The rapid surge of clean energy is pushing battery technology to the forefront, serving as the primary driver for the energy revolution. Batteries, spanning a spectrum of types, are pivotal players across diverse applications—from power batteries used in Electric Vehicles (EVs) to rechargeable batteries used in energy storage systems. Yet, the key is ensuring the safety, performance, and reliability of these batteries, which manufacturers will conduct a series of rigorous tests before they go to market. In this issue, we delve into the electrical safety tests of two major battery standards: UL 2580 for EVs batteries, and UL 1973 for energy storage batteries. To help you understand the battery electrical safety tests, we also share the efficiency of battery electrical safety testing solutions associated with these standards.
UL 2580: Batteries Used in EV
Ensuring the reliability and electrical safety of EV batteries is crucial for ensuring the safety of drivers and passengers, making rigorous testing imperative. Therefore, a series of tests, including the essential UL 2580 electrical safety tests, are conducted.
One of the key tests is the Hipot test. This test involves applying a specified testing voltage, typically ranging from 600 Vdc to 1200 Vdc, between the battery's enclosure and the positive and negative terminals. The purpose is to assess the insulation integrity of the battery and ensure that it can withstand high voltage without leakage or breakdown.
Additionally, in EV battery testing, it is important to evaluate the potential for electrical shock hazards. This is achieved by applying the testing voltage between the accessible metallic part of the vehicle, such as the charging plug, and the positive and negative terminals of the battery. By conducting these rigorous tests, manufacturers can verify its ability to operate safely within the EV system.
UL 1973: Batteries Used in the Energy Storage System
Different from UL 2580, which is the standard for batteries used in EVs, UL 1973 covers a wide range of battery applications in stationary and motive auxiliary power applications, with energy storage systems battery being one of them. Ensuring the safety and stability of batteries in these systems is critical. To meet this requirement, UL 1973 requires the Hipot test to evaluate electrical insulation integrity and the battery's capability to withstand abnormal voltage scenarios.
In the Hipot test, a specified testing voltage is applied between the battery's enclosure and its positive and negative terminals. The magnitude of testing voltage is determined by the working voltage and insulation level of the battery. Typically, the testing voltage falls within the range of 1kVdc to 4kVdc. However, for applications requiring specialized considerations, such as high-voltage systems, the testing voltage may be significantly escalated, reaching levels of up to 20kVdc. This ensures that the battery can endure high voltages without experiencing leakage or breakdown.
Battery Electrical Safety Testing Solution
Whether the battery is used in an EV or an energy storage system, testing often involves not just one point to another, but the application of testing voltage across multiple points. This complexity increases the potential for human error, which can lead to the need for retesting, thereby reducing testing efficiency or even resulting in critical issues requiring product recalls.
We understand how important optimizing efficiency and productivity is for battery manufacturers, so we provide a complete battery electrical safety testing solution. The HypotULTRA® Series Electrical Safety Tester paired with SC6540 Multiplexers delivers up to 6kVdc for the Hipot test and simplifies testing across multiple points with a one-click testing solution. You no longer need to switch testing leads between each test step. Now, you can start all test steps with just one click.
With the escalating energy storage capacities, the working voltages also surge. Thus, an increasing number of customers approach us seeking ultra-high Hipot test solutions to meet their evolving needs. The HypotMAX® Series High Voltage Hipot Tester, capable of providing up to 20kVdc to ensure the safety of energy storage systems operating at these heightened voltage levels.
If you wish to learn more about our battery solutions, we invite you to reach out to us today. Let us empower your journey towards enhanced safety and efficiency in the electrical safety test of batteries.
