Certification Requirements for Battery System Compliance to IEEE

Certification Requirements for Battery System Compliance to IEEE
Certification Requirements for Battery
System Compliance to IEEE 1725
December 2015
Revision 2.10
CTIA Certification Program
CTIA Certification Program
1400 16th Street, NW, Suite 600
Washington, DC 20036
E-mail: certification@ctia.org
Telephone: 1.202.785.0081
www.ctia.org/certification
© 2006 CTIA – The Wireless Association®. All rights reserved.
CTIA hereby grants to CTIA Authorized Testing Laboratories (CATLs), and only to CATLs, a limited, non-transferable license to use
this Test Plan for the sole purpose of testing devices for the CTIA Certification Program, and to reproduce this Test Plan for internal use
only. Any other use of this Test Plan must be authorized in writing by CTIA.
Any reproduction or transmission of all or part of this Test Plan, in any form or by any means, electronic or mechanical, including
photocopying, recording, or via any information storage and retrieval system, without the prior written permission of CTIA, is
unauthorized and strictly prohibited.
Any reproduction of this Test Plan shall display the notice: “Copyright by CTIA. All rights reserved.”
TABLE OF CONTENTS
SECTION 1
INTRODUCTION............................................................................................. 1
1.1
PURPOSE....................................................................................................................................................................... 1
1.2
SCOPE .......................................................................................................................................................................... 1
1.3
APPLICABLE DOCUMENTS ............................................................................................................................................... 1
1.4
ACRONYMS AND DEFINITIONS .......................................................................................................................................... 2
SECTION 2
VALIDATION PROCESS ............................................................................... 4
SECTION 3
SYSTEM INTEGRATION VALIDATION ................................................... 5
3.1
SYSTEM INTEGRATION CONSIDERATIONS ......................................................................................................................... 5
3.2
AC SUBSYSTEM REQUIREMENTS ..................................................................................................................................... 5
3.3
DC SUBSYSTEM REQUIREMENTS ..................................................................................................................................... 6
3.4
SUBSYSTEM REQUIREMENTS, TRANSPORT OF DANGEROUS GOODS, BATTERY PACK .......................................................... 6
3.5
SUBSYSTEM REQUIREMENTS, TRANSPORT OF DANGEROUS GOODS, CELL ......................................................................... 6
3.6
SUBSYSTEM REQUIREMENTS, DESTINATION COUNTRY ...................................................................................................... 6
3.7
SUBSYSTEM REQUIREMENTS, UL 1642 OR IEC 62133 (WITH US DEVIATIONS IF APPLICABLE) ............................................. 7
SECTION 4
CELL VALIDATION....................................................................................... 8
4.1
STABILITY ...................................................................................................................................................................... 8
4.2
ISOLATION PROPERTIES .................................................................................................................................................. 8
4.3
STRENGTH AND PHYSICAL INTEGRITY .............................................................................................................................. 8
4.4
SHRINKAGE ALLOWANCE, AMBIENT TEMPERATURE ........................................................................................................... 9
4.5
SHRINKAGE ALLOWANCE, ELEVATED TEMPERATURE ......................................................................................................... 9
4.6
SHRINKAGE ALLOWANCE................................................................................................................................................. 9
4.7
ELECTRODE DESIGN CRITERIA ........................................................................................................................................ 9
4.8
ELECTRODE CAPACITY BALANCE ................................................................................................................................... 10
4.9
ELECTRODE GEOMETRY ............................................................................................................................................... 10
4.10
ELECTRODE GEOMETRY ............................................................................................................................................... 10
4.11
ELECTRODE TABS (CONNECTION TO CELL TERMINALS) .................................................................................................... 10
4.12
APPLICATION OF INSULATION ......................................................................................................................................... 11
4.13
APPLICATION OF INSULATION ......................................................................................................................................... 11
4.14
APPLICATION OF SUPPLEMENTARY INSULATION .............................................................................................................. 11
4.15
INSULATION CHARACTERISTICS ..................................................................................................................................... 12
4.16
CELL VENT MECHANISM ................................................................................................................................................ 12
4.17
RETENTION OF CELL CONTENTS AND PROJECTILE TESTING ............................................................................................. 12
4.18
OVERCURRENT PROTECTION DEVICE............................................................................................................................. 13
4.19
MAXIMUM RECOMMENDED VOLTAGE .............................................................................................................................. 13
4.20
MATERIALS SPECIFICATIONS ......................................................................................................................................... 13
4.21
CLEANLINESS OF MANUFACTURING OPERATIONS ............................................................................................................ 13
4.22
MANUFACTURING TRACEABILITY .................................................................................................................................... 14
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4.23
UNIFORM COATING OF ACTIVE MATERIALS ..................................................................................................................... 14
4.24
BURR CONTROL ........................................................................................................................................................... 14
4.25
BURR CONTROL ........................................................................................................................................................... 15
4.26
PREVENTION OF DAMAGE TO ELECTRODES .................................................................................................................... 15
4.27
CHARACTERISTICS OF MANUFACTURING EQUIPMENT ...................................................................................................... 16
4.28
DEFECTIVE ELECTRODES .............................................................................................................................................. 16
4.29
PREVENTIVE MAINTENANCE PLAN .................................................................................................................................. 16
4.30
TENSION AND DAMAGE ................................................................................................................................................. 16
4.31
COLLECTION OF LOOSE MATERIAL ................................................................................................................................. 17
4.32
DETECTION OF DAMAGED CORES .................................................................................................................................. 17
4.33
CONTROL OF ELECTRODE SPACING ............................................................................................................................... 17
4.34
UNIFORMITY OF INTERNAL ELECTRODE PRESSURE ......................................................................................................... 17
4.35
AVOIDANCE OF CONTAMINANTS ..................................................................................................................................... 18
4.36
INTERNAL SHORT AVOIDANCE ....................................................................................................................................... 18
4.37
INTERNAL SHORT AVOIDANCE ....................................................................................................................................... 18
4.38
TAB POSITIONING ......................................................................................................................................................... 19
4.39
TAB POSITIONING ......................................................................................................................................................... 19
4.40
INTEGRITY OF CELL CORE ASSEMBLY ............................................................................................................................ 19
4.41
POSITIONING OF INSULATING MATERIAL ......................................................................................................................... 19
4.42
POSITIONING OF INSULATING PLATE ............................................................................................................................... 20
4.43
ELECTRODE ALIGNMENT ............................................................................................................................................... 20
4.44
CELL AGING AND VALIDATION OF AGING PROCESS.......................................................................................................... 20
4.45
CELL LEAKAGE ............................................................................................................................................................. 21
4.46
CARE DURING CELL ASSEMBLY ..................................................................................................................................... 21
4.47
QUALIFICATION OF NEW CELL DESIGNS ......................................................................................................................... 21
4.48
QUALIFICATION OF PRODUCTION CELLS ......................................................................................................................... 21
4.49
CELL TRANSPORTATION REGULATIONS .......................................................................................................................... 22
4.50
CELL THERMAL TEST .................................................................................................................................................... 22
4.51
CELL THERMAL TEST .................................................................................................................................................... 22
4.52
EVALUATION OF EXCESS LITHIUM PLATING AND SHORT-CIRCUIT TEST ON CYCLED CELLS ................................................. 22
4.53
EXTERNAL SHORTING OF CELL TERMINALS .................................................................................................................... 23
SECTION 5
BATTERY PACK VALIDATION ................................................................ 27
5.1
TRACEABILITY .............................................................................................................................................................. 27
5.2
PART NUMBER ............................................................................................................................................................. 27
5.3
VOLTAGE ..................................................................................................................................................................... 27
5.4
CHEMISTRY.................................................................................................................................................................. 27
5.5
PACK VENDOR IDENTIFICATION ...................................................................................................................................... 28
5.6
CIRCUIT LAYOUT .......................................................................................................................................................... 28
5.7
CELL POLARITY ............................................................................................................................................................ 28
5.8
AMBIENT THERMAL CONSIDERATION .............................................................................................................................. 28
5.9
COMPONENT SPECIFICATIONS ....................................................................................................................................... 29
5.10
THERMAL CONSIDERATION ............................................................................................................................................ 29
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5.11
LIMIT OUTPUT CURRENT ............................................................................................................................................... 29
5.12
PACK MECHANISMS ...................................................................................................................................................... 30
5.13
THERMAL PROTECTION ................................................................................................................................................. 30
5.14
THERMAL SENSOR DESIGN ........................................................................................................................................... 30
5.15
ACTION, THERMAL PROTECTION .................................................................................................................................... 31
5.16
CHARGING SPECIFICATIONS .......................................................................................................................................... 31
5.17
CHARGE CONSIDERATIONS ........................................................................................................................................... 31
5.18
CHARGER DESIGN ........................................................................................................................................................ 31
5.19
PROTECTION ................................................................................................................................................................ 32
5.20
PROTECTION ................................................................................................................................................................ 32
5.21
SPECIFICATION ............................................................................................................................................................. 32
5.22
PACK OVERCURRENT PROTECTION REQUIREMENT ......................................................................................................... 32
5.23
EXTERNAL MECHANICAL FORCE .................................................................................................................................... 33
5.24
CELL DIMENSIONAL ALLOWANCE ................................................................................................................................... 33
5.25
ELECTRICAL CELL CONNECTIONS .................................................................................................................................. 33
5.26
CELL VENT .................................................................................................................................................................. 33
5.27
HOST REQUIREMENT .................................................................................................................................................... 34
5.28
ESD............................................................................................................................................................................ 34
5.29
WELDING ..................................................................................................................................................................... 34
5.30
CELL SHORTS .............................................................................................................................................................. 34
5.31
FOREIGN OBJECTS ....................................................................................................................................................... 35
5.32
SOLDERING PROCESS .................................................................................................................................................. 35
5.33
REWORKED CELLS ....................................................................................................................................................... 35
5.34
CIRCUIT CARE .............................................................................................................................................................. 35
5.35
PACK COMPONENT CARE .............................................................................................................................................. 36
5.36
WELDING CARE ............................................................................................................................................................ 36
5.37
ESD............................................................................................................................................................................ 36
5.38
PACK TESTING DURING PRODUCTION ............................................................................................................................ 37
5.39
QUALITY CONTROL ....................................................................................................................................................... 37
5.40
CELL CARE .................................................................................................................................................................. 37
5.41
SPECIFICATION ............................................................................................................................................................. 37
5.42
CELL CHEMISTRY ......................................................................................................................................................... 38
5.43
FAULT CONSIDERATIONS............................................................................................................................................... 38
5.44
QUALIFICATION OF NEW PACK DESIGNS ......................................................................................................................... 38
5.45
QUALIFICATION OF PRODUCTION PACKS ........................................................................................................................ 38
5.46
BATTERY TRANSPORTATION REGULATIONS .................................................................................................................... 39
5.47
PACK OVERVOLTAGE PROTECTION, VERIFICATION, AND TESTING .................................................................................... 39
5.48
PACK DROP TEST ......................................................................................................................................................... 39
SECTION 6
HOST DEVICE VALIDATION .................................................................... 44
6.1
INPUT .......................................................................................................................................................................... 44
6.2
INPUT .......................................................................................................................................................................... 44
6.3
OVERVOLTAGE ............................................................................................................................................................. 45
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6.4
OVERCURRENT ............................................................................................................................................................ 45
6.5
OVERCURRENT, FAULTED ............................................................................................................................................. 46
6.6
FAULT ISOLATION AND TOLERANCE ................................................................................................................................ 46
6.7
FAULT ISOLATION AND TOLERANCE ................................................................................................................................ 46
6.8
SAFETY ....................................................................................................................................................................... 46
6.9
PACK IDENTIFICATION ................................................................................................................................................... 47
6.10
PACK IDENTIFICATION ................................................................................................................................................... 47
6.11
ALGORITHM VERIFICATION ............................................................................................................................................ 47
6.12
TIMER FAULT ............................................................................................................................................................... 47
6.13
COMMUNICATION FAULT ............................................................................................................................................... 48
6.14
VOLTAGE RANGE VALIDATION ....................................................................................................................................... 48
6.15
INITIATION OF CHARGING ABOVE SPECIFIED VOLTAGE THRESHOLD .................................................................................. 48
6.16
INITIATION OF CHARGING BELOW VOLTAGE THRESHOLD ................................................................................................. 48
6.17
OVERDISCHARGE PROTECTION ..................................................................................................................................... 49
6.18
CHARGING BATTERY PACKS .......................................................................................................................................... 49
6.19
REQUIREMENTS ........................................................................................................................................................... 49
6.20
ELECTROSTATIC DISCHARGE ......................................................................................................................................... 49
6.21
TEMPERATURE SPECIFICATION ...................................................................................................................................... 50
6.22
MATING OF PINS ........................................................................................................................................................... 50
6.23
MATING OF PINS ........................................................................................................................................................... 50
6.24
PIN SEPARATION .......................................................................................................................................................... 50
6.25
PIN POLARITY .............................................................................................................................................................. 51
6.26
CONDUCTOR RATINGS .................................................................................................................................................. 51
6.27
CONNECTOR STRENGTH ............................................................................................................................................... 51
6.28
PERFORMANCE OVER EXPECTED LIFE ........................................................................................................................... 51
6.29
METALLURGY CONSIDERATION ...................................................................................................................................... 51
6.30
MATING FORCE ............................................................................................................................................................ 52
6.31
SHOCK ........................................................................................................................................................................ 52
6.32
INTEGRITY OF HOST CHARGING AND CHARGE PROTECTION CIRCUITRY IN THE SYSTEM FOREIGN OBJECTS ........................... 52
6.33
FOREIGN OBJECTS ....................................................................................................................................................... 52
6.34
QUALIFICATION OF NEW HOST DEVICE DESIGNS ............................................................................................................. 53
6.35
QUALIFICATION OF PRODUCTION HOST DEVICES ............................................................................................................ 53
SECTION 7
AC/DC ADAPTER, DC/DC ADAPTER VALIDATION ........................... 58
7.1
ADAPTER ATTRIBUTES .................................................................................................................................................. 58
7.2
ADAPTER AND SAFETY FEATURES ................................................................................................................................. 58
7.3
ADAPTER ESD REQUIREMENTS ..................................................................................................................................... 58
7.4
CONNECTOR DESIGN OF ADAPTER AND HOST AND ADAPTER-HOST RELIABILITY ............................................................... 59
7.5
SEPARATION OF PINS ................................................................................................................................................... 59
7.6
ELECTRICAL COMPLIANCE ............................................................................................................................................. 59
7.7
CURRENT RATINGS....................................................................................................................................................... 60
7.8
PIN METALLURGY ......................................................................................................................................................... 60
7.9
SHOCK ........................................................................................................................................................................ 60
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7.10
ADAPTER AND FOREIGN OBJECTS.................................................................................................................................. 60
7.11
ADAPTER MARKING AND TRACEABILITY REQUIREMENTS .................................................................................................. 60
7.12
CHARGER CONSIDERATIONS (AC/DC CHARGER, DC/DC CHARGER) ............................................................................... 61
7.13
CRITICAL TESTING PRACTICES ...................................................................................................................................... 61
7.14
QUALIFICATION OF NEW ADAPTER DESIGNS ................................................................................................................... 61
7.15
QUALIFICATION OF PRODUCTION ADAPTERS ................................................................................................................... 61
7.16
COMMON POWER SUPPLY (CPS) MINIMUM OUTPUT LOAD CURRENT ............................................................................... 62
7.17
COMMON POWER SUPPLY (CPS) COMMON MODE NOISE MEASUREMENT – AC VOLTAGE COMPONENT ............................. 62
7.18
COMMON POWER SUPPLY (CPS) COMMON MODE NOISE MEASUREMENT – SWITCHING FREQUENCY ................................. 62
7.19
CHARGING PORT REQUIREMENTS – OVERSHOOT ........................................................................................................... 63
7.20
CHARGING PORT REQUIREMENTS – MAXIMUM CURRENT ................................................................................................. 64
7.21
CHARGING PORT REQUIREMENTS – SHUTDOWN OPERATION ........................................................................................... 64
7.22
CHARGING PORT REQUIREMENTS – FAILURE VOLTAGE ................................................................................................... 65
7.23
CHARGING PORT REQUIREMENTS – MULTIPLE PORTS ..................................................................................................... 65
7.24
CHARGING DOWNSTREAM – REQUIRED OPERATING RANGE ............................................................................................ 66
7.25
CHARGING DOWNSTREAM – UNDERSHOOT ..................................................................................................................... 66
7.26
CHARGING DOWNSTREAM – DETECTION SIGNALING ........................................................................................................ 67
7.27
CHARGING DOWNSTREAM – CONNECTOR....................................................................................................................... 68
7.28
DETACHABLE CABLE – VOLTAGE DROP TEST ................................................................................................................. 68
SECTION 8
8.1
TOTAL SYSTEM RELIABILITY VALIDATION .................................... 73
USER INTERACTIONS AND RESPONSIBILITIES .................................................................................................................. 73
SECTION 9
SYSTEM SECURITY VALIDATION ......................................................... 75
9.1
HOST AND BATTERY AUTHENTICATION ........................................................................................................................... 75
9.2
ENSURING SUPPLY CHAIN SECURITY ............................................................................................................................. 75
9.3
AVOIDING DEFECTIVE PARTS......................................................................................................................................... 75
9.4
BATTERY PACK IDENTIFICATION ..................................................................................................................................... 76
SECTION 10
VALIDATION................................................................................................. 77
10.1
COMPONENT REQUIREMENTS ........................................................................................................................................ 77
10.2
RECORD KEEPING ........................................................................................................................................................ 77
10.3
QUALITY SYSTEM REQUIREMENTS ................................................................................................................................. 77
10.4
DEFINITION OF SAFETY CRITICAL VARIABLES .................................................................................................................. 77
10.5
DEFINITION OF CRITICAL MEASUREMENT PROCESSES ..................................................................................................... 78
10.6
CONFIRMATION OF CRITICAL MEASUREMENT PROCESS CAPABILITY ................................................................................. 78
10.7
CONFIRMATION OF PROCESS STABILITY ......................................................................................................................... 78
10.8
CONFIRMATION OF PROCESS CAPABILITY ....................................................................................................................... 79
10.9
PROCESS MONITORING AND REACTION TO OUT-OF-CONTROL EVENTS ............................................................................ 79
10.10
PROCESS IMPROVEMENT ACTIONS ................................................................................................................................ 79
APPENDIX I – ADAPTER SIMULATOR .............................................................................. 80
APPENDIX II – HOST SIMULATOR ..................................................................................... 81
APPENDIX III – CHANGE HISTORY ................................................................................... 82
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Certification Requirements Document
Section 1
1.1
Introduction
Purpose
The purpose of this document is to define the CTIA Certification Program requirements for
validating compliance to the IEEE Std 1725™ 1 -2011 (“IEEE 1725”) Standard for
Rechargeable Batteries for Cellular Telephones.
The process and procedures for battery system validation are described in the CTIA Battery
Program Management Document (BPMD).
The Certification Requirements Status List (CRSL) defines the current status of each
requirement within this document. Refer to the BPMD for further details.
1.2
Scope
This document defines the process to validate each requirement in the IEEE 1725
specification.
1.3
Applicable Documents
The following documents are referenced in this Certification Requirements Document
(CRD). Unless otherwise specified, the latest released version shall be used:
Standard for Rechargeable Batteries for Cellular Telephones, IEEE Std 1725-2011, June
2011, Institute of Electrical and Electronics Engineers, Inc.
CTIA Battery Program Management Document, Latest Revision, CTIA.
UL 1642, Standard for Lithium Batteries.
Recommendations on the Transport of Dangerous Goods, Manual of Tests and Criteria,
Part III, Sub-section 38.3, Fifth Revised Edition, United Nations, New York and Geneva.
UL 2054, Household and Commercial Batteries, Second Edition (with revisions),
September 14, 2011.
IEC 61000-4-2, Electromagnetic Compatibility (EMC) Part 4-2 Testing and measurement
techniques - Electrostatic discharge immunity test.
IEC 61000-4-5, Electromagnetic Compatibility (EMC) Part 4-5: Testing and measurement
techniques - Surge immunity test.
1
IEEE Std 1725 is a registered trademark of the Institute of Electrical and Electronics Engineers, Inc.
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IEC 60068-2-32, Environmental testing. Part 2: Tests. Test Ed: Free fall.
IEC 60068-2-30, Environmental testing. Part 2: Tests. Test Db: Damp heat, cyclic (12 h +
12 h cycle).
IEC 60950-1, Information technology equipment - Safety - Part 1: General requirements.
MIL-STD-810F, Department of Defense Test Method Standard for Environmental
Engineering Considerations and Laboratory Tests.
ANSI/ISO/ASQ-Q9001, Quality Management System – Requirements.
Universal Serial Bus Specification, Revision 2.0, April 27, 2000.
Universal Serial Bus Cables and Connectors Class Document, USB Implementers Forum,
Inc., Revision 2.0, August 2007.
Common Charging and Local Data Connectivity, OMTP Limited, Version 1.1, 8th June
2010.
IEC 62684:2011, Interoperability specifications of common external power supply (EPS)
for use with data-enabled mobile telephones.
Battery Charging Specification, USB Implementers Forum, Inc., Revision 1.2, March 15,
2012.
1.4
Acronyms and Definitions
Ambient Temperature: 20 ± 5 °C
Breaching: Any opening in the cell structure excluding proper vent activation.
BPMD – Battery Program Management Document
C – Rated capacity of a Battery or Cell as defined by IEC 62133 and UL 2054
CRD – Certification Requirements Document
CRSL – Certification Requirements Status List
DOE – Design of Experiment
ESD – Electrostatic Discharge
FMEA – Failure Mode and Effects Analysis
PCM – Protection Circuit Module
PM – Preventive Maintenance
PMD – Program Management Document
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PTC – Positive Temperature Coefficient. Refers to a passive overcurrent protection device
that is technically a resettable conductive polymer-based thermistor. Also known
as a CID (Current Interrupt Device).
SOC – State of Charge based on Coulomb counting. 100% SOC can be achieved by
following the cell vendor’s recommended algorithm.
SOP – Standard Operating Procedure
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Section 2
Validation Process
Compliance of battery systems to the IEEE 1725 standard shall be validated through a
combination of reviewing of evidence, auditing of facilities and processes, and testing of
products. The descriptive fields provided for each line item requirement in the CRSL define the
validation process for each requirement in this CRD. Definitions for these entries are provided
within the CRSL itself.
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Section 3
3.1
System Integration Validation
System Integration Considerations
Reference:
IEEE 1725, Section 4.1
Purpose:
Conduct a system analysis that considers two independent faults.
Procedure:
Review an FMEA or equivalent analysis of the energy storage system, including the
cell, pack, host, charger and accompanying accessories and the interaction between
the subsystems, to determine that hazards (as defined in IEEE1725 clause 3) are
minimized from two independent faults for charge or one fault for discharge or one
fault for system storage.
Compliance: Shall include all of the following:
Documents include all system components as described in the system registration
with CTIA.
Analysis considers a minimum of two independent faults for charge.
Analysis considers a minimum of one independent fault for discharge.
Analysis considers the impact of hazards occurring due to reasonable and
foreseeable misuse.
Analysis identifies end-user responsibilities for reliable total system operation per
Clause 9 of IEEE 1725.
Analysis identifies vendor responsibilities for independent and/or distributed control
schemes for reliable total system operation.
Analysis considers all system usage scenarios to include charge, discharge, and
storage.
Analysis includes the cell, pack, host, adapter, and accompanying accessories that
are a part of the system.
Analysis includes interactions between the subsystems.
3.2
AC Subsystem Requirements
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to IEC 60950-1 or standard of destination country.
Procedure:
Confirm compliance to IEC 60950-1 or standard of destination country.
Compliance: Ensure compliance to electrical safety requirements of the country of destination.
Minimum marking shall be NRTL (Nationally Recognized Testing Laboratory). Refer
to: www.OSHA.gov.
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3.3
DC Subsystem Requirements
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to standard of destination country.
Procedure:
Confirm compliance to standard of destination country.
Compliance: Ensure compliance to electrical safety requirements of the country of destination.
Minimum marking shall be NRTL (Nationally Recognized Testing Laboratory). Refer
to: www.OSHA.gov.
3.4
Subsystem Requirements, Transport of Dangerous Goods, Battery Pack
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to UN Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria.
Procedure:
Review test report confirming compliance to UN Recommendations on the Transport
of Dangerous Goods, Manual of Tests and Criteria.
Compliance: Test report confirming compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists.
3.5
Subsystem Requirements, Transport of Dangerous Goods, Cell
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to UN Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria.
Procedure:
Review test report confirming compliance to UN Recommendations on the Transport
of Dangerous Goods, Manual of Tests and Criteria.
Compliance: Test report confirming compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists.
3.6
Subsystem Requirements, Destination Country
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to standard of destination country.
Procedure:
Confirm compliance to standard of destination country.
Compliance: Vendor declaration of compliance document provided.
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3.7
Subsystem Requirements, UL 1642 or IEC 62133 (With US Deviations if applicable)
Reference:
IEEE 1725, Section 4.2
Purpose:
Ensure compliance to UL 1642 or IEC 62133 (with US deviations if applicable).
Procedure:
Confirm compliance to UL 1642 or IEC 62133 (with US deviations if applicable).
Compliance: Vendor declaration of compliance document provided, including evidence showing
that all tests called for in UL 1642 or IEC 62133 (with US deviations if applicable)
have passed.
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Section 4
4.1
Cell Validation
Stability
Reference:
IEEE 1725, Section 5.2.1.1
Purpose:
To ensure that separator materials have the appropriate properties to meet
expectations of performance and safety.
Procedure:
Review the engineering report for separator selection. Verify that chemical,
electrochemical, thermal, and mechanical properties of the separator have been
addressed.
Compliance: Engineering report contains data that indicates evaluation for chemical,
electrochemical, thermal, and mechanical stability of separator is done.
4.2
Isolation Properties
Reference:
IEEE 1725, Section 5.2.1.3
Purpose:
To ensure that the separator/cell design shall maintain isolation under high
temperature stress conditions for a reasonable period of time to maintain the safety
of the cell.
Procedure:
5 cells at 80% +/- 5%SOC to be placed in oven at ambient temperature. The oven
temperature shall be ramped at 5 ± 2°C per minute to 150 ± 2°C. After 10 minutes at
150 ± 2°C, the test is complete.
Compliance: No fire, smoke, explosion or breaching of the cell is allowed within the first 10
minutes. Venting is permitted.
4.3
Strength and Physical Integrity
Reference:
IEEE 1725, Section 5.2.1.4
Purpose:
To ensure that the design of separator thickness is made through engineering
judgment such that the separator has the requisite strength to ensure cell safety and
robustness to handling.
Procedure:
Review engineering studies, FMEA and design studies.
Compliance: Documentation reviewed supports that the separator has sufficient physical integrity
to withstand handling during the cell manufacturing process and provides adequate
strength in the z direction (normal to the electrode plane) to ensure cell safety
performance.
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4.4
Shrinkage Allowance, Ambient Temperature
Reference:
IEEE 1725, Section 5.2.1.5
Purpose:
To ensure that the separator is designed such that shrinkage characteristics of the
material are taken into account to maintain anode and cathode separation.
Procedure:
Tear down 5 cells and measure separator coverage on each side at ambient
temperature.
Compliance: Measurements shall demonstrate at least 0.1 mm separator coverage on each side
(plus process margin). If less than 0.1 mm overlap is observed, the cell vendor shall
submit supporting safety evidence.
4.5
Shrinkage Allowance, Elevated Temperature
Reference:
IEEE 1725, Section 5.2.1.5
Purpose:
To ensure that the separator is designed such that shrinkage characteristics of the
material are taken into account to maintain anode and cathode separation.
Procedure:
5 cells at 100% SOC shall be placed in an oven at ambient temperature. The oven
temperature shall be ramped at 5 ± 2°C per minute to 110 ± 2°C. After 1 hour at 110
± 2°C, the test is complete. Allow cells to cool down to ambient temperature. Cells
shall be torn down and separator width measured.
Compliance: Width of separator after tear down at ambient temperature shall be larger than the
positive electrode.
4.6
Shrinkage Allowance
Reference:
IEEE 1725, Section 5.2.1.5
Purpose:
To ensure that the separator is designed such that shrinkage characteristics of the
material are taken into account to maintain anode and cathode separation.
Procedure:
Review design analysis and data on separator shrinkage characteristics for 32
samples.
Compliance: Design analysis has been done and analytically verified by the vendor.
Measurement data from the 32 samples shall demonstrate a minimum of 0.1 mm
separator coverage on each side (plus process margin). If less than 0.1 mm overlap
is observed, the cell vendor shall submit supporting safety evidence.
4.7
Electrode Design Criteria
Reference:
IEEE 1725, Section 5.2.2
Purpose:
Electrode design constituents for both the anode and the cathode shall be designed
to assure performance, safety, and durability in the designated application.
Procedure:
Verify the design validation report for electrodes design.
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Compliance: Design validation report for electrodes design is available that specifies material
content and purity. Design validation report has evidence that indicates
environmental factors such as temperature and relative humidity appropriate for the
designated application are considered.
4.8
Electrode Capacity Balance
Reference:
IEEE 1725, Section 5.2.3
Purpose:
To ensure that the charge capacity of the electrodes are properly balanced.
Procedure:
Verify the engineering report for capacity (mAh/cm2) of the anode and cathode
electrodes.
Compliance: The ratio of Anode to Cathode capacity per unit area (Ca/Cc) at first charge is equal
to or greater than 1.001.
4.9
Electrode Geometry
Reference:
IEEE 1725, Section 5.2.3
Purpose:
To ensure that the electrode alignment parameters are designed and controlled such
that the safety of the cell is not compromised.
Procedure:
Tear down 5 cells.
Compliance: The negative electrode active area shall extend beyond all positive electrode active
area edges by at least 0.1 mm (plus process margin) unless process
capability/stability is demonstrated to be less than 0.1 mm.
4.10 Electrode Geometry
Reference:
IEEE 1725, Section 5.2.3
Purpose:
To ensure that the electrode alignment parameters are designed and controlled such
that the safety of the cell is not compromised.
Procedure:
Verify the design validation report for complete coverage of active area of positive
electrode by negative electrode.
Compliance: Vendor provides data for 32 samples. The data must indicate that the negative
electrode extends beyond all positive electrode edges by at least 0.1 mm (plus
process margin) unless process capability/stability is demonstrated to be less than
0.1 mm.
4.11 Electrode Tabs (connection to cell terminals)
Reference:
IEEE 1725, Section 5.2.4
Purpose:
To ensure proper design and control of electrode tab length and overhang such that
safety of the cell is not compromised. (Refer to Figure 5 of IEEE1725).
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Procedure:
Review design and test data regarding the extending (electrically conductive) tab
end. Verify on 5 samples that tabs do not overhang both sides of the electrode.
Compliance: Engineering data for tab design (exposed tab length and tab overhang) is available.
Exposed tab length is within vendor specification. Tabs do not overhang both sides of
the electrode.
4.12 Application of Insulation
Reference:
IEEE 1725, Section 5.2.5.1
Purpose:
Reduce the potential of short circuit by ensuring the proper insulation of the internal
cell tab.
Procedure:
Verify on 5 samples that the insulation scheme (may contain multiple components)
continues until it reaches the point of attachment to the cell terminal. Not applicable
to the cells that have more than one single tab at cell core initiation (such as stacking
or folding configurations).
Compliance: Tabs with opposite polarity as the enclosure shall be insulated from its electrode
assembly (electrodes and separator) exit point until it reaches the point of attachment
to the cell terminal.
4.13 Application of Insulation
Reference:
IEEE 1725, Section 5.2.5.1
Purpose:
Reduce the potential of short circuit by ensuring the proper insulation of the internal
cell tab.
Procedure:
Visually inspect the placement of tab insulation scheme (may contain multiple
components). Compare the observations with vendor’s cell specifications. Not
applicable to the cells that have more than one single tab at cell core initiation (such
as stacking or folding configurations).
Compliance: Insulation exists and complies with vendor’s cell specification unless demonstrated
by documented evaluation report.
4.14 Application of Supplementary Insulation
Reference:
IEEE 1725, Section 5.2.5.1
Purpose:
To confirm compliance to the requirement for supplementary insulation where only a
single separator layer exists adjacent to the internal tab.
Procedure:
Analyze 5 units for isolation of tab from the opposite electrode. Not applicable to the
cells that have more than one single tab at cell core initiation (such as stacking or
folding configurations).
Compliance: Additional insulation has been used if only a single layer of separator isolates the tab
from the opposite electrode.
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4.15 Insulation Characteristics
Reference:
IEEE 1725, Section 5.2.5.2
Purpose:
To verify that the insulator material will be stable in a temperature range of -40°C to
150°C.
Procedure:
Verify the existence of insulation material test/evaluation report and specification
sheet as applied to its usage within the cell at a temperature range of -40°C to
150°C.
Compliance: Evaluation report indicates that the insulation material has electrochemical, chemical,
mechanical (permanent adherence & good puncture resistance) and thermal stability
in a temperature range of -40°C to 150°C.
4.16 Cell Vent Mechanism
Reference:
IEEE 1725, Section 5.2.6
Purpose:
To ensure cell designs include a consistent vent mechanism.
Procedure:
Test lab to verify vent design and operation on 5 cells per their internal procedure.
1) Take 5 samples at ambient temperature (SOC is not critical; HOWEVER, to reduce
hazards discharged cells are recommended).
2) Penetrate the cell
a) Canister type cell: Penetrate the can on opposite end of the cell canister. Not the same
side as the vent.
b) Pouch type cell: Use a needle to penetrate the pouch as far away from the seam.
3) Connect cell to an inflow mechanism without disturbing the cell internals.
4) Seal using appropriate sealing method (e.g. epoxy, o-ring).
5) Use compressed inert gas (e.g. Air or inert gas (eg. N2, Ar etc.)) and pressurize at a rate
of 5 +/-1 psi (35 kPa +/- 7 kPa) intervals.
6) Hold pressure for a minimum of 5 sec per interval.
7) Note the activation pressure of the vent.
Compliance: Vent operates per the vendor specification. Visual inspection confirms that the vent
operated at its intended location.
4.17 Retention of Cell Contents and Projectile Testing
Reference:
IEEE 1725, Section 5.2.6.1 and 5.2.6.2
Purpose:
To confirm vent design performance.
Procedure:
Verify the availability of a report and/or certificate demonstrating UL 1642 Section 20
Projectile Test (Mar. 2012 release).
Compliance: Compliance per UL 1642 Projectile Test.
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4.18 Overcurrent Protection Device
Reference:
IEEE 1725, Section 5.2.7
Purpose:
To confirm that cells qualified with ancillary protective measures are employed at the
pack level with such measures intact.
Procedure:
Review cell specifications to determine if component cell was qualified with a PTC or
other protective device. Review current construction of 1 sample to see if same
device is in evidence in pack construction.
Compliance: If the cell design was qualified with a PTC or other protective device, this protective
device is present in the battery pack.
4.19 Maximum Recommended Voltage
Reference:
IEEE 1725, Section 5.2. 8
Purpose:
To confirm that the cell vendor has provided a recommended maximum voltage for
the appropriate pack overvoltage protection function.
Procedure:
Confirm the existence of an overvoltage limit in the cell specification.
Compliance: Recommended maximum cell voltage is listed in the cell specification.
4.20 Materials Specifications
Reference:
IEEE 1725, Section 5.3.1
Purpose:
To validate that impurity limits have been defined.
Procedure:
Verify that the design report defines impurities and their critical limits. Verify that the
raw material specifications for impurities are within critical limits. Verify the raw
material data/records comply with the raw material specifications.
Compliance: Raw material specifications for impurities are within critical limits as listed in the
design report. Actual raw material meets the specification.
4.21 Cleanliness of Manufacturing Operations
Reference:
IEEE 1725, Section 5.3.3
Purpose:
To ensure that proper environmental controls are in place and effective in the
manufacturing and staging area. Measures are in place to prevent the introduction of
metal contamination.
Procedure:
Verify that the temperature, humidity and impurity levels in the manufacturing area
are specified in the control plan and implemented. Verify vendor has systems in place
to prevent the introduction of metal contamination.
Compliance: Temperature, humidity and impurity levels are within specification. Methods and
survey operations by which manufacturing and supporting supply chain facilities
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present no conditions that can cause degradation or damage to materials before,
during and after production.
4.22 Manufacturing Traceability
Reference:
IEEE 1725, Section 5.3.4
Purpose:
To ensure that an effective cell traceability plan has been implemented.
Procedure:
Confirm traceability method and validate incorporation within the product.
Compliance: Cell has traceability from the market back to manufacturing site and production lot.
4.23 Uniform Coating of Active Materials
Reference:
IEEE 1725, Section 5.3.5
Purpose:
To ensure that the electrode coating process has been properly characterized,
optimized, controlled, and continuously improved.
Procedure:
Verify that the negative and positive electrodes’ weight and thickness are controlled
within the specifications.
Compliance: Material specifications exist and are current. Negative and positive electrodes weight
and thickness are controlled within specifications.
4.24 Burr Control
Reference:
IEEE 1725, Section 5.3.6
Purpose:
The manufacturer shall have a method to prevent internal short circuit caused by
burrs, either by manufacturing control or design prevention.
Procedure:
Verify that the manufacturer has a method to prevent internal short circuit caused by
burrs, either by:
1) Manufacturing control, which consists of measurements at least once per shift or
once per manufacturing lot at each cutting point to determine whether or not burr
heights are less than 50% of the lower tolerance limit of the separator thickness; or
2) Design prevention, which may include insulation taping or coating at uncoated
foil, or documented engineering analysis (such as FMEA) that shows that burr
heights may exceed 50% of the lower tolerances of the separator without resulting in
internal shorts. Considerations may include coating thickness, separator thickness,
coated versus uncoated electrodes areas, insulators and electrode overlap.
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Figure 1
Compliance: Either 1) manufacturing control ensures that burrs do not exceed 50% of the lower
tolerance limit of the thickness of the separator or 2) design prevention with
documented engineering analysis (such as an FMEA) shows that burr lengths with
greater limits cannot cause internal shorts.
4.25 Burr Control
Reference:
IEEE 1725, Section 5.3.6
Purpose:
To ensure that the tolerance on burr height is controlled to limit the potential for
internal shorts. This is not applicable if design prevention is present.
Procedure:
Confirm design parameters to the reference. Using inspection data, confirm that the
manufacturing process is in control. This is not applicable if design prevention is
present.
Compliance: Inspection data shows compliance to specified tolerances. For those cases where an
out of control condition was noted, action was taken. This is not applicable if design
prevention is present.
4.26 Prevention of Damage to Electrodes
Reference:
IEEE 1725, Section 5.3.7
Purpose:
To ensure that the manufacturing process has methods to detect damaged
electrodes.
Procedure:
Check the vendor’s manufacturing process for handling of electrodes. Verify the
criteria for damaged electrodes (wrinkling, tearing or deformation). Verify that the
system for removal of damaged electrodes is installed in manufacturing process and
is effective.
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Compliance: Availability of criteria for damaged electrodes (wrinkling, tearing or deformation).
Damaged electrode detection system removes the damaged electrodes.
4.27 Characteristics of Manufacturing Equipment
Reference:
IEEE 1725, Section 5.3.8
Purpose:
Ensure that manufacturing processes not directly specified in the referenced
standard have been properly characterized, optimized, controlled, and continuously
improved.
Procedure:
Verify production flow and process control documentation. Verify that the equipment
is selected based on engineering analysis and capability studies. Ensure product
consistently meets or exceeds specs.
Compliance: Equipment characterization/optimization documentation is available. In-process
quality controls are implemented.
4.28 Defective Electrodes
Reference:
IEEE 1725, Section 5.3.9
Purpose:
To ensure that non-conforming electrodes are scrapped.
Procedure:
Confirm compliance parameters and implementation. When possible, inspect
discarded material and verify proper disposal process. Verify that the non-conforming
electrodes are actually scrapped.
Compliance: Verify that all electrode material meets primary specification. Confirm that all nonconforming material is safely discarded and not reworked. “Scrapped” means
“destroyed”.
4.29 Preventive Maintenance Plan
Reference:
IEEE 1725, Section 5.3.10
Purpose:
To ensure that the vendor has implemented an effective Preventative Maintenance
(PM) plan.
Procedure:
Review PM Process and schedule.
Compliance: Verify the preventive maintenance schedule and its implementation. Verify that PM
plan clearly identifies routine and critical maintenance activities. The PM intervals are
established based on inputs from equipment vendors and in house data collection.
4.30 Tension and Damage
Reference:
IEEE 1725, Section 5.4.1.1
Purpose:
To ensure that the electrode winding process has been properly characterized,
optimized, and controlled.
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Procedure:
Review documentation in order to establish proper winding and stacking process
considerations.
Compliance: Tension (winding processes only) and damage characterization/optimization
documentation is available. Actual winding tension settings are per the conditions in
the engineering report and product meets the specification.
4.31 Collection of Loose Material
Reference:
IEEE 1725, Section 5.4.1.2
Purpose:
To ensure that the vendor has an effective method for collection of loose material
produced.
Procedure:
Verify that the report identifies possible sources of contamination by loose material
and identifies processes which control loose material within acceptable limits. Cell
vendor’s process demonstrates effectiveness for collection of loose material.
Compliance: Engineering report identifying possible sources of contamination by loose material is
available. Controls are placed to collect the loose material produced in the process.
4.32 Detection of Damaged Cores
Reference:
IEEE 1725, Section 5.4.1.3
Purpose:
To ensure that the vendor has a method to detect non-conforming cell cores.
Procedure:
Verify detection method for the non-conforming cell cores.
Compliance: Non-conforming cell cores detection methods are in place.
4.33 Control of Electrode Spacing
Reference:
IEEE 1725, Section 5.4.2
Purpose:
To ensure that the cell core design and the associated core assembly processes
have been properly characterized, optimized, and controlled to prevent damage to
the cell core.
Procedure:
Verify engineering report for uniform compression, dimensional characteristics and
winding spindle removal process. Verify that the actual core assembly settings are
per the engineering report. Verify product compliance to parameters documented in
the engineering report.
Compliance: Materials are inspected and meet primary specification upon completion of core
assembly. Confirm that process equipment does not damage and/or modify the cell
core during process movement (input and output) of this operation.
4.34 Uniformity of Internal Electrode Pressure
Reference:
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Purpose:
To ensure that the cell core assembly processes have been properly characterized,
optimized, and controlled to prevent damage to the cell core.
Procedure:
Verify documentation referring to tension, uniform compression and dimensional
characteristics. Note the actual settings.
Compliance: Documentation is available showing process parameters. Actual settings comply with
the documentation.
4.35 Avoidance of Contaminants
Reference:
IEEE 1725, Section 5.4.4
Purpose:
To ensure that the winding process has controls to prevent contaminants from
entering the cell.
Procedure:
Identify possible sources of contamination (flaking, dust, etc.) during the winding
process via FMEA or equivalent. Evaluate the control plans or equivalent referred to
in the FMEA. Review and validate that the winding process keeps contamination
within the allowed limits as listed in the engineering report.
Compliance: Vendor shall provide an FMEA or equivalent and control plan. Ensure that FMEA
items are covered in the control plan. Review and validate that the winding process
keeps contamination within the allowed limits as listed in the control plan.
4.36 Internal Short Avoidance
Reference:
IEEE 1725, Section 5.5.1
Purpose:
To ensure that the method of assembly for insulating material (whether for electrode,
current collectors, or internal insulation) is designed to provide reliable protection
against latent shorts for the product lifetime of the cell.
Procedure:
Lab to tear down 5 fresh samples and verify proper insulation placement. Lab to
review insulating material specifications in regards to stability of the material’s
insulating property over time.
Compliance: Validate that all likely material interfaces that may result in a latent internal short are
insulated. Validate the method of assembly for insulating material properties is
sufficient to provide protection from shorts over the projected lifetime of the cell.
4.37 Internal Short Avoidance
Reference:
IEEE 1725, Section 5.5.1
Purpose:
To ensure that the method of assembly for insulating material (whether for electrode,
current collectors, or internal insulation) is designed to provide reliable protection
against latent shorts for the product lifetime of the cell.
Procedure:
Verify documentation that includes design and method of assembly, and
manufacturing inspection processes for insulating material to prevent internal short
occurrence.
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Compliance: Insulation placement and material shall comply with the documentation. Validate that
inspection processes exist to ensure compliance.
4.38 Tab Positioning
Reference:
IEEE 1725, Section 5.5.2
Purpose:
To ensure that the process for positive and negative tab placement has been
properly characterized, optimized, and controlled to prevent cell core assembly
damage or tab/can short circuits.
Procedure:
Tear down 5 samples or conduct inspection by an appropriate vision system
(example x-ray).
Compliance: Verify the position of negative and positive tabs do not create cell core assembly
damage or tab/can short circuits. Alternatively, verify an insulator gasket isolates the
tabs from the cell core assembly and can walls.
4.39 Tab Positioning
Reference:
IEEE 1725, Section 5.5.2
Purpose:
To ensure that the process for positive and negative tab placement has been
properly characterized, optimized, and controlled to prevent short circuit.
Procedure:
Verify the positive and negative tab design documentation. Verify assembly process
documentation for proper tab alignment and positioning. Review factory x-ray
measurement data from a minimum of 5 samples showing tab placement. Review
calibration certificate and measurement systems analysis for x-ray equipment used to
produce data to ensure sufficient repeatability. Review design analysis to confirm
design demonstrates sufficient margin from short circuit concerns due to tab
placement variation.
Compliance: Tab placement meets product design specification. Ensure that vendor’s vision
system is calibrated and repeatable. Vendor to show design analysis demonstrating
safety and prove that they are meeting Design Specification.
4.40 Integrity of Cell Core Assembly
Reference:
IEEE 1725, Section 5.5.3
Purpose:
To ensure that the integrity of the electrodes is verified through resistance or
continuity check or equivalent means.
Procedure:
Confirm product specification to inspection parameters. Validate that an effective
real time (Hi-Pot or equivalent) 100% testing process is in place.
Compliance: Validate test procedures and test parameters. Verify test parameters via review of
engineering documentation. 100% testing is required.
4.41 Positioning of Insulating Material
Reference:
December 2015
IEEE 1725, Section 5.5.4
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Purpose:
To ensure an insulating method prevents shorting of cell core to the cell casing.
Procedure:
Tear down 5 samples and inspect for insulating method.
Compliance: Verify insulating method and verify insulating material is readily visible.
4.42 Positioning of Insulating Plate
Reference:
IEEE 1725, Section 5.5.4 (NA - See 4.41)
Purpose:
To confirm the characteristics of the material, color, proper positioning and presence
of insulating materials.
Procedure:
Inspect insulating plate placement process and associated controls documentation.
Compliance: If the cell has insulating plates, the insulating plates are properly positioned and
readily visible (refer to Figure 7 of IEEE 1725) and meets the insulating plate’s
specification for insulating characteristics. Additionally, the process control
documentation confirms that the insulating material is checked with resistive
measurement or other technological means or methods.
4.43 Electrode Alignment
Reference:
IEEE 1725, Section 5.5.5
Purpose:
The vendor shall use a vision system to inspect 100% of the cell cores.
Procedure:
Cell vendor to conduct 100% inspection using a vision system to ensure the overlap
on top and bottom of the electrode assembly. Also, conduct 100% inspection to
ensure no damage is caused by the case insertion process. Polymer cells shall be
inspected via a vision system either prior to or following complete assembly.
Verify that the negative electrode overlaps the positive electrode by at least 0.1 mm
unless the vendor shows supporting evidence (DOE, engineering studies, etc.) that
justifies less than 0.1 mm overlap on each side is acceptable. Ensure that vendor’s
vision system is calibrated and repeatable.
Compliance: 100% inspection is done with vision system for overlap. Overlap is at least 0.1 mm on
all sides or vendors supporting evidence justifies a lesser minimum overlap.
4.44 Cell Aging and Validation of Aging Process
Reference:
IEEE 1725, Section 5.5.6 and 5.5.7
Purpose:
To ensure that the cell aging, grading, and sorting processes have been properly
characterized, optimized, controlled, and continuously improved to remove early term
failures.
Procedure:
Review cell aging process and supporting records. Review cell aging process
validation.
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Compliance: Cell aging, grading, and/or sorting process has been developed and implemented.
Process is in control. Performance variations for each production lot are identified.
Cell aging process validation conducted per IEEE 1725 Section 5.5.7.
4.45 Cell Leakage
Reference:
IEEE 1725, Section 5.5.8
Purpose:
To ensure that a process has been implemented to remove cells that are leaking
electrolyte.
Procedure:
Verify that the end product (Cell) is inspected and all leaking cells are removed.
Compliance: The inspection process does not damage and/or modify the cell. All leaking cells are
removed. All non-conforming material is safely discarded and not reworked. Process
feedback is in place to modify and rectify process if out of control.
4.46 Care During Cell Assembly
Reference:
IEEE 1725, Section 5.5.9
Purpose:
To ensure that the welding and other operations have been properly characterized,
optimized, controlled, and continuously improved to prevent damage to the cell.
Procedure:
Review cell welding process and inspection data during cell assembly operations.
Compliance: Cell enclosure, cell case, and critical cell design elements are not damaged or altered
during cell assembly and post assembly operations. Inspection processes are in
place and are effective to maintain compliance. Process feedback is in place to
modify and rectify the process if out of control.
4.47 Qualification of New Cell Designs
Reference:
IEEE 1725, Section 5.6.1
Purpose:
To ensure that the cell qualification processes have been properly characterized,
optimized, controlled, and continuously improved. Additionally, to ensure that all cells
are required to pass such tests before being given production status.
Procedure:
Review design procedure. Verify that the new cell model approval process follows
that procedure. Validate that an effective real time or sample plan inspection process
is established.
Compliance: Design review procedure shall include performance, reliability and safety related
testing. Verify that the testing is being performed and results meet the specification.
4.48 Qualification of Production Cells
Reference:
IEEE 1725, Section 5.6.2
Purpose:
To establish production cell qualification and periodic re-qualification requirements.
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Procedure:
Verify specification availability which lists the qualification tests and intervals and
review qualification test data. Cell vendor provides justification regarding the requalification interval and test regimen.
Compliance: Verify that the cell vendor is conducting qualification tests at specified intervals and
that work instruction is available.
4.49 Cell Transportation Regulations
Reference:
IEEE 1725, Section 5.6.4.
Purpose:
Ensure compliance to UN Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria.
Procedure:
Review test report confirming compliance to UN Recommendations on the Transport
of Dangerous Goods, Manual of Tests and Criteria.
Compliance: Test report confirming compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists.
4.50 Cell Thermal Test
Reference:
IEEE 1725, Section 5.6.5
Purpose:
To ensure cells demonstrate thermal stability.
Procedure:
5 fully charged cells (per cell manufacture's specifications) shall be suspended (no
heat transfer allowed to non-integral cell components) in a gravity convection or
circulating air oven at ambient temperature. The oven temperature shall be ramped
at 5 ± 2°C per minute to 130 ± 2°C. After 1 hour at 130 ± 2°C, the test is ended.
Compliance: Cells shall not flame or explode when exposed to 130°C for 1h.
4.51 Cell Thermal Test
Reference:
IEEE 1725, Section 5.6.5
Purpose:
To ensure cells demonstrate thermal stability.
Procedure:
Test 5 cells per IEEE 1725, Section 5.6.5.
Compliance: Test equipment, test procedure and test results compliant to IEEE 1725, Section
5.6.5.
4.52 Evaluation of Excess Lithium Plating and Short-Circuit Test on Cycled Cells
Reference:
IEEE 1725, Section 5.6.6, 5.6.6.1
Purpose:
To ensure cells are cycled and inspected to look for latent defects due to excess
lithium plating.
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Procedure:
5 Cells shall be cycled 25 times at the maximum charge/discharge rate specified by
the vendor at 25 ± 5 °C. Test shall be performed with fully charged cells.
Each test sample cell, in turn, is to be short-circuited by connecting the positive and
negative terminals of the cell with a circuit load having a resistance load of 80 +/- 20
milliohms. The cell is to be discharged until a fire or explosion is obtained, or until it
has reached a completely discharged state of less than 0.1 volts and the cell case
temperature has returned to ±10°C of the elevated chamber ambient temperature
(i.e. 55 5°C).
Tests are to be conducted at 55 ± 5°C. The cells are to reach equilibrium at 55
5°Cas applicable, before the short circuit is applied.
Compliance: No fire, no explosion, and maximum temperature less than 150 °C.
4.53 External Shorting of Cell Terminals
Reference:
IEEE 1725, Section 5.6.7(N/A - See 4.52, IEEE reference deleted in 2011 edition)
Section 4 - CATL Sample Submission Requirements
Section
Name
4.1
Stability
4.2
Isolation Properties
4.3
Strength and
Physical Integrity
4.4
Shrinkage
Allowance,
Ambient
Temperature
4.5
Shrinkage
Allowance,
Elevated
Temperature
Shrinkage
Allowance
4.6
4.7
Electrode Design
Criteria
December 2015
Purpose
To ensure that separator materials have the
appropriate properties to meet expectations of
performance and safety.
To ensure that the separator/cell design shall
maintain isolation under high temperature stress
conditions for a reasonable period of time to
maintain the safety of the cell.
To ensure that the design of separator thickness
is made through engineering judgment such that
the separator has the requisite strength to ensure
cell safety and robustness to handling.
To ensure that the separator is designed such
that shrinkage characteristics of the material are
taken into account to maintain anode and cathode
separation.
To ensure that the separator is designed such
that shrinkage characteristics of the material are
taken into account to maintain anode and cathode
separation.
To ensure that the separator is designed such
that shrinkage characteristics of the material are
taken into account to maintain anode and cathode
separation.
Electrode design constituents for both the anode
and the cathode shall be designed to assure
23
Samples
for Test
0
5
Reusable?
Samples
cannot be
reused
0
5
5
Same
samples
are to be
used for
4.9, 4.11,
4.12, 4.14,
4.36, 4.41,
Samples
cannot be
reused
0
0
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4.10
Electrode
Geometry
4.11
Electrode Tabs
(connection to cell
terminals)
4.12
Application of
Insulation
performance, safety, and durability in the
designated application.
To ensure that the charge capacity of the
electrodes are properly balanced.
To ensure that the electrode alignment
parameters are designed and controlled such that
the safety of the cell is not compromised.
To ensure that the electrode alignment
parameters are designed and controlled such that
the safety of the cell is not compromised.
To ensure proper design and control of electrode
tab length and overhang such that safety of the
cell is not compromised. (Refer to Figure 5 of
IEEE1725).
Reduce the potential of short circuit by ensuring
the proper insulation of the internal cell tab.
4.13
Application of
Insulation
Application of
Supplementary
Insulation
Insulation
Characteristics
Cell Vent
Mechanism
Reduce the potential of short circuit by ensuring
the proper insulation of the internal cell tab.
To confirm compliance to the requirement for
supplementary insulation where only a single
separator layer exists adjacent to the internal tab.
To verify that the insulator material will be stable
in a temperature range of -40°C to 150°C.
To ensure cell designs include a consistent vent
mechanism.
0
Retention of Cell
Contents and
Projectile Testing
Overcurrent
Protection Device
To confirm vent design performance.
0
To confirm that cells qualified with ancillary
protective measures are employed at the pack
level with such measures intact.
To confirm that the cell vendor has provided a
maximum over-voltage limit.
0
To validate that impurity limits have been defined.
0
To ensure that proper environmental controls are
in place and effective in the manufacturing and
staging area. Measures are in place to prevent
the introduction of metal contamination.
To ensure that an effective cell traceability plan
has been implemented.
To ensure that the electrode coating process has
been properly characterized, optimized,
controlled, and continuously improved.
To ensure that burrs are controlled.
To ensure that the tolerance on burr height is
controlled to limit the potential for internal shorts.
To ensure that the manufacturing process has
methods to detect damaged electrodes.
0
4.8
4.9
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.22
4.23
Electrode Capacity
Balance
Electrode
Geometry
Maximum
Recommended
Voltage
Materials
Specifications
Cleanliness of
Manufacturing
Operations
Manufacturing
Traceability
Uniform Coating of
Active Materials
4.24
4.25
Burr Control
Burr Control
4.26
Prevention of
Damage to
Electrodes
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4.27
Characteristics of
Manufacturing
Equipment
4.28
Defective
Electrodes
Preventive
Maintenance Plan
Tension and
Damage
4.29
4.30
4.31
4.32
4.33
4.34
4.35
4.36
Collection of Loose
Material
Detection of
Damaged Cores
Control of
Electrode Spacing
Uniformity of
Internal Electrode
Pressure
Avoidance of
Contaminants
Internal Short
Avoidance
4.37
Internal Short
Avoidance
4.38
Tab Positioning
4.39
Tab Positioning
4.40
Integrity of Cell
Core Assembly
4.41
Positioning of
Insulating Material
4.42
Positioning of
Insulating Plate
4.43
Electrode
Alignment
December 2015
Ensure that manufacturing processes not directly
specified in the referenced standard have been
properly characterized, optimized, controlled, and
continuously improved.
To ensure that non-conforming electrodes are
scrapped.
To ensure that the vendor has implemented an
effective Preventative Maintenance (PM) plan.
To ensure that the electrode winding process has
been properly characterized, optimized, and
controlled.
To ensure that the vendor has an effective
method for collection of loose material produced.
To ensure that the vendor has a method to detect
non-conforming cell cores.
To ensure that the cell core design and the
associated core assembly processes have been
properly characterized, optimized, and controlled
to prevent damage to the cell core.
To ensure that the cell core assembly processes
have been properly characterized, optimized, and
controlled to prevent damage to the cell core.
To ensure that the winding process has controls
to prevent contaminants from entering the cell.
To ensure that the method of assembly for
insulating material (whether for electrode, current
collectors, or internal insulation) is designed to
provide reliable protection against latent shorts for
the product lifetime of the cell.
To ensure that the method of assembly for
insulating material (whether for electrode, current
collectors, or internal insulation) is designed to
provide reliable protection against latent shorts for
the product lifetime of the cell.
To ensure that the process for positive and
negative tab placement has been properly
characterized, optimized, and controlled to
prevent short circuit.
To ensure that the process for positive and
negative tab placement has been properly
characterized, optimized, and controlled to
prevent short circuit.
To ensure that the integrity of the electrodes is
verified through resistance or continuity check or
equivalent means.
To confirm the characteristics of the material,
color, proper positioning and presence of
insulating materials.
To confirm the characteristics of the material,
color, proper positioning and presence of
insulating materials.
The proper alignment of positive and negative
electrodes is critical to prevent hazards. The
vendor shall conduct 100% inspection (post-
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4.44
Cell Aging and
Validation of Aging
Process
4.45
Cell Leakage
4.46
Care During Cell
Assembly
4.47
Qualification of
New Cell Designs
4.48
Qualification of
Production Cells
Cell Transportation
Regulations
4.49
4.50
Cell Thermal Test
4.51
4.52
Cell Thermal Test
Evaluation of
Excess Lithium
Plating and ShortCircuit Test on
Cycled Cells
External Shorting
of Cell Terminals
4.53
December 2015
winding or stacking of electrodes) and should use
a vision system to inspect 100% of the electrode
assemblies.
To ensure that the cell aging, grading, and sorting
processes have been properly characterized,
optimized, controlled, and continuously improved
to remove early term failures.
To ensure that a process has been implemented
to remove cells that are leaking electrolyte.
To ensure that the welding and other operations
have been properly characterized, optimized,
controlled, and continuously improved to prevent
damage to the cell.
To ensure that the cell qualification processes
have been properly characterized optimized,
controlled, and continuously improved.
Additionally, to ensure that all cells are required to
pass such tests before being given production
status.
To establish production cell qualification and
periodic re-qualification requirements.
To ensure the cell model meets transportation
regulatory testing requirements including those
listed in appropriate sections of UN Manual of
Tests and Criteria.
To ensure cells demonstrate thermal stability.
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5
Samples
cannot be
reused
To ensure cells demonstrate thermal stability.
To ensure cells are cycled and inspected to look
for latent defects due to excess lithium plating.
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To ensure that cells pass an elevated temperature
short circuit test.
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Section 5
Battery Pack Validation
All tests will be performed on a minimum of 5 samples unless otherwise specified.
Audit criteria shall be done on a sample of one.
5.1
Traceability
Reference:
IEEE 1725, Section 6.2.1
Purpose:
Ensure that the vendor has a traceability plan that includes traceability of the cell.
Procedure:
Review vendor documentation of traceability plan.
Compliance: Traceability plan shall enable vendor to identify cell lot code / date code without
disassembly of the pack.
5.2
Part Number
Reference:
IEEE 1725, Section 6.2.2.1
Purpose:
Ensure part number is identified on battery pack.
Procedure:
Visually inspect battery pack.
Compliance: Part number is identified and correct.
5.3
Voltage
Reference:
IEEE 1725, Section 6.2.2.2
Purpose:
Ensure typical voltage of pack is identified on battery pack.
Procedure:
Visually inspect battery pack.
Compliance: Typical voltage is identified and correct on battery pack. Embedded batteries are
exempt from this requirement.
5.4
Chemistry
Reference:
IEEE 1725, Section 6.2.2.3
Purpose:
Ensure chemistry of battery pack.
Procedure:
Visually inspect battery pack.
Compliance: Chemistry type is identified and correct on battery pack. Embedded batteries are
exempt from this requirement.
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5.5
Pack Vendor Identification
Reference:
IEEE 1725, Section 6.2.2.4
Purpose:
Ensure Host or Pack Vendor identified properly.
Procedure:
Visually inspect battery pack.
Compliance: Host or Pack Vendor is identified and correct on battery pack.
5.6
Circuit Layout
Reference:
IEEE 1725, Section 6.3.2
Purpose:
Ensure adequate runner spacing, soldering pad area size, and distance between
solder pads as well as separation between traces.
Procedure:
Review electronic PCB layout file, populated PCBs, and manufacturing process
capabilities documentation.
Compliance: Based on design analysis completed per Section 4 of IEEE 1725 spacing shall
ensure safe operation through predictable life of product. Spacing at a minimum
shall be greater than or equal to minimum spacing capabilities of the manufacturing
processes.
5.7
Cell Polarity
Reference:
IEEE 1725, Section 6.3.3
Purpose:
Ensure battery pack has individual cells oriented properly.
Procedure:
Review schematic, mechanical drawing and one open (unwelded) sample.
Compliance: Cells are oriented with proper polarity (Positive on cell to positive on PCB and
Negative on cell to Negative on PCB).
5.8
Ambient Thermal Consideration
Reference:
IEEE 1725, Section 6.3.4
Purpose:
Confirm that thermal specifications of battery pack components are not exceeded
when the host-pack combination is operated at the maximum-rated charge and the
maximum rated discharge current, with the host-pack combination ambient
temperature elevated to the maximum temperature specification of the host (such as
maximum RF transmit power, gaming applications, video capture or playback, etc.).
Procedure:
Review component data sheets (including the cell) and compare to test results. A
sample of one is required for both the inspection/analysis and test portions of this
criterion.
Instrument the critical components within the pack to monitor temperature. Operate
the host-pack combination at the maximum rated charge and discharge conditions
and ensure heat rise does not exceed the maximum specified ratings of each
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component when operated at maximum operating temperature specified by host
vendors (system operating temperature range for host).
Some systems may require more or less components to be monitored.
Place the host-pack combination in a thermal chamber at the maximum specified
host operating temperature for charging. Operate the host-pack combination at the
maximum rated charge condition, allow the test to run until there is no more change
in monitored temperatures (This simulates operating conditions in a host that are
expected to produce maximum temperatures in the battery pack).
Place the host-pack combination in a thermal chamber at the maximum specified
host discharge operating temperature. Operate the host-pack combination at the
maximum rated discharge condition, allow the test to run until there is no more
change in monitored temperatures (This simulates operating conditions in a host that
are expected to produce maximum temperatures in the battery pack).
Compliance: Components are rated properly and no component temperature specification is
exceeded.
5.9
Component Specifications
Reference:
IEEE 1725, Section 6.3.5
Purpose:
Ensure battery pack components meet minimum and maximum temperature
requirements with adequate margin and protection circuit components are rated for
operating range of -25°C to +85°C.
Procedure:
Review component data sheets.
Compliance: Protection circuit components are rated for a minimum operating range of
-25°C to +85°C and other components meet minimum and maximum storage
temperature requirements of the pack.
5.10 Thermal Consideration
Reference:
IEEE 1725, Section 6.3.6
Purpose:
Ensure that the proper operating (charging and discharging) temperature ranges for
the battery pack have been set.
Procedure:
Review cell, battery pack, and host vendor specifications.
Compliance: Proper temperature ranges for operation have been specified based on the cell
vendor recommendations (example: do not charge/discharge outside of cell vendor’s
recommendations).
5.11 Limit Output Current
Reference:
IEEE 1725, Section 6.4.1
Purpose:
Validate performance of battery pack short circuit protection.
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Procedure:
Before the test, the battery pack shall be fully charged according to Table A.2—Brief
description of battery pack electrical tests of IEEE1725, or according to the vendor’s
specifications. Perform short circuit tests with a resistance of 80 +/- 20 milliohms at
minimum and maximum operating temperatures for 1 hour.
Compliance: The battery pack has short circuit protection and limits the discharge current. All
safety features shall remain operational, or the pack shall be permanently disabled.
No fire, smoke, or explosions occurs.
5.12 Pack Mechanisms
Reference:
IEEE 1725, Section 6.4.2
Purpose:
Ensure pack has at least one method to limit current from cells independent of the
cell separator shutdown mechanism.
Procedure:
Review product documentation.
Compliance: A method is present to limit current from cells independent of the cell separator
shutdown mechanism. Method to limit output current may include active or passive
protective circuits.
5.13 Thermal Protection
Reference:
IEEE 1725, Section 6.5.1
Purpose:
Ensure over-temperature protection has been incorporated that will prevent operation
outside current, temperature, and time limits as agreed to by battery pack, cell, and
host vendor.
Procedure:
Review product documentation.
Compliance: Over-temperature protection has been incorporated that is in agreement with the
specifications of the cell, pack, and host vendors. Operating modes where the cell
discharge rate is less than C/10 are exempted, as they do not induce a thermal
stress on the cell.
5.14 Thermal Sensor Design
Reference:
IEEE 1725, Section 6.5.2
Purpose:
Validate that a thermal sensor either in the battery pack and/or host monitors cell
temperature and enables the system to limit operation within the cell's thermal
specifications.
Procedure:
Place the device(s) that contain(s) the thermal sensor in an environmental chamber
and monitor the output of the thermal sensor over the operating temperature range of
the cell. Do not charge or discharge the pack during this test.
Compliance: Verify the output of the thermal sensor meets its specification over the operating
temperature range of the cell.
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5.15 Action, Thermal Protection
Reference:
IEEE 1725, Section 6.5.3 and 7.3.7
Purpose:
Validate performance of temperature protection during charging.
Procedure:
Charge in a host at a temperature exceeding the charge temperature specified. A
sample size of one is required.
Compliance: Charging is disabled or other protective action is taken when the operating limits of
the cell are exceeded.
5.16 Charging Specifications
Reference:
IEEE 1725, Section 6.6.1
Purpose:
Ensure maximum charging voltage and current have been set based on the
component specifications provided by the cell, battery pack, and host device
vendors.
Procedure:
Review cell, battery pack, and host component specifications.
Compliance: Maximum charging voltage and current have been set to comply with the
specifications provided. Agreement is shown by specification analyses that consider
cell/pack and host parameters.
5.17 Charge Considerations
Reference:
IEEE 1725, Section 6.6.2
Purpose:
Verify system has one overcurrent protection function that meets maximum current
specified in IEEE 1725 section 6.6.1.
Procedure:
Review system documentation and identify how current limiting protection has been
implemented. Also review the system analysis to identify if redundant protection is
required.
Compliance: Overcurrent protection has been implemented properly. Charge current limiting that
is resident in the charge control IC does meet this requirement provided it limits the
current to the maximum current specified in IEEE 1725 Section 6.6.1.
5.18 Charger Design
Reference:
IEEE 1725, Section 6.6.3
Purpose:
Validate design of charging system voltage and current control is within maximum
specified values.
Procedure:
Review design documentation that demonstrates the charging system voltage and
current are maintained within specification over tolerances.
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Compliance: The charging system voltage and current do not exceed the component
specifications provided by the cell, battery pack, and host device vendor.
5.19 Protection
Reference:
IEEE 1725, Section 6.6.5
Purpose:
Identify that the combination of the cell and pack has at least one overvoltage
protection function.
Procedure:
Review cell and pack documentation and identify all overvoltage protection functions.
Compliance: A minimum of one overvoltage protection function is present at the cell or pack level.
5.20 Protection
Reference:
IEEE 1725, Section 6.6.5
Purpose:
Validate performance of the pack/cell overvoltage protection mechanism under a
single fault condition in the charger/host and to ensure that two overcharge
mechanisms are present in the system.
Procedure:
Review the pack to worst-case single faulted charger/host system voltage. Worstcase faulted system voltage shall be defined with design analysis tools identified in
IEEE 1725 chapter 4.
Compliance: Each system component’s maximum rated voltage is greater than the worst-case
single fault charger/host system voltage. There must be two overcharge protection
mechanisms in the system. One of the overcharge protection mechanisms must be
in the pack or cell.
Chemistry may be accepted as a form of overvoltage protection mechanism upon
providing supporting evidence that the system is two faults tolerant and the protection
mechanism does not create a hazard.
5.21 Specification
Reference:
IEEE 1725, Section 6.8.1
Purpose:
Ensure proper upper limit discharge current and time limitations have been set.
Procedure:
Review cell, battery pack, and host vendor documentation.
Compliance: Proper upper limit discharge current and time limitations have been set and are in
agreement with the specifications provided by the cell, battery pack, and host vendor.
5.22 Pack Overcurrent Protection Requirement
Reference:
IEEE 1725, Section 6.8.2
Purpose:
Validate performance of pack discharge overcurrent protection.
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Procedure:
Subject the pack to a load in excess of discharge overcurrent protection identified in
IEEE 1725 6.8.1 at the minimum operating temperature, ambient temperature, and
maximum operating temperature.
Compliance: Operation of pack/cell overcurrent protection is within specified time and current over
the temperatures tested.
5.23 External Mechanical Force
Reference:
IEEE 1725, Section 6.9.9, UL 2054
Purpose:
Validate mechanical robustness for purpose of use.
Procedure:
If the battery pack is non-embedded, perform the Steady Force test per UL 2054 on 3
samples of the battery pack. If the pack is embedded, the test may optionally be
performed on the host device with the battery pack installed.
Compliance: Per UL 2054.
5.24 Cell Dimensional Allowance
Reference:
IEEE 1725, Section 6.9.2
Purpose:
Ensure proper consideration for the cell and battery pack dimensional tolerances.
Procedure:
Review mechanical drawing and tolerance analysis.
Compliance: Tolerances of cell, battery pack, and host do not overlap and create mechanical
constraints that affect form, fit, or function over lifetime of product.
5.25 Electrical Cell Connections
Reference:
IEEE 1725, Section 6.9.4
Purpose:
Ensure that the connections directly to cells are not soldered.
Procedure:
Review product documentation and one partially assembled or disassembled
representative sample.
Compliance: Connections directly to cells are not soldered.
5.26 Cell Vent
Reference:
IEEE 1725, Section 6.9.7
Purpose:
Ensure that the battery pack construction does not prevent cell gases from escaping.
Procedure:
Review battery pack design, component placement, and construction.
Compliance: Battery pack design does not physically obstruct the cell vents such that it prevents
the cell vent mechanism from operating as designed.
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5.27 Host Requirement
Reference:
IEEE 1725, Section 6.10.2
Purpose:
Ensure that the connector / terminal adhere to the host device mechanical
considerations.
Procedure:
Review connector documentation and sample.
Compliance: Connector adheres to host mechanical considerations.
5.28 ESD
Reference:
IEEE 1725, Section 6.10.3.1
Purpose:
Validate the ability of the pack to withstand ESD.
Procedure:
Subject pack to ESD in accordance with IEC 61000-4-2 per product level 2 at a
minimum.
Compliance: Performance of pack protection circuitry per Section 5.11 of this document after the
ESD test. If the pack includes an over voltage protection mechanism that could be
susceptible to ESD damage, it shall be verified as functional after the ESD test. All
compliance testing shall be done at ambient temperature only.
5.29 Welding
Reference:
IEEE 1725, Section 6.10.3.2
Purpose:
Ensure welding is only occurring in areas designated by cell vendor.
Procedure:
Review battery pack documentation and one partially assembled or disassembled
representative sample.
Compliance: Welding is only applied in areas designated by cell vendor.
5.30 Cell Shorts
Reference:
IEEE 1725, Section 6.11.1
Purpose:
Ensure assembly process avoids cell and battery pack short-circuit.
Procedure:
Review battery pack assembly process documentation and identify any areas of risk
for cell or battery pack short-circuit. Review process documentation to insure proper
placement and insulation of electrical connections and material handling. Review
manufacturing line to ensure process documentation is being enforced.
Compliance: Process documentation exists showing cell and battery pack short-circuit risks are
mitigated. Production facilities are operating per specified process documentation.
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5.31 Foreign Objects
Reference:
IEEE 1725, Section 6.11.2
Purpose:
Ensure assembly process prevents foreign objects from contacting cell or protection
circuit.
Procedure:
Review battery pack assembly process documentation and identify any areas of risk
for cell or battery pack short-circuit from foreign objects. Review manufacturing line to
ensure process documentation is being enforced.
Compliance: Process documentation exists showing cell and battery pack short-circuit risks from
foreign objects are mitigated. Production facilities are operating per specified
process documentation.
5.32 Soldering Process
Reference:
IEEE 1725, Section 6.11.3
Purpose:
Ensure adequate means have been provided to prevent solder balls, flashes, bridges
and other solder defects from being introduced during the soldering process.
Procedure:
Review soldering process documentation and manufacturing lines.
Compliance: If soldering process is done in house, soldering process has been characterized to
minimize defects. If soldering process is not resident, e.g. soldered components are
a purchased sub-assembly, evidence is available confirming that the subcontractor's
soldering process has been characterized to minimize defects. Adequate visual
inspection and/or testing process is in place to ensure that soldering, cutting, spot
welding, and any other manufacturing steps do not allow for debris becoming
airborne and entering into any of the sub-assemblies.
Soldering process has been characterized to minimize defects.
5.33 Reworked Cells
Reference:
IEEE 1725, Section 6.11.4
Purpose:
Ensure cells salvaged from batteries that are recovered / returned from end users are
not used to manufacture battery packs. Review SOP for returned Materials or
products.
Procedure:
Review battery pack documentation to ensure proper processes have been put in
place to prevent salvaged cells from being manufactured into battery packs.
Compliance: Battery packs are not being manufactured from cells recovered/ returned from end
users.
5.34 Circuit Care
Reference:
December 2015
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Purpose:
Ensure precautions have been taken to avoid damage to protection devices and
circuits. Review process documentation for handling and assembly of safety and/or
critical components and devices.
Procedure:
Review handling and assembly process documentation to ensure precautions have
been taken to avoid damage to protection devices and circuits.
Compliance: Handling and assembly processes exist for protection devices and circuits, and
address areas of risk. Production facilities are in compliance per specified process
documentation.
5.35 Pack Component Care
Reference:
IEEE 1725, Section 6.12
Purpose:
Ensure precautions have been taken to avoid damage to conductors and insulators,
for example, from sharp edges, burrs, pinching, or kinking.
Procedure:
Review handling and assembly process documentation to ensure precautions have
been taken to avoid damage to conductors and insulators.
Compliance: Handling and assembly processes exist for conductors and insulators, and address
areas of risk. Production facilities are in compliance per specified process
documentation.
5.36 Welding Care
Reference:
IEEE 1725, Section 6.12.1
Purpose:
Ensure precautions have been taken to avoid damage to cells, protective circuit
module, and battery pack housing during housing assembly (ultrasonic welding, over
molding, etc.).
Procedure:
Review process documentation for pack assembly. Identify areas of risk of damaging
cells, protective circuit module, and battery pack housing during housing assembly.
Production facilities are in compliance per specified process documentation.
Compliance: Housing assembly processes exist such that safety critical components shall not be
damaged.
5.37 ESD
Reference:
IEEE 1725, Section 6.12.2
Purpose:
Ensure precautions have been taken to avoid damage to protection circuits and other
devices from ESD during handling.
Procedure:
Review process documentation for ESD protection throughout the assembly process.
Identify areas of risk to protection circuits and other devices from ESD during
handling and storage.
Compliance: All ESD sensitive components and parts shall be stored and handled in an ESD safe
environment. Containers used for transport of such parts shall be ESD safe
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container. The need for appropriate ESD precautions for operators and equipment
shall be documented in work instructions. Evidence shall exist that the elements of
ESD protection have been implemented.
5.38 Pack Testing During Production
Reference:
IEEE 1725, Section 6.12.3
Purpose:
Ensure that all electronic protection circuit operations shall be directly or indirectly
verified at the pack (or pack sub assembly) level and 100% of shipped battery packs
are tested / verified.
Procedure:
Review battery pack design documentation to identify all electronic protection circuit
operations. Review battery pack manufacturing documentation to identify all
electronic protection circuit tests and corresponding pack (or pack sub assembly)
level tests that are performed during manufacturing. Also note the frequency that
testing is conducted, e.g. is testing done on all production units (100%).
Compliance: 100% testing of the electronic protection circuit(s) is performed during the
manufacturing process.
5.39 Quality Control
Reference:
IEEE 1725, Section 6.12.4
Purpose:
Ensure that critical manufacturing processes have quality control and maintenance
plans to ensure the consistency of the assembly process and adherence to
specifications.
Procedure:
Review manufacturing process documentation to identify all critical processes and
corresponding quality and maintenance plans.
Compliance: Critical manufacturing processes have quality control and maintenance plans.
5.40 Cell Care
Reference:
IEEE 1725, Section 6.12.5
Purpose:
Ensure that no damage has occurred during welding and other operations to the cell
case or other critical cell design elements.
Procedure:
Review battery pack assembly documentation and production facilities to identify any
areas of risk to cell case or other critical cell design elements during welding and
other operations.
Compliance: The assembly process does not cause damage to the cell case or other critical cell
design elements during welding and other operations.
5.41 Specification
Reference:
December 2015
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Purpose:
Ensure voltage, capacity, size, impedance, and other critical specifications have
been considered per application for use of cells connected in parallel.
Procedure:
Review cell, battery pack, and host specifications.
Compliance: Cell has proper parameters for application when connected in parallel to another cell
to form a battery pack based on specifications agreement among the cell, battery
pack, and host device vendor specifications demonstrating the suitability of the cell
selection and configuration.
5.42 Cell Chemistry
Reference:
IEEE 1725, Section 6.13.4
Purpose:
Ensure no cells from significantly different electrochemical systems are used to
manufacture battery packs.
Procedure:
Review battery pack and cell specifications.
Compliance: Cells from significantly different electrochemical systems are NOT used to
manufacture battery packs.
5.43 Fault Considerations
Reference:
IEEE 1725, Section 6.13.5
Purpose:
Ensure that adequate precautions have been taken to limit the charge rate to the
maximum rating of any single cell. FMEA analysis should consider such faults.
Procedure:
Review cell and charging system specifications.
Compliance: The vendor shall take adequate precautions to ensure that the charge rate does not
exceed the maximum of any single cell in the event that a single fault causes the
other cell(s) should become electrically disconnected. This does not apply to single
cell packs.
5.44 Qualification of New Pack Designs
Reference:
IEEE 1725, Section 6.14.1
Purpose:
Ensure that new pack designs have passed specified tests identified by the vendor
before qualification as a production pack.
Procedure:
Review battery pack documentation that defines qualification testing requirements
and test results for the design being evaluated.
Compliance: Proper qualification tests were performed and passed.
5.45 Qualification of Production Packs
Reference:
December 2015
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Purpose:
To establish that qualification requirements continue to be met after product has
been released for production.
Procedure:
Review procedures that define post-production qualification requirements. These
requirements may be termed continuous accelerated life testing (C-ALT), ongoing
reliability testing (ORT), among other names. Review post-production qualification
data with particular attention to required test regime, test frequency, and resultant
tolerance requirements.
Compliance: The pack vendor is conducting qualification tests at specified intervals per their
internally defined procedures.
5.46 Battery Transportation Regulations
Reference:
IEEE 1725, Section 4.2 Table 2
Purpose:
Ensure compliance to UN Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria.
Procedure:
Review test report confirming compliance to UN Recommendations on the Transport
of Dangerous Goods, Manual of Tests and Criteria.
Compliance: Test report confirming compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists.
5.47 Pack Overvoltage Protection, Verification, and Testing
Reference:
IEEE 1725, Section 6.14.3
Purpose:
To determine if hazards occur when cells are charged to the maximum limit of the
battery’s overcharge protection function as defined in Clause 6.6.5 in the event that
charge control per Clause 6.6 is not functioning.
Procedure:
Shall be performed per IEEE 1725, Section 6.14.3.1, with the following clarifications,
IEEE 1725, Section 6.14.3.1.4, the charge controller is defined in IEEE 1725 figure 1.
Parallel Multi-cell packs will be tested with all the cells in parallel.
Alternative method to insulate the cells (with minimum thermal resistance with R
value of 5) can be used to perform this test.
Compliance: Complies with IEEE 1725, Section 6.14.3.1.7.
5.48 Pack Drop Test
Reference:
IEEE 1725, Section 6.14.4
Purpose:
Validate the ability of the pack to withstand a drop.
Procedure:
One of the following tests is conducted based on the end use application defined by
the pack vendor. If the pack can be used in both applications, the worst case test
condition shall be used.
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HEAD LEVEL:
Where the normal use of the device is at the head level, 5 packs shall be fully
charged according to the vendor’s specifications. Packs are rested a maximum of 1
hour. The open circuit voltage is then recorded. Each pack shall then be drop tested
from a height of 1.5 meters (5 feet) onto a smooth concrete surface 18 times (three
repetitions of six sides). Record the open circuit voltage of the packs within 5
minutes after the 18 drops. Testing shall continue up to 36 times (a total of six
repetitions of six sides). Allow packs to rest for at least one hour after the final 18
drops. Record the open circuit voltage of the packs within 1 hour after the final 18
drops.
ALL OTHER CASES:
For all other devices, 5 fully charged packs shall be subjected to the drop test in
accordance to UL 2054.
For non-user replaceable packs (embedded batteries) this test shall be conducted
either on batteries or on batteries installed in the host device.
Compliance: Based on the test conducted, one of the following applies.
After 18 drops, no temporary internal shorts causing a total voltage of the cells or
pack decrease of more than 0.010V open circuit voltage, no heating, no smoke, no
fire and / or leakage. After 36 drops, no permanent internal shorts causing a voltage
decrease to 75% or less of the initial open circuit voltage.
The compliance requirement in UL 2054 shall be satisfied.
Section 5 - CATL Sample Submission Requirements
CRD
Sec
4.18
Name
Overcurrent
Protection Device
Purpose
To confirm that cells qualified with ancillary protective
measures are employed at the pack level with such
measures intact.
Ensure that the vendor has a traceability plan that
includes traceability of the cell.
Ensure part number is identified on battery pack
Ensure typical voltage of pack is identified on battery
pack.
#
Samples
1
5.1
Traceability
5.2
5.3
Part Number
Voltage
5.4
Chemistry
Ensure chemistry of battery pack
0
5.5
Pack Vendor
Identification
Ensure Host or Pack Vendor identified properly.
0
5.6
Circuit Layout
Ensure adequate runner spacing, soldering pad area
size, and distance between solder pads as well as
separation between traces.
0
December 2015
40
Reusable?
0
5
0
Use
samples
from 5.2
Use
samples
from 5.2
Use
samples
from 5.2
Revision 2.10
Certification Requirements Document
5.7
Cell Polarity
5.8
Ambient Thermal
Consideration
5.9
Component
Specifications
5.10
5.11
Thermal
Consideration
Limit Output
5.12
Pack Mechanisms
5.13
Thermal Protection
5.14
Thermal Sensor
Design
5.15
Action, Thermal
Protection
Charging
Specifications
5.16
5.17
Charge
Considerations
5.18
Charger Design
5.19
Protection
5.20
Protection
5.21
Specification
5.22
Pack Overcurrent
Protection
Requirement
External
Mechanical Force
Cell Dimensional
Allowance
5.23
5.24
December 2015
Ensure battery pack has individual cells oriented
properly
Confirm that the pack and system operate within their
specified temperature ranges and that the total
system interaction does not exceed the temperature
ratings of any components at worst case conditions
specified by host vendor.
Ensure battery pack components meet minimum and
maximum temperature requirements with adequate
margin and protection circuit components are rated for
operating range of -25°C to +85°C.
Ensure proper operating (charging and discharging)
ranges for battery pack have been set.
Validate performance of battery pack short circuit
protection.
0
Ensure pack has at least one method to limit current
from cells independent of the cell separator shutdown
mechanism.
Ensure over-temperature protection has been
incorporated that will prevent operation outside
current, temperature, and time limits as agreed to by
battery pack, cell and host vendor.
Validate that a thermal sensor either in the battery
pack and/or host monitors cell temperature and
enables the system to limit operation within the cell's
thermal specifications
Validate performance of temperature protection during
charging.
Ensure maximum charging voltage and current have
been set based on the component specifications
provided by the cell, battery pack and host device
vendors.
Verify system has one overcurrent protection function
that meets maximum current specified in IEEE 1725
section 6.5.1.
Validate design of charging system voltage and
current control is within maximum specified values.
Identify that the combination of the cell and pack has
at least one overvoltage protection function.
Validate performance of the pack/cell overvoltage
protection mechanism under a single fault condition in
the charger/host and to ensure that two overcharge
mechanisms are present in the system.
Ensure proper upper limit discharge current and time
limitations have been set.
Validate performance of pack discharge overcurrent
protection.
0
5
N
Validate mechanical robustness for purpose of use.
3
N
Ensure proper consideration for the cell and battery
pack dimensional tolerances.
0
41
0
0
0
0
Use
samples
from 5.2
0
5
N
0
0
0
0
0
0
0
Revision 2.10
Certification Requirements Document
5.25
5.26
Electrical Cell
Connections
Cell Vent
5.27
Host Requirement
5.28
5.29
ESD
Welding
5.30
Cell Shorts
5.31
Foreign Objects
5.32
Soldering Process
5.33
Reworked Cells
5.34
Circuit Care
5.35
Pack Component
Care
5.36
Welding Care
5.37
ESD
5.38
Pack Testing
During Production
5.39
Quality Control
5.40
Cell Care
5.41
Specification
5.42
Cell Chemistry
5.43
Fault
December 2015
Ensure that the connections directly to cells are not
soldered.
Ensure that the battery pack construction does not
prevent cell gases from escaping.
Ensure connector / terminal adhere to the host device
mechanical considerations.
Validate the ability of the pack to withstand ESD.
Ensure welding is only occurring in areas designated
by cell vendor.
Ensure assembly process avoids cell and battery pack
short-circuit.
Ensure assembly process prevents foreign objects
from contacting cell or protection circuit.
Ensure adequate means have been provided to
prevent solder balls, flashes, bridges, and other solder
defects from being introduced during the soldering
process.
Ensure cells salvaged from batteries that are
recovered / returned from end users are not used to
manufacture battery packs. Review SOP for returned
Materials or products.
Ensure precautions have been taken to avoid damage
to protection devices and circuits. Review SOP for
handling of safety and/or critical components and
devices.
Ensure precautions have been taken to avoid damage
to conductors and insulators, for example, from sharp
edges, burrs, pinching, or kinking.
Ensure precautions have been taken to avoid damage
to cells, protective circuit module, and battery pack
housing during housing assembly (ultrasonic welding,
over molding, etc.).
Ensure precautions have been taken to avoid damage
to protection circuits and other devices from ESD
during handling.
Ensure that all protection circuit operations shall be
directly or indirectly verified at the pack level (or pack
sub assembly) and 100% of shipped battery packs are
tested / verified.
Ensure that critical manufacturing processes have
quality control and maintenance plans to ensure the
consistency of the assembly process and adherence
to specifications.
Ensure that no damage has occurred during welding
and other operations to the cell case or other critical
cell design elements.
Ensure voltage, capacity, size, impedance, and other
critical specifications have been considered per
application for use of cells connected in parallel.
Ensure no cells from significantly different
electrochemical systems are used to manufacture
battery packs.
Ensure that adequate precautions have been taken to
42
0
0
0
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Revision 2.10
N
Certification Requirements Document
Considerations
5.44
Qualification of
New Pack Designs
5.45
Qualification of
Production Packs
5.46
Battery
Transportation
Regulations
5.47
Pack Overvoltage
Protection,
Verification and
Testing
5.48
Pack Drop Test
December 2015
limit charge rate to the maximum rating of any single
cell. FMEA analysis should consider such faults.
Ensure new pack designs have passed specified tests
identified by the vendor before qualification as a
production pack.
To establish that qualification requirements continue
to be met after product has been released for
production.
Ensure that vendor complies with transportation
regulatory testing requirements including the
appropriate sections of UN Manual of Tests and
Criteria.
To determine if hazards occur when cells are charged
to the maximum limit of the battery's overcharge
protection function as defined in Clause 6.6.5 in the
event that charge control per Clause 6.6 is not
functioning.
Validate the ability of pack to withstand a drop.
Total Packs Required
43
0
0
0
0
5
29
Revision 2.10
N
Certification Requirements Document
Section 6
Host Device Validation
All tests will be performed on a minimum of 5 samples unless otherwise specified (all samples
must pass compliance).
Inspection/Analysis criteria shall be done on a sample of one.
6.1
Input
Reference:
IEEE 1725, Section 7.2.1
Purpose:
Ensure specific surge and transient limits are included in the system design
specifications.
Procedure:
Review system design specifications.
Compliance: For systems with recognized adapters, ensure specific surge and transient limits are
included in specification.
For systems without adapters, ensure that the system design specifies the use of a
CTIA certified Adapter and/or a USB port in a device that complies with the USB-IF
certification requirements.
6.2
Input
Reference:
IEEE 1725, Section 7.2.1
Purpose:
Validate the ability of the system to filter damaging conducted transient voltages to
prevent damage to either the host device's charge control circuitry or the battery
pack's safety circuitry.
Procedure:
For adaptors with AC mains ports apply transients of 1.2/50(8/20)µs waveform in
accordance with IEC 61000-4-5. Ten transients (five positive and five negative) at
levels of 1kV line to neutral, 2kV line to ground and 2kV neutral to ground, shall be
applied at each zero crossing and peak (0, 90, 180 and 270 degrees phase angle) of
the applied ac voltage. Transients shall be applied at a rate of one per minute or less.
If testing done at rates faster than one per minute cause failures and tests done at
one per minute do not, the test done at one per minute prevails.
For adaptors connected to a vehicle wiring harness, apply pulses 1, 2a, 2b, 3a and
3b in accordance with ISO 7637-2:2011, at test level III, for at least the minimum
number of pulses or test time and for the minimum burst duration or at the minimum
pulse repetition time.
The equipment shall be on during the test and the battery pack shall be in the fully
discharged state at the beginning of the test. If the adaptor has no ground
connection only line to neutral transients need to be applied.
When a DC-DC adapter is connected to an AC adapter then the combined unit needs
to be tested as an AC adapter.
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Certification Requirements Document
For systems without specified adapters (which must have a USB port) shall be tested
with certified adapter, three representative adapters shall be tested with the host.
The adapters shall be selected by the host manufacturer from available CTIA certified
AC and DC adapters. At least one of each type (AC-DC and DC-DC) adapters shall
be used for testing.
Compliance: For systems without specified adapters (which must have a USB port) shall be tested
with a certified adapters, the battery pack safety circuitry functionality (overcharge,
overcurrent, undervoltage) remains after surge regime application, and one full
charge/discharge cycle is successfully completed per section 6.11. Compliance can
alternatively be met if the host fails in a demonstrated safe mode. A host "failing
safe" for this requirement is defined as the host can neither charge nor discharge a
battery. An example might be a fusible link clearing thus fully disabling the charge
circuitry.
For hosts without adapters, hosts shall meet the above compliance criteria when
tested with representative CTIA certified adapters.
6.3
Overvoltage
Reference:
IEEE 1725, Section 7.1, 7.2.2
Purpose:
Ensure host device is designed to indefinitely withstand the maximum voltage from
the adapter, under a single fault condition, to prevent a cascading failure through the
system to the battery pack and/or cell.
Procedure:
Initiate a charging condition via a way that allows host to charge. Once charging is
verified introduce the worst-case faulted overvoltage condition identified in the
charging system analysis described in the design analysis tools identified in IEEE
1725 section paragraph 4.1. One sample is required for this test.
Compliance: For systems with recognized adapters, no cascading failure through the system to
the battery pack and/or cell after 24 hours. At a minimum a complete charge cycle
shall be performed under normal operating conditions to validate performance
system specification after application of overvoltage.
For systems without adapters, no cascading failure through the system to the battery
pack and/or cell after charging at 9 V for 24 hours. At a minimum a complete charge
cycle shall be performed under normal operating conditions to validate performance
system specification after application of overvoltage.
6.4
Overcurrent
Reference:
IEEE 1725, Section 7.2.3
Purpose:
Ensure that the host limits current in such a way that the battery is not charged with a
current greater than the maximum charge current specified by the battery vendor.
Procedure:
Charge in a system with a battery (or emulated battery) and monitor current through
the entire charge cycle. One sample is required for this test.
Compliance: After an initial settling period, the maximum charge current specified by the battery
vendor is not exceeded. Such transient effects are limited to charge initiation
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including the pre-charge condition. Repetitive undesirable transients may constitute
non-compliance.
6.5
Overcurrent, Faulted
Reference:
IEEE 1725, Section 7.2.3
Purpose:
Ensure that the host limits current in such a way that the battery is not charged with a
current greater than the maximum charge current specified by the battery vendor
under the maximum faulted charge current from the adapter.
Procedure:
Initiate a charging condition via a way that allows host to charge. Once charging is
verified introduce the worst case faulted overcurrent condition identified in the design
analysis tools per IEEE 1725 paragraph 4.
Compliance: Maximum charge current specified by the battery vendor is not exceeded.
6.6
Fault Isolation and Tolerance
Reference:
IEEE 1725, Section 7.2.4, 6.6.5
Purpose:
Ensure that if a system design allows overvoltage or overcurrent to propagate to the
battery pack, the battery pack can withstand this overvoltage and / or overcurrent.
Procedure:
Review system documentation.
Compliance: Ensure that an overvoltage or overcurrent condition that propagates to the battery
back can be survived by the battery pack.
6.7
Fault Isolation and Tolerance
Reference:
IEEE 1725, Section 7.2.4, 6.6.5
Purpose:
Validate performance of system level charge over current or over voltage protection
during a worst case single fault condition as identified in section 6.6.
Procedure:
Setup worst case conditions as identified in section 6.6 for overcurrent situations.
Measure current and voltage at the battery pack. Setup worst case conditions as
identified in section 6.6 for overvoltage situations. Measure current and voltage at
the battery pack. A sample of one is required.
Compliance: Current and voltage are limited or prevented from propagating to the cell or the pack
so the cell/pack can withstand the condition (via protection either in host or pack, or
cell).
6.8
Safety
Reference:
IEEE 1725, Section 7.3.1
Purpose:
Ensure the charging system, or any part of the host device, does not disable or
override the safety features inside the battery pack.
Procedure:
Review system documentation.
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Compliance: Ensure that charging system or any part of the host device does not disable or
override the safety features inside the battery pack.
6.9
Pack Identification
Reference:
IEEE 1725, Section 7.3.2
Purpose:
Ensure proper identification scheme is employed and at a minimum communicates or
indicates the maximum charge voltage.
Procedure:
Review system documentation.
Compliance: Determine the identification scheme employed within the system and verify that the
maximum charging voltage is communicated or indicated. A mechanical scheme
only is not sufficient.
6.10 Pack Identification
Reference:
IEEE 1725, Section 7.3.2
Purpose:
Exercise the identification scheme in a faulted mode to ensure charging is
terminated.
Procedure:
Based on analysis interrupt the identification / communication scheme and insert
battery and initiate charge. Sample of one is required.
Compliance: Charge current is terminated or not initiated. This requirement applies to removable
and embedded packs. For embedded packs the method of compliance may be
verifying the cell/pack part number.
6.11 Algorithm Verification
Reference:
IEEE 1725, Section 7.3.3
Purpose:
Validate proper charge algorithm is identified and executed.
Procedure:
Insert fully discharged battery (or emulator) into system and monitor current and
voltage during charge cycle. Compare to specification to ensure proper charge
current and voltage is provided as specified by the pack vendor. One sample is
required.
Compliance: Ensure proper charge current and voltage is provided as specified by the pack
vendor.
6.12 Timer Fault
Reference:
IEEE 1725, Section 7.3.5
Purpose:
Validate the host does not charge for a time period exceeding the system
specification.
Procedure:
Determine whether a system specification for maximum charge time exists. If a
maximum charge time does exist, charge a battery for a period exceeding the system
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specification. This is accomplished by using a simulated failed battery or equivalent
method that will force the system to continue to charge past the intended time out.
Conduct a full charge cycle noting when the system stops charging. A sample size of
one is required.
Compliance: Charging stops when specified system charge time is exceeded.
6.13 Communication Fault
Reference:
IEEE 1725, Section 7.3.6
Purpose:
Validate integrity of communication interface (if present, for example SMBus or I2C)
and proper actions are taken if communication is prevented or interrupted.
Procedure:
Prevent or interrupt communications per system specifications and monitor current.
A sample of one is required.
Compliance: Charging is terminated or not initiated for systems that employ an electronic
communications interface.
6.14 Voltage Range Validation
Reference:
IEEE 1725, Section 7.3.8
Purpose:
Ensure system checks initial battery voltage.
Procedure:
Review system documentation.
Compliance: Ensure system validates initial battery voltage.
6.15 Initiation of Charging Above Specified Voltage Threshold
Reference:
IEEE 1725, Section 7.3.8.1
Purpose:
Validate charging system does not initiate charging when a battery is above a
specified voltage.
Procedure:
Charge a battery (or emulator) above the specified voltage or simulate the voltage
condition and insert into the charging system (Power applied to charging system prior
to insert AND power applied to charging system post insert). A sample of one is
required.
Compliance: Monitor current to ensure charging does not initiate per specification.
6.16 Initiation of Charging Below Voltage Threshold
Reference:
IEEE 1725, Section 7.3.8.2
Purpose:
Validate charging system does not initiate normal charging when a battery is below a
specified voltage.
Procedure:
Discharge a battery (or emulator) below the specified voltage or simulate the voltage
condition and insert into the charging system (Power applied to charging system prior
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to insert AND power applied to charging system post insert). A sample of one is
required.
Compliance: Monitor current to ensure charging does initiate per pack and cell specification.
6.17 Overdischarge Protection
Reference:
IEEE 1725, Section 7.3.8.3
Purpose:
If the host incorporates a battery discharge capability feature (normal operation is
excluded), Validate that host terminates discharge as defined by pack/cell vendor’s
specification.
Procedure:
Reduce the voltage at the host/pack interface until the host terminates discharge.
Specified nominal discharge current should be utilized to reduce voltage. A sample
of one is required.
Compliance: Verify that the pack discharge limit is not exceeded.
6.18 Charging Battery Packs
Reference:
IEEE 1725, Section 7.4.2
Purpose:
Ensure that in a multi-battery system that the system prevents a battery pack from
directly charging another battery pack without use of an appropriate charging
subsystem.
Procedure:
Review system documentation.
Compliance: Ensure multi-battery systems utilize appropriate charging subsystem to charge
batteries.
6.19 Requirements
Reference:
IEEE 1725, Section 7.4.1
Purpose:
Ensure that multi-battery pack systems implement requirements for the charging
algorithm to each battery pack independently.
Procedure:
Review system documentation.
Compliance: Ensure multi-battery pack systems have implemented charging algorithm to each
battery pack independently.
6.20 Electrostatic Discharge
Reference:
IEEE 1725, Section 7.5
Purpose:
Validate ESD tolerance of the host to withstand ESD as specified in Annex A table
A3 section 8.
Procedure:
Subject host to ESD in accordance with IEC 61000-4-2 per product level 2 at
minimum. If a host supports a removable battery pack, ESD testing should be
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performed on the battery contacts of the host (the battery pack is tested separately
under section 5.28). A sample size of one is required.
Additionally, systems without specified adapters, perform the test with the host
connected to the Adapter Simulator described in Appendix I – Adapter Simulator.
Compliance: No safety critical failures, such as loss of charge control or damage to battery
protection circuitry provided in the host.
6.21 Temperature Specification
Reference:
IEEE 1725, Section 7.6
Purpose:
Ensure system has incorporated temperature limitations as agreed by cell, battery
pack, and host vendor.
Procedure:
Review system documentation.
Compliance: System temperature limitation specifications are in agreement with cell, battery pack,
and host vendor specifications.
6.22 Mating of Pins
Reference:
IEEE 1725, Section 7.8.1.1
Purpose:
Ensure host and battery connections mate properly and capable of good electrical
contact.
Procedure:
Review host and battery pack connector specification.
Compliance: Ensure designs coordinate.
6.23 Mating of Pins
Reference:
IEEE 1725, Section 7.8.1.1
Purpose:
Validate integrity of connection throughout respective product lifetimes of mating
components.
Procedure:
Measure contact resistance after life cycle (defined in system specification).
Compliance: Verify that contact resistance is within specification and mechanical integrity
precludes shorting of contacts.
6.24 Pin Separation
Reference:
IEEE 1725, Section 7.8.1.2
Purpose:
Ensure power and ground pins are sufficiently separated.
Procedure:
Review host device battery interface.
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Compliance: Power and ground pins are electrically isolated with a minimum distance of 2.5 mm
or by a dielectric material between the power and ground contact points.
6.25 Pin Polarity
Reference:
IEEE 1725, Section 7.8.1.3
Purpose:
Verify battery pack is able to be connected with proper polarity only.
Procedure:
Analyze mechanical design of battery pack and host.
Compliance: Ensure that the battery cannot be inserted with incorrect polarity and that electrical
contact is made only when the battery pack is properly installed into the host.
6.26 Conductor Ratings
Reference:
IEEE 1725, Section 7.8.2
Purpose:
Ensure conductors and connectors have proper current rating for the current load
with adequate margin as determined by the system vendor.
Procedure:
Review electrical tolerance analysis.
Compliance: Conductors and connectors have proper current rating.
6.27 Connector Strength
Reference:
IEEE 1725, Section 7.8.3.1
Purpose:
Verify connector robustness.
Procedure:
Review system documentation and connector specifications.
Compliance: Connection between battery and host is mechanically robust.
6.28 Performance Over Expected Life
Reference:
IEEE 1725, Section 7.8.3.2
Purpose:
Verify connector robustness.
Procedure:
Perform design analysis on connection system.
Compliance: Acceptable contact resistance per specification is maintained over the lifetime of the
connection system.
6.29 Metallurgy Consideration
Reference:
IEEE 1725, Section 7.8.5
Purpose:
Ensure host device and battery pack have compatible metallurgy composition to
minimize corrosion and resistance changes.
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Procedure:
Review host device and battery pack connector specifications. IEC60950-1 Annex J
has a list of metallurgical compatibilities that may be referred to for additional
information.
Compliance: Proper metallurgy composition exists within the connection system.
6.30 Mating Force
Reference:
IEEE 1725, Section 7.8.6
Purpose:
Ensure proper mechanical force between the electrical contact points is maintained.
Procedure:
Review system documentation.
Compliance: Design minimizes fretting or other electrical degradation of electrical contact points.
6.31 Shock
Reference:
IEEE 1725, Section 7.8.7
Purpose:
Validate mechanical robustness of host device for purpose of use.
Procedure:
Subject host with a battery pack installed to the following drop test: Drop height 1
meter; one drop per plane; 6 mutually perpendicular planes; drop surface concrete.
A sample of one is required for each test.
Compliance: No abnormal heating, no smoke, no fire and / or leakage from battery pack or host.
6.32 Integrity of host charging and charge protection circuitry in the system Foreign
Objects
Reference:
IEEE 1725, Section 7.8.8
Purpose:
Ensure precautions were taken to minimize the potential for foreign objects and / or
liquids to enter the host device and cause a short circuit either during the
manufacturing process or end-user operation.
Procedure:
Review system documentation.
Compliance: Ensure proper precautions were taken to minimize the potential for foreign objects
and / or liquids to enter the host device and cause a short circuit either during the
manufacturing process or end-user operation.
6.33 Foreign Objects
Reference:
IEEE 1725, Section 7.9
Purpose:
Ensure preproduction testing includes all system design criteria in IEEE 1725 7.2,
7.3, 7.4, and 7.5.
Procedure:
Review system verification documentation.
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Compliance: Preproduction testing and production sampling include all of the design criteria
specified in IEEE 1725, sections 7.2 through 7.5.
6.34 Qualification of New Host Device Designs
Reference:
IEEE 1725, Section 7.9.1
Purpose:
Ensure new host device designs pass specified tests identified by the vendor before
qualification as a production host.
Procedure:
Review host device documentation.
Compliance: Ensure tests specified by the vendor were performed and passed.
6.35 Qualification of Production Host Devices
Reference:
IEEE 1725, Section 7.9.2
Purpose:
Ensure production host devices pass qualification tests at specified intervals.
Procedure:
Review host device documentation.
Compliance: Qualification tests are performed and passed as specified by the host vendor at the
prescribed intervals.
Section 6 - CATL Sample Submission Requirements
CRD
Sec
5.8
Name
Ambient
Considerations
5.14
5.14
Thermal
Sensor Design
5.15
Action, Thermal
Protection
5.23
Mechanical
Considerations
(Embedded
December 2015
Purpose
Confirm that the pack and host
operate within their specified
temperature ranges and that the
total system interaction does not
exceed the temperature ratings of
any components at worst case
conditions specified by host vendor
(such as maximum RF transmit
power, gaming applications, video
capture or playback, etc.).
Validate that a thermal sensor
either in the battery pack and/or
host monitors cell temperature and
enables the system to limit
operation within the cell's thermal
specifications
Validate performance of
temperature protection during
charging.
Validate mechanical robustness for
purpose of use.
53
Host
Samples
1
Pack
Samples
1
Adapter
Samples
1
Reusable?
5
5
0
Y
1
1
1
N
3
3
0
N
Revision 2.10
N
Certification Requirements Document
5.47
5.48
Packs Only
unless tested
during pack
recognition)
Pack
Overvoltage
Protection,
Verification, and
Testing
6.1
Pack Drop Test
(Embedded
Packs Only
unless tested
during pack
recognition)
Input
6.2
Input
6.3
Overvoltage
6.4
Overcurrent
6.5
Overcurrent,
Faulted
6.6
Fault Isolation
and Tolerance
6.7
Fault Isolation
and Tolerance
December 2015
To determine if hazards occur when
cells are charged to the maximum
limit of the battery’s overcharge
protection function as defined in
Clause 6.6.5 in the event that
charge control per Clause 6.6 is not
functioning.
Validate the ability of the pack to
withstand a drop.
0
5
0
N
5
5
0
N
Ensure specific surge and transient
limits are included in the system
design specifications.
Validate the ability of the system to
filter damaging conducted transient
voltages to prevent damage to
either the host device's charge
control circuitry or the battery pack's
safety circuitry.
Ensure host device is designed to
indefinitely withstand the maximum
voltage from the adapter, under a
single fault condition, to prevent a
cascading failure through the
system to the battery pack and/or
cell.
Ensure that the host limits current in
such a way that the battery is not
charged with a current greater than
the maximum charge current
specified by the battery vendor.
Ensure that the host limits current in
such a way that the battery is not
charged with a current greater than
the maximum charge current
specified by the battery vendor
under the maximum faulted charge
current from the adapter.
Ensure that IF a system design
allows overvoltage or overcurrent to
propagate to the battery pack, the
battery pack can withstand this
overvoltage and / or overcurrent.
Validate performance of system
level charge over current or over
voltage protection during a worst
case single fault condition as
0
0
0
1
1
1
N
1
1
1
N
0
0
0
Use
samples
from 6.10
0
0
0
0
0
0
1
1
1
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identified in Section 6.6.
6.8
Safety
6.9
Pack
identification
6.10
Pack
identification
6.11
Algorithm
Verification
6.12
Timer Fault
6.13
Communications
Fault
6.14
Voltage Range
Validation
Initiation of
Charging Above
Specified
Voltage
Threshold
Initiation of
Charging Below
Voltage
Threshold
Overdischarge
Protection
6.15
6.16
6.17
6.18
Charging
Battery Packs
6.19
Requirements
6.20
ESD
6.21
Temperature
December 2015
Ensure the charging system, or any
part of the host device, does not
disable or override the safety
features inside the battery pack.
Ensure proper identification scheme
is employed and at a minimum
communicates or indicates the
maximum charge voltage.
Exercise the identification scheme
in a faulted mode to ensure
charging is terminated.
Validate proper charge algorithm is
identified and executed.
0
0
0
0
0
0
1
1
1
Y
0
0
0
Validate the host does not charge
for a time period exceeding the
system specification.
Validate integrity of communication
interface (if present and periodic
update communication is used) and
proper actions are taken upon
interruption of the interface.
Ensure system checks initial battery
voltage.
Validate charging system does not
initiate charging when a battery is
above a specified voltage
0
0
0
0
0
0
Use
samples
from 6.10
Use
samples
from 6.10
Use
samples
from 6.10
0
0
0
0
0
0
Use
samples
from 6.10
Validate charging system does not
initiate normal charging when a
battery is below a specified voltage
0
0
0
Use
samples
from 6.10
If the host incorporates a battery
discharge capability feature (normal
operation is excluded), Validate that
host terminates discharge as
defined by pack/cell vendor’s
specification.
Ensure that in a multi-battery
system that the system prevents a
battery pack from directly charging
another battery pack without use of
an appropriate charging subsystem.
Ensure that multi-battery pack
systems implement requirements
for the charging algorithm to each
battery pack independently.
Validate ESD tolerance of the host
to withstand ESD as specified in
Annex A table A3 section 8.
Ensure charging system has
0
0
0
Use
samples
from 6.10
0
0
0
0
0
0
1
1
1
0
0
0
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Specification
6.22
Mating of Pins
6.23
Mating of Pins
6.24
Pin Separation
6.25
Pin Polarity
6.26
Conductor
Ratings
6.27
Connector
Strength
Performance
Over Expected
Life
Metallurgy
Consideration
6.28
6.29
6.30
Mating Force
6.31
Shock and
Vibration
Integrity of host
charging and
charge
protection
circuitry in the
system Foreign
Objects
Critical Testing
Practices
6.32
6.33
6.34
Qualification of
New Host
Device Designs
6.35
Qualification of
Production Host
Devices
Adapter ESD
Requirements
7.3
December 2015
incorporated temperature limitations
as agreed by cell, battery pack, and
host vendor.
Ensure host and battery
connections mate properly and
capable of good electrical contact.
Validate integrity of connection
throughout respective product
lifetimes of mating components.
Ensure power and ground pins are
sufficiently separated.
Verify battery pack is able to be
connected with proper polarity only.
Ensure conductors and connectors
have proper current rating for the
current load with adequate margin
as determined by the system
vendor.
Verify connector robustness.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Verify connector robustness.
0
0
0
Ensure host device and battery
pack have compatible metallurgy
composition to minimize corrosion
and resistance changes.
Ensure proper mechanical force
between the electrical contact
points is maintained.
Validate mechanical robustness of
host device for purpose of use.
Ensure precautions were taken to
minimize the potential for foreign
objects and / or liquids to enter the
host device and cause a short
circuit either during the
manufacturing process or end-user
operation.
Ensure preproduction testing
include all system design criteria in
IEEE 1725 7.2, 7.3, 7.4 and 7.5.
Ensure new host device designs
pass specified tests identified by the
vendor before qualification as a
production host.
Ensure production host devices
pass qualification tests at specified
intervals.
Validate ESD tolerance of the
adapter and system to withstand
ESD per IEC 61000-4-2.
Total Samples Required
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
8 (16 for
embedded
13
(21 for
8
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packs)
embedded
packs)
Sample count in table is based on single sample submission (1 battery & 1 adapter type).
Sample count is based on Recognized Adapter / Battery in system certification. If request
is for multiple adapters/batteries (recognized) additional sample count is required.
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Section 7
AC/DC Adapter, DC/DC Adapter Validation
All tests will be performed on a single sample unless otherwise specified (all samples must pass
compliance).
7.1
Adapter Attributes
Reference:
IEEE 1725, Section 8.2.1
Purpose:
Ensure listed attributes are specified for the adapter.
Procedure:
Review adapter specification.
Compliance: Verify adapter specifications include a) maximum output voltage, b) minimum output
voltage, c) maximum output voltage under a single fault, d) mechanical attributes that
define connector interface (including mechanical design, electrical pin-out, and
metallurgy), e) minimum output current, and f) if applicable, electrical interface
attributes for identification, authentication, etc.
For certified adapters, ensure that the adapter output is rated 5 ± 0.25 V, 1000 ± 500
mA.
7.2
Adapter and Safety Features
Reference:
IEEE 1725, Section 8.2.2
Purpose:
Ensure adapter does not disable or degrade the safety features of the supported host
device.
Procedure:
Review adapter and supported host device documentation.
For certified adapters, perform the single fault test in Section 6.3 and the input test in
Section 6.2 utilizing the host simulator in Appendix II – Host Simulator at 0% and
100% loads. During surge testing, voltages on the output of the adapter shall be
measured differentially at the host adapter using an oscilloscope. The oscilloscope
shall be triggered from the surge generator. During the test the oscilloscope
horizontal setting shall be adjusted from 1V/div to 50mV/div and the vertical setting
shall be adjusted from 2ms/div to 400ns/div. The largest transients shall be
recorded.
Compliance: For systems with recognized adapters, adapter does not disable or degrade the
safety features of the supported host device.
For certified adapters, the adapter does not: disable or degrade the safety features of
the supported host device; exceed 9 V during the worst case single fault test
specified in Section 6.3; or result in transients or voltages greater than ±1 V
superimposed on the nominal 5V output circuits during or after the application of the
input test specified in Section 6.2.
7.3
Adapter ESD Requirements
Reference:
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IEEE 1725, Section 8.2.3
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Purpose:
Validate ESD tolerance of the adapter and/or system to withstand ESD per IEC
61000-4-2.
Procedure:
Subject adapter and system to ESD in accordance with IEC 61000-4-2 per product
level 2 as a minimum. Certified adapters must be connected to host simulator for the
test.
Compliance: For systems with recognized adapters, no safety critical failures, such as loss of
charge control or damage to battery protection circuitry.
For certified adapters, the adapter output must not exceed 9 V after the test.
Note: N/A is only applicable for systems without specified adapters.
7.4
Connector Design of Adapter and Host and Adapter-Host Reliability
Reference:
IEEE 1725, Section 8.2.4.1 and 8.2.4.6
Purpose:
Verify connector robustness.
Procedure:
Perform or review design analysis on connection system.
Compliance: For systems with recognized adapters, acceptable contact resistance is maintained
per specification and contact and insulator integrity.
For certified adapters, connectors shall be robust and conform to USB specifications.
7.5
Separation of Pins
Reference:
IEEE 1725, Section 8.2.4.2
Purpose:
Ensure power and ground pins are sufficiently separated and polarized to ensure that
the connection can only be made with proper polarity.
Procedure:
Review adapter and host connector specifications.
Compliance: For systems with recognized adapters, spacing and connection are compatible.
For certified adapters, connectors shall conform to the spacings defined in USB
specifications.
7.6
Electrical Compliance
Reference:
IEEE 1725, Section 8.2.4.3
Purpose:
Ensure adapters that are powered by ac mains comply with all electrical safety
requirements of the country of destination.
Procedure:
Review adapter documentation.
Compliance: Ensure compliance to electrical safety requirements of the country of destination.
Minimum marking shall be NRTL (Nationally Recognized Testing Laboratory). Refer
to: www.OSHA.gov.
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7.7
Current Ratings
Reference:
IEEE 1725, Section 8.2.4.4
Purpose:
Ensure conductors and connectors have proper current rating.
Procedure:
Review adapter documentation.
Compliance: Ensure conductors and connectors have proper current rating.
7.8
Pin Metallurgy
Reference:
IEEE 1725, Section 8.2.4.5
Purpose:
Ensure adapter and charger or host connector pins have proper composition to
minimize corrosion and resistance changes.
Procedure:
Review host device and adapter connector specifications. IEC60950-1 Annex J has a
list of metallurgical compatibilities that may be referred to for additional information.
Compliance: For systems with recognized adapters, pin metallurgy is compatible.
For certified adapters, connectors shall comply with USB specifications.
7.9
Shock
Reference:
IEEE 1725, Section 8.2.4.7
Purpose:
Validate mechanical robustness of adapter for purpose of use.
Procedure:
Subject adapter to drop test, six mutually perpendicular planes, 1 (one) drop per
plane, height 1 (one), meter drop surface concrete. A sample of one per test is
required.
Compliance: Adapters functional normally per product specification. No physical deformation is
evident and no mating parts separate during testing.
7.10 Adapter and Foreign Objects
Reference:
IEEE 1725, Section 8.2.5
Purpose:
Ensure adapter design has taken precautions to minimize the potential for foreign
objects and / or liquids to enter the adapter and cause short circuit either during the
manufacturing process or end-user operation.
Procedure:
Review adapter design.
Compliance: Ensure precautions have been taken to minimize the potential for foreign objects and
/ or liquids to enter the adapter.
7.11 Adapter Marking and Traceability Requirements
Reference:
December 2015
IEEE 1725, Section 8.2.6
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Purpose:
Ensure each vendor has a traceability plan and each adapter carries markings of the
production lot and / or date code on the label.
Procedure:
Review the adapter documentation.
Compliance: Ensure adapter markings carry the production lot and / or date code on the label and
a traceability plan is in place.
7.12 Charger Considerations (AC/DC Charger, DC/DC Charger)
Reference:
IEEE 1725, Section 8.3
Purpose:
Ensure chargers meet requirements in IEEE1725 clauses 7 and 8.2.
Procedure:
Review charger documentation.
Compliance: Compliance to above mentioned clauses.
7.13 Critical Testing Practices
Reference:
IEEE 1725, Section 8.4
Purpose:
Ensure testing and verification of preproduction and production units includes all
system design criteria in IEEE1725 8.2 and 8.3.
Procedure:
Review adapter documentation.
Compliance: Testing and verification includes all system design criteria in IEEE1725, Section 8.2
and 8.3.
7.14 Qualification of New Adapter Designs
Reference:
IEEE 1725, Section 8.4.1
Purpose:
Ensure new adapter designs pass specified tests identified by the vendor before
qualification as a production adapter.
Procedure:
Review system documentation.
Compliance: Ensure specified tests pass before qualification as a production adapter.
7.15 Qualification of Production Adapters
Reference:
IEEE 1725, Section 8.4.2
Purpose:
Ensure qualification tests are passed at intervals as specified by the vendor.
Procedure:
Review adapter qualification test procedures (to determine required interval and test
programs), and adapter test reports.
Compliance: Qualification tests are conducted at the specified intervals and all specified test
requirements are passed.
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7.16 Common Power Supply (CPS) Minimum Output Load Current
Reference:
OMTP 4.3 Req. ID CPS-0140
Purpose:
To verify that the CPS is able to deliver at least 850mA at 5V (±5%) dc.
Procedure:
Load the output of the CPS with a variable resistive load. Starting from around 7 Ω,
reduce the resistance, while monitoring output current and output voltage of the CPS
to verify that output current/voltage requirement is met.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output current shall rise to at least 850mA while maintaining the output voltage at
the 5V ± 5% dc (Charging Port Output Voltage: VCHG from table 5-1 USB-IF BCS)
7.17 Common Power Supply (CPS) Common Mode Noise Measurement – AC Voltage
Component
Reference:
OMTP 4.3 Req. ID CPS-0170, OMTP 4.3 Req. ID CPS-0180
Purpose:
To verify the AC voltage frequency common mode noise of the output voltage of the
CPS.
Procedure:
Measure the common mode noise in accordance with Clause 6.2 of IEC 62684:2011,
but with a mains voltage of 264Vac, 60Hz.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The AC voltage frequency component of the common mode noise at the CPS output
shall be no more than 95V peak to peak.
7.18 Common Power Supply (CPS) Common Mode Noise Measurement – Switching
Frequency
Reference:
OMTP 4.3 Req. ID CPS-0170, OMTP 4.3 Req. ID CPS-0190
Purpose:
To verify the switching frequency common mode noise of the output voltage of the
CPS. Switching frequency in this instance means the fundamental frequency at which
the switching element of the power supply operates.
Procedure:
Measure the common mode noise in accordance with Clause 6.2 of IEC 62684:2011
but with a mains voltage of 264Vac, 60Hz.
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CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The switching frequency component of the common mode noise at the CPS output
shall be no more than 1V peak to peak.
7.19 Charging Port Requirements – Overshoot
Reference:
OMTP 4.3 Req. ID CPS-0170, USB-IF Battery Charging Specification Clause 4.1.1
Purpose:
To verify that the output voltage of the CPS does not exceed VCHG_OVRSHT for any
step change in load current, nor when the CPS is powered on or off.
Procedure:
Connect the CPS to a mains supply. Monitor the output voltage of the CPS while
changing the load as follows:
(i) Connecting and disconnecting a load which has been chosen to draw the
maximum rated current from the CPS.
(ii) Turning the CPS on and off under no load and maximum load conditions
(maximum rated current).
(iii) Step change sequence of 0 % - 100%, 100% - 50%, 50% - 0%, 0% - 75%,
75% - 100% and 100% - 0% of rated current.
Monitor the output voltage of the CPS during test.
Perform the test at 90 & 264 Vac, 60Hz.
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CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output voltage shall not exceed 6V at any time (Charging Port Overshoot
Voltage: VCHG_OVRSHT from table 5-1 USB-IF BCS).
7.20 Charging Port Requirements – Maximum Current
Reference:
OMTP 4.3 Req. ID CPS-0170, USB-IF Battery Charging Specification Clause 4.1.2
Purpose:
To verify that the CPS output current never exceeds ICDP max under any conditions.
Procedure:
Connect the CPS to a mains supply. Monitor the output current of the CPS under the
following conditions:(i) Short Circuit of the output
(ii) Overload of the output
(iii) Any other single fault condition in the secondary circuit that may result in an
increase of output current based on circuit, FMEA or similar analysis by the
adapter manufacturer. Only 1 single fault is applied at a time, at the end of
each test verification that the CPS is still functioning correctly is required before
performing the next single fault.
Perform the test at 264Vac, 60Hz.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output current shall not exceed 5A at any time (Charging Downstream Port
Rated Current: ICDP from table 5-2 USB-IF BCS)
7.21 Charging Port Requirements – Shutdown Operation
Reference:
OMTP 4.3 Req. ID CPS-0170, USB-IF Battery Charging Specification Clause 4.1.4
Purpose:
To verify the CPS operation if the load on its output causes it to go outside its
required operating range.
Procedure:
Connect the CPS to a mains supply. Monitor the output voltage and current while
varying the output load from open circuit to short circuit.
Perform the test at 90 & 264Vac, 60Hz.
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CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output of the CPS shall meet the requirements of USB Battery Charging
Specification Rev 1.2, Clause 4.4.1. The CPS is allowed to shut down when output
load causes it to go outside its required operating range, under this condition the
CPS shall turn off the output voltage, enter constant current limiting or enter foldback
current limiting.
7.22 Charging Port Requirements – Failure Voltage
Reference:
OMTP 4.3 Req. ID CPS-0170, USB-IF Battery Charging Specification Clause 4.1.5
Purpose:
To verify that the output voltage of the CPS remains within VCHG_FAIL for any single
fault conditions in the CPS.
Procedure: Connect the CPS to a mains supply of 264Vac, 60Hz. Introduce a single fault condition
into the CPS and monitor the output voltage with an output load drawing the nominal
rated current from the CPS. The fault shall be in the secondary circuit and which may
result in an increase of output voltage based on circuit, FMEA or similar analysis by
the adapter manufacturer. Only 1 single fault is applied at a time, at the end of each
test the CPS shall be verified that it is still functioning correctly before applying the
next single fault.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output voltage of the CPS shall remain within -0.3V and 9.0V (Charging Port
Failure Voltage: VCHG_FAIL from table 5-1 USB-IF BCS).
7.23 Charging Port Requirements – Multiple Ports
Reference:
Purpose:
Procedure:
USB-IF Battery Charging Specification Clause 4.1.6, OMTP 4.3 Req. ID CPS-0171,
OMTP 4.3 Req. ID CPS-0170
To verify that for a CPS with multiple output ports, that each output port stays within
its required operating range regardless of the operation of the other output ports.
Monitor the output voltage and current of all ports of the CPS while varying the load
conditions on one port, whilst all other ports of the CPS are loaded to maximum rated
load current.
Perform the test at 90 & 264Vac, 60Hz.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
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Compliance: The output of each port of the CPS shall stay within the Required Operating Range
for DCP of Figure 4-2 of USB Battery Charging Specification Rev 1.2, Clause 4.4.1.
7.24 Charging Downstream – Required Operating Range
Reference:
USB-IF Battery Charging Specification Clause 4.4.1, OMTP 4.3 Req. ID CPS-0170
Purpose:
To verify that the output voltage vs current characteristics meet the required
operating range for a dedicated charging port.
Procedure:
Connect the CPS to a mains supply. Monitor the output voltage and current of the
CPS while decreasing the load resistance from no load to one which draws more
than the maximum rated output current.
Perform the test at 90 & 264Vac, 60Hz.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output voltage vs current characteristics of the CPS shall at all times meet the
required operating range of the USB Battery Charging Specification Rev 1.2, Clause
4.4.1, or the CPS will have shut down by turning off the output voltage, entering
constant current limiting or entering foldback current limiting.
7.25 Charging Downstream – Undershoot
Reference:
USB-IF Battery Charging Specification Clause 4.4.2, OMTP 4.3 Req. ID CPS-0170
Purpose:
To verify that the output voltage of the CPS is at least VCHG_UNDHST during step
changes in the output current.
Procedure:
Connect the CPS to a mains supply. Monitor the output voltage while varying the
output load so that the output current is made to step change from:
a) 30mA to 100mA,
b) from 100mA to the CPS rated output current,
c) from 30mA to 100mA then 20ms later from 100mA to the CPS rated output
current.
Perform the test at 90 & 264Vac, 60Hz.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
Compliance: The output voltage shall not fall below 4.1V at any time (Charging Port Undershoot
Voltage : VCHG_UNDSHT from table 5-1 USB-IF BCS). Reductions in the output
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voltage from the nominal starting output voltage shall not last more than 10ms (DCP
undershoot voltage time: T DCP_UNDSHT from table 5-5 USB-IF BCS).
7.26 Charging Downstream – Detection Signaling
Reference:
USB-IF Battery Charging Specification Clause 4.4.3, OMTP 4.3 Req. ID CPS-0170
Purpose:
To verify that the impedance between, the leakage from and the capacitance between
D+ and D- of the CPS output meet the requirements of USB Battery charging
Specification Rev 1.2.
Procedure:
With the CPS unpowered, measure the following:
i) the impedance between D+ and D- of the output of the CPS .
ii) the capacitance between :
a) D+ and 0 V,
b) D- and 0 V,
c) D+ and +5 V
d) D- and +5 V.
With the CPS powered from 264Vac, 60Hz, measure the leakage current from:
a) D+ to 0 V,
b) D- to 0 V
c) D+ to +5 V
d) D- to +5 V.
CPS with a captive output cable measurements are made at the Micro-B connector.
For CPS with detachable cable measurements are made at CPS output connector,
USB Standard-A connector.
The test leads shall be kept to a minimum length and the selection of measurement
instruments shall not adversely influence the result. An appropriate 4 wire resistance
meter and measuring bridge are examples of measurement instruments that may be
used.
Compliance: The impedance between D+ and D- shall be no more than 200Ω (RDCP_DAT from
table 5-3 USB-IF BCS)
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The leakage current shall be no more than 24 μA
(3.6V through two 300kΩ in parallel. This is VDAT_LKG from table 5-1 and RDAT_LKG
from table 5-3 USB-IF BCS).
The capacitance shall be no more than 1nF (CDCP_PWR from table 5-4 USB-IF BCS)
7.27 Charging Downstream – Connector
Reference:
OMTP 4.3 Req. ID CPS-0110, CPS-0111, CPS-0120, CPS-0130 & CPS-0170 USBIF Battery Charging Specification Clause 4.4.4
Purpose:
To verify CPS connector.
Procedure:
Verify that the CPS has a one of the following means of connection to the host device:
(i) USB Standard –A Receptacle meeting Ruggedized category of the USB-IF
standard with a USB Standard –A to Micro-B detachable cable
(ii) Captive cable terminated with USB Micro-B plug
Compliance: The CPS has one of the above options provided. The connector/cable is being in
compliance with USB-IF USB Cable and Connectors Class Document 2.0 standard.
This is verified by visual inspection and documented evidence of compliance to USBIF USB Cable and Connectors Class Document 2.0.
7.28 Detachable Cable – Voltage Drop Test
Reference:
Purpose:
Procedure:
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USB Cables and Connectors Class Document Rev.2.0 clause 3, OMTP 4.3 Req. ID
CPS-0170, USB Specification 2.0 Rev.2.0 Clause 7.2.2 Figure 7-47.
To verify the voltage drop introduced by the detachable output cable does not exceed
the USB Class requirement.
Configure the test set up as below:
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Compliance: The voltage measured across the Micro-B USB connector shall be ≥ (Vin – 2 x
125mV) under a load of 500mA.
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Section 7 - CATL Sample Submission Requirements
Section
Name
7.1
Adapter Attributes
7.2
Adapter & Safety
Features
7.2
Adapter & Safety
Features (Certified
Adapters Only)
Adapter ESD
Requirements
7.3
7.3
7.5
Adapter ESD
Requirements
(Certified Adapters
Only)
Connector Design of
Adapter and Host and
Adapter-Host
Reliability
Separation of Pins
7.6
Electrical Compliance
7.7
Current Ratings
7.8
Pin Metallurgy
7.9
Shock
7.10
Adapter and Foreign
Objects
7.11
Adapter Marking and
Traceability
Requirements
7.12
Charger
Considerations
(AC/DC Charger,
DC/DC Charger)
Critical Testing
Practices
7.4
7.13
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Purpose
Ensure adapter meets input requirements
of the supported host charging device.
Ensure adapter does not disable or
degrade the safety features of the
supported host device.
Ensure adapter does not disable or
degrade the safety features of the
supported host device.
Validate ESD tolerance of the adapter and
system to withstand ESD per IEC 610004-2.
Validate ESD tolerance of the adapter and
system to withstand ESD per IEC 610004-2.
Adapter
Samples
0
0
2
N
0
1
Verify connector robustness.
0
Ensure power and ground pins are
sufficiently separated and polarized to
ensure that the connection can only be
made with proper polarity.
Ensure adapters that are powered by ac
mains comply with all electrical safety
requirements of the country of destination.
Ensure conductors and connectors have
proper current rating.
Ensure adapter and host connector pins
have proper composition to minimize
corrosion and resistance changes.
Validate mechanical robustness of adapter
for purpose of use.
Ensure adapter design has taken
precautions to minimize the potential for
foreign objects and / or liquids to enter the
adapter and cause short circuit either
during the manufacturing process or enduser operation.
Ensure each vendor has a traceability plan
and each adapter carries markings of the
production lot and / or date code on the
label.
Ensure chargers meet requirements in
IEEE1725 clauses 7 and 8.2.
0
Ensure testing and verification of
preproduction and production units
0
70
Reusable
?
N
0
0
0
0
0
0
0
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Certification Requirements Document
7.14
Qualification of New
Adapter Designs
7.15
Qualification of
Production Adapters
Common Power
Supply (CPS)
Minimum Output Load
Current
Common Power
Supply (CPS)
Common Mode Noise
Measurement –AC
Voltage Component
Common Power
Supply (CPS)
Common Mode Noise
Measurement –
Switching Frequency
7.16
7.17
7.18
7.19
Charging Port
Requirements –
Overshoot
7.20
Charging Port
Requirements –
Maximum Current
Charging Port
Requirements –
Shutdown Operation
Charging Port
Requirements –Failure
Voltage
Charging Port
Requirements –
Multiple Ports
7.21
7.22
7.23
7.24
7.25
Charging Downstream
-Required Operating
Range
Charging Downstream
-Indershoot
7.26
Charging Downstream
– Detection Signalling
7.27
Charging Downstream
– Connector
December 2015
includes all system design criteria in
IEEE1725 8.2 and 8.3.
Ensure new adapter designs pass
specified tests identified by the vendor
before qualification as a production
adapter.
Ensure qualification tests are passed at
intervals as specified by the vendor.
To verify that the CPS is able to delivery at
least 850mA at 5V (±5%) dc
0
0
1
Y
To verify the AC voltage frequency
common mode noise of the output voltage
of the CPS.
0
Use
sample
from 7.16
To verify the switching frequency common
mode noise of the output voltage of the
CPS. Switching frequency in this instance
means the fundamental frequency at
which the switching element of the power
supply operates.
To verify that the output voltage of the
CPS does not exceed VCHG_OVRSHT for
any step change in load current, nor when
the CPS is powered on or off.
To verify that the CPS output current
never exceeds ICDP max under any
conditions.
To verify the CPS operation if the load on
its output causes it to go outside its
required operating range.
To verify that the output voltage of the
CPS remains within VCHG_FAIL for any
single fault conditions in the CPS.
To verify that for a CPS with multiple
output ports, that each output port stays
within its required operating range
regardless of the operation of the other
output ports.
To verify that the output voltage vs current
characteristics meet the required operating
range for a dedicated charging port.
To verify that the output voltage of the
CPS is at least VCHG_UNDHST during step
changes in the output current.
To verify that the impedance between, the
leakage from and the capacitance
between D+ and D- of the CPS output
meet the requirements of USB Battery
charging Specification Rev 1.2.
To verify CPS connector.
0
Use
sample
from 7.16
0
Use
sample
from 7.16
1
N
1
N
1
N
0
Use
sample
from 7.16
1
N
0
Use
sample
from 7.16
Use
sample
from 7.16
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7.28
Detachable Cable –
Voltage Drop Test
To verify the voltage drop introduced by
the detachable output cable does not
exceed the USB Class requirement.
Total Samples Required
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1
N
0 (8for
Certified
Adapters
)
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Section 8
8.1
Total System Reliability Validation
User Interactions and Responsibilities
Reference:
IEEE 1725, Section 9.2
Purpose:
Determine that required user information is provided.
Procedure:
Determine by inspection that the following information is made available to the user
by one or more of (a) printed on the label for the battery, (b) printed on the label for
the host device, (c) printed in the owner's manual, and/or (d) posted in a help file or
Internet web site.
a) Do not disassemble or open crush, bend or deform, puncture or shred
b) Do not modify or remanufacture, attempt to insert foreign objects into the battery,
immerse or expose to water or other liquids, expose to fire, explosion or other
hazard.
c) Only use the battery for the system for which it is specified
d) Only use the battery with a charging system that has been qualified with the
system per CTIA Certification Requirements for Battery System Compliance to IEEE
1725. Use of an unqualified battery or charger may present a risk of fire, explosion,
leakage, or other hazard.
e) Do not short circuit a battery or allow metallic conductive objects to contact battery
terminals.
f) Replace the battery only with another battery that has been qualified with the
system per this standard, IEEE-Std-1725. Use of an unqualified battery may present
a risk of fire, explosion, leakage or other hazard.
Only authorized service providers shall replace battery. (If the battery is non-user
replaceable).
g) Promptly dispose of used batteries in accordance with local regulations
h) Battery usage by children should be supervised.
j) Avoid dropping the phone or battery. If the phone or battery is dropped, especially
on a hard surface, and the user suspects damage, take it to a service center for
inspection.
k) Improper battery use may result in a fire, explosion or other hazard.
For those host devices that utilize a USB port as a charging source, the host device's
user manual shall include a statement that the phone shall only be connected to
CTIA certified adapters, products that bear the USB-IF logo or products that have
completed the USB-IF compliance program.
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Compliance: Language that communicates the intention of each of the above warnings is included
with the product. For non-user-replaceable batteries use sections: a, b, d, f, g, j, k
and the final USB-IF statement.
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Section 9
9.1
System Security Validation
Host and Battery Authentication
Reference:
IEEE 1725, Section 10.2.1
Purpose:
To ensure that there is an authentication method in place
Procedure:
Identify method of authentication that has been implemented.
Compliance: A method of active or passive authentication has been implemented. Embedded
batteries are exempt from this requirement.
9.2
Ensuring Supply Chain Security
Reference:
IEEE 1725, Section 10.4.1
Purpose:
To ensure that adequate security of supply chain is in place and that a security audit
plan exists and is being followed.
Procedure:
Audit supply chain security process.
Verify that the vendors have documented processes which address the integrity of
their supply chain such that no materials enter the supply chain inappropriately.
Verify that these processes have been implemented, are being followed and the
vendor is periodically verifying compliance to the processes.
Compliance: Practices and/or procedures exist and are followed to ensure supply chain security.
9.3
Avoiding Defective Parts
Reference:
IEEE 1725, Section 10.4.2
Purpose:
To ensure that adequate security of supply chain, including defective components, is
in place and that a security audit plan exists and is being followed. Ensure defective
components do not re-enter the supply chain.
Procedure:
Audit supply chain security process.
Verify that the vendors have documented processes which address the integrity of
their supply chain such that no defective materials enter the supply chain. Verify
that these processes have been implemented, are being followed, and the vendor is
periodically verifying compliance to the processes.
Compliance: Practices and/or procedures exist and are followed to ensure supply chain security.
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9.4
Battery Pack Identification
Reference:
IEEE 1725, Section 10.4.3
Purpose:
Determine the vendor has a means of identification within a battery pack to allow
verification, by said vendor, of the battery pack and cells if the external housing is
destroyed.
Procedure:
Review the battery pack documentation to determine the method implemented.
Compliance: A means of identification within the battery pack has been implemented to allow
identification of cell(s) and pack, if the external housing is destroyed.
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Section 10 Validation
10.1 Component Requirements
Reference:
IEEE 1725, Section 11.3.1
Purpose:
Determine by analysis that all system components used in design under test comply
with this standard.
For a design to be considered compliant to this standard, all system components
used in a design shall be compliant to this standard
Procedure:
Determine by analysis that all system components used in design under test comply
with this standard.
Compliance: System components comply.
10.2 Record Keeping
Reference:
IEEE 1725, Section 11.3.3
Purpose:
Determine by inspection that records defining compliance are maintained by the
vendor of record.
Records defining compliance shall be maintained by the vendor of record. The
specific format of such records is not specified.
Procedure:
Inspect documentation.
Compliance: Documentation exists and meets minimum requirements.
10.3 Quality System Requirements
Reference:
IEEE 1725, Section 11.4
Purpose:
Determine that manufacturer/supplier's quality system meets requirements of ISO9000.
Procedure:
Determine by inspection that manufacturer/supplier holds valid relevant ISO-9000
certificate.
Compliance: Manufacturer/supplier is registered to ISO-9000:2000.
10.4 Definition of Safety Critical Variables
Reference:
IEEE 1725, Section 11.5.1 (N/A - See compliance)
Purpose:
To ensure that the vendor has defined and documented product and process
variables that relate to product safety (safety critical variables).
Procedure:
Evaluate the vendor’s product and process documentation.
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Compliance: Safety critical variables have been defined. Compliance to this requirement will not
be evaluated separately, but instead will be demonstrated as a part of the cell, pack,
host, and system requirements.
10.5 Definition of Critical Measurement Processes
Reference:
IEEE 1725, Section 11.5.2 (N/A - See compliance)
Purpose:
To ensure that the vendor has defined critical measurement processes for safety
critical variables.
Procedure:
Evaluate the vendor’s product and process documentation.
Compliance: Critical Measurement processes have been defined for the safety critical variables.
Compliance to this requirement will not be evaluated separately, but instead will be
demonstrated as a part of the cell, pack, host, and system requirements.
10.6 Confirmation of Critical Measurement Process Capability
Reference:
IEEE 1725, Section 11.5.3 (N/A - See compliance)
Purpose:
To ensure that the vendor has validated the measurement capability of those critical
measurement processes used to assess safety critical variables to both understand
and minimize the impact of measurement error.
Procedure:
Evaluate the vendor’s product and process documentation, with particular attention to
measurement system analysis studies.
Compliance: Critical Measurement processes have been shown to be capable to assess the
safety critical variables defined. Compliance to this requirement will not be evaluated
separately, but instead will be demonstrated as a part of the cell, pack, host, and
system requirements.
10.7 Confirmation of Process Stability
Reference:
IEEE 1725, Section 11.5.4 (N/A - See compliance)
Purpose:
To ensure that the vendor’s processes that relate to safety critical variables (both
product and process) are sufficiently stable such that they can be reliably predicted
and thus controlled.
Procedure:
Evaluate the vendor’s product and process documentation, with particular attention to
process tracking data used to substantiate process stability for process or part
qualification.
Compliance: Vendor’s processes that relate to safety critical variables (both product and process)
are sufficiently stable. Compliance to this requirement will not be evaluated
separately, but instead will be demonstrated as a part of the cell, pack, host, and
system requirements.
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10.8 Confirmation of Process Capability
Reference:
IEEE 1725, Section 11.5.5 (N/A - See compliance)
Purpose:
To ensure that the vendor’s processes that relate to safety critical variables (both
product and process) have sufficient process capability in regards to their respective
specifications, thus minimizing the chance of an out of specification condition.
Procedure:
Evaluate the vendor’s product and process documentation, with particular attention to
process capability studies.
Compliance: Vendor’s processes have been shown to be capable of meeting the specifications for
the safety critical variables defined with acceptable margin. Compliance to this
requirement will not be evaluated separately, but instead will be demonstrated as a
part of the cell, pack, host, and system requirements.
10.9 Process Monitoring and Reaction to Out-of-Control Events
Reference:
IEEE 1725, Section 11.5.6 (N/A - See compliance)
Purpose:
To ensure that the vendor has defined and implemented appropriate process
monitoring and control to those processes that relate to safety critical variables (both
product and process). Additionally, should an out-of-control event occur, that the
vendor conducts an appropriate investigation and, if required, implements necessary
corrective actions to bring the process back in control.
Procedure:
Evaluate the vendor’s product and process documentation, with particular attention to
process control plans and process control data for safety critical process variables,
and vendor-provided or incoming inspection data for safety critical product variables.
Compliance: The vendor has defined and implemented appropriate process monitoring and control
such that safety critical product and process variables are adequately controlled.
Evidence exists that out-of-control events are properly investigated and corrective
actions applied where appropriate. Compliance to this requirement will not be
evaluated separately, but instead will be demonstrated as a part of the cell, pack,
host, and system requirements.
10.10 Process Improvement Actions
Reference:
IEEE 1725, Section 11.5.7 (N/A - See compliance)
Purpose:
To ensure that the vendor documents and implements an appropriate process
improvement strategy to enhance the capability of safety critical product and process
variables.
Procedure:
Evaluate the vendor’s product and process documentation, with particular attention to
product and process improvement strategies and actions.
Compliance: A program of process improvement has been implemented on those processes
related to safety critical product and process variables. Compliance to this
requirement will not be evaluated separately, but instead will be demonstrated as a
part of the cell, pack, host, and system requirements.
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Appendix I – Adapter Simulator
USB Connector
Host
470k
USB Connector
470k
Details: Adapter simulator is constructed in a plastic box with 1.5V batteries. Power output shall be
between 4.75 - 5.25 under load. Data pins shall be shorted together. Cable is 1m ±5cm USB cable with
drain attached to the shield within 5cm of Adapter Simulator. 10nF, 20% max capacitor and 1N54 series
diode placed between the batteries. Shield drain wire grounded to horizontal ground plane via drain wire
as illustrated.
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Appendix II – Host Simulator
10k
Adapter
USB Connector
TP
+
+
-
1uF
TP
Details: Host simulator is constructed in a plastic box and contains non-inductive resistive loads. Cable
is 1m ±5cm USB cable. Test points shall be available for monitoring of surge waveform. First resistor is
10k, 10% max tolerance to simulate 0% loads. Other resistors added for 100% loading. More than one
path can be created if one host simulator is used for multiple capacities of adapters. Capacitor is ceramic
1uF capacitor with 20% max tolerance. Number of resistors in the Host Simulator is variable, and may be
replaced with one or more variable resistors of sufficient power rating.
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Appendix III – Change History
Date
Revision
Description
October 2006
1.0
 First Revision
December
2006
1.1
 Updated entire document
April 2007
1.2
 Updated requirements in all sections
July 2007
1.3
 Updated Validation Process section
 Changed section headings to match IEEE 1725 section headings
 Removed validation type from section titles
 Converted types to either Test or Audit (eliminated Inspection and
Analysis)
 Changed “Subsystem Requirements, Battery Pack” to
“Subsystem Requirements, Transport of Dangerous Goods,
Battery Pack”
 Changed “Subsystem Requirements, Transport of Dangerous
Goods” to “Subsystem Requirements, Transport of Dangerous
Goods, Cell”
 Updated procedure and compliance criteria for Cell Validation Internal Short Avoidance
 Added Cell Thermal Test (Audit) section back in
 Updated procedure for Cell Validation - Evaluation of Excess
Lithium Plating and Short-Circuit Test on Cycled Cells
 Clarified procedure for Battery Pack Validation - Ambient
Consideration
 Clarified compliance criteria for Battery Pack Validation - Thermal
Consideration
 Updated procedure and compliance criteria for Battery Pack
Validation - Mechanical Considerations
 Updated purpose and compliance criteria for Host Device
Validation - Input
 Clarified procedure for Host Device Validation - Timer Fault
October 2007
1.4
 Section 1.3 (Applicable Documents) – clarified that latest version
shall be used
 Section 1.4 – added definitions to acronyms
 Section 2.2 (Test) – updated description
 Section 4.2 (Isolation Properties) – updated compliance
 Section 4.38 (Tab Positioning) – updated procedure
 Section 4 Sample Size and Re-use Table – added Section 4.51
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 Section 5 introduction – changed inspection/analysis to audit
 Section 5.10 (Thermal Consideration) – updated purpose and
compliance
 Section 5.23 (Mechanical Considerations) – updated reference
and procedure
 Section 5.28 (ESD) – updated procedure
 Section 5.38 (Pack Testing During Production) – updated
procedure and compliance
 Section 5 Sample Requirements Summary table – updated #
Samples for Section 5.23 and Total Packs Required
 Section 6.9 (Pack Identification) – updated Compliance
 Section 6.31 (Shock and Vibration) – updated procedure
 Section 6 Samples Table – updated # Samples in Section 6.2
 Section 7.3 (Adapter ESD Requirements) – updated procedure
 Section 7.9 (Shock and Vibration Effects) – updated procedure
 Section 7 – added Samples Table
 Section 8.1 (User Interactions and Responsibilities) – updated
procedure
January 2008
1.5
 ALL Sections – Removed “Type” Headings and content
 Section 1.3 – Removed date reference for UL1642
 Section 1.4 – Correction of Abbreviation of PCM and addition of a
definition of “C”
 Section 3.2 - Added details of minimum marking requirements
 Section 3.3 - Added details of minimum marking requirements
 Section 4.6 – Clarification
 Section 4.13 – Added “Supplementary” to Title
 Section 4.43 – Addition of vision inspection of insertion process
 Section 4.52 – Replaced UL1642 procedure with IEEE1725 short
circuit procedure.
 Section 5.13 - Removal of requirement for low discharge
(Standby) rates.
 Section 5.15 – “Cell” changed to “Pack” and temperature spec
clarified
 Section 5.26 – Re wording of compliance statement
 Section 6, Sample table – 6.31 requirement reduced from 2 to 1
 Section 7.3 – Changed “adapter” to “adapter and system”
 Section 7.6 – Added details of minimum marking requirements
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March 2008
December 2015
1.6

Section 4.2 – Updated procedure for clarification.

Section 4.3 – Updated procedure to remove “Auditor to ask for”
and added review

Section 4.6 – Updated compliance, replaced measurements with
measurement data

Section 4.11 – Updated purpose and added “tab”. Updated
procedure to remove “Auditor to ask for”

Section 4.12 – Updated procedure to add “Not applicable to the
cells that have more than one single tab at cell core initiation
(such as stacking or folding configurations).”

Section 4.13 – Updated procedure to add “Not applicable to the
cells that have more than one single tab at cell core initiation
(such as stacking or folding configurations).”

Section 4.14 – Updated procedure to delete randomly selected.
Added “Not applicable to the cells that have more than one
single tab at cell core initiation (such as stacking or folding
configurations).”

Section 4.15 – Updated procedure for clarification. Deleted
“Inspect production line and note the insulation material used.”

Section 4.16 – Updated procedure, replaced “Air, N2, Ar etc.”
with “Air or inert gas (e.g. N2, Ar etc.)”

Section 4.23 – Updated procedure for clarification, deleted “by
sampling”

Section 4.24 – Updated procedure to add “heights” and delete
“lengths”

Section 4.25 – Deleted “length” from clause title, Updated
purpose to replace lengths with heights

Section 4.30 – Updated compliance, added missing letter “m”
and (winding processes only)

Section 4.33 – Updated purpose, procedure and compliance,
added “core assembly” and deleted “winding”.

Section 4.37 – Updated procedure, added “and manufacturing
inspection processes”

Section 4.39 – Updated procedure for clarification

Section 4.42 – Updated procedure for clarification. Updated
compliance to add “Additionally, the process control
documentation confirms that the insulating material is checked
with resistive measurement or other technological means or
methods.”

Section 4.43 – Updated procedure for clarification, added
“Ensure that manufacturer’s vision system is calibrated and
repeatable.”

Section 4.48 – Updated procedure and compliance, deleted
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“Auditor”
July 2008
December 2015
1.7

Section 5.47 – Updated procedure, added “Alternative method
to insulate the cells (with minimum thermal resistance with R
value of 5) can be used to perform this test.”

Section 6.4 – Updated compliance, added “After an initial
settling period, the” and “Such transient effects are limited to
charge initiation including the pre-charge condition. Repetitive
undesirable transients may constitute non-compliance.”

Section 9.2 – Updated procedure, deleted “The auditor shall”

Section 9.3 – Updated procedure, deleted “The auditor shall”

Section 4 – Updated Sample Size and Re-use Table, added
purpose

Section 7 - Updated Samples table, added purpose

Section 1.4 - Replaced "C" definition with C – Rated capacity of
a Battery or Cell as defined by IEC 62133 and UL 2054.

Section 2 - Revised paragraph to refer to CRSL for variable
definitions.

Section 2.1 - Deleted based on change to Section 2.

Section 2.2 - Deleted based on change to Section 2.

Section 4.13 - Added "unless demonstrated by documented
evaluation report" to Compliance statement.

Section 4.43 - Deleted repetitive "4.43".

Section 5.14 - Changed procedure statement from "one" to "five"
samples.

Section 5.19 - Edited Purpose, Procedure and Compliance
statements to require one overvoltage protection function for the
combination of the cell and pack. Deleted any references to
"host" and "overcharge".

Section 5.28 - Deleted "6.11" from Compliance statement.

Section 5.38 - Added "electronic" to Purpose and Procedure
statement. Replaced Compliance statement with "100% testing
of the electronic protection circuit(s) is performed during the
manufacturing process".

Section 5.43 - Replaced Compliance statement with "The
manufacturer/supplier shall take adequate precautions to ensure
that the charge rate does not exceed the maximum of any single
cell in the event that the other cell(s) should become electrically
disconnected."

Section 5 - Sample Requirements Summary - Changed "#
Samples" to "5".

Section 6.31 - Deleted "and Vibration" from section title.
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October 2008
December 2015
1.8

Section 7.9 - Deleted "and Vibration Effects" from section title.
Deleted " Vibration: Directly secure adapters to the vibration
table. The adapters shall be randomly vibrated per MIL-STD810F method 514.5, Procedure I, Category 24, per Figure
514.5C-17. The test time shall be one hour per plane for three
planes." from Procedure statement.

General - Ambient Temperature defined in Section 1.4 as 20 ± 5
°C. "Room" replaced with "ambient" in Sections 4.2, 4.4, 4.5,
4.50, 4.52, 5.8, 5.22 and 5.28; Table of Contents 4.4 and 5.8;
and Section 5 - Sample Requirements Summary Table CRD
Sec 5.8.

Section 3.7 Compliance - Replaced "documentation from UL
that the cell is recognized and how the recognition was
achieved" with "evidence showing that all tests called for in UL
1642 (user-replaceable) have passed".

Section 4.4 Compliance - Replaced "Measurements shall
demonstrate 0.1 mm separator coverage on each side (plus
process margin). If less than 0.1 mm overlap is observed, the
cell manufacturer shall submit supporting safety evidence" with
"Measurements shall demonstrate at least 0.1 mm separator
coverage on each side (plus process margin). If less than 0.1
mm overlap is observed, the cell manufacturer shall submit
supporting safety evidence".

Section 4.36 Compliance - Deleted extra "4" from header.
Deleted "that" and "are" from "Validate the method of assembly
for insulating material properties is sufficient to provide
protection from shorts over the projected lifetime of the cell" in
Compliance statement. Inserted "method of assembly for" after
"Validate the" in second sentence.

Section 4.50 Compliance - Replaced "5 cells at 100% SOC shall
be suspended (no heat transfer allowed to non-integral cell
components) in a gravity convection or circulating air oven at
room temperature. The oven temperature shall be ramped at 5 ±
2°C per minute to 130 ± 2°C. After 1 hour at 130 ± 2°C, the test
is ended." with "5 fully charged cells (per cell manufacture's
specifications) shall be suspended (no heat transfer allowed to
non-integral cell components) in a gravity convection or
circulating air oven at ambient temperature. The oven
temperature shall be ramped at 5 ± 2°C per minute to 130 ±
2°C. After 1 hour at 130 ± 2°C, the test is ended".

Section 5.14 Compliance - Replaced "The thermistor continues
to track cell temperature throughout the entire operating
temperature range of the battery pack. Packs of the same
model shall have the same voltage to temperature translation
(acceptable tolerance no more than ±10%)" with "Verify the
resistance of the battery pack's thermistor circuit, if used, is
within +/-10% of the temperature-resistance translation, as
specified by the thermistor manufacturer and battery pack
designer, over the operating temperature range of the battery".
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January 2009
March 2009
December 2015
1.9
1.10

Section 5.23 Procedure - Replaced "Steady Force test shall be
performed per UL 2054 paragraph 19" with "If the battery pack is
user replaceable, perform the Steady Force test per UL 2054 on
the battery pack. If the pack is non-user replaceable, the test
may optionally be performed on the host device with the battery
pack installed".

Section 5 - Sample Requirements Summary Table - Changed
"Y" to "N" in "# Samples" column in "CRD Sec" rows 5.11 and
5.22.

Section 6.16 Compliance - Replaced "cell" with "pack".

Section 9.4 Purpose - Replaced "Determine that the
manufacturer has a means of identification within a battery pack
to allow verification, by said manufacturer, of the battery pack
and cells" with "Determine the manufacturer has a means of
identification within a battery pack to allow verification, by said
manufacturer, of the battery pack and cells if the external
housing is destroyed".

Section 9.4 Compliance - Replaced "A means of identification
has been implemented" with "A means of identification within the
battery pack has been implemented to allow identification of
cell(s) and pack, if the external housing is destroyed".

Section 4 Sample Table - Corrected sample count and reuse
status based on current CRD and CRSL.

Section 5 Sample Table - Section 4 Sample Table - Corrected
sample count and reuse status based on current CRD and
CRSL.

Section 6 Sample Table - Section 4 Sample Table - Corrected
sample count and reuse status based on current CRD and
CRSL.

Section 7 Sample Table - Section 4 Sample Table - Corrected
sample count and reuse status based on current CRD and
CRSL.

Section 6.2 Purpose - Replaced " Connect the system and
ensure the charging process is operating; the battery pack
should have a state of charge greater than 90%. Inject Power
Surges and transients per IEC 61000-4-5. Perform verification of
over-current, overvoltage, and undervoltage functionality. Also
conduct one charge-discharge cycle per section 6.11." with ” For
adaptors with AC mains ports apply transients of 1.2/50(8/20)µs
waveform in accordance with IEC 61000-4-5. Ten transients
(five positive and five negative) at levels of 1kV line to neutral,
2kV line to ground and 2kV neutral to ground, shall be applied at
each zero crossing and peak (0, 90, 180 and 270 degrees
phase angle) of the applied ac voltage. Transients shall be
applied at a rate of one per minute. The equipment shall be on
during the test and the battery pack shall be in the fully
discharged state at the beginning of the test. If the adaptor has
no ground connection only line to neutral transients need to be
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applied." and " When a DC-DC adapter is connected to an AC
adapter then the combined unit needs to be tested as an AC
adapter."
June 2009
November
2009
December 2015
1.11
1.12

Section 5.14 Compliance - Add "Verify that the thermistor
resistance represents the temperature of the cell based on the
pack manufacturers specification."

Section 4 Sample Table 4.9 - Removed "Electrode Capacity
Balance and" in "Name" column.

Section 4 Sample Table 4.14 - Added "Supplementary" after "of"
in "Name" column.

Section 5 Sample Table 4.18 - Removed "Y" from "Reusable"
column.

Section 5 Sample Table 5.2 - Replaced "0" with "5" in "#
samples" column.

Section 5 Sample Table 5.2 - Removed "Use samples from
4.18" from "Reusable" column.

Section 5 Sample Table 5.2-5.5, 5.11 - Replaced "Use samples
from 4.18" with "Use samples form 5.2" in "Reusable" column.

Section 5 Sample Table 5.11 - Replace "5" with "0" in "# of
samples" column.

Section 5 Sample Table Total Packs Required - Replaced "28"
with "29" in "# of samples" column.

Section 5.48 Compliance - Added "of the cells or pack" after
"voltage" in the first sentence.

Section 5 Sample Table 5.47 - Replaced "5" with "0" in "# of
samples" column and removed "N" from "Reusable?" column.

Section 5 Sample Table 5.48 - Replaced "0" with "5" in "# of
samples" column and added "N" to "Reusable?" column.

Section 6.2 Procedure - Added "or less. If testing done at rates
faster than one per minute cause failures and tests done at one
per minute do not, the test done at one per minute prevails." to
the last sentence of first paragraph.

Section 6.2 Procedure - Added " For adaptors connected to a
vehicle wiring harness, apply pulses 1, 2a, 2b, 3a, 3b and 4 in
accordance with ISO 7637-2, at test level III, for at least the
minimum number of pulses or test time and for the minimum
burst duration or at the minimum pulse repetition time." after first
paragraph.

Section 6 Sample Table 6.5 - Deleted "Use samples from 6.4"
from "Reusable?" column.

Section 6 Sample Table - Added Rows for 5.23 and 5.48 to
address embedded packs requiring 5 pack samples.

Section 1.4 Ambient Temperature - Changed "20" to "25".
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April 2010
December 2015
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1.14

Section 4.52 Procedure - Changed "25ºC" to "Ambient
Temperature".

Section 4 Sample Table - Changed title of Table from "Samples
Table" to "CATL Sample Submission Requirements".

Section 5.11 Reference - Deleted repetitious "Section".

Section 5.11 Procedure - Added "Before the test, the battery
pack shall be fully charged according to Table A.2—Brief
description of battery pack electrical tests of IEEE1725-2006, or
according to the manufacturer’s specifications."

Section 5.23 Procedure - Added "3 samples of" after "on" in the
first sentence.

Section 5.48 Procedure - Added "at least" after "for" in sentence
6.

Section 5.48 Compliance - Deleted "measured one hour after
completing drop test" from last sentence.

Section 5 Sample Table - Changed title of Table from "Samples
Table" to "CATL Sample Submission Requirements".

Section 6.16 Compliance - Added "and cell" after "pack" to
sentence.

Section 6.20 Compliance - Added "provided in the host" to
sentence.

Section 6 Sample Table - Changed title of Table from "Samples
Table" to "CATL Sample Submission Requirements".

Section 6 Sample Table 5.23 - Changed "5" to "3".

Section 6 Sample Table Total Samples Required - Added "16 for
embedded packs" to Host column.

Section 7 Sample Table - Changed title of Table from "Samples
Table" to "CATL Sample Submission Requirements".

Replaced "supplier" and "manufacturer" with "Vendor".

Table of Contents, 4.15 - Deleted comma after "ADHERENCE".

Sections 1.1 and 1.3 – Removed references to CTIA
Certification Program Management document

Section 4.15 Title - Deleted comma after "Adherence".

Section 4.44 Reference - Replaced "&" with "and".

Section 5.15 Reference - Replaced "Section" with "and".

Section 6.9 Title - Capitalize "I" in "Identification".

Section 7.8 Purpose - Added "charger or" to first sentence.

Section 1.3 - Added "or latest Revision" after
"(ST/SG/AC.10/11/Rev4)".

Section 1.3 - Added " Universal Serial Bus Specification,
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Revision 2.0 (27 April 2000)" and " Battery Charging
Specification (15 April 2009). USB Implementers Forum, Inc." to
Applicable Documents list.
December 2015

Section 4.16 Procedure, Item 2a - Added "Penetrate the can"
after "cell". Deleted "Drill hole" and "(bottom)".

Section 4.16 Procedure, Item 3 - Replaced "Insert needle
without disturbing the cell internals" with "Connect cell to an
inflow mechanism".

Section 4.52 Procedure - Added " Test shall be performed with
fully charged cells." to first paragraph of Procedure

Section 5.48 Procedure - Deleted "For user replaceable
batteries".

Section 6.1 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For systems
without adapters, ensure that the system design specifies the
use of a CTIA certified adapter and/or a USB port in a device
that complies with the USB-IF certification requirements."

Section 6.2 Procedure - Added "For hosts without adapters,
three representative adapters shall be tested with the host. The
adapters shall be selected by the host manufacturer from
available CTIA recognized or certified AC and DC adapters. At
least one of each type (AC-DC and DC-DC) adapters shall be
used for testing."

Section 6.2 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For hosts
without adapters, hosts shall meet the above compliance criteria
when tested with representative CTIA recognized or certified
adapters."

Section 6.3 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For systems
without adapters, no cascading failure through the system to the
battery pack and/or cell after charging at 9 V for 24 hours. At a
minimum a complete charge cycle shall be performed under
normal operating conditions to validate performance system
specification after application of overvoltage."

Section 6.20 Procedure - Added "For systems without adapters,
perform the test with the host connected to the Adapter
Simulator described in Appendix I."

Section 7.1 Compliance - Added "For systems with recognized
adapters, verify host" to beginning of first paragraph. Added
"For certified adapters, ensure that the adapter output is rated 5
± 0.25 V, 1000 ± 500 mA."

Section 7.2 Procedure - Added " For certified adapters, perform
the single fault test in Section 6.3 and the input test in Section
6.2 utilizing the host simulator in Appendix II at 0% and 100%
loads. During surge testing, voltages on the output of the
adapter shall be measured differentially at the host adapter
using an oscilloscope."
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2010
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
Section 7.2 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For certified
adapters, the adapter does not: disable or degrade the safety
features of the supported host device; exceed 9 V during the
worst case single fault test specified in Section 6.3; or result in
transients or voltages greater than 12 V on the output circuits
during or after the application of the input test specified in
Section 6.2."

Section 7.3 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For certified
adapters, the adapter output must not exceed 9 V after the test."

Section 7.4 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For certified
adapters, connectors shall be robust and conform to USB
specifications."

Section 7.5 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For certified
adapters, connectors shall conform to the spacings defined in
USB specifications."

Section 7.8 Compliance - Added "For systems with recognized
adapters" to beginning of first paragraph. Added "For certified
adapters, connectors shall comply with USB specifications."

Section 8.1 Procedure - Added "CTIA certified adapters" after
"connected to" in last paragraph.

Added Appendix I - Adapter Simulator.

Added Appendix II - Host Simulator.

Moved Change History to Appendix III.

Section 3.4 Purpose and Procedure - Deleted "UN
(ST/SG/AC.10/11) Rev 4-2003 Section 38.3 Lithium Batteries"

Section 3.5 Purpose and Procedure - Deleted "UN
(ST/SG/AC.10/11) Rev 4-2003 Section 38.3 Lithium Batteries".

Section 4.16 Procedure 3) - Replace "Insert needle" with
"Connect cell to an inflow mechanism".

Section 5.46 Purpose - Replace "Ensure that vendor complies
with transportation regulatory testing requirements including the
appropriate sections of UN Manual of Tests and Criteria" with
"Ensure compliance to UN Recommendations on the Transport
of Dangerous Goods, Manual of Tests and Criteria".

Section 5.46 Procedure - Replace "Review results of UN
Transport testing for the design under evaluation" with "Confirm
compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria"

Section 5.46 Compliance - Replace "Complies with UN Manual
of Tests and Criteria, 4th edition, Part III, sub-section 38.3" with
"Vendor declaration of compliance document provided".
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November
2010
May 2011
December 2015
1.16
1.17

Section 7.2 Procedure - Add "The oscilloscope shall be triggered
from the surge generator. During the test the oscilloscope
horizontal setting shall be adjusted from 1V/div to 50mV/div and
the vertical setting shall be adjusted from 2ms/div to 400ns/div.
The largest transients shall be recorded." to end of second
paragraph.

Section 7.2 Compliance - Added "±1 V superimposed on the
nominal 5V" after "greater than" and deleted "12 V on the" in
second paragraph.

Appendix I - Added "Power output shall be between 4.75 - 5.25
under load." after "1.5 V batteries". Deleted "Batteries are
“floating” to ground".

Appendix I - Moved shield to ground short to inside of Adapter
simulator.

Appendix II - Added "Number of resistors in the Host Simulator
is variable, and may be replaced with one or more variable
resistors of sufficient power rating." to end of paragraph.

Appendix II - Moved shield to ground short at inside of Host
simulator.

Section 7 Sample Table - Added sample requirement of "1" to
7.2 and 7.3 for Certified Adapters.

Section 8.1 Procedure - Added letters a through k (no i) to the
beginning of each item.

Section 8.1 Compliance - Added " For non-user-replaceable
batteries use sections: a, b, d, g, j, k and the final USB-IF
statement."

Section 1.3 - Replaced "Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria, Fourth Revised
Edition, United Nations, New York and Geneva, 2003,
(ST/SG/AC.10/11/Rev4) or latest Revision." with
"Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria, Part III, Sub-section 38.3, Fourth
or Fifth Revised Edition, United Nations, New York and
Geneva."

Section 1.4 - Replaced "Ambient Temperature: 25 ± 5 °C" with
"Ambient Temperature: 20 ± 5 °C".

Section 3.4 Procedure - Replaced "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Review test report
confirming compliance to UN Recommendations on the
Transport of Dangerous Goods, Manual of Tests and Criteria.”

Section 3.4 Compliance - Replace "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Test report confirming
compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists."
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December 2015
2.0

Section 3.5 Procedure - Replaced "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Review test report
confirming compliance to UN Recommendations on the
Transport of Dangerous Goods, Manual of Tests and Criteria.”

Section 3.5 Compliance - Replace "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Test report confirming
compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists."

Section 4.49 Purpose - Replace "To ensure the cell model
meets transportation regulatory testing requirements including
those listed in appropriate sections of UN Manual of Tests and
Criteria." with "Ensure compliance to UN Recommendations on
the Transport of Dangerous Goods, Manual of Tests and
Criteria.”

Section 4.49 Procedure - Replace "Refer to 3.5" with "Review
test report confirming compliance to UN Recommendations on
the Transport of Dangerous Goods, Manual of Tests and
Criteria."

Section 4.49 Compliance - Replace "Refer to 3.5" with "Test
report confirming compliance to UN Recommendations on the
Transport of Dangerous Goods, Manual of Tests and Criteria
exists."

Section 4.52 - Replaced "Ambient Temperature" with "25 ± 5
°C".

Section 5.46 Procedure - Replaced "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Review test report
confirming compliance to UN Recommendations on the
Transport of Dangerous Goods, Manual of Tests and Criteria.”

Section 5.46 Compliance - Replace "Confirm compliance to UN
Recommendations on the Transport of Dangerous Goods,
Manual of Tests and Criteria." with "Test report confirming
compliance to UN Recommendations on the Transport of
Dangerous Goods, Manual of Tests and Criteria exists."

Section 1.1 - Replace "2006" with "2011".

Section 1.3 - Update IEEE 1725 with current revision.

Section 3.7 Purpose - Delete "User Replaceable Batteries".

Section 3.7 Procedure - Delete "User Replaceable Batteries".

Section 3.7 Compliance - Delete "(user-replaceable)".

Section 4.15 Title - Delete "Adherence and".

Section 4.15 Reference - Delete "and 5.2.5.3".

Section 4.24 Purpose, Procedure and Compliance - Complete
rewrite.
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
Section 5.25 Purpose - Add "This is not applicable if design
prevention is present."

Section 5.25 Procedure - Add "This is not applicable if design
prevention is present."

Section 5.25 Compliance - Add "This is not applicable if design
prevention is present."

Section 4.38 Purpose - Replace "controlled to prevent short
circuit" with "controlled to prevent cell core assembly damage or
tab/can short circuits."

Section 4.38 Compliance - Replace "The position of negative
and positive tabs are staggered so they do not overlap each
other." to "Verify the position of negative and positive tabs do not
create cell core assembly damage or tab/can short circuits.
Alternatively, verify an insulator gasket isolates the tabs from the
cell core assembly and can walls."

Section 4.40 Title - Replace "/Stack" with "Assembly".

Section 4.41 Title - Replace "Plate" with "Material".

Section 4.41 Purpose - Replace "To confirm the characteristics
of the material, color, proper positioning and presence of
insulating materials" with "To ensure an insulating method
prevents shorting of cell core to the cell casing."

Section 4.41 Procedure - Replace "insulation plate" with
"insulating method".

Section 4.41 Compliance - Replace "If the design requires an
insulation plate, the plate shall be properly positioned and
readily visible" with " Verify insulating method and verify
insulating material is readily visible".

Section 4.42 Reference - Add "(NA - See 4.41)".

Section 4.43 Purpose - Replace "The proper alignment of
positive and negative electrodes is critical to prevent hazards.
The vendor shall conduct 100% inspection (post-winding or
stacking of electrodes) and should use a vision system to
inspect 100% of the electrode assemblies." with "The vendor
shall use a vision system to inspect 100% of the cell cores".

Section 4.43 Compliance - Replace "each" with "all" and add "s
or vendors supporting evidence justifies a lesser minimum
overlap" to "side".

Section 4.46 Title - Capitalize "during".

Section 4.53 Reference - Add "(N/A - See 4.52, IEEE reference
deleted in 2011 edition)".

Section 5.3 Compliance - Add "Embedded batteries are exempt
from this requirement."

Section 5.4 Compliance - Add "Embedded batteries are exempt
from this requirement."
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
Section 5.8 Title - Add "Thermal" after "Ambient"

Section 5.8 Purpose - Replace "Confirm that the pack and host
operate within their specified temperature ranges and that the
total system interaction does not exceed the temperature ratings
of any components at worst case conditions specified by host
vendor" with "Confirm that thermal specifications of battery pack
components are not exceeded when the pack is operated at the
maximum-rated charge and the maximum rated discharge
current, with the pack ambient temperature elevated to the
maximum temperature specification of the host"

Section 5.8 Procedure - Replace "battery pack vendors
specification" with " test results". Replace "worst case" with
"maximum rated" in paragraphs 2, 5 and 6. Replace
"temperature extremes" with "maximum operating temperature
in paragraph 2". Add "(This simulates operating conditions in a
host that are expected to produce maximum temperatures in the
battery pack)" after "monitored temperatures" in paragraphs 5
and 6.

Section 5.14 Title - Replace "Protection" with "Sensor"

Section 5.14 Purpose - Replace "the thermistor, if used,
adequately represents the temperature of the cell" with "a
thermal sensor either in the battery pack and/or host monitors
cell temperature and limits works with the system to limit
operation within the cell's thermal specifications".

Section 5.14 Procedure - Replace "thermistor resistance" with
"cell temperature". Add "operating the system and" after "while"
and "and "beyond" after "throughout". Delete "of the system. A
sample of five is required".

Section 5.14 Compliance - Replace "resistance of the battery
pack's thermistor circuit, if used, is within +/-10% of the
temperature-resistance translation, as specified by the
thermistor vendor and battery pack designer, over the operating
temperature range of the battery. Verify that the thermistor
resistance represents the temperature of the cell based on the
pack vendors specification" with "thermal protection mechanism
limits operation within the cell's thermal specification".

5.15 Compliance - Replace " Charging is disabled when
operating temperature limits of the Pack are exceeded" with
Charging is disabled or other protective action is taken when the
operating limits of the cell are exceeded".

Section 5.17 Compliance - Add "provided it limits the current to
the maximum current specified in IEEE 6.6.1".

Section 5.23 Title - Replace "Mechanical Considerations" with
"External Mechanical Force".

Section 5.23 Reference - Replace "6.9" with "6.9.9".

Section 5.23 Procedure - Replace "user replaceable" with "nonembedded" and "non-user replaceable" with "embedded".
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
Section 5.43 Compliance - Add "a single fault causes" after
"that".

Section 5.48 Procedure - Add "For embedded packs, one of the
following tests is conducted based on the end use application
defined by the pack vendor. If the pack can be used in both
applications, the worst case test condition shall be used.". Add
"Where the normal use of the device is at the head level".
Replace "for at least" with "a maximum of". Add "within 5
minutes" after "packs" and "within 1 hour" after "packs". Add
"For all other devices the pack shall be subjected to the drop
test in UL 2054."

Section 5.48 Compliance - Add "Based on the test conducted,
one of the following applies." and "The compliance requirement
in UL 2054 shall be satisfied."

6.3 Reference - Add "7.1".

6.13 Purpose - Replace "and periodic update communication is
used" with "for example SMBus or I2C" and "upon interruption of
the interface" with "if communication is prevented or
interrupted".

6.13 Procedure - Add "Prevent or" to beginning of first sentence.

6.13 Compliance - Add "for systems that employ an electronic
communications interface".

6.20 Title - Replace "ESD" with "Electrostatic Discharge"

6.33 Title - Replace "Foreign Objects Critical Testing Practices"
with "Foreign Objects".

Section 6 - CATL Sample Submission Requirements, 7.3 Replace "0" with "1" for "Host, Pack, and Adapter". Delete "Use
samples from 6.20" from "Reusable column".

7,1 Title - Add "Attributes"

7.1 Purpose - Replace "Ensure adapter meets input
requirements of the supported host charging device" with
"Ensure listed attributes are specified for the adapter".

7.1 Procedure - Replace "Review adapter and host
documentation" with "Review adapter specification".

7.1 Compliance - Replace "For systems with recognized
adapters, verify host input requirements are not violated" with"
Verify adapter specifications include a) maximum output voltage,
b) minimum output voltage, c) maximum output voltage under a
single fault, d) mechanical attributes that define connector
interface (including mechanical design, electrical pin-out, and
metallurgy), e) minimum output current, and f) if applicable,
electrical interface attributes for identification, authentication,
etc.".

7.4 Title - Replace "Mating of Adapter and Charger" with
"Connector Design of Adapter and Host and Adapter-Host
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Reliability".
December
2011
May 2012
December 2015
2.1
2.2

9.1 Compliance - Add "Embedded batteries are exempt from this
requirement."

9.3 Title - Add "ing" to "Avoid".

10.1 Title - Add "s" to "Requirements"

10.4 - 10.10 Reference - Add "(N/A - See compliance)"

4.52 Procedure - Replace " a maximum resistance load of 0.1
ohm" with "a resistance load of 80 +/- 20 milliohms.

4.53 - Delete Purpose, Procedure and Compliance.

5.11 Procedure - Delete "-2006" from IEEE 1725 reference.

5.11 Compliance - Replace "Current is limited to a value that
does not cause failures to safety features of the pack. No fire,
smoke, or explosions occur" with "The battery pack has short
circuit protection and limits the discharge current. All safety
features shall remain operational, or the pack shall be
permanently disabled. No fire, smoke, or explosions occurs".

5.43 Compliance - Add "This does not apply to single cell
packs."

8.1 Procedure (f) - Delete "-200x" from IEEE 1725 reference.

Section 4 Sample Table 4.53 - Replace "5" with "0" in "Samples
for Test" column and delete ” Samples cannot be reused" from
"Reusable" column.

Section 4 Sample Table 4.18 - Replace " Use samples from 4.4"
with "See pack sample table" in "Reusable" column.

Section 4 Sample Table 4.38 - Delete "Use samples from 4.4" in
"Reusable" column.

Section 5.5 Purpose - Add "Host or Pack" before "Vendor".

Section 5.5 Compliance - Add "Host or Pack" before "Vendor".

Section 5.11 Procedure - Replace "<=100 mohms" with "of 80
+/- 20 milliohms"

Section 5.14 Purpose - Replace " Validate that a thermal sensor
either in the battery pack and/or host monitors cell temperature
and limits works with the system to limit operation within the
cell's thermal specifications" with " Validate that a thermal
sensor either in the battery pack and/or host monitors cell
temperature and enables the system to limit operation within the
cell's thermal specifications".

Section 5.14 Procedure - Replace "Instrument pack with
thermocouples located on the warmest part of the cell (typically
the center of the largest surface). Monitor cell temperature while
operating the system and causing the cell temperature to
change throughout and beyond the operating range" with "Place
the device(s) that contain(s) the thermal sensor in an
environmental chamber and monitor the output of the thermal
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sensor over the operating temperature range of the cell. Do not
charge or discharge the pack during this test".
August 2012
December
December 2015
2.3
2.4

Section 5.14 Compliance - Replace "Verify the thermal
protection mechanism limits operation within the cell's thermal
specification" with "Verify the output of the thermal sensor meets
its specification over the operating temperature range of the
cell".

Section 5.48 Reference - Replace "6.14.6" with 6.14.4".

Section 5.48 Procedure - Add comma after "head level" in
second paragraph.

Section 5 Sample Table - Add "CATL" before "Sample" title.

Section 6 Sample Table - Add 5.14 and specify 5 Host, 5 Pack
and 0 Adapter samples.

Section 6 Sample Table 5.23 - Replace "0" with "3" in "Host
Samples" column.

Section 6 Sample Table 5.48 - Replace "0" with "5" in "Host
Samples" column.

Section 6 Sample Table 6.4 - Replace all samples of "1" with "0"
and add "Use samples from 6.10 to "Reusable" column.

Section 8.1 Procedure - Add "Only authorized service providers
shall replace battery. (If the battery is non-user replaceable).

Section 1.3 - Remove "2000" from "ANSI/ISO/ASQ-Q9001"
reference.

Section 4 Sample Table 4.4 - Delete 4.38 in reusable column.

Section 5.47 Reference - Replace "6.14.5" with "6.14.3".

Section 5.47 Procedure - Replace "6.14.5.1" with "6.14.3.1" and
"6.14.5.1.4" with "6.14.3.1.4.

Section 5.47 Compliance - Replace "6.14.5.1.7" with "6.12.3.1.7"

Section 6.10 Compliance - Add "This requirement applies to
removable and embedded packs" after initiated.

Section 6 Sample Table 7.3 - Add "N" to reusable column.

Section 6 Sample Table Total Samples Required - Add "(16 for
embedded packs)" in Host column. Change "16" to "21" in Pack
column.

Section 6 Sample Table 5.23 and 5.48 - Add "unless tested
during pack recognition" after "Only" in Name column.

Section 10.3 Purpose, Procedure and Compliance - Replace
"vendor" with "manufacturer/supplier".

Section 10.3 Purpose, Procedure and Compliance - Replace
"ISO-9000: 2000 or equivalent" with "ISO-9000".

Section 3.2 Purpose and Procedure - Add "-1" to "60950".
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2.5
2.6
2.7

Section 4.5 Procedure - Add "shall be" after "SOC" and "an"
after "in".

Section 6.10 Compliance - Add "For embedded packs the
method of compliance may be verifying the cell/pack part
number."

Section 6.21 Purpose and Compliance - Delete "charging".

Section 6.23 Procedure - Delete "A sample of one is required."

Section 6 Sample Table - Add "Sample count in table is based
on single sample submission (1 battery & 1 adapter type).
Sample count is based on Recognized Adapter / Battery in
system certification. If request is for multiple adapters/batteries
(recognized) additional sample count is required." after Sample
Table.

Section 5.20 Purpose – Add “and to ensure that two overcharge
mechanisms are present in the system.”

Section 5 Sample Table 5.19 and 5.20.

Section 6.2 Procedure and Compliance – Modified “For systems
without specified adapters (which must have a USB port) shall
be tested with a certified adapter” and removed “recognized or”
from both the Procedure and Compliance. Remove pulse “4”
from requirement. Add revision 2011.

Section Clause 6.20 Procedure - Add “Additionally” and
“specified”, remove “For”.

Section 7.3 Procedure – Add “Certified adapters must be
connected to host simulator for the test.”

Section 7.3 Compliance – Add “Note: N/A is only applicable for
systems without specified adapters.”

Section 4.19 Reference - Modified "IEEE 1725, Section 5.2.8".

Section 4.19 Purpose - Modified "recommended maximum
voltage for the appropriate pack overvoltage protection function."

Section 5.17 Compliance - Modified "IEEE 1725 Section 6.6.1".

Section 5.20 Compliance - Add "be" and two "Protection".

Section 5.46 Reference change to "4.2 Table 2".

Section 5.47 Procedure "Figure 1".

Section 1.3 Applicable Documents - Updated UL 2054 to
September 14, 2011.

Section 1.3 Applicable Documents - Updated Battery Charging
Specification to Revision 1.2, March 15, 2012.

Section 1.3 Applicable Documents - Added Universal Serial Bus
Cables and Connectors Class Document.

Section 1.3 Applicable Documents - Added OMTP Common
Charging and Local Data Connectivity.
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2.8
2.9
2.10

Section 1.3 Applicable Documents - Added IEC
62684:2011, Interoperability specifications of common external
power supply (EPS) for use with data-enabled mobile
telephones.

Section 5.48 Procedure - Remove "For embedded packs". Add
“HEAD LEVEL” and “ALL OTHER CASES”.

Section 6. Sample Table - for 6.3 Adapter sample: add 1 and
total 7.

Added Sections 7.16 ~ 7.28, and updated Sample Table for
Certified Adapter.

Section 4.17 - Updated the version of UL 1642 to “Mar. 2012
release”.

Section 6.2 Compliance - Modified the second and third
sentences.

Section 3. 7 Title, Purpose, Procedure, Compliance - Included
IEC 62133 (with US deviations if applicable).

Sections 4, 5, 6, 7 - Editorial updates.

Section 8. 1 Compliance - Added section “f”.

Section 5.8 Purpose - Changed “pack” to “host-pack
combination”.

Section 6.5 Procedure - Removed “A sample of one is required.”

Section 6.7 Procedure - Added “A sample of one is required.”

Section 7 - Added at the beginning “All tests will be performed
on a single sample unless otherwise specified (all samples must
pass compliance)”.
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