Regulation No. 136-00 Proposal

Name:Regulation No. 136-00 Proposal
Description:Approval of Category L Vehicles with Electric Power Train - Proposal.
Official Title:Draft Regulation on Electric Vehicles of Category L.
Country:ECE - United Nations
Date of Issue:2015-06-26
Amendment Level:Original
Number of Pages:86
Vehicle Types:Component, Motorcycle
Subject Categories:Drafts and Proposals (Historical)
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Keywords:

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

Text Extract:

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ECE/TRANS/WP.29/2015/69
DRAFT REGULATION ON ELECTRIC VEHICLES
OF CATEGORY L (EV-L)
(ECE 136-00)
ADOPTED AT THE 166 SESSION – JUNE 2015
PROVISIONAL DATE OF ENTRY INTO FORCE: JANUARY 20, 2016

Contents (Continued)
Annexes
Annex 5
Confirmation method for function of on-board isolation resistance monitoring system
Annex6 Part 1 - Essential characteristics of road vehicles or systems
Part 2 -
Part 3 -
Essential characteristics of REESS
Essential characteristics of road vehicles or systems with chassis connected to
electrical circuits
Annex 7
Determination of hydrogen emissions during the charge procedures of the REESS
Appendix 1 -
Appendix 2 -
Calibration of equipment for hydrogen emission testing
Essential characteristics of the vehicle family
Annex 8
REESS test procedures
Appendix - Procedure for conducting a standard cycle
Annex 8A
Annex 8B
Annex 8C
Annex 8D
Annex 8E
Vibration test
Thermal shock and cycling test
Mechanical Drop Test for removable REESS
Mechanical shock
Fire resistance
Appendix - Dimension and technical data of firebricks
Annex 8F
Annex 8G
Annex 8H
Annex 8I
Annex 9A
Annex 9B
External short circuit protection
Overcharge protection
Over-discharge protection
Over-temperature protection
Withstand voltage test
Protection against ingress of water

2.6. "Conductive connection" means the connection using connectors to an external power
supply when the REESS is charged.
2.7. "Coupling system for charging the REESS" means the electrical circuit used for
charging the REESS from an external electric power supply including the vehicle inlet or
a permanently affixed charging cable.
2.8. "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.
2.9. "Direct contact" means the contact of persons with live parts.
2.10. "Double insulation" means insulation comprising both basic insulation and
supplementary insulation.
2.11. "Electrical chassis" means a set made of conductive parts electrically linked together,
whose potential is taken as reference.
2.12. "Electrical circuit" means an assembly of connected live parts which is designed to be
electrically energized in normal operation.
2.13. "Electric energy conversion system" means a system that generates and provides
electric energy for electric propulsion.
2.14. "Electric power train" means the electrical circuit which includes the traction motor(s),
and may include the REESS, the electric energy conversion system, the electronic
converters, the associated wiring harness and connectors, and the coupling system for
charging the REESS.
2.15. "Electronic converter" means a device capable of controlling and/or converting electric
power for electric propulsion.
2.16. "Enclosure" means the part enclosing the internal units and providing protection against
direct contact from any direction of access.
2.17. "Exposed conductive part" means the conductive part which can be touched under the
provisions of the protection IPXXB, and which becomes electrically energized under
isolation failure conditions. This includes parts under a cover that can be removed
without using tools.
2.18. "Explosion" means the sudden release of energy sufficient to cause pressure waves
and/or projectiles that may cause structural and/or physical damage to the surrounding
of the tested-device.
2.19. "External electric power supply" means an alternating current (AC) or direct current
(DC) electric power supply outside of the vehicle.
2.20. "High Voltage" means the classification of an electric component or circuit, if its working
voltage is >60V and ≤1,500V DC or >30V and ≤1,000V AC root mean square (rms).
2.21. "Fire" means the emission of flames from a tested-device. Sparks and arcing shall not
be considered as flames.

2.34. "Removable REESS" means a REESS that by design can be taken out from the vehicle
by the vehicle user for off-board charging.
2.35. "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).
2.36. "Service disconnect" means the device for deactivation of the electrical circuit when
conducting checks and services of the REESS, fuel cell stack, etc.
2.37. "State of Charge (SOC)" means the available electrical charge in a tested-device
expressed as a percentage of its rated capacity.
2.38. "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.
2.39. "Subsystem" means any functional assembly of REESS components.
2.40. "Supplementary insulation" means independent insulation applied in addition to basic
insulation for protection against electric shock in the event of a failure of the basic
insulation.
2.41. "Tested-device" means either the complete REESS or the subsystem of a REESS that
is subjected to the tests prescribed by this Regulation.
2.42. "Type of REESS" means systems which do not differ significantly in such essential
aspects as:
(a)
(b)
(c)
(d)
(e)
The manufacturer's trade name or mark;
The chemistry, capacity and physical dimensions of its cells;
The number of cells, the mode of connection of the cells and the physical support
of the cells;
The construction, materials and physical dimensions of the casing; and
The necessary ancillary devices for physical support, thermal management and
electronic control.
2.43. "Vehicle type" means vehicles which do not differ in such essential aspects as:
(a)
(b)
Installation of the electric power train and the galvanically connected high voltage
bus;
Nature and type of electric power train and the galvanically connected high voltage
components.
2.44. "Withstand voltage" means voltage to be applied to a specimen under prescribed test
conditions which does not cause breakdown and/or flashover of a satisfactory specimen.

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 00 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.
4.4. There shall be affixed, conspicuously and in a readily accessible place specified on the
approval form, to every vehicle or REESS or separate technical unit conforming to a type
approved under this Regulation an international approval mark consisting of:
4.4.1. A circle surrounding the letter "E" followed by the distinguishing number of the country
which has granted approval.
4.4.2. The number of this Regulation, followed by the letter "R", a dash and the approval
number to the right of the circle described in Paragraph 4.4.1.
4.4.3. In the case of an approval of a REESS or a separate technical unit of the REESS the "R"
shall be followed by the symbol "ES".
4.5. If the vehicle or REESS conforms to a type approved under one or more other
Regulations annexed to the Agreement in the country which has granted approval under
this Regulation, the symbol prescribed in Paragraph 4.4.1. need not be repeated; in this
case the Regulation and approval numbers and the additional symbols of all the
Regulations under which approval has been granted in the country which has granted
approval under this Regulation shall be placed in vertical columns to the right of the
symbol prescribed in Paragraph 4.4.1.
4.6. The approval mark shall be clearly legible and shall be indelible.
4.6.1. In the case of a vehicle, the approval mark shall be placed on or close to the vehicle data
plate affixed by the manufacturer.
4.6.2. In the case of a REESS or separate technical unit approved as a REESS, the approval
mark shall be affixed on the major element of the REESS by the manufacturer.
4.7. Annex 2 to this Regulation gives examples of the arrangements of the approval mark.

5.1.1.5. Marking
5.1.1.5.1. 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
5.1.1.5.2. The symbol shall also be visible on enclosures and barriers, which, when removed
expose live parts of high voltage circuits. This provision is optional to any connector for
high voltage buses. This provision shall not apply to any of the following cases:
(a)
(b)
Where barriers or enclosures cannot be physically accessed, opened, or removed;
unless other vehicle components are removed with the use of tools
Where barriers or enclosures are located underneath the vehicle floor.
5.1.1.5.3. Cables for high voltage buses which are not located within enclosures shall be identified
by having an outer covering with the colour orange.
5.1.2. Protection Against Indirect Contact
Protection against indirect contact is also required for vehicles with high voltage live
parts equipped with any REESS type approved under Part II of this Regulation.
5.1.2.1. For protection against electrical shock which could arise from indirect contact, the
exposed conductive parts, such as the conductive barrier and enclosure, shall be
galvanically connected securely to the electrical chassis by connection with electrical
wire or ground cable, or by welding, or by connection using bolts, etc. so that no
dangerous potentials are produced.
5.1.2.2. The resistance between all exposed conductive parts and the electrical chassis shall be
lower than 0.1Ω when there is current flow of at least 0.2A.
This requirement is satisfied if the galvanic connection has been established by welding.

5.1.2.4.3. Handling instructions Appropriate instructions for charging shall be provided and
included in the manual.
5.1.3. Isolation Resistance
This Paragraph shall not apply to chassis connected electrical circuits where the
maximum voltage between any live part and the electrical chassis or any exposed
conductive part does not exceed 30V AC (rms) or 60V DC.
5.1.3.1. Electric power train consisting of separate Direct Current- or Alternating Current-buses
If AC buses and DC buses are galvanically isolated from each other, the isolation
resistance between the high voltage bus and the electrical chassis shall have a minimum
value of 100Ω/V of the working voltage for DC buses, and a minimum value of 500Ω/V of
the working voltage for AC buses.
The measurement shall be conducted according to Annex 4A "Isolation resistance
measurement method for vehicle based tests".
5.1.3.2. Electric power train consisting of combined DC- and AC-buses
If AC buses and DC buses are galvanically connected, isolation resistance between any
high voltage bus and the electrical chassis shall have a minimum value of 500Ω/volt of
the working voltage.
However, if all AC high voltage buses are protected by one of the two following
measures, isolation resistance between any high voltage bus and the electrical chassis
shall have a minimum value of 100 Ω/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".

5.2.4. Accidental or Unintentional Detachment
The REESS and its components shall be installed in the vehicle in such a way so as to
preclude the possibility of inadvertent or unintentional detachment of the REESS.
The REESS in the vehicle shall not be ejected when the vehicle is tilted.
The REESS components shall not be ejected when the REESS is put upside-down.
5.3. Functional Safety
A momentary indication shall, as minimum, be given to the driver when the vehicle is in
"active driving possible mode''.
However, this provision does not apply under conditions where an internal combustion
engine directly or indirectly provides the vehicle´s propulsion power.
When leaving the vehicle, the driver shall be informed by a signal (e.g. optical or audible
signal) if the vehicle is still in the active driving possible mode.
If the onboard REESS can be externally charged by the user, movement caused by the
vehicle's propulsion system shall not be possible while the external electric power supply
is physically connected to the vehicle inlet.
For vehicles with a permanently connected recharge cable, the requirement above is not
applicable if using the cable to charge the vehicle prevents the use of the vehicle (e.g.
seat cannot be closed, the cable position does not allow the rider to sit in or step into the
vehicle). This requirement shall be demonstrated by using the connector specified by the
vehicle manufacturer. The state of the drive direction control unit shall be identified to the
driver.
5.3.1. Additional Functional Safety Requirements
5.3.1.1. At least two deliberate and distinctive actions shall be performed by the driver at the
start-up to select the active driving possible mode.
5.3.1.2. Only a single action shall be required to deactivate the active driving possible mode.
5.3.1.3. Indication of temporary reduced power (i.e. not resulting from a failure) and/or of state of
charge (SOC) of REESS.
5.3.1.3.1. The vehicle shall have a function/device that indicates to the driver/rider if the power is
automatically reduced below a certain level, (e.g. due to activation of the output
controller to protect the REESS or the propulsion system) or due to a low SOC.
5.3.1.3.2. The conditions under which these indications are given shall be determined by the
manufacturer.
A brief description of the power reduction and indicating strategy will be prescribed in
Annex 6.

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/Volt.
6.3. Thermal Shock and Cycling
6.3.1. The test shall be conducted in accordance with Annex 8B to this Regulation.
6.3.2. Acceptance Criteria
6.3.2.1. 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.
6.3.2.2. For a high voltage REESS, the isolation resistance measured after the test in
accordance with Annex 4B of this Regulation shall not be less than 100Ω/Volt.
6.4. Mechanical Tests
6.4.1. Drop Test for Removable REESS
6.4.1.1. The test shall be conducted in accordance with Annex 8C of this Regulation.
6.4.1.2. Acceptance Criteria
6.4.1.2.1. During the test there shall be no evidence of
(a)
(b)
Electrolyte leakage;
Rupture (applicable to high voltage REESS(s) only);

6.5.1. Vehicle Based Test
The test shall be conducted in accordance with Annex 8E in due consideration of
Paragraph 3.2.1. of Annex 8E.
The approval of a REESS tested according to this Paragraph shall be limited to
approvals for a specific vehicle type.
6.5.2. Component Based Test
The test shall be conducted in accordance with Annex 8E in due consideration of
Paragraph 3.2.2. of Annex 8E.
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.

6.8.2. Acceptance criteria
6.8.2.1. 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.
6.8.2.2. 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.
6.9. Over-temperature Protection
6.9.1. The test shall be conducted in accordance with Annex 8I to this Regulation.
6.9.2. Acceptance Criteria
6.9.2.1. 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.
6.9.2.2. 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.

8.3.5. Ensure that for each type of vehicle or component type at least the tests prescribed in
the relevant part(s) of this Regulation are carried out;
8.3.6. Ensure that any set of samples or test pieces giving evidence of non-conformity with the
type of test in question shall give rise to a further sampling and test. All necessary steps
shall be taken to re-establish conformity of the corresponding production.
8.4. The Type Approval Authority which has granted type approval may at any time verify the
conformity control methods applied in each production unit.
8.4.1. At every inspection, the test records and production records shall be presented to the
visiting inspector.
8.4.2. The inspector may take samples at random to be tested in the manufacturer's laboratory.
The minimum number of samples may be determined according to the results of the
manufacturer's own checks.
8.4.3. When the quality level appears unsatisfactory or when it seems necessary to verify the
validity of the tests carried out in application of Paragraph 8.4.2., the inspector shall
select samples to be sent to the technical service which has conducted the type approval
tests.
8.4.4. The Type Approval Authority may carry out any test prescribed in this Regulation.
8.4.5. The normal frequency of inspections by the Type Approval Authority shall be one per
year. If unsatisfactory results are recorded during one of these visits, the Type Approval
Authority shall ensure that all necessary steps are taken to re-establish the conformity of
production as rapidly as possible.
9. PENALTIES FOR NON-CONFORMITY OF PRODUCTION
9.1. The approval granted in respect of a vehicle/REESS type, pursuant to this Regulation
may be withdrawn if the requirements laid down in Paragraph 8. above are not complied
with, or if the vehicle/REESS or its components fail to pass the tests provided for in
Paragraph 8.3.5. above.
9.2. If a Contracting Party to the Agreement applying this Regulation withdraws an approval it
has previously granted, it shall forthwith so notify the other Contracting Parties applying
this Regulation, by means of a communication form conforming to the Model in Annex 1
(Part 1 or Part 2) to this Regulation.
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.

ANNEX 1 - PART 1
COMMUNICATION
(Maximum format: A4 (210 × 297mm))
Issued by:
Name of administration
.....................................
.....................................
.....................................
.....................................
Concerning:
Approval granted
Approval extended
Approval refused
Approval withdrawn
Production definitively discontinued
of a vehicle type with regard to its electrical safety pursuant to Regulation No. [XXX]
Approval No. ............................................................ Extension No. ....................................................
1. Trade name or mark of the vehicle: ................................................................................................
2. Vehicle type: ....................................................................................................................................
3. Vehicle category: .............................................................................................................................
4. Manufacturer's name and address: .................................................................................................
........................................................................................................................................................
5. If applicable, name and address of manufacturer's representative: ...............................................
........................................................................................................................................................
6. Description of the vehicle: ...............................................................................................................
6.1. REESS type: ...................................................................................................................................
6.1.1. The approval number of the REESS or descriptions of the REESS
6.2. Working voltage: .............................................................................................................................
6.3. Propulsion system (e.g. hybrid, electric): ......................................................................

ANNEX 1 – PART 2
COMMUNICATION
(Maximum format: A4 (210 × 297mm))
Issued by:
Name of administration
.....................................
.....................................
.....................................
.....................................
Concerning:
Approval granted
Approval extended
Approval refused
Approval withdrawn
Production definitively discontinued
of a REESS type as component/separate technical unit pursuant to Regulation No. [XXX]
Approval No. ............................................................ Extension No. ....................................................
1. Trade name or mark of the REESS: ...............................................................................................
2. Type of REESS: ..............................................................................................................................
3. Manufacturer's name and address: .................................................................................................
4. If applicable, name and address of manufacturer's representative: ...............................................
5. Description of the REESS: ..............................................................................................................
6. Installation restrictions applicable to the REESS: ...........................................................................
7. REESS submitted for approval on: .................................................................................................
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): .....................................................................

ANNEX 2
ARRANGEMENTS OF THE APPROVAL MARKS
Model A
(See Paragraph 4.2. of this Regulation)
a = 8mm min.
Figure 1
The approval mark in Figure 1 affixed to a vehicle shows that the road vehicle type concerned has been
approved in the Netherlands (E 4), pursuant to Regulation No. [XXX], and under the approval number
002492. The first two digits of the approval number indicate that the approval was granted in accordance
with the requirements of Regulation No. [XXX] in its original form.
Figure 2
a = 8mm min.
The approval mark in Figure 2 affixed to a REESS shows that the REESS type ("ES") concerned has
been approved in the Netherlands (E 4), pursuant to Regulation No. [XXX], and under the approval
number 002492. The first two digits of the approval number indicate that the approval was granted in
accordance with the requirements of Regulation No. [XXX] in its original form.

ANNEX 3
PROTECTION AGAINST DIRECT CONTACTS OF PARTS UNDER VOLTAGE
1. ACCESS PROBES
Access probes to verify the protection of persons against access to live parts are given in Table 1.
2. TEST CONDITIONS
The access probe is pushed against any openings of the enclosure with the force specified in
Table 1. If it partly or fully penetrates, it is placed in every possible position, but in no case shall
the stop face fully penetrate through the opening.
Internal barriers are considered part of the enclosure.
A low-voltage supply (of not less than 40V and not more than 50V) in series with a suitable lamp
should be connected, if necessary, between the probe and live parts inside the barrier or
enclosure.
The signal-circuit method should also be applied to the moving live parts of high voltage
equipment.
Internal moving parts may be operated slowly, where this is possible.
3. ACCEPTANCE CONDITIONS
The access probe shall not touch live parts.
If this requirement is verified by a signal circuit between the probe and live parts, the lamp shall not
light.
In the case of the test for IPXXB, the jointed test finger may penetrate to its 80mm length, but the
stop face (diameter 50mm × 20mm) shall not pass through the opening. Starting from the straight
position, both joints of the test finger shall be successively bent through an angle of up to 90° with
respect to the axis of the adjoining section of the finger and shall be placed in every possible
position.
In case of the tests for IPXXD, the access probe may penetrate to its full length, but the stop face
shall not fully penetrate through the opening.

Figure 1
Jointed Test Finger
Material: metal, except where otherwise specified
Linear dimensions in millimeters
Tolerances on dimensions without specific tolerance:
(a) On angles: 0/-10°;
(b)
On linear dimensions: up to 25mm: 0/-0.05mm over 25mm: ±0.2mm
Both joints shall permit movement in the same plane and the same direction through an angle of
90° with a 0 to +10° tolerance.

2.2. Measurement Method using the Vehicle’s Own REESS as DC Voltage Source
2.2.1. Test Vehicle Conditions
The high voltage-bus shall be energized by the vehicle’s own REESS and/or energy
conversion system and the voltage level of the REESS and/or energy conversion system
throughout the test shall be at least the nominal operating voltage as specified by the
vehicle manufacturer.
2.2.2. Measurement Instrument
The voltmeter used in this test shall measure DC values and shall have an internal
resistance of at least 10MΩ.
2.2.3. Measurement Method
2.2.3.1. First step
The voltage is measured as shown in Figure 1 and the high voltage bus voltage (Vb) is
recorded. Vb shall be equal to or greater than the nominal operating voltage of the REESS
and/or energy conversion system as specified by the vehicle manufacturer.
Figure 1
Measurement of Vb, V1, V2

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
Volts).
Calculate the electrical isolation (Ri) according to the following formula:
Ri = Ro × (Vb/V2’ – Vb/V2) or Ri = Ro × Vb × (1/V2’ – 1/V2)
2.2.3.5. Fifth Step
Figure 3
Measurement of V2’
The electrical isolation value Ri (in Ω) divided by the working voltage of the high voltage bus
(in Volts) results in the isolation resistance (in Ω/V).
Note: The standard known resistance Ro (in Ω) should be the value of the minimum
required isolation resistance (in Ω/V) multiplied by the working voltage of the vehicle
plus/minus 20% (in volts). Ro is not required to be precisely this value since the equations
are valid for any Ro; however, a Ro value in this range should provide good resolution for
the voltage measurements.

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 (e.g. 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
can be measured separately by applying at least half of their own working voltage with those
component disconnected.
1.2. Measurement Method using the Tested-Device as DC Voltage Source
1.2.1. Test Conditions
The voltage level of the tested-device throughout the test shall be at least the nominal
operating voltage of the tested-device.
1.2.2. Measurement Instrument
The voltmeter used in this test shall measure DC values and shall have an internal
resistance of at least 10MΩ.
1.2.3 Measurement Method
1.2.3.1. First Step
The voltage is measured as shown in Figure 1 and the operating voltage of the testeddevice
(Vb, Figure 1) is recorded. Vb shall be equal to or greater than the nominal operating
voltage of the tested-device.
Figure 1

Figure 3
1.2.3.5. Fifth Step
The electrical isolation value Ri (in Ω) divided by the nominal voltage of the tested-device (in
Volts) results in the isolation resistance (in Ω/V).
Note 1: The standard known resistance Ro (in Ω) should be the value of the minimum
required isolation resistance (in Ω/V) multiplied by the nominal voltage of the tested-device
plus/minus 20% (in volts). Ro is not required to be precisely this value since the equations
are valid for any Ro; however, a Ro value in this range should provide good resolution for
the voltage measurements.

ANNEX 6 - PART 1
ESSENTIAL CHARACTERISTICS OF ROAD VEHICLES OR SYSTEMS
1. GENERAL
1.1. Mark (trade name of manufacturer): .....................................................................................
1.2. Type: .....................................................................................................................................
1.3. Vehicle category: ..................................................................................................................
1.4. Commercial name(s) if available: .........................................................................................
..............................................................................................................................................
1.5. Manufacturer's name and address: ......................................................................................
..............................................................................................................................................
1.6. If applicable, name and address of manufacturer's representative: .....................................
1.7. Drawing and/or photograph of the vehicle: ...........................................................................
1.8. Approval number of the REESS: ..........................................................................................
1.9. Passenger compartment: Yes/No: ....................................................................................
1.10. Centre and/or side stand: Yes/No ......................................................................................
2. ELECTRIC MOTOR (TRACTION MOTOR)
2.1. Type (winding, excitation): ....................................................................................................
2.2. Maximum net power and / or maximum 30min power (kW): ................................................
3. REESS
3.1. Trade name and mark of the REESS: ..................................................................................
3.2. Indication of all types of cells: ...............................................................................................
3.2.1. The cell chemistry: ................................................................................................................
3.2.2. Physical dimensions: ...........................................................................................................
3.2.3. Capacity of the cell (Ah): .......................................................................................................

6. POWER WIRING HARNESS
6.1. Type: .....................................................................................................................................
7. PROTECTION AGAINST ELECTRIC SHOCK
7.1. Description of the protection concept: ..................................................................................
8. ADDITIONAL DATA
8.1. Brief description of the power circuit components installation or drawings/pictures
showing the location of the power circuit components installation: ......................................
8.2. Schematic diagram of all electrical functions included in power circuit: ...............................
8.3. Working voltage (V): .............................................................................................................
8.4. System descriptions for low performance driving mode(s) ..................................................
8.4.1. Systems’ SOC level(s) for which power reduction is activated, descriptions,
rationales .............................................................................................................................
8.4.2. Descriptions for systems’ reduced power mode(s) and similar mode(s),
rationales ..............................................................................................................................
..............................................................................................................................................

ANNEX 6 - PART 3
ESSENTIAL CHARACTERISTICS OF ROAD VEHICLES OR SYSTEMS WITH CHASSIS
CONNECTED TO ELECTRICAL CIRCUITS
1. GENERAL
1.1. Mark (trade name of manufacturer): ..........................................................................................
1.2. Type: ..........................................................................................................................................
1.3. Vehicle category: ........................................................................................................................
1.4. Commercial name(s) if available: ...............................................................................................
1.5. Manufacturer's name and address: ...........................................................................................
...................................................................................................................................................
1.6. If applicable, name and address of manufacturer's representative: ..........................................
...................................................................................................................................................
1.7. Drawing and/or photograph of the vehicle: ................................................................................
1.8. Approval number of the REESS: ...............................................................................................
1.9. Passenger compartment: Yes/No: ..........................................................................................
1.10. Centre and/or side stand: Yes/No: ..........................................................................................
2. REESS
2.1. Trade name and mark of the REESS: .......................................................................................
2.2. The cell chemistry: .....................................................................................................................
2.3. Electrical specification:
2.3.1. Nominal voltage (V):...................................................................................................................
2.3.2. Rated capacity (Ah):...................................................................................................................
2.3.3. Maximum current (A):.................................................................................................................
2.4. Gas combination rate (in %): .....................................................................................................
2.5. Description or drawing(s) or picture(s) of the installation of the RESSS in the vehicle:
...................................................................................................................................................

ANNEX 7
DETERMINATION OF HYDROGEN EMISSIONS DURING THE CHARGE PROCEDURES
OF THE REESS
1. INTRODUCTION
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. 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 gas-tight 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.
4.2. Analytical Systems
4.2.1. Hydrogen Analyser
4.2.1.1. 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.
4.2.1.2. 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.
4.2.1.3. 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.
4.2.1.4. The operational ranges of the analyser shall be chosen to give best resolution over the
measurement, calibration and leak checking procedures.

4.6. Fans
4.7. 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.
4.7.1. The following pure gases shall be available for calibration and operation:
(a)
(b)
Purified synthetic air (purity < 1ppm C equivalent; < 1ppm CO; < 400ppm
CO ; < 0.1ppm NO ); oxygen content between 18 and 21% by volume,
Hydrogen (H ), 99.5% minimum purity.
4.7.2. 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 two minutes 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 + 5h, 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 two minutes 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

T
× P







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 is the initial reading
f is the final reading
6.1.
Results of Test
The hydrogen mass emissions for the REESS are:
M
=
hydrogen mass emission for normal charge test, in grams
M
=
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 4h.
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 ± 2K, 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 five minutes 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.

3.3. The calibration curve shall not differ by more than 2% from the nominal value of each
calibration gas.
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
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.

Table 1
Frequency and Acceleration
(Gross Mass of Tested-Device less than 12kg)
Frequency [Hz] Acceleration [m/s ]
7 – 18 10
18 - approximately 50 gradually increased from 10 to 80
50 – 200 80
Table 2
Frequency and Acceleration
(Gross Mass of Tested-Device of 12kg or more)
Frequency [Hz] Acceleration [m/s ]
7 – 18 10
18 - approximately 25 gradually increased from 10 to 20
25 – 200 20

ANNEX 8C
MECHANICAL DROP TEST FOR REMOVABLE REESS
1. PURPOSE
Simulates a mechanical impact load which may occur at an unintended drop after
REESS removal.
2. PROCEDURES
2.1. General Test Conditions
The following conditions shall apply to the removed REESS at the start of the test:
(a) Adjust the SOC to at least 90% of the rated capacity as specified in the Annex 6
Part 1, Paragraph 3.4.3. or Annex 6 Part 2 Paragraph 1.4.3. or Annex 6 Part 3
Paragraph 2.3.2.
(b) The test shall be performed at 20°C ± 10°C
2.2. Test Procedure
Free fall of the removed REESS from a height of 1.0m (from bottom of the REESS) to a
smooth, horizontal concrete pad or other flooring type with equivalent hardness.
The removed REESS shall be dropped six times from different orientations as decided
by the Technical Service. The manufacturer may decide to use a different removed
REESS for each drop.
Directly after the termination of the drop test a standard cycle as described in Annex 8,
Appendix 1 shall be conducted, if not inhibited.
The test shall end with an observation period of 1h at the ambient temperature
conditions of the test environment.

For both the tested-device shall be subjected to three shocks in the positive direction
followed by three shocks in the negative direction of each three mutually perpendicular
mounting positions of the tested-device for a total of 18 shocks.
Directly after the termination of the mechanical shock test a standard cycle as described
in Annex 8, Appendix 1 shall be conducted, if not inhibited.
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 2.5 km/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)
Figure 3
Phase C: Indirect Exposure to Flame
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)
The test shall be conducted at a ambient temperature of 20°C ± 10°C or at higher
temperature if requested by the manufacturer;
(b) At the beginning of the test, the SOC shall be adjusted to a value in the upper 50%
of the normal operating SOC range;
(c)
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 1h.

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°C ± 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°C ± 10°C or at higher
temperature if requested by the manufacturer;
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.

ANNEX 8I
OVER-TEMPERATURE PROTECTION
1. PURPOSE
The purpose of this test is to verify the performance of the protection measures of the
REESS against internal overheating during the operation, even under the failure of the
cooling function if applicable. In the case that no specific protection measures are
necessary to prevent the REESS from reaching an unsafe state due to internal overtemperature,
this safe operation must be demonstrated.
2. INSTALLATIONS
2.1. The following test shall be conducted with the complete REESS (maybe as 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.
2.2. Where a REESS is fitted with a cooling function and where the REESS will remain
functional without a cooling function system being operational, the cooling system shall
be deactivated for the test.
2.3. The temperature of the tested-device shall be continuously measured inside the casing
in the proximity of the cells during the test in order to monitor the changes of the
temperature. The on-board sensor if existing may be used. The manufacturer and
Technical Service shall agree on the location of the temperature sensor(s) used.
3. PROCEDURES
3.1. At the beginning of the test, all protection devices which affect the function of the testeddevice
and are relevant to the outcome of the test shall be operational, except for any
system deactivation implemented in accordance with Paragraph 2.2. above.
3.2. During the test, the tested-device shall be continuously charged and discharged with a
steady current that will increase the temperature of cells as rapidly as possible within the
range of normal operation as defined by the manufacturer.
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.

ANNEX 9A
WITHSTAND VOLTAGE TEST
1. GENERAL
2. PROCEDURE
Insulation resistance shall be measured after application of the test voltage to the vehicle
with the on-board (built-in) charger.
The following testing procedure shall be applicable to vehicles with on-board (built-in)
chargers:
between all the inputs of the charger (plug) and the vehicle’s exposed conductive parts
including the electrical chassis if present, apply a AC test voltage of
2 × (Un + 1,200)V rms at a frequency of 50Hz or 60Hz for one minute, where Un is the
AC input voltage (rms);
the test shall be performed on the complete vehicle;
all the electrical devices shall be connected.
Instead of the specified AC voltage, the DC voltage whose value is equivalent to the
specified AC voltage’s peak value may be applied for one minute.
After the test, measure the insulation resistance when applying 500V D.C. between all
the inputs and the vehicle’s exposed conductive parts including the electrical chassis if
present.

Approval of Category L Vehicles with Electric Power Train - Proposal.