Regulation No. 136-00

Name:Regulation No. 136-00
Description:Approval of Category L Vehicles with Electric Power Train.
Official Title:Uniform Provisions Concerning the Approval of Vehicles of Category L with Regard to Specific Requirements for the Electric Power Train.
Country:ECE - United Nations
Date of Issue:2016-02-05
Amendment Level:Original
Number of Pages:87
Vehicle Types:Component, Motorcycle
Subject Categories:Electrical and Electronic, Miscellaneous
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Keywords:

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

Text Extract:

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E/ECE/324
) Rev.2/Add.135
E/ECE/TRANS/505 )
February 5, 2016
STATUS OF UNITED NATIONS REGULATION
ECE 136-00
UNIFORM PROVISIONS CONCERNING THE APPROVAL OF
VEHICLES OF CATEGORY L WITH REGARD TO SPECIFIC
REQUIREMENTS FOR THE ELECTRIC POWER TRAIN
Incorporating:
00 series of amendments Date of Entry into Force: 20.01.16

REGULATION NO. 136-00
UNIFORM PROVISIONS CONCERNING THE APPROVAL OF
VEHICLES OF CATEGORY L WITH REGARD TO SPECIFIC
REQUIREMENTS FOR THE ELECTRIC POWER TRAIN
CONTENTS
REGULATION
Contents
1. Scope
2. Definitions
3. Application for approval
4. Approval
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 its 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
Annexes
Annex 1
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. 136
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. 136
Annex 2
Annex 3
Annex 4A
Annex 4B
Arrangements of the approval marks
Protection against direct contacts of parts under voltage
Isolation resistance measurement method for vehicle based tests
Isolation resistance measurement method for component based tests of a REESS

REGULATION NO. 136-00
UNIFORM PROVISIONS CONCERNING THE APPROVAL OF
VEHICLES OF CATEGORY L WITH REGARD TO SPECIFIC
REQUIREMENTS FOR THE ELECTRIC POWER TRAIN
1. SCOPE
This Regulation does not cover post-crash safety requirements of road vehicles.
1.1. Part I: Safety requirements with respect to the electric power train of vehicles of
category L with a maximum design speed exceeding 6km/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.
1.2. Part II: Safety requirements with respect to the Rechargeable Electrical Energy
Storage System (REESS) of vehicles of category L with a maximum design
speed exceeding 6km/h, equipped with one or more traction motors operated
by electric power and not permanently connected to the grid.
2. DEFINITIONS
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.
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. "Basic insulation" means insulation applied to live parts for protection against direct
contact under fault-free conditions.
2.4. "Cell" means a single encased electrochemical unit containing one positive and one
negative electrode which exhibits a voltage differential across its two terminals.
2.5. "Chassis connected to the electric circuit" means AC and DC electric circuits
galvanically connected to the electrical chassis.

2.22. "Flammable electrolyte" means an electrolyte that contains substances classified as
Class 3 "flammable liquid" under "UN Recommendations on the Transport of Dangerous
Goods – Model Regulations (Revision 17 from June 2011), Volume I, Chapter 2.3"
2.23. "High voltage bus" means the electrical circuit, including the coupling system for
charging the REESS that operates on high voltage.
Where electrical circuits, that are galvanically connected to each other, are galvanically
connected to the electrical chassis and the maximum voltage between any live part and
the electrical chassis or any exposed conductive part is ≤30V AC and ≤60V DC, only the
components or parts of the electric circuit that operate on high voltage are classified as a
high voltage bus.
2.24. "Indirect contact" means the contact of persons with exposed conductive parts.
2.25. "Live parts" means the conductive part(s) intended to be electrically energized in
normal use.
2.26. "Luggage compartment" means the enclosed space in the vehicle intended for
luggage accommodation.
2.27. "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.
2.28. "Onboard isolation resistance monitoring system" means the device which monitors
the isolation resistance between the high voltage buses and the electrical chassis.
2.29. "Open type traction battery" means a liquid type battery requiring refilling with water
and generating hydrogen gas released to the atmosphere.
2.30. "Passenger compartment" means the space for occupant accommodation, bounded
by at least 4 of the following: 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.
2.31. "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.
2.32. "Rechargeable Electrical Energy Storage System (REESS)" means the rechargeable
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.
2.33. "Reinforced insulation" means insulation of live parts for protection against electric
shock equivalent to double insulation. Insulation may compromise several layers which
cannot be tested individually as supplementary or basic insulation.

2.45. "Working voltage" means the highest value of an electrical circuit voltage rms,
specified by the manufacturer, which may occur between any conductive parts in open
circuit conditions or under normal operating condition. If the electrical circuit is divided by
galvanic isolation, the working voltage is defined for each divided circuit, respectively.
3. APPLICATION FOR APPROVAL
3.1.
Part I:
Approval of a Vehicle Type with Regard to its Electrical Safety, Including
the High Voltage System
3.1.1. The application for approval of a vehicle type with regard to specific requirements for the
electric power train shall be submitted by the vehicle manufacturer or by his duly
accredited representative.
3.1.2. It shall be accompanied by the below-mentioned documents in triplicate and following
particulars:
3.1.2.1. Detailed description of the vehicle type as regards the electric power train and the
galvanically connected high voltage bus.
3.1.2.2. For vehicles with REESS, additional evidence showing that the REESS is in compliance
with the requirements of Paragraph 6. of 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 their 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.

5. PART I: REQUIREMENTS OF A VEHICLE WITH REGARD TO ITS ELECTRICAL
SAFETY
5.1. Protection Against Electrical Shock
These electrical safety requirements apply to high voltage buses under conditions where
they are not connected to external high voltage power supplies.
5.1.1. Protection Against Direct Contact
Protection against direct contact with high voltage live parts is also required for vehicles
equipped with any REESS type approved under Part II of this Regulation.
The protection against direct contact with the live parts, shall comply with
Paragraphs 5.1.1.1. and 5.1.1.2.
These protections (solid insulator, barrier, enclosure, etc.) shall not be able to be
opened, disassembled or removed without the use of tools.
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. Protection of live parts in areas other than the passenger compartment or luggage
compartment
5.1.1.2.1. For vehicles with a passenger compartment, the protection degree IPXXB shall be
satisfied.
5.1.1.2.2 For vehicles without passenger compartment, the protection degree IPXXD shall be
satisfied.
5.1.1.3. Connectors
Connectors (including vehicle inlet) are deemed to meet this requirement if:
(a)
(b)
(c)
(d)
They comply with 5.1.1.1. and 5.1.1.2. when separated without the use of tools; or
They are located underneath the floor and are provided with a locking mechanism;
or
They are provided with a locking mechanism and other components shall be
removed with the use of tools in order 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 one second after the connector is separated.
5.1.1.4. Service Disconnect
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.

5.1.2.3. In the case of motor vehicles which are intended to be connected to the grounded
external electric power supply through the conductive connection, a device to enable the
galvanical connection of the electrical chassis to the earth ground shall be provided.
The device shall enable connection to the earth ground before exterior voltage is applied
to the vehicle and retain the connection until after the exterior voltage is removed from
the vehicle.
Compliance to this requirement shall be demonstrated either by using the connector
specified by the vehicle manufacturer, or by analysis.
5.1.2.4. The requirement of Paragraph 5.1.2.3. above shall not apply to the vehicles which satisfy
(a) or (b) below:
(a)
The vehicle´s REESS can be charged via the external electric power supply only
by using an off-board charger with a double insulation or reinforced insulation
structure between input and output.
The performance requirements regarding the previously mentioned insulation
structure shall comply with the following requirements of Paragraph 5.1.2.4.1. and
Paragraph 5.1.2.4.3. and stated in its documentation.
(b)
The on-board charger has a double or reinforced insulation structure between
input and the vehicle’s exposed conductive parts/electrical chassis.
The performance requirements regarding the previously mentioned insulation
structure shall comply with the following requirements of Paragraphs 5.1.2.4.1.,
5.1.2.4.2., and 5.1.2.4.3.
If both systems are installed (a) and (b) have to be fulfilled.
5.1.2.4.1. Withstand Voltage
5.1.2.4.1.1. For vehicle with on-board charger the test shall be conducted according to Annex 9A to
this Regulation.
5.1.2.4.1.2. Acceptance Criteria
The insulation resistance shall be equal to or greater than 7MΩ when applying 500V DC
between all the inputs connected together and the vehicle’s exposed conductive
parts/electrical chassis.
5.1.2.4.2. Protection against ingress of water
5.1.2.4.2.1. This test shall be conducted according to Annex 9B of this Regulation.
5.1.2.4.2.2. Acceptance Criteria
The insulation resistance shall be equal to or greater than 7MΩ, when applying
500V DC.

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 and the electrical chassis need not be monitored, because
the coupling system for charging is only energized during charging of the REESS.
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 used to charge the REESS
5.2. REESS
For the coupling system (used to charge the REESS and intended to be conductively
connected to the grounded external AC power supply) the isolation resistance shall be at
least 1MΩ when the charger coupler is disconnected. During the measurement, the
REESS may be disconnected.
5.2.1. For a vehicle with a REESS, the requirement of either Paragraph 5.2.1.1. or
Paragraph 5.2.1.2. shall be satisfied.
5.2.1.1. For a REESS which has been type approved in accordance with Part II of this
Regulation, installation shall be in accordance with the instructions provided by the
manufacturer of the REESS, and in conformity with the description provided in Part 2 of
Annex 6 to this Regulation.
5.2.1.2. The REESS shall comply with the respective requirements of Paragraph 6. of this
Regulation.
5.2.2. Accumulation of Gas
Spaces for open type traction batteries that may produce hydrogen gas shall be
equipped with a ventilation fan, a ventilation duct or any other suitable means to prevent
the accumulation of hydrogen gas.
5.2.3. Protection against Electrolyte Spills
Vehicles shall foresee that no spilled electrolyte from the REESS and its components
shall reach the driver, rider or passenger nor any person around the vehicle during
normal condition of use and/or functional operation.
When the REESS is in the upside-down position, no electrolyte shall spill.

5.3.1.4. Driving or Riding Backwards
It shall not be possible to activate the vehicle reverse control function whilst the vehicle is
in forward motion.
5.4. Determination of Hydrogen Emissions
5.4.1. This test shall be carried out on all vehicles equipped with open type traction batteries. If
the REESS has been approved under Part II of this Regulation and installed in
accordance with Paragraph 5.2.1.1., this test can be omitted for the approval of the
vehicle.
5.4.2. The test shall be conducted according to the method in Annex 7 of the present
Regulation. The hydrogen sampling and analysis shall be prescribed. Other analysis
methods can be approved if it is proven that they give equivalent results.
5.4.3. During a normal charge procedure in the conditions given in Annex 7, hydrogen
emissions shall be below 125g during 5h, or below 25 × t g during t (in h).
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. The charger shall limit such a failure
to 30min maximum.
5.4.5. All the operations linked to the REESS charging shall be controlled automatically,
including the stop for charging.
5.4.6. Manual control of the charging phases shall not be possible.
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 shall indicate, the vehicle's conformity in the owner's manual 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 of this Regulation.

(c)
(d)
Fire;
Explosion.
Evidence of electrolyte leakage shall be verified by visual inspection without
disassembling any part of the tested-device.
6.4.1.2.2. 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/V.
6.4.2. Mechanical Shock
6.4.2.1. This test shall apply to vehicles with a centre and/or side stand.
The test shall be conducted in accordance with Annex 8D of this Regulation.
6.4.2.2. Acceptance Criteria
6.4.2.2.1. 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.
6.4.2.2.2. For a high voltage REESS the isolation resistance of the tested-device shall ensure at
least 100Ω/Volt for the whole REESS measured after the test in accordance with
Annex 4B to this Regulation.
6.5. Fire Resistance
This test applies for vehicles with a passenger compartment only.
This test is required for REESS containing flammable electrolyte.
The test shall be carried out on one test sample.
At the manufacturer´s choice the test may be performed as, either:
(a)
(b)
A vehicle based test in accordance with Paragraph 6.5.1. of this Regulation, or
A component based test in accordance with Paragraph 6.5.2. of this Regulation.

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.
6.8. Over-discharge Protection
6.8.1. The test shall be conducted in accordance with Annex 8H to 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.

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;
8.3.2. Have access to the testing equipment necessary for checking the conformity of each
approved type;
8.3.3. Ensure that test result data are recorded and that the annexed documents remain
available for a period to be determined in agreement with the Type Approval Authority;
8.3.4. Analyse the results of each type of test, in order to verify and ensure the consistency of
characteristics of the vehicle or REESS, making allowance for permissible variations in
industrial production;
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.

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. 136
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. 136
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. 136, 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. 136 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. 136, 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. 136 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
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
vehicle-manufacturer, 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 or Table 2. 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 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 DC between all the
inputs and the vehicle’s exposed conductive parts including the electrical chassis if
present.

(v)
(vi)
Test duration per square metre of enclosure surface area likely to be sprayed: 1min;
Minimum test duration: 3min;
(vii) Distance from nozzle to enclosure surface: between 2.5m and 3m.
(b)
Subsequently, apply 500V DC between all high voltage inputs and the vehicle’s
exposed conductive parts/electrical chassis if present to measure the isolation
resistance.
Approval of Category L Vehicles with Electric Power Train.