emission for charging failure test, in grams

2.2.6. The enclosure is allowed to stand undisturbed with the mixing fan on for a period of four
hours.
2.2.7. At the end of this time the same analyser is used to measure the hydrogen concentration in
the chamber. The temperature and the barometric pressure are also measured. These are
the final readings C , T and P .
2.2.8. The change in mass of hydrogen in the enclosure shall be calculated over the time of the
test in accordance with Paragraph 2.4. of this Annex and shall not exceed 0.5g.
2.3. Calibration and Hydrogen Retention Test of the Chamber
The calibration and hydrogen retention test in the chamber provides a check on the
calculated volume (Paragraph 2.1. above) and also measures any leak rate. The enclosure
leak rate shall be determined at the enclosure's introduction to service, after any operations
in the enclosure which may affect the integrity of the enclosure, and at least monthly
thereafter. If six consecutive monthly retention checks are successfully completed without
corrective action, the enclosure leak rate may be determined quarterly thereafter as long as
no corrective action is required.
2.3.1. The enclosure shall be purged until a stable hydrogen concentration is reached. The mixing
fan is turned on, if not already switched on. The hydrogen analyser is zeroed, calibrated if
required, and spanned.
2.3.2. The enclosure shall be latched to the nominal volume position.
2.3.3. The ambient temperature control system is then turned on (if not already on) and adjusted
for an initial temperature of 293K.
2.3.4. When the enclosure temperature stabilizes at 293K ± 2 K, the enclosure is sealed and the
background concentration, temperature and barometric pressure measured. These are the
initial readings C , T and P used in the enclosure calibration.
2.3.5. The enclosure shall be unlatched from the nominal volume.
2.3.6. A quantity of approximately 100g of hydrogen is injected into the enclosure. This mass of
hydrogen shall be measured to an accuracy of ±2% of the measured value.
2.3.7. The contents of the chamber shall be allowed to mix for 5min and then the hydrogen
concentration, temperature and barometric pressure are measured. These are the final
readings C , T and P for the calibration of the enclosure as well as the initial readings
C , T and P for the retention check.
2.3.8. On the basis of the readings taken in Paragraphs 2.3.4 and 2.3.7 above and the formula in
Paragraph 2.4. below, the mass of hydrogen in the enclosure is calculated. This shall be
within ±2% of the mass of hydrogen measured in Paragraph 2.3.6. above.
2.3.9. The contents of the chamber shall be allowed to mix for a minimum of 10h. At the
completion of the period, the final hydrogen concentration, temperature and barometric
pressure are measured and recorded. These are the final readings C , T and P for the
hydrogen retention check.

3.4. Using the coefficients of the polynomial derived from Paragraph 3.2. above, a table of
analyser readings against true concentrations shall be drawn by steps no greater than 1% of
full scale. This is to be carried out for each analyser range calibrated.
This table shall also contain other relevant data such as:
(a)
(b)
(c)
(d)
(e)
(f)
Date of calibration;
Span and zero potentiometer readings (where applicable);
Nominal scale;
Reference data of each calibration gas used;
Real and indicated value of each calibration gas used together with the percentage
differences;
Calibration pressure of analyser.
3.5. Alternative methods (e.g. computer, electronically controlled range switch) can be used if it
is proven to the technical service that these methods give equivalent accuracy.

ANNEX 8
REESS TEST PROCEDURES
ANNEX 8 - APPENDIX 1
Procedure for conducting a standard cycle
A standard cycle will start with a standard discharge followed by a standard charge.
Standard discharge:
Discharge rate:
Discharge limit (end voltage):
Rest period after discharge:
Standard charge:
The discharge procedure including termination criteria shall be defined
by the manufacturer. If not specified, then it shall be a discharge with
1C current.
Specified by the manufacturer
Minimum 30min.
The charge procedure including termination criteria shall be defined by
the manufacturer. If not specified, then it shall be a charge with
C/3 current.

The correlation between frequency and acceleration shall be as shown in Table 1:
Table 1
Frequency and Acceleration
Frequency (Hz) Acceleration (m/s )
7-18 10
18-30 Gradually reduced from 10 to 2
30-50 2
At the request of the manufacturer, a higher acceleration level as well as a higher maximum
frequency may be used.
At the request of the manufacturer a vibration test profile determined by the vehiclemanufacturer,
verified for the vehicle application and agreed with the Technical Service may
be used as a substitute for the frequency – acceleration correlation of Table 1. The approval
of a REESS tested according to this condition shall be limited to approvals for a specific
vehicle type.
After the vibration, a standard cycle as described in Annex 8, Appendix 1 shall be
conducted, if not inhibited by the tested-device.
The test shall end with an observation period of 1h at the ambient temperature conditions of
the test environment.

ANNEX 8C
MECHANICAL SHOCK
1. PURPOSE
The purpose of this test is to verify the safety performance of the REESS under inertial
loads which may occur during a vehicle crash.
2. INSTALLATION
2.1. This test shall be conducted either with the complete REESS or with related REESS
subsystem(s) including the cells and their electrical connections. If the manufacturer
chooses to test with related subsystem(s), the manufacturer shall demonstrate that the test
result can reasonably represent the performance of the complete REESS with respect to its
safety performance under the same conditions. If the electronic management unit for the
REESS is not integrated in the casing enclosing the cells, then the electronic management
unit may be omitted from installation on the tested-device if so requested by the
manufacturer
2.2. The tested-device shall be connected to the test fixture only by the intended mountings
provided for the purpose of attaching the REESS or REESS subsystem to the vehicle.
3. PROCEDURES
3.1. General Test Conditions and Requirements
The following condition shall apply to the test:
(a)
(b)
(c)
The test shall be conducted at an ambient temperature of 20 ± 10°C,
At the beginning of the test, the SOC shall be adjusted to a value in the upper 50% of
the normal operating SOC range;
At the beginning of the test, all protection devices which effect the function of the
tested-device and which are relevant to the outcome of the test, shall be operational.
3.2. Test Procedure
The tested-device shall be decelerated or, at the choice of the applicant, accelerated in
compliance with the acceleration corridors which are specified in Tables 1 to 3. The
Technical Service in consultation with the manufacturer shall decide whether the tests shall
be conducted in either the positive or negative direction or both.
For each of the test pulses specified, a separate tested-device may be used.
The test pulse shall be within the minimum and maximum value as specified in
Tables 1 to 3. A higher shock level and /or longer duration as described in the maximum
value in Tables 1 to 3 can be applied to the tested-device if recommended by the
manufacturer.

Point
Time (ms)
Table 2
For M and N Vehicles:
Longitudinal
Acceleration (g)
Transverse
A 20 0 0
B 50 10 5
C 65 10 5
D 100 0 0
E 0 5 2.5
F 50 17 10
G 80 17 10
H 120 0 0
Point
Time (ms)
Table 3
For M and N Vehicles:
Longitudinal
Acceleration (g)
Transverse
A 20 0 0
B 50 6.6 5
C 65 6.6 5
D 100 0 0
E 0 4 2.5
F 50 12 10
G 80 12 10
H 120 0 0
The test shall end with an observation period of 1h at the ambient temperature conditions of
the test environment.

Figure 1
A higher crush force, a longer onset time, a longer hold time, or a combination of these, may
be applied at the request of the manufacturer.
The application of the force shall be decided by the manufacturer together with the
Technical Service having consideration to the direction of travel of the REESS relative to its
installation in the vehicle. The application force being applied horizontally and perpendicular
to the direction of travel of the REESS.
The test shall end with an observation period of 1h at the ambient temperature conditions of
the test environment.

3.2.2. Component Based Test
The tested-device shall be placed on a grating table positioned above the pan, in an
orientation according to the manufacturer’s design intent.
The grating table shall be constructed by steel rods, diameter 6-10mm, with 4-6cm in
between. If needed the steel rods could be supported by flat steel parts.
3.3. The flame to which the tested-device is exposed shall be obtained by burning commercial
fuel for positive-ignition engines (hereafter called "fuel") in a pan. The quantity of fuel shall
be sufficient to permit the flame, under free burning conditions, to burn for the whole test
procedure.
The fire shall cover the whole area of the pan during whole fire exposure. The pan
dimensions shall be chosen so as to ensure that the sides of the tested-device are exposed
to the flame. The pan shall therefore exceed the horizontal projection of the tested-device by
at least 20cm, but not more than 50cm. The sidewalls of the pan shall not project more than
8cm above the level of the fuel at the start of the test.
3.4. The pan filled with fuel shall be placed under the tested-device in such a way that the
distance between the level of the fuel in the pan and the bottom of the tested-device
corresponds to the design height of the tested-device above the road surface at the unladen
mass if Paragraph 3.2.1. above is applied or approximately 50cm if Paragraph 3.2.2. above
is applied. Either the pan, or the testing fixture, or both, shall be freely movable.
3.5. During phase C of the test, the pan shall be covered by a screen. The screen shall be
placed 3cm ± 1cm above the fuel level measured prior to the ignition of the fuel. The screen
shall be made of a refractory material, as prescribed in Annex 8E - Appendix 1. There shall
be no gap between the bricks and they shall be supported over the fuel pan in such a
manner that the holes in the bricks are not obstructed. The length and width of the frame
shall be 2cm to 4cm smaller than the interior dimensions of the pan so that a gap of 1cm to
2cm exists between the frame and the wall of the pan to allow ventilation. Before the test the
screen shall be at least at the ambient temperature. The firebricks may be wetted in order to
guarantee repeatable test conditions.
3.6. If the tests are carried out in the open air, sufficient wind protection shall be provided and
the wind velocity at pan level shall not exceed 2.5km/h.
3.7. The test shall comprise of three phases B-D, if the fuel is at least at temperature of 20°C.
Otherwise the test shall comprise four Phases A–D.
3.7.1. Phase A: Pre-heating (Figure 1)
The fuel in the pan shall be ignited at a distance of at least 3m from the tested-device. After
60s pre-heating, the pan shall be placed under the tested-device. If the size of the pan is too
large to be moved without risking liquid spills etc. then the tested-device and test rig can be
moved over the pan instead.

3.7.4. Phase D: End of Test (Figure 4)
The burning pan covered with the screen shall be moved back to the position described in
Phase A. No extinguishing of the tested-device shall be done. After removal of the pan the
tested-device shall be observed until such time as the surface temperature of the
tested-device has decreased to ambient temperature or has been decreasing for a minimum
of 3h.
Figure 4
Phase D: End of Test

ANNEX 8F
EXTERNAL SHORT CIRCUIT PROTECTION
1. PURPOSE
The purpose of this test is to verify the performance of the short circuit protection. This
functionality, if implemented, shall interrupt or limit the short circuit current to prevent the
REESS from any further related severe events caused by short circuit current.
2. INSTALLATIONS
This test shall be conducted either with the complete REESS or with related REESS
subsystem(s), including the cells and their electrical connections. If the manufacturer
chooses to test with related subsystem(s), the manufacturer shall demonstrate that the test
result can reasonably represent the performance of the complete REESS with respect to its
safety performance under the same conditions. If the electronic management unit for the
REESS is not integrated in the casing enclosing the cells, then the electronic management
unit may be omitted from installation on the tested-device if so requested by the
manufacturer.
3. PROCEDURES
3.1. General Test Conditions
The following condition shall apply to the test:
(a)
(b)
(c)
The test shall be conducted at a ambient temperature of 20 ± 10°C or at higher
temperature if requested by the manufacturer;
At the beginning of the test, the SOC shall be adjusted to a value in the upper 50% of
the normal operating SOC range;
At the beginning of the test, all protection devices which would affect the function of
the tested-device and which are relevant to the outcome of the test shall be
operational.
3.2. Short Circuit
At the start of the test all relevant main contactors for charging and discharging shall be
closed to represent the active driving possible mode as well as the mode to enable external
charging. If this cannot be completed in a single test, then two or more tests shall be
conducted.
The positive and negative terminals of the tested-device shall be connected to each other to
produce a short circuit. The connection used for this purpose shall have a resistance not
exceeding 5mΩ.
The short circuit condition shall be continued until the operation of the REESS´s protection
function to interrupt or limit the short circuit current is confirmed, or for at least one hour after
the temperature measured on the casing of the tested-device has stabilised, such that the
temperature gradient varies by a less than 4°C through 1 hour.

ANNEX 8G
OVERCHARGE PROTECTION
1. PURPOSE
The purpose of this test is to verify the performance of the overcharge protection.
2. INSTALLATIONS
This test shall be conducted, under standard operating conditions, either with the complete
REESS (this maybe a complete vehicle) or with related REESS subsystem(s), including the
cells and their electrical connections. If the manufacturer chooses to test with related
subsystem(s), the manufacturer shall demonstrate that the test result can reasonably
represent the performance of the complete REESS with respect to its safety performance
under the same conditions.
The test may be performed with a modified tested-device as agreed by the manufacturer
and the Technical Service. These modifications shall not influence the test results.
3. PROCEDURES
3.1. General Test Conditions
The following requirements and conditions shall apply to the test:
(a)
(b)
The test shall be conducted at an ambient temperature of 20 ± 10°C or at higher
temperature if requested by the manufacturer;
At the beginning of the test, all protection devices which would affect the function of
the tested-device and which are relevant to the outcome of the test shall be
operational.
3.2. Charging
At the beginning all relevant main contactors for charging shall be closed.
The charge control limits of the test equipment shall be disabled.
The tested-device shall be charged with a charge current of at least 1/3C rate but not
exceeding the maximum current within the normal operating range as specified by the
manufacturer.
The charging shall be continued until the tested-device (automatically) interrupts or limits the
charging. Where an automatic interrupt function fails to operate, or if there is no such
function the charging shall be continued until the tested-device is charged to twice of its
rated charge capacity.

ANNEX 8H
OVER-DISCHARGE PROTECTION
1. PURPOSE
The purpose of this test is to verify the performance of the over-discharge protection. This
functionality, if implemented, shall interrupt or limit the discharge current to prevent the
REESS from any severe events caused by a too low SOC as specified by the manufacturer.
2. INSTALLATIONS
This test shall be conducted, under standard operating conditions, either with the complete
REESS (this maybe a complete vehicle) or with related REESS subsystem(s), including the
cells and their electrical connections. If the manufacturer chooses to test with related
subsystem(s), the manufacturer shall demonstrate that the test result can reasonably
represent the performance of the complete REESS with respect to its safety performance
under the same conditions.
The test may be performed with a modified tested-device as agreed by the manufacturer
and the Technical Service. These modifications shall not influence the test results.
3. PROCEDURES
3.1. General Test Conditions
The following requirements and condition shall apply to the test:
(a)
(b)
The test shall be conducted at an ambient temperature of 20 ± 10°C or at higher
temperature if requested by the manufacturer;
At the beginning of the test, all protection devices which would affect the function of
the tested-device and which are relevant for the outcome of the test shall be
operational.
3.2. Discharging
At the beginning of the test, all relevant main contactors shall be closed.
A discharge shall be performed with at least 1/3 C rate but shall not exceed the maximum
current within the normal operating range as specified by the manufacturer.
The discharging shall be continued until the tested-device (automatically) interrupts or limits
the discharging. Where an automatic interrupt function fails to operate, or if there is no such
function then the discharging shall be continued until the tested-device is discharged to 25%
of its nominal voltage level.
3.3. Standard Charge and Observation Period
Directly after termination of the discharging the tested-device shall be charged with a
standard charge as specified in Annex 8, Appendix 1 if not inhibited by the tested-device.
The test shall end with an observation period of 1h at the ambient temperature conditions of
the test environment.

3.3. The tested-device shall be placed in a convective oven or climatic chamber. The
temperature of the chamber or oven shall be gradually increased until it reaches the
temperature determined in accordance with Paragraph 3.3.1. or 3.3.2. below as applicable,
and then maintained at a temperature that is equal to or higher than this, until the end of the
test.
3.3.1. Where the REESS is equipped with protective measures against internal overheating, the
temperature shall be increased to the temperature defined by the manufacturer as being the
operational temperature threshold for such protective measures, to insure that the
temperature of the tested-device will increase as specified in Paragraph 3.2. above.
3.3.2. Where the REESS is not equipped with any specific measures against internal over-heating,
the temperature shall be increased to the maximum operational temperature specified by
the manufacturer.
3.4. The End of Test:
The test will end when one of the followings is observed:
(a)
(b)
(c)
The tested-device inhibits and/or limits the charge and/or discharge to prevent the
temperature increase;
The temperature of the tested-device is stabilised, which means that the temperature
varies by a gradient of less than 4°C through 2h;
Any failure of the acceptance criteria prescribed in Paragraph 6.9.2.1. of the
Regulation.
Approval of Vehicles with Electric Power Train.