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UN 38.3 Testing
Nearly all lithium batteries are required to pass section 38.3 of the UN Manual of Tests and Criteria, to ensure the safety of lithium batteries during shipping. UN/DOT 38.3 Transportation Testing for Lithium Batteries 5th edition was issued in 2009, with Amendment 1 in 2011.
It includes eight sections:
1, Altitude Simulation
This is low pressure testing that simulates unpressurized airplane space (cargo area) at 15,000 meter altitude. After storing batteries at 11.6kPa for >6 hours, these criteria shall be met: no mass loss, leaking, venting, disassembly, rupture or fire, and voltage within 10% of pre-test voltage.
2, Thermal Test
This test covers changes in temperature extremes from -40°C to +75°C. Batteries are stored for 6 hours at -40°C (12 hours for large cells/batteries), then 6 hours at +75°C (12 hours for large cells/batteries), for a total of 10 cycles. Testing may be performed in a single chamber or thermal shock chamber, but less than 30 minute transitions shall be used. Same pass criteria as 1.
3, Vibration
This test simulates vibration during transportation. Test is a Sine Sweep: 7Hz – 200Hz – 7Hz in 15 Minutes; 12 Sweeps (3 hours); 3 mutually perpendicular axes. Same pass criteria as 1.
4, Shock
This test also simulates vibration during transportation. Test is a Half-Sine pulse: 150G/6ms for small cells/batteries; 50G/11ms for large cells/batteries; 3 pulses per direction; 6 directions (+/-z, +/-x, +/-y). Same pass criteria as 1.
5, External Short Circuit
This test simulates an external short to the terminals of the cell or battery. At temperature of +55°C, apply short circuit (<0.1ohm) across terminals. Maintain at least an hour after sample temperature returns to +55 +/-2°C. Pass criteria are: Case temperature does not exceed +170°C and no disassembly, rupture, or fire within 6 hours of test. Fuse, current limiting circuit, and venting mechanism activation are allowable.
6, Impact
This test is only applicable to primary and secondary cells. For cylindrical cells >20mm diameter, it simulates impact to case of cell. For cylindrical cells <20mm diameter and all other cell constructions, it simulates crushing of a cell. Pass criteria for any type is: Case temperature does not exceed +170°C & no disassembly or fire within 6 hours of test.
7, Overcharge
This test is for secondary or rechargeable batteries only. It simulates an overcharge condition on a rechargeable battery: 2x the manufacturer’s recommended charge current for 24 hours. Then battery shall be monitored for 7 days for fire or disassembly.
8, Forced Discharge
This testing simulates a forced discharge condition for primary and secondary cells only. Same pass criteria as 7.
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