THE DEMOCRATIC SOCIALIST REPUBLIC OF SRI LANKA

MINISTRY OF INDUSTRIES

Standard Rules and Regulations for Design and Fabrication for Electric
Vehicles

Version 1.0
September 2022

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1 ABBREVIATION ........................................................................................................ 3
2 INTRODUCTION ........................................................................................................ 5
2.1 GENERAL REGULATIONS ................................................................................................. 6
3 CHASSIS AND STRUCTURAL ................................................................................. 9
3.1 DEFINITIONS ........................................................................................................................ 9
3.2 PRIMARY STRUCTURE ...................................................................................................... 9
3.3 FASTENERS IN PRIMARY STRUCTURE ....................................................................... 10
3.4 DRIVER TEMPLATE .......................................................................................................... 10
3.5 ATTACHMENTS ................................................................................................................. 11
3.6 FASTENERS ........................................................................................................................ 11
3.7 WELDING ............................................................................................................................ 12
4 TRACTIVE SYSTEM & TRACTIVE SYSTEM ACCUMULATOR ..................... 14
4.1 DEFINITIONS ...................................................................................................................... 14
4.2 MAINTENANCE ................................................................................................................. 14
4.3 ELECTRICAL LIMITATIONS ........................................................................................... 15
4.4 ELECTRICAL CONFIGURATION .................................................................................... 15
4.5 TRACTIVE SYSTEM ACCUMULATOR .......................................................................... 16
4.6 MOTORS & MOTOR CONTROLLER ............................................................................... 16
4.7 ACCUMULATOR CONTAINER ........................................................................................ 16
4.8 ACCUMULATOR ISOLATION RELAYS – AIR .............................................................. 19
4.9 PRECHARGE & DISCHARGE CIRCUITS ........................................................................ 19
4.10 VOLTAGE INDICATOR ..................................................................................................... 20
4.11 GROUNDED LOW VOLTAGE SYSTEM.......................................................................... 20
4.12 OVERCURRENT PROTECTION ....................................................................................... 20
4.13 GROUNDING ...................................................................................................................... 21
4.14 ACCUMULATOR MANAGEMENT SYSTEM-AMS ....................................................... 21
4.15 ACCUMULATOR TEMPERATURE .................................................................................. 22
4.16 TRACTIVE SYSTEM .......................................................................................................... 22
5 DOCUMENT REQUIREMENTS-DR ...................................................................... 23
5.1 DEFINITIONS ...................................................................................................................... 23
5.2 ATTACHMENTS ................................................................................................................. 24

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1 ABBREVIATION

EV - Electric Vehicle
EV2 - Electric two-wheel vehicle
EV3 - Electric three-wheel vehicle
EV4 - Electric four-wheel vehicle
EV2/I - Electric two-wheel import vehicle
EV3/I - Electric three-wheel import vehicle
EV4/I - Electric four-wheel import vehicle
EV2/A - Electric two-wheel domestically assembled/manufactured vehicle
EV3/A - Electric three-wheel domestically assembled/manufactured vehicle
EV4/A - Electric four-wheel domestically assembled/manufactured vehicle
EV2/C - Electric two-wheel converted vehicle
EV3/C - Electric three-wheel converted vehicle
EV4/C - Electric four-wheel converted vehicle
GLV - Grounded low voltage
MAG - Metal active gas
MIG - Metal inactive gas
HV - High voltage
LV - Low voltage
AIR - Accumulator insulation relay
AMS - Accumulator management system
TS - Tractive system
DR - Document requirements
PMSM - Permanent magnet synchronous motor
SAE - Society of automotive engineers
DC - Direct current
AC - Alternative current
RMS - Root mean square
PTC - Positive temperature coefficient
ISEV -Imports and sales of Electric Vehicles

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DAMEV -Domestic assembling/manufacturing of Electric Vehicles
CCEEV -Convert Internal Combustion Engines (ICE) to Electric Vehicles
VDAC -Vehicle Design Approval Certificate
CMWTC -Chassis Material & Weld Testing Certificate
CMTC -Composite Material Testing Certificate
NFMTC -Non-Flammable Material Testing Certificate
ADAC -Accumulator Design Approval Certificate
ESIR -Electrical System Inspection Report
BAAC -Buyback Agreement for Accumulator Cells
ACDP - Accumulator Cell Disposal Proposal
SLAB -Sri Lanka Accreditation Board
ABS -Anti-lock braking system
EPR -Extended Producer Responsibility
LED -Light Emitting Diode
DMT -Department of Motor Traffic

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2 INTRODUCTION

The lack of proper Policy guidelines for e-mobility/Electric Vehicle design, assembling,
manufacture, and imports directly affected the development of green transportation services in
Sri Lanka. Most other countries have been developing EVs and utilizing them to fulfill their
transportation requirement sustainably.
Ministry of Industries has pointed out the requirement of proper guidelines to develop EVs in
Sri Lanka and the following officer and industrial experts have been appointed to the committee
to develop proper guidelines for the EVs development and registration under the present legal
& regulatory framework.
The EVs have been categorized in the following manner for future reference and to absorb the
sustainable development opportunities in the domestic market in the mobility sector.
a. ISEV
b. DAMEV
c. CCEEV
The EVs guidelines for the above three categories are focused on the following main three
areas.
1. Technical perspectives:
 Design,
 Fabrication/Assembling
 Maintenance
 After-sales services.
2. Safety, utility, and disposal perspectives
3. Authorizations (License) & Registration perspectives.

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2.1 GENERAL REGULATIONS
2.1.1 Body
S/N Item Description
2.1.1.1 Type of Body The construction of the body shall be in such a way that the Traction
structure Motor and Battery Compartment that constitutes the heaviest loads,
be mounted on structures that are directly mounted on the chassis.
Before commencing the assembling manufacturing, the body
structure design should be certified by the Ministry Appointed
Technical Committee.
2.1.1.2 Ground Ground Clearance shall be adequate to protect all electrical
Clearance components including the Traction Motor from getting immersed or
splashed by any surface water that may be expected on the tarmac
under normal driving conditions. Ground Clearance should be
specifically mentioned in the design in millimeters.
2.1.1.3 Rim/Wheel As per the existing regulations and standards of SAE or any
Specifications internationally accredited regulations, design, construction,
material selection, and type of rim/wheel should be certified by the
Ministry Appointed Technical Committee.
2.1.1.4 Seating Two-Wheeler: two passengers including the driver
Capacity Three-Wheeler: four passengers (driver + three)
Four-Wheeler: refer to Annexure 1.
Seating/cabin capacity should be according to the standard design
and certified by the Ministry Appointed Technical Committee.
2.1.1.5 Turning Angle Shall be designed and limited appropriately according to
internationally accredited standards.
2.1.1.6 Protection The arrangement of the start/on key/button/switch shall be such that
Interlocks it can be released or off only with the drive mode selected to
neutral/park/drive-lock position.
An overload protection system should be available.
Battery Overheating Protection should be available.
2.1.1.7 Safety features The following safety features shall be provided in accordance with
the following conditions.
 ABS, Airbags must be available to protect as per
Annexure 1.
 Seat belts must be available to protect all passengers of any
four-wheelers.
2.1.1.8 Tractive The Tractive system accumulator must meet 4.5
System
Accumulator
2.1.1.9 Auxiliary 12V If any auxiliary battery is used, then it must be installed in a place
Battery with adequate ventilation.
Housing
2.1.1.10 Vehicle Refer to Annexure 1.
Weight
Table 1: General Requirements

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2.1.2 Drive Train
 Drive Modes -Drive/ Neutral/Reverse/Park.
The reverse mode must not be enabled for electric bikes (EV2).
2.1.3 Operation
 Steering Type
o Electric bikes/Three wheelers - Handle Bar with Acceleration Control
on the Right-Hand Grip.
o Four-wheel vehicles – Steering wheel including necessary controls if
provided.
 Braking System- A disc drum-based mechanical or hydraulic braking system.
o EV2 – brake arms or a foot pedal can be used to initiate the brake force.
o EV3 – brake arms or a foot pedal can be used to initiate the brake force.
o EV4 - only a foot pedal should be used to initiate the brake force.
The same pedal/arm can also activate the regenerative braking system.
 Dashboard Displays-Shall indicates the following through either a panel or an
equivalent LED display for EV2, EV3, and EV4.
o Riding Speed
o The State of Charge
o Odometer
o Estimated range (not compulsory)
o Battery overheat warning
o All the other warning signals should be indicated by the standard
symbol
 Dashboard Controls - The Dashboard shall be equipped with the following
controls for EV2, EV3, and EV4.
o Drive and Reverse Control
o Entry Key Switch
o All other essential controls such as headlights, taillights, and wiper as
usual
 Safety Controls – Relay-controlled Emergency Cut-off(AIR)
2.1.4 Electrical Power Train
 Motor Type-PMSM (or equivalent) mid-shaft or hub motor for all types
of EV.
2.1.5 Rechargeable Energy Storage System (RESS)
Any kind of electric vehicle should meet the following requirements.
 Supply to Motor Control and Battery Management System - Shall
be powered by the Auxiliary 12V DC Battery or by the high voltage
battery with the support of a DC-DC Converter.
 Regenerative Breaking - The vehicle may be equipped with an
electronically actuated regenerative braking system in addition to the
regular mechanical braking system, which shall be engaged in advance
to recover the kinetic braking energy back to the Accumulator. In the
absence of the regenerative braking system, the motor power supply
shall be cut-off by the control system, when the brake arms/pedal is
depressed.

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  Battery Technology
o Low voltage – Lead acid or better
o High voltage (4.1.1) - Lithium-ion/ Lithium-polymer/Nickel-metal
hydride or better.
 Tractive System Accumulator - All the cells shall be housed inside a
fire-retardant (3.1.3) enclosure with the end terminals accessible from
the enclosure through standard connectors, other advanced technologies
have a chance to implement their own design and they must be certified
by the Ministry Appointed Technical Committee.
 Offered Range & Speed
o All Electric Vehicles must meet the following requirement.

Figure 1: Vehicle Speed Evaluation Test

This experiment is evaluated on a ramp as shown in the above figure.
First your vehicle should stop at a point and then start to run. The
vehicle should be able to speed up to 15 – 20 km/h (V) within 50 m
distance (l) on the ramp. The ramp angle is 30 (theta) degrees. This
is evaluated by the DMT and the certificate (VSEC) must be
submitted.
Vehicle Range (km per a single Maximum allowable
charge) speed (km/h)
EV2 More than 60 km 70
EV3 More than 60 km 60
EV4 More than 100 km Refer to Annexure 1
Table 2: Range and Speed

2.1.6 Grounded Low Voltage System (GLV)

Including the Motor Control and AMS, all electrical systems, such as Headlights,
Break Lights, Signal Lights, Horn, Dashboard Displays, Audio, and other
entertainment systems shall be powered through a GLV Battery, independent of the
Traction Batteries. GLV through DC-DC conversion from the Traction Battery shall
not be allowed, other than for any special reasons.
 GLV System Voltage- 12V DC
2.1.7 Ingress Protection
All electrical equipment shall be provided with an IP65 (or above) Rating.

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3 CHASSIS AND STRUCTURAL

Every local chassis manufacturer should follow the below guidelines and
Imported/Converted vehicles must be submitted proof of Equivalency (VDAC). The
certification must be issued or evaluated by the Ministry Appointed Technical Committee.

Otherwise, advanced technologies have a chance to implement their own design and it
must be certified by the Ministry Appointed Technical Committee. It must be included in
the VDAC.

3.1 DEFINITIONS
3.1.1 Chassis
a. The fabricated structural assembly that supports all functional vehicle systems.
b. This assembly may be a single fabricated structure, multiple fabricated
structures, or a combination of composite and welded structures.
3.1.2 Frame Member – Space frame chassis
a. A minimum representative single piece of uncut, continuous tubing.
3.1.3 Non-Flammable Material
Metal or a Non-Metallic material that meets UL94-V0, FAR25, or approved
equivalent.

3.2 PRIMARY STRUCTURE

3.2.1 The Primary Structure must be constructed from one or a combination of the
following:
 Steel or equivalent.
 Composite Material.
3.2.2 Vehicle chassis primary structure must meet,
Space-frame chassis All members of the primary structure must be seamless tubes or
square bars
Chassis-unibody Must not be modified from the original approved design certificate
Body on a frame (VADC)
Table 3: Primary Structure

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3.3 FASTENERS IN PRIMARY STRUCTURE
All EVs must meet the following requirement.
3.3.1 Bolted connections in the Primary Structure must use a removable bolt and nut.
Bonded fasteners and blind nuts and bolts do not meet this requirement.
3.3.2 Threaded fasteners used in Primary Structure are Critical Fasteners.
3.3.3 Bolted connections in the Primary Structure using tabs or brackets must have an edge
distance ratio “e/D” of 1.5 or greater.
“D” equals the hole diameter. And “e” equals the distance from the edge of the hole to
the nearest free edge.
Tabs attaching the Suspension to the Primary Structure are NOT “in the Primary
Structure”.

3.4 DRIVER TEMPLATE

The following driver template is for all ergonomic purposes of EVs.
3.4.1 A two-dimensional template used to represent the 95th percentile male is made to the
following dimensions (see figure below):
 A circle of diameter 200 mm will represent the hips and buttocks.
 A circle of diameter 200 mm will represent the shoulder/cervical region.
 A circle of diameter 300 mm will represent the head.
 A straight line measuring 490 mm will connect the centers of the two
200 mm circles.
 A straight line measuring 280 mm will connect the centers of the upper
200 mm circle and the 300 mm head circle.

Figure 2: Driver Template

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3.5 ATTACHMENTS
3.5.1 The laminate, brackets, backing plates, and inserts must have sufficient stiffness, shear
area, bearing area, weld area, and strength to carry the load specified in any direction.
3.5.2 Each attachment point requires backing plates that meet one of:
 Steel with a minimum thickness of 2 mm.
 Alternate materials, if Equivalency is approved.

3.6 FASTENERS
3.6.1 Critical Fasteners
a. A fastener (bolt, screw, pin, etc.) is used in a location designated as such in the
applicable rule.
3.6.2 Critical Fastener Requirements
a. Any Critical Fastener must meet, at minimum, one of the following:
 SAE Grade 5.
 Metric Grade 8.8.
 AN/MS Specifications.
 Equivalent to or better than above.
b. All threaded Critical Fasteners must be one of the following:
 Hex head.
 Hexagonal recessed drive (Socket Head Cap Screws or Allen
screws/bolts).
c. All Critical Fasteners must be secured from unintentional loosening by the use
of Positive Locking Mechanisms.
d. A minimum of two full threads must project from any lock nut.
e. Some Critical Fastener applications have additional requirements that are
provided in the applicable section.
3.6.3 Positive Locking Mechanisms
a. Positive Locking Mechanisms are defined as those which:
 Do not rely on the clamping force to apply the locking or anti-vibration
feature.
Meaning: If the fastener begins to loosen, the locking device still
prevents the fastener from coming completely loose.
 Acceptable Positive Locking Mechanisms include, but are not limited
to:
 Correctly installed safety wiring.
 Cotter pins.
 Nylon lock nuts (where the temperature does not exceed
80°C).
 Prevailing torque lock nuts.
Lock washers, bolts with nylon patches, and thread locking compounds
(Loctite®) DO NOT meet the positive locking requirement.

3.6.4 Requirements for All Fasteners

Adjustable tie rod ends must be constrained with a jam nut to prevent loosening.

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3.7 WELDING
3.7.1 Metal Active Gas (MAG) is recommended for steel tubes, plates, attachments, and
motor car body welding.
3.7.2 Metal Active Gas (MAG) Welding

Figure 3: Principle of MAG Welding

1. Arc 8. Power Source
2. Electrode 9. Contact Nozzle
3. Drum 10. Shielding Gas
4. Feed Roller 11. Gas Nozzle
5. Electrode Conduit
6. Cable & Hose Package
7. Welding Gun

 During MIG/MAG welding, the process is controlled by several

different parameters. Values should be mentioned for the following
parameters in CMWTC.
o Voltage (arc length)
o Wire-feed speed (which then determines current strength)
o Inductance (can be adjusted on most power sources)
o Shielding gas
o Feed speed
o Gun angle
o Electrode stick out /contact
o nozzle distance
 During MAG welding an electric arc between a welding wire and the
workpiece metal is formed (direct current is used), which heats the
workpiece metal(s), causing them to join.
 The carbon dioxide as a shielding gas is active, therefore it partially
reacts with the molten steel, which means the shield is not perfect – due
to the intense heat, MAG welding namely causes CO2 to split into carbon
monoxide (CO) and oxygen (O), which causes partial oxidation.

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  Recommended Welding Fillet Dimensions are given for further
reference

Figure 4: Welding Throat

Plate/pipe Gap Electrode Electrode Deposition Wire Welding Welding speed

Thickness Consumption rate feed current
rate
mm mm Kg/m Ø mm Kg/m m/h A m/h cm/min
1 0 0.02 0.6 1.0 7.0 60 50 83
1,5 0.5 0.02 0.8 1.0 6.0 90 48 80
2 1.0 0.03 0.8 1.0 6.8 110 50 83
3 2.0 0.06 1.8 1.0 8.0 125 50 55
3 2.0 0.06 2.1 1.0 6.0 150 50 63
4 1 0.09 1.0 2.2 6.4 160 24 40
5 1 0.09 1.0 2.2 6.4 160 17 28
6 1.5 0.17 1.0/1.0 2.1/2.9 6.8/1.0 150/200 32/26 60/43
8 1.5 0.30 1.0/1.2 1.0/3.9 6.0/7.6 150/260 26/17 43/28
10 2 0.50 1.0/1.2 1.0/5.1 6.0/10.0 150/320 21/31 35/21
Throat
Thickness
2 2 or 0.05 0.6 1.2 8.4 70 24 40
2 more 0.05 0.8 1.6 6.8 110 32 53
3 runs 0.10 0.8 1.9 8.3 130 19 32
3 0.10 1.0 2.4 7.0 170 24 40
4 0.16 1.0 2.7 8.2 195 17 28
5 0.25 1.2 3.9 7.8 260 16 26
6 0.33 1.2 3.9 7.8 260 12 20
8 0.33 1.2 4.8 9.5 300 14 22
8 0.58 1.2 4.8 9.5 300 8.5 14
1,5 0.02 0.6 1.0 7.0 60 50 83
2 0.03 0.8 1.6 6.8 110 53 88
3 0.05 0.8 1.9 8.2 130 38 63
4 0.07 1.8 2.0 9.0 140 29 48
4 0.07 1.0 2.6 7.5 180 37 62
5 0.10 1.0 2.6 7.5 180 26 43
6 0.15 1.2 3.5 7.0 240 23 38
8 0.26 1.2 3.7 7.5 250 19 30
10 0.40 1.2 5.0 10.0 320 12 20
12 0.58 1.2 5.0 10.0 320 9 15
Table 4: Welding Fillet Thickness

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3.7.3 Alternative Welding Methods
 If an alternative welding method is used, all details/ welding parameters
should be included in the CMWTC.
 Sample welding pieces should be tested before starting construction.

4 TRACTIVE SYSTEM & TRACTIVE SYSTEM ACCUMULATOR

Every Accumulator local manufacturer should follow the below guidelines Imported
Accumulators must be submitted proof of Equivalency. The certification must be issued by
an authorized institute.

Otherwise, advanced technologies have a chance to implement their own design and it
must be verified by the Ministry Appointed Technical Committee. It must be included in
the CMWTC.

4.1 DEFINITIONS
4.1.1 High Voltage – HV
Any voltage greater than 60V DC or 25V AC RMS.
4.1.2 Low Voltage – LV
Any voltage below and including 60V DC or 25V AC RMS.
4.1.3 Tractive System
Every part is electrically connected to the Motor(s) and/or Accumulator.
4.1.4 Grounded Low Voltage – GLV
Every electrical part is not part of the Tractive System.
4.1.5 Accumulator
All the battery cells or supercapacitors store the electrical energy to be used by
the Tractive System as a whole.
4.1.6 Normally Open
A type of electrical relay or contactor that allows current flow only in the
energized state.

4.2 MAINTENANCE
4.2.1 After-sale services and maintenance facilities must be provided by the supplier.
4.2.2 The spare parts must be available at the supplier and the quantity of the spare parts will
be defined by the Ministry of Industries.
4.2.3 Proper recycling/disposal method must be presented and it is evaluated before approval
OR buyback agreement including local power management method is needed.

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4.3 ELECTRICAL LIMITATIONS
4.3.1 Power and Voltage

Vehicle Maximum motor Maximum

power (kW) Accumulator
Voltage (V)
EV2 8 84
EV3 7 84
EV4 Refer to Annexure 1
Table 5: Power and Voltage

a. Regenerating energy is allowed and unrestricted when the vehicle speed is

greater than 5 km/h.
b. Supplying power to the motor such that the vehicle is driven in reverse is
prohibited.
c. A violation occurs when one or both of the following exist:
i. Exceed the maximum voltage continuously for 100 ms or more.
ii. Exceed the maximum voltage after a moving average of e over 500 ms is
applied.

4.4 ELECTRICAL CONFIGURATION

4.4.1 All Tractive System components must be rated for the maximum Tractive System
voltage.
4.4.2 If the Accumulator Container is made from an electrically conductive material:
a. The poles of the Accumulator Segment(s) and/or cells must be isolated from the
inner wall of the Accumulator Container with an insulating material that is rated
for the maximum Tractive System voltage.
b. All conductive surfaces on the outside of the Accumulator Container must have
a low resistance connection to the GLV System Ground.
c. Any conductive penetrations, such as mounting hardware, must be protected
against puncturing the insulating barrier.
4.4.3 Each Accumulator Segment must be electrically insulated by the use of suitable
material (not air) between the segments in the container and on top of the segment.
The intent is to prevent arc flashes caused by inter-segment contact or by
parts/tools accidentally falling into the container during maintenance for
example.
4.4.4 Soldering electrical connections in the high current path is prohibited.
Soldering wires to cells for the voltage monitoring input of the AMS is allowed,
these wires are not part of the high current path.
4.4.5 Every wire used in an Accumulator Container, whether it is part of the GLV or Tractive
System, must be rated to the maximum Tractive System voltage.

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4.5 TRACTIVE SYSTEM ACCUMULATOR
4.5.1 All cells or supercapacitors which store the Tractive System energy are built into
Accumulator Segments and must be enclosed in (an) Accumulator Container(s).
4.5.2 Each Accumulator Segment must contain:
 Maximum static voltage
Vehicle Maximum Static
Voltage (VDC)
EV2 84
EV3 84
EV4 130
Table 6: Segment Voltage

 Maximum energy of 6 MJ.

The contained energy of a stack is calculated by multiplying the maximum
stack voltage with the nominal capacity of the used cell(s).

4.6 MOTORS & MOTOR CONTROLLER

4.6.1 Motors
a. Only electrical motors are allowed.
b. The Tractive System Motors(s) must be connected to the Accumulator through
a Motor Controller. No direct connections between Motor(s) and Accumulator.

4.7 ACCUMULATOR CONTAINER

4.7.1 General Requirements
a. Accumulator Container(s) must be built of mechanically robust material.
b. The Accumulator Container must be made from a Nonflammable Material.
c. All Accumulator Containers must be designed to withstand forces from
deceleration in all directions.
d. The Accumulator Container(s) must be removable from the vehicle while the
remaining rules are compliant.
e. The Accumulator Container(s) must be completely closed at all times (when
mounted to the vehicle and when removed from the vehicle) without the need
to install extra protective covers.
f. Holes, both internal and external, are only allowed for the wiring harness,
ventilation, cooling, or fasteners. External holes must be sealed.
g. Any Accumulators that may vent an explosive gas must have a ventilation
system or pressure relief valve to prevent the vented gas from reaching an
explosive concentration.
h. Each Accumulator Container(s) must be sealed with the:
i. Symbol specified in ISO 7010-W012 (triangle with a black lightning bolt
on yellow background) with a triangle side length of 100mm minimum.
ii. Text “Always Energized”
iii. Text “High Voltage” if the voltage meets the high voltage requirements.

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4.7.2 Design
a. Accumulator Container design requirements:
i. The floor or bottom must be constructed of steel with 1.25 mm minimum
thickness or aluminum with 3.2 mm minimum thickness.
ii. The external vertical walls must be constructed of steel with 0.9 mm
minimum thickness or aluminum with 2.3 mm minimum thickness.
iii. Internal vertical walls separating cells and/or segments must be:
 Minimum of 75 percent of the height of the external vertical walls.
 Constructed of steel with 0.9 mm minimum thickness or aluminum 2.3
mm minimum thickness.
iv. The floor and walls must be joined by welds and/or fasteners. Any fasteners
must be 6 mm or 1/4” minimum diameter Critical Fasteners.
v. Internal vertical walls divide the Accumulator Container into “Sections”:
 A maximum of 12 kg is allowed in any Section.
 Fastened connections between the floor and any vertical wall of each
Section must have a minimum of two fasteners.
 Fastened connections between internal vertical walls and external
vertical walls must be located in the top half of the internal vertical wall.
 Sections containing 8 kg or less must have a minimum of two fasteners
connecting any two vertical walls.
 Sections containing between 8 kg and 12 kg must have a minimum of
three fasteners connecting any two vertical walls.
vi. Folding or bending plate material to create flanges or to eliminate joints
between walls is recommended.
Example: An Accumulator Container with 2 internal walls has 3 Sections.
Each Section contains less than 8 kg. Therefore 18 floor-to-wall joints are
required in total with a minimum of two fasteners per joint.
vi. Covers and lids must be constructed of steel with 0.9 mm minimum
thickness or aluminum with 2.3 mm minimum thickness.
vii. Covers and lids must be fastened with a minimum of one fastener for each
external vertical wall per section.
viii. Alternate / Composite materials are allowed with proof of equivalency.
ix. The Accumulator Container design guidelines are intended to generate a
structure that does not fail under the following accelerations:
 40 g in the longitudinal direction (forward/aft)
 40 g in the lateral direction (left/right)
 20 g in the vertical direction (up/down)
b. The cells and/or segments must be appropriately secured against moving inside
the Container.
This mounting system must be designed to withstand the following
accelerations:
 40 g in the longitudinal direction (forward/aft)
 40 g in the lateral direction (left/right)
 20 g in the vertical direction (up/down)

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 c. The Accumulator Segments contained inside the Accumulator must be
separated by an electrically insulating barrier made from Nonflammable
Material.
d. Composite Accumulator Containers must satisfy the following requirements:
 Data obtained from laminate perimeter shear strength and 3-point
bending tests must be used for any strength calculations.
4.7.3 Attachment
a. Accumulator Containers must be attached to the Major Structure of the chassis.
b. Any fasteners used to attach Accumulator Container(s) are Critical Fasteners.
c. Each attachment point to a composite Accumulator Container requires steel
backing plates with a thickness of 2 mm minimum.
Alternate materials may be used for backing plates when proven Equivalent.
d. Teams may justify the Accumulator Container attachment using one of the:
 Corner Attachments and Analysis per e.
 Load Based Analysis per f.
e. Accumulator Attachment – Corner Attachments
i. Eight or more attachments are required for any configuration.
 One attachment for each corner of a rectangular arrangement of multiple
Accumulator Segments.
 More than the minimum number of fasteners may be required for non-
rectangular arrangements.
Examples: an extruded L shape would require attachments at 10 convex
corners (the corners at the inside of the L are not convex); an extruded
hexagon would require 12 attachments.
ii. The mechanical connections at each corner must be:
 50 mm or less from the corner of the Segment.
 Spaced a minimum of 50 mm from the mechanical connection of any
other corner.
 The same fastener diameter and grade.
iii. Each attachment point must be able to withstand a Test Load.
 The Test Load is equal to 1/4 of the total mass of the container
accelerating at 40 g
 Every fastener must withstand the Test Load in pure shear, using the
minor diameter if any threads are in shear.
 Every Accumulator bracket, chassis bracket, or monocoque attachment
point must withstand the Test Load in bending, in pure tear out, pure
pullout, pure weld shear if welded, and pure bond shear and pure bond
tensile if bonded.
f. Accumulator Attachment – Load Based
i. The number of attachment points that must be used depends on the total
mass of the container:
Accumulator Weight Minimum Attachment Points
< 20 kg 4
20 – 30 kg 6
30 – 40 kg 8

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 > 40 kg 10
ii. Any brackets which attach the Accumulator Container to the chassis must:
 Be made with steel of 1.6 mm minimum thickness or aluminum of 4 mm
minimum thickness.
 Have gussets to carry bending loads.
iii. Each attachment point, including any brackets, backing plates, and inserts,
must be able to withstand 15 kN in any direction.
iv. Fasteners must be spaced a minimum of 50 mm apart to be counted as
separate attachment points.

4.8 ACCUMULATOR ISOLATION RELAYS – AIR

4.8.1 Every Accumulator Container must contain at minimum one fuse and one Accumulator
Isolation Relays (AIR).
4.8.2 The Accumulator Isolation Relay must:
 Be a Normally Open type
4.8.3 When the AIR is open, High Voltage must not be present outside of the Accumulator
Container.
4.8.4 The Accumulator Isolation Relays and fuses must be separated from the rest of the
Accumulator with an electrically insulated and Non-flammable Material.

4.9 PRECHARGE & DISCHARGE CIRCUITS

4.9.1 The Accumulator must contain a Pre-charge Circuit. The Pre-charge Circuit must:
a. Be able to charge the intermediate circuit to a moving minimum of 90% of the
Accumulator Voltage before closing the AIR.
b. Not be fused.
4.9.2 The Intermediate Circuit must pre-charge before closing the AIR. The end of pre-charge
must be controlled by one of the following two options:
a. Feedback by monitoring the voltage in the intermediate circuit.
b. A conservative time defined by the longer of:
 Twice the time to charge to 90%.
 The time to charge to 90% plus 500 ms.
4.9.3 The Tractive System must contain a Discharge Circuit. The Discharge Circuit must be:
a. Wired in a way that it is always active when the Shutdown Circuit is open.
b. Not be fused.
4.9.4 The discharge circuit must be designed to handle maximum discharge current for a
minimum of 15 seconds.
4.9.5 Positive Temperature Coefficient (PTC) devices must not be used to limit current for
the Pre-charge Circuit or Discharge Circuit.
4.9.6 The Pre-charge relay must be a mechanical type relay.

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4.10 VOLTAGE INDICATOR
Each Accumulator Container must have a prominent indicator when High Voltage is
present at the vehicle side of the AIRs.
4.10.1 The Voltage Indicator must always function, including when the Accumulator
Container is disconnected or removed.
4.10.2 The voltage being present at the connectors must directly control the Voltage Indicator
using hard-wired electronics with no software control.
4.10.3 The control signal which closes the AIRs must not control the Voltage Indicator.
4.10.4 The Voltage Indicator must:
a. Be located where early visible when connecting/disconnecting the Accumulator
Tractive Systems connections.
b. Be labeled “High Voltage Present”.

4.11 GROUNDED LOW VOLTAGE SYSTEM

4.11.1 The GLV System must be a Low Voltage system that is grounded to the Chassis
4.11.2 All batteries and onboard power supplies must be attached securely to the Chassis.
4.11.3 All Low Voltage batteries must have Overcurrent Protection that trips at or below the
maximum specified discharge current of the cells.
4.11.4 The hot (ungrounded) terminal must be insulated.
4.11.5 Any wet cell battery located in the driver compartment must be enclosed in a
nonconductive marine-type container or equivalent.
4.11.6 Battery packs based on Lithium chemistry must:
 Have a rigid, sturdy, and flame-resistant casing.
 Be separated from the driver by a Firewall.
4.11.7 All batteries using chemistries other than lead-acid must be presented at Technical
Inspection with markings identifying it for comparison to a datasheet or other
documentation proving the pack and supporting electronics meet all rules requirements.

4.12 OVERCURRENT PROTECTION

4.12.1 All electrical systems (both Low Voltage and High Voltage) must have appropriate
Overcurrent Protection/Fusing.
4.12.2 Unless otherwise allowed in the Rules, all Overcurrent Protection devices must:
a. Be rated for the highest voltage in the systems they protect. Overcurrent
Protection devices used for DC must be rated for DC and must carry a DC rating
equal to or greater than the system voltage.
b. Have a continuous current rating less than the continuous current rating of any
electrical component that it protects.
c. Have an interrupt current rating higher than the theoretical short circuit current
of the system that it protects.

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4.12.3 Any conductors (wires, bus bars, etc.) conducting the entire pack current must meet one
of:
a. Be appropriately sized for the total current that the individual Overcurrent
Protection devices could transmit.
b. Contain additional Overcurrent Protection to protect the conductors.
4.12.4 Battery packs with Low Voltage or non-voltage rated fusible links for cell connections
may be used when all conditions are met:
a. An Overcurrent Protection device rated at a current three times lower than the
sum of the parallel fusible links.
b. Fusible link current rating is specified in manufacturer’s data or suitable test
data is provided.
4.12.5 Cells with internal Overcurrent Protection may be used without external Overcurrent
Protection if suitably rated.

4.13 GROUNDING
4.13.1 The GLV System must meet a Low Voltage system that is grounded to the Chassis.
4.13.2 The GLV System must include a Master Switch.
4.13.3 Parts of the vehicle that are 100 mm or less from any Tractive System component must
have a resistance to GLV System Ground less than the values specified below.
a. Electrically conductive parts 300 mΩ (measured with a current of 1 A).
Examples: parts made of steel, (anodized) aluminum, and any other metal parts.
b. Parts that may become electrically conductive 5 Ω.
Example: carbon fiber parts.
Carbon fiber parts may need special measures such as using copper mesh or
similar to keep the ground resistance below 5 Ω.
4.13.4 Electrical conductivity of any part may be tested by checking any point which is likely
to be conductive.
Where no convenient conductive point is available, an area of coating may be
removed.

4.14 ACCUMULATOR MANAGEMENT SYSTEM-AMS

4.14.1 An Accumulator Management System must monitor the Accumulator(s) Voltage and
Temperature when the:
a. Tractive System is Active.
b. Accumulator is connected to a Charger.
4.14.2 Cell balancing when the Accumulator Isolation Relays (AIR) is open is not permitted.
4.14.3 The AMS must monitor for:
a. Voltage values outside the allowable range.
b. Voltage sense Overcurrent Protection device(s) blown or tripped.
c. Temperature values outside the allowable range.
d. Missing or interrupted voltage or temperature measurements.
e. A fault in the AMS.

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4.15 ACCUMULATOR TEMPERATURE
4.15.1 The AMS must measure the temperatures of critical points of the Accumulator.
4.15.2 Temperatures must remain below the allowed maximum cell temperature limit stated
in the cell datasheet or 60°C, whichever is lower. Measurement accuracy must be
considered.
4.15.3 Cell temperatures must be measured at the negative terminal of the respective cell.
4.15.4 The temperature sensor used must be in direct contact with one of:
 The negative terminal itself.
 The negative terminal bus bar is less than 10 mm away from the cell
terminal.
4.15.5 For lithium-based cells,
a. The temperature of a minimum of 20% of the total number of cells must be
monitored by the AMS.
b. The monitored cells must be equally distributed inside the Accumulator
Container(s).
Every cell temperature should be monitored.
c. Multiple cells may be monitored with one temperature sensor if accumulator
temperature is met for all cells sensed by the sensor.
d. Temperature sensors must have appropriate electrical isolation that meets one
of:
 Between the sensor and cell.
 In the sensing circuit.
The isolation must consider both GLV/TS isolation as well as common
mode voltages between sense locations.

4.16 TRACTIVE SYSTEM

Tractive System Location and Protection are subject to approval during Technical
Inspection.
4.16.1 Location
All Accumulator Containers must lie inside the Primary Structure.
4.16.2 Protection
All Accumulator Containers must be protected from side impact or rear impact by Side
Impact Structure.
The Accumulator Container must not form part of the equivalent structure.

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5 DOCUMENT REQUIREMENTS-DR

5.1 DEFINITIONS
5.1.1 Vehicle Design Approval Certificate – VDAC
 All ISEV and DAMEV products must submit an approval certificate
issued by an authorized body for the country concerned. The validity of
the submitted certificate will be evaluated by the Ministry Appointed
Committee.
 All CCEEV or DAMEV (if locally designed) products must meet the
above-provided guidelines and obtain an approval certificate from the
Ministry Appointed Committee.
 All Engineering Simulations, Calculations, Experiments, and results will
be evaluated.
5.1.2 Chassis Material & Weld Testing Certificate – CMWTC
 All ISEV products must submit an inspection certificate issued by an
authorized body for the country concerned. The validity of the submitted
certificate will be evaluated by the Ministry Appointed Committee.
 All CCEEV and DAMEV products must meet the above-provided
guidelines and obtain an approval certificate for a sample from any
authorized institute accredited by the SLAB or Ministry Appointed
Committee.
5.1.3 Composite Material Testing Certificate – CMTC
 CMTC must be submitted to all local fabricated body works issued from
any authorized institute accredited by the SLAB or Ministry Appointed
Committee.
 All imported body parts or all ISEV must be approved by an authorized
body for the country concerned and the validity will be evaluated of it by
the Ministry Appointed Committee.
5.1.4 Non-Flammable Material Testing – NFMTC
 All local Accumulator manufacturers must obtain approval for the Non-
Flammable materials from the material manufactured company, or any
authorized institute accredited by the SLAB or Ministry Appointed
Committee.
 All imported accumulators must obtain certification from the parent
company that manufactured them, or this can be in the VDAC. The
validity will be evaluated of it by the Ministry Appointed Committee.
5.1.5 Accumulator Design Approval Certificate – ADAC
 All imported accumulators must obtain certification from an authorized
body for the country concerned, or this can be in the VDAC or ESIR. The
validity will be evaluated of it by the Ministry Appointed Committee.

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  All local accumulator manufacturers must obtain approval for a complete
tractive system accumulator from any authorized institute accredited by
SLAB or Ministry Appointed Committee.
 All Engineering Simulations, Calculations, Experiments, and results will
be evaluated.
5.1.6 Electrical System Inspection Report – ESIR
 All ISEV products must obtain certification from an authorized body for the
country concerned, or this can be in the VDAC. The validity will be
evaluated of it by the Ministry Appointed Committee.
 All DAMEV products must obtain certification from an authorized body for
the country concerned or any authorized institute accredited by the SLAB.
This can be in the VDAC. The validity will be evaluated of it by the Ministry
Appointed Committee.
 All CCEEV products must obtain certification from any authorized institute
accredited by the SLAB or Ministry Appointed Committee. This can be in
the VDAC.
5.1.7 Buyback Agreement for Accumulator Cells – BAAC
 Buyback agreement for accumulator cells must obtain from the parent
company that manufactured them. This will be evaluated by the Ministry
Appointed Committee.
5.1.8 Accumulator Cell Disposal Proposal – ACDP
 Proper battery cell disposal method should be included clearly. This will be
evaluated by the Ministry Appointed Committee.
 EPR system-(Extended Producer Responsibility)-Importers or producers
have responsibility for waste collection and recycling.
 There is a responsibility of the dealer to maintain the details about the
customers who bought the Accumulators (batteries) and need to report what
happened to the Accumulators (batteries), after the specific time. Vehicle
companies should be responsible for maintaining the details of the vehicle
customers who buy vehicles.
5.1.9 Vehicle Speed Evaluation Certificate – VSEC
 The vehicle speed evaluation for all Electric Vehicles is done by DMT on a
standard ramp.
5.1.10 Tractive System Accumulator replacement
 New Tractive System Accumulators (High Voltage batteries) must be issued
only after submitting the previous accumulators or cells. The serial number
should be submitted.

5.2 ATTACHMENTS
All Required certifications must be submitted as below.
 Attachment ref no. RE/(company name)/(vehicle name)/01
1. VDAC
2. CMWTC

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 3. CMTC
4. NFMTC
 Attachment ref no. RE/(company name)/(vehicle name)/02
5. ADAC
6. ESIR
7. BAAC or ACDP
8. VSEC

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Annexure 1
Maximum Maximum
Gross Maximum
Name of the Allowable Allowable
Vehicle Seating ABS / Air Allowable
S/N Vehicle Motor Accumulator
Weight Capacity Bags Speed
Category Power Voltage
(kg) (km/h)
(kw) (VDC)
Quadro Less than
EV4.1 84 4 Not required 50
Cycle or Equal 7

ABS should be
All Cars/All
Less available for all
Dual Less than
than or Less than vehicles that
EV4.2 Purpose or Equal 600 140
Equal 15 exceed a speed
Electric 160
3500 of more than 60
Vehicles
km/h

Less than
Electric More
EV4.3 or Equal 600 Only ABS 100
Buses than 33
180

If there any deviations compared to the given values, it must be mentioned in the relevant section of
the submission. The changes will be evaluated by the Ministry Appointed Committee.

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