ATTC Technology Sharing丨ECE UN R100 Single Product Certification Requirements Interpretation - Zhejiang ATTC Automotive Technology Service Co., Ltd

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ATTC Technology Sharing丨ECE UN R100 Single Product Certification Requirements Interpretation

2025-08-18 10:55:13

As the core standard of the European Union for the electrical safety of electric vehicles, the ECE R100 regulation is of irreplaceable importance to the development of the industry and consumer protection. As a mandatory entry condition for the EU market, ECE R100 has become an important reference for global electric vehicle safety standards. Battery safety standards in China, Japan, and other countries (such as GB 38031) have borrowed from their frameworks to help companies reduce cross-border compliance costs. The previous article interpreted the requirements of the whole vehicle, and this article interpreted the single product certification of the European standard regulation R100 electrical safety, hoping to help you with the certification work.

Single product certification definition

Standard cycle: The standard cycle consists of a standard discharge and a standard charge.

Standard Discharge: The discharge procedure, including termination standards, should be defined by the manufacturer. If not specified, the discharge current should be 1C.

Discharge limit (termination voltage): specified by the manufacturer.

Rest period after discharge: minimum 30 minutes.

Standard Charging: The charging procedure, including termination standards, should be defined by the manufacturer. If not specified, the charge current should be C/3.

Testing requirements

1. Vibration test

The ambient temperature is 20±10°C; At the beginning of the test, the SOC of the tested equipment should be more than 50%. At the beginning of the test, all protective devices related to the test results that affect the functionality of the device under test should be operated.

The device under test should withstand vibration from the sinusoidal waveform, with a logarithmic scan between 7Hz and 50Hz and return 7Hz within 15 minutes. The cycle should be repeated 12 times in the vertical direction of the REESS installation as specified by the manufacturer for a total of 3 hours.

Relationship between frequency and acceleration:

During the test, the following must not be present:

electrolyte leakage;
Rupture (only for high-pressure REESS);
Fire;
explode

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V.

Depending on the manufacturer's requirements, greater acceleration can be used, as well as higher maximum frequencies.

After vibration, standard discharge and standard charging (if not hindered by the device under test) should be carried out, with a minimum of 30 minutes of rest after discharge.

The test should end with a 1-hour observation period at the test ambient temperature.

2. Thermal shock and cyclic testing

The device under test should be stored at a test temperature equal to or equal to 60±2°C or higher (if required by the manufacturer) for at least 6 hours, and then stored at a test temperature equal to -40±2°C or lower (if required by the manufacturer) for at least 6 hours. The maximum interval between test temperature limits should be 30 minutes (this is important, as it requires a higher environmental chamber). The procedure should be repeated until at least 5 cycles have been completed, after which the device under test should be stored at an ambient temperature of 20±10°C for 24 hours.

After 24 hours of storage, standard discharge and standard charging should be performed (if not hindered by the device under test)

The test should end with a 1-hour observation period at the test ambient temperature.

During the test, the following must not be present:

electrolyte leakage;
Rupture (only for high-pressure REESS);
Fire;
Explode;

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V.

3. Mechanical impact

(Vehicle-based or component-based tests or any combination of the two, depending on the manufacturer's choice, can be performed for different driving directions)

a. Component-based testing

The equipment under test shall be decelerated or accelerated according to the acceleration channels specified in Tables 1 to 3 (at the applicant's choice). The technical service department should consult with the manufacturer to decide whether to conduct the test in the positive or negative direction, or both.

For each specific test pulse, a separate device under test can be used. The test pulse should be within the minimum and maximum values specified in Table 1 to Table 3. If recommended by the manufacturer, the higher shock levels and/or longer durations described in the maximum values in Table 1 to Table 3 may be applied to the device under test. The test should end with a 1-hour observation period at the test ambient temperature.

After a component-based test, the device under test should be secured by a bracket and its components should remain within its boundaries.

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test.

b. Vehicle-based testing

According to the provisions of Annex 3 of Regulation No. 12 or Annex 3 of Regulation No. 94 (frontal collision) and Annex 4 of Regulation No. 95 (side impact), REESS installed on vehicles subjected to vehicle crash tests can be certified. The ambient temperature and SOC should comply with the regulations.

Question: If an M1 SUV has a maximum full load mass of 2760 and the height of the R-point horizontal ground of the lowest seat on the car is 722mm, would you recommend that they do it based on the vehicle or the parts?

After carrying out vehicle-based testing, REESS located in the passenger compartment must remain in the installation position, while REESS components should remain within REESS boundaries. No part of any REESS located outside the passenger compartment is allowed to enter the passenger compartment during or after the crash test.

If necessary, an appropriate coating should be applied to the physical protection device (housing) to confirm whether the crash test caused the REESS electrolyte to leak. Unless the manufacturer provides a way to distinguish between different liquid leaks, all liquid leaks should be treated as electrolytes.

During the test, the following must not be present:

Fire;
Explode;
Electrolyte leakage

(Vehicle-based testing) a. No electrolyte should spill from REESS into the passenger compartment from the start of the impact to 30 minutes after the impact.

(Component-based testing) b. The volume of REESS electrolyte leaking from REESS to the outside of the passenger compartment must not exceed 7% of the volume (also not more than 5 liters for open traction batteries)

For high-voltage REESS, the insulation resistance of the entire REESS measured after the test should be at least 100 Ω/V, or it should meet the protection class IPXXB of the test device

Mechanical integrity

(Vehicle-specific or component-based testing can be performed depending on the manufacturer's choice)

This test is only applicable to REESS intended for installation on M1 and N1 class vehicles.

Vehicle-specific testing (vehicle-based dynamic testing or vehicle-specific component testing, or any combination of both, depending on the manufacturer's choice, for different directions of travel)

When REESS is installed between a straight line perpendicular to the center line of the vehicle from the trailing edge of the vehicle and a straight line forward and parallel to the line 300 mm, the manufacturer shall certify the mechanical integrity performance of REESS in the vehicle to the technical service department at the following locations.

a. Vehicle-based dynamic testing

b. Vehicle-specific component testing

The manufacturer can decide on the replacement crush force based on actual crash tests or simulation data, in the direction of travel in the direction of travel according to Annex 3 or Annex 94 of Regulation No. 12 and Annex 4 of Regulation 95, perpendicular to the direction of travel.

c. Vehicle-specific component testing/component-based testing

The ambient temperature is 20±10°C; At the beginning of the test, the SOC of the tested equipment should be more than 50%. At the beginning of the test, all internal and external protection devices related to the test results that affect the functionality of the device under test should be operated.

Unless otherwise specified, a force of at least 100 kN, but not more than 105 kN, should be used to squeeze the device under test between the resistance plate and the extrusion plate shown in Figure 1. It has a start time of less than 3 minutes and a hold time of at least 100 ms but not more than 10 s.

Higher extrusion forces, longer starting times, longer holding times, or a combination of these factors can be applied at the manufacturer's request.

The application of force should be determined by the manufacturer in conjunction with the technical service, taking into account the direction of travel of the REESS in relation to which it is installed on the vehicle. Force is applied horizontally and perpendicular to the direction of travel of the REESS.

The test should end with a 1-hour observation period at the test ambient temperature.

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test.

Extrusion plate size: 600 mm x 600 mm or less

REESS should be installed in a position between two planes; (a) Perpendicular plane perpendicular to the center line of the vehicle, located 420 mm behind the front edge of the vehicle; and (b) a vertical plane perpendicular to the centerline of the vehicle, 300 mm forward to the rear edge of the vehicle.

During the test, the following must not be present:

Fire;
Explode;
Electrolyte leakage

(Vehicle-based testing) a. No electrolyte shall spill from REESS into the passenger compartment from the start of the impact to 30 minutes after the impact.

(Component-based testing) b. The volume of REESS electrolyte leaking from REESS to the outside of the passenger compartment must not exceed 7% of the volume (nor 5 liters for open traction batteries);

For high-voltage REESS, the insulation resistance of the entire REESS measured after the test should be at least 100Ω/V, or the protection level of the test device should be IPXXB;

Used to confirm that the electrolyte leak is in compliance and, if necessary, an appropriate coating should be applied to the physical protection device (housing) to confirm whether the crash test caused the REESS electrolyte leak. Unless the manufacturer provides a way to distinguish between different liquid leaks, all liquid leaks should be treated as electrolytes.

5. Fire resistance (for REESS containing flammable electrolyte, this test is required)

This test is not required if the REESS lower shell is more than 1.5 meters above the ground

The test temperature is at least 0°C; At the beginning of the test, the SOC of the tested equipment should be more than 50%. At the beginning of the test, all protective devices related to the test results that affect the functionality of the device under test should be operated.

The device under test should be placed on the grille table above the disk as the manufacturer intended. The grille table should be built with steel strips with a diameter of 6-10mm and a spacing of 4-6cm. If required, the steel bar can be supported by flat steel parts. (Component-based testing)

The test equipment should be installed in a test fixture that simulates actual installation conditions as much as possible. No flammable materials other than those that are part of the REESS must not be used. The method of fixing the device under test in the fixture should comply with the relevant specifications for its installation on the vehicle. (Vehicle-based testing)

The flame in contact with the device under test should be obtained by burning commercial fuel used in the positive ignition engine (hereinafter referred to as "fuel") in the disc. The amount of fuel should be sufficient for the flame to burn throughout the test under free combustion conditions.

Throughout the fire, the fire should cover the entire area of the disc. The size of the disc should be selected to ensure that the sides of the device under test are exposed to the flame. Therefore, the disc should exceed the horizontal projection of the device under test by at least 20 cm, but not more than 50 cm (this distance also needs to be measured). At the beginning of the test, the side wall of the disc should not protrude more than 8 cm above the liquid level height.

The tray containing the fuel should be placed under the equipment under test in such a way that the distance between the fuel level in the tray and the bottom of the device under test is approximately 50 cm (note that this distance should be measured before testing). The disc or the test fixture, or both, can be moved freely.

During phase C of the test (lasting 60s), the disc should be covered with a partition. The partition should be placed 3 cm ±1 cm above the liquid level height measured before the fuel ignites. The partition should be made of refractory material. There should be no gaps between the bricks, and they should be supported on the fuel pan in a way that does not block the brick holes. The length and width of the frame should be 2 to 4 cm smaller than the internal dimensions of the disc so that there is a gap of 1 to 2 cm between the frame and the walls of the disc for ventilation. The partition should be at least ambient temperature before testing. To ensure repeatable test conditions, the refractory bricks can be wetted.

If the test is conducted in the open air, sufficient wind protection facilities should be provided, and the wind speed on the disk should not exceed 2.5 km/h. During the test, the tested equipment must not explode.

If the temperature of the fuel is at least 20°C, the test should include three stages B-D, otherwise the test should include four stages A-D.

Stage A: Warm-up

The fuel in the tray should be ignited at least 3 meters away from the equipment under test. After 60 seconds of warm-up, the disk should be placed under the device under test. If the size of the disc is too large to move without the risk of liquid spillage, the device under test and the test bench can be moved to the disc.

Stage B: Direct exposure to fire

The device under test should be exposed to flames in free-burning fuel for 70 seconds.

Stage C: Indirect exposure to fire, burn for 70 seconds

Phase D: End of trial

The combustion pan covered with a partition should be moved back to the position described in stage A. The device under test shall not be extinguished. After removing the disk, the device under test should be observed until the surface temperature of the device under test drops to ambient temperature or decreases for at least 3 hours.

耐火性: (Seger cone) SK 30

Alumina content: 30 - 33 %

Po opening: 20 - 22 % volume.

Density: 1900 - 2000 kg/m3

Effective Opening Area: 44.18 %

6. External short circuit protection

Ambient temperature of 20±10°C or higher (as required by the manufacturer); At the beginning of the test, the SOC of the tested equipment should be more than 50%. At the beginning of the test, all protective devices related to the test results that affect the functionality of the device under test should be operated.

At the beginning of the trial, all relevant main contactors for charging and discharging should be closed to indicate possible active drive modes as well as modes for achieving external charging. If one test cannot be completed, two or more tests should be performed.

The positive and negative electrodes of the device under test should be connected to each other to create a short circuit. The connection resistance used for this purpose should not exceed 5mΩ (short-circuit resistance needs to be recorded).

The short-circuit condition should continue until the operation of the REESS interruption or short-circuit current limiting protection function is confirmed, or at least one hour after the temperature measured on the test device enclosure is stable, so that the temperature gradient change is less than 4°C within 1 hour.

After the short circuit is terminated, standard discharge and standard charging (if not hindered by the device under test) should be performed

The test should end with a 1-hour observation period at the test ambient temperature.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V

During the test, the following must not be present:

electrolyte leakage;
rupture (only applicable to a high-pressure REESS);
Fire;
explode

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test

7. Overcharge protection

Ambient temperature of 20±10°C or higher (as required by the manufacturer); At the beginning of the test, all protective devices related to the test results that affect the functionality of the device under test should be operated.

At the beginning, all main contactors used for charging should be closed.

The charge control limit of the test equipment should be disabled.

The device under test should be charged at least 1/3C of the charging current, but not more than the maximum current within the normal operating range specified by the manufacturer.

Charging should continue until the device under test (automatically) interrupts or limits charging. If the auto-interrupt function does not work, or if there is no auto-interrupt function, charging should continue until the device under test is charged to twice its rated capacity.

After the charge is terminated, standard discharge and standard charging should be performed (if not hindered by the device under test)

The test should end with a 1-hour observation period at the test ambient temperature.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V

During the test, the following must not be present:

electrolyte leakage;
Rupture (only for high-pressure REESS);
Fire;
explode

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test

8. Over-discharge protection

All relevant main contactors should be closed at the start of the test.

Discharge should be carried out at a rate of at least 1/3C, but not more than the maximum current within the normal operating range specified by the manufacturer.

The discharge should continue until the device under test (automatically) interrupts or limits the discharge. If the auto-interrupt function does not work, or there is no auto-interrupt function, the discharge should continue until the device under test is discharged to 25% of its rated voltage.

After the discharge is terminated, the device under test should be charged as standard (if not hindered by the device under test)

The test should end with a 1-hour observation period at the test ambient temperature.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V

During the test, the following must not be present:

electrolyte leakage;
Rupture (only for high-pressure REESS);
Fire;
explode

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test

9. Over-temperature protection

If the REESS is equipped with cooling and the REESS is still functioning properly when the cooling system is not working, the cooling system should be deactivated during the test.

During the test, the temperature of the device under test should be continuously measured in the enclosure near the battery to monitor temperature changes. On-board sensors (if any) can be used. The manufacturer and technical service should agree on the location of the temperature sensor to be used.

At the beginning of the test, all protective devices related to the test results that affect the functionality of the device under test should be operated, except for the deactivated cooling system.

During the test, the device under test should be continuously charged and discharged using a stable current, which will raise the battery temperature as soon as possible within the normal operating range specified by the manufacturer.

The equipment under test should be placed in a convection oven or environmental test chamber. The temperature of the test chamber or oven should be gradually increased until it reaches the temperature applicable to both of the following cases, and then maintained at a temperature equal to or higher than this until the end of the test.

a. If the REESS is equipped with safeguards against internal overheating, the temperature should be raised to the temperature of the operating temperature limits of such safeguards as defined by the manufacturer to ensure that the temperature of the device under test will be raised as specified.

b. If the REESS is not equipped with any specific measures to prevent internal overheating, the temperature should be increased to the maximum operating temperature specified by the manufacturer.

The trial will end when one of the following is observed: (a) the device under test prohibits and/or restricts charging and/or discharging to prevent temperature escalation; (b) The temperature of the device under test is stable, which means that the temperature gradient changes less than 4°C in 2 hours; (c) fails to meet the acceptance criteria set forth on the next page.

During the test, the following must not be present:

electrolyte leakage;
Rupture (only for high-pressure REESS);
Fire;
explode

Evidence of electrolyte leakage should be verified by visual inspection without disassembling any part of the device under test.

For high-voltage REESS, the insulation resistance measured after the test must not be less than 100Ω/V

Electric vehicle power batteries are an important part of it, and the safety of batteries has become the focus of national regulations, and the product needs to carry out multiple tests such as vibration, thermal shock, fire resistance, etc. for ECE R100 certification, and the product must meet the above items to pass the certification, so manufacturers should strictly comply with the regulations when manufacturing to avoid the difficulty of passing the certification after product production.

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