For lithium ion batteries, there are three standards that are tested the most often: UN/DOT 38.3 5th revision, IEC 62133 2nd Edition, and UL 2054 2nd Edition. UN/DOT 38.3 is a self-certifying standard that presents a combination of significant environmental, mechanical, and electrical stresses, in sequence. They are Altitude Simulation (T.1), Thermal Test (T.2), Vibration (T.3), Shock (T.4), External Short Circuit (T.5), Impact (T.6), Overcharge (T.7) and Forced Discharge (T.8). Some tests are easier to pass than others. The altitude test is the easiest. The vibration test, on the other hand, is intensive and long-running; 3 hours in each of the three cardinal planes, and the T.1-T.5 sequence typically has a negative cumulative effect. IEC 62133 is mandated by many IEC end-device standards and is the de facto standard for international compliance.
UN 38.3 transportation testing is an integral requirement, but does not need to be repeated for certification purposes. The standard includes four tests: Molded Case Stress, External Short Circuit, Free Fall and Overcharging of Battery. Compared to the requirements of UN 38.3, these tests are relatively easy to pass. UL 2054 is a challenging standard involving roughly double the number of tests found in the UN or IEC requirements. Compliance with the requirements of UL 2054 is mandated by a number of U.S. end-device standards. Testing includes: 7 electrical tests, 4 mechanical tests, 4 battery enclosure tests, 1 fire exposure test and 2 environmental tests, with the inclusion of single fault criteria and worst-case operation, the electrical tests are the most challenging. The abusive overcharge test is the most difficult given the overvoltage conditions applied to the faulted pack. Abnormal charge, forced discharge, and two short circuit tests also involve significant risk of failure. For lithium batteries, UL 2054 defers all component cell level testing to UL 1642.
