BRITISH STANDARD BS EN

50272-3:2002
Incorporating
Corrigendum No. 1

Safety requirements for

secondary batteries
and battery
installations —
Part 3: Traction batteries

The European Standard EN 50272-3:2002 has the status of a

British Standard

ICS 29.220.20

12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:
BS EN 50272-3:2002

National foreword
This British Standard is the official English language version of
EN 50272-3:2002. It supersedes BS 6287:1982, which is withdrawn.
The UK participation in its preparation was entrusted to Technical Committee
PEL/21, Secondary cells and batteries, which has the responsibility to:

— aid enquirers to understand the text;

— present to the responsible international/European committee any

enquiries on the interpretation, or proposals for change, and keep UK
interests informed;
— monitor related international and European developments and
promulgate them in the UK.

A list of organizations represented on this committee can be obtained on

request to its secretary.
Cross-references
The British Standards which implement international or European
publications referred to in this document may be found in the BSI Catalogue
under the section entitled “International Standards Correspondence Index”, or
by using the “Search” facility of the BSI Electronic Catalogue or of British
Standards Online.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

This British Standard, having Summary of pages

been prepared under the This document comprises a front cover, an inside front cover, the EN title page,
direction of the
Electrotechnical Sector Policy pages 2 to 16, an inside back cover and a back cover.
and Strategy Committee, was The BSI copyright date displayed in this document indicates when the
published under the authority
of the Standards Policy and document was last issued.
Strategy Committee on
24 October 2002

Amendments issued since publication

Amd. No. Date Comments

16575 29 September 2006 Addition of supersession details

© BSI 2006 Corrigendum No. 1

ISBN 0 580 40642 3

EUROPEAN STANDARD EN 50272-3
NORME EUROPÉENNE
EUROPÄISCHE NORM October 2002
ICS 29.220.20

English version

Safety requirements for secondary batteries and battery installations

Part 3: Traction batteries

Règles de sécurité pour les batteries Sicherheitsanforderungen an Batterien

et les installations de batteries und Batterieanlagen
Partie 3: Batteries de traction Teil 3: Antriebsbatterien für
Elektrofahrzeuge

This European Standard was approved by CENELEC on 2002-07-01. CENELEC members are bound to
comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and
notified to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Czech Republic,
Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta,
Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2002 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. EN 50272-3:2002 E

EN 50272-3:2002 -2-

Foreword

This European Standard was prepared by the Technical Committee CENELEC TC 21X, Secondary cells and
batteries.

The text of the draft was submitted to the formal vote and was approved by CENELEC as EN 50272-3 on
2002-07-01.

The following dates were fixed:

- latest date by which the EN has to be implemented

at national level by publication of an identical
national standard or by endorsement (dop) 2003-07-01

- latest date by which the national standards conflicting

with the EN have to be withdrawn (dow) 2005-07-01
 -3- EN 50272-3:2002

Contents

1 Scope .......................................................................................................................................................4

2 Normative references ...............................................................................................................................4

3 Definitions .................................................................................................................................................5

4 Protection against electric shock..............................................................................................................6

5 Prevention of short circuits and protection from other effects of electric current .....................................8

6 Provisions against explosion hazards by ventilation ................................................................................9

7 Provision against electrolyte hazard.......................................................................................................12

8 Battery containers and enclosures .........................................................................................................12

9 Accommodation for charging maintenance ............................................................................................13

10 Battery peripheral equipment/accessories .............................................................................................13

11 Identification labels, warning notices and instructions for use, installation and maintenance ...............15

12 Transportation, storage, disposal and environmental aspects...............................................................16

13 Inspection and monitoring ......................................................................................................................16

Table 1 ..............................................................................................................................................................10
EN 50272-3:2002 -4-

1 Scope

This standard applies to secondary batteries and battery installations used for electric vehicles, e.g. in
electric industrial trucks (including - lift trucks, tow trucks, cleaning machines, automatic guided vehicles), in
battery powered locomotives, in electric road vehicles (e.g. passenger and goods vehicles, golf carts,
bicycles, wheelchairs).

The nominal voltages are limited to 1 000 V a.c. and 1 500 V d.c. respectively and describe the principal
measures for protection against hazards generally from electricity, gas emission and electrolyte.

It provides requirements on safety aspects associated with the installation, use, inspection, maintenance and
disposal of batteries.

It covers lead-acid, nickel cadmium and other alkaline secondary batteries.

NOTE It is intended to amend this standard to include other battery systems when they become available.

2 Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply
to this European Standard only when incorporated in it by amendment or revision. For undated references
the latest edition of the publication referred to applies (including amendments).

EN 166 1995 Personal eye-protection - Specifications

EN 1175-1 1998 Safety of electrical trucks - Electrical requirements

Part 1: General requirements for battery powered trucks

EN 1987-1 1987 Electrically propelled road vehicles - Specific requirements for safety -
Part 1: On board energy storage

EN 60204-1 1986 Electrical equipment of industrial machines

Part 1: General requirements

EN 60900 1993 Hand tools for live working up to 1 kV a.c. and 1,5 kV d.c.

EN 61140 2001 Protection against electric shock - Common aspects for installation and
equipment (IEC 61140:1997)

EN 61429 1996 Marking of secondary cells and batteries with the international recycling
+ A11 1998 symbol ISO 7000-1135 and indications regarding directives 93/86/EEC and
91/157/EEC

HD 22.1 S3 1997 Rubber insulated cables of rated voltages up to and including 450 V/750 V -
Part 1: General requirements

IEC 60364-4-41 1992 Electrical installations of buildings -

Part 4: Protection for safety -
Chapter 41: Protection against electric shock

IEC 60050-486 1991 International Electrotechnical Vocabulary -

Chapter 486: Secondary cells and batteries

IEC/TR3 61431 1995 Guide for the use of monitor systems for lead-acid traction batteries

ISO 7000 1989 Graphical symbols for use on equipment - Index and synopsis
 -5- EN 50272-3:2002

3 Definitions

For the purposes of this European Standard the following definitions apply.

3.1
(secondary) cell; (rechargeable) cell; single cell
an assembly of electrodes and electrolyte which constitutes the basic unit of a secondary battery
(see IEV 60050: 486-01-02)

NOTE This assembly is contained in an individual case and closed by a cover.

3.2
lead-acid cell or battery
a secondary battery in which the electrodes are made mainly from lead and the electrolyte is a sulphuric acid
solution (H2SO4) (see IEV 60050: 486-01-04)

3.3
nickel-cadmium cell or battery
an alkaline secondary battery in which the positive material is made mainly from nickel and the negative
material is made mainly from cadmium (see IEV 60050: 486-01-07). The electrolyte is an alkaline solution
(potassium hydroxide, KOH)

3.4
vented (secondary) cell
a secondary cell having a cover provided with an opening through which gaseous products may escape
(see IEV 60050: 486-01-18)

3.5
valve regulated (secondary) cell
a secondary cell which is closed under normal conditions but has an arrangement which allows the escape
of gas if the internal pressure exceeds a predetermined value. The cell cannot normally receive addition to
the electrolyte (see IEV 60050: 486-01-20)

3.6
gas-tight sealed (secondary) cell
a secondary cell which remains closed and does not release either gas or liquid when operated within the
limits of charge and temperature specified by the manufacturer. The cell may be equipped with a safety
device to prevent dangerously high internal pressure.
The cell does not require addition to the electrolyte and is designed to operate during its life in its original
sealed state (see IEV 60050: 486-01-21)

3.7
secondary battery
two or more secondary cells connected together and used as a source of electrical energy
(see IEV 60050: 486-01-03)

3.8
traction battery
a secondary battery which is designed to provide the propulsion energy for electric vehicles

3.9
monobloc battery
a secondary battery in which the plate packs are fitted in a multi-compartment container
(see IEV 60050: 486-01-17)

3.10
electrolyte
a liquid or solid phase containing mobile ions which render the phase ionically conductive
(see IEV 60050: 486-02-19)
EN 50272-3:2002 -6-

3.11
gassing; gas emission
the formation of gas produced by electrolysis of the electrolyte (see IEV 60050: 486-03-24)

3.12
charge; charging (of a battery)
An operation during which a battery receives from an external circuit electrical energy which is converted into
chemical energy (see IEV 60050: 486-01-11)

3.13
equalisation charge
extended charge which ensures complete charging of all cells in a battery

3.14
opportunity charging
the use of free time during a work period to top up the charge and thus extend the work period of a battery
whilst avoiding excessive discharge

3.15
overcharge; overcharging (of a cell or battery)
continued charging after the full charge of a cell or battery (see IEV 60050: 486-03-35)

3.16
discharge; discharging (of a battery)
an operation during which a battery delivers current to an external circuit by the conversion of chemical
energy into electrical energy (see IEV 60050: 486-01-12)

3.17
battery peripheral equipment
equipment installed on the battery, which supports or monitors the operation of the battery, e.g. central water
filling system, electrolyte agitation system, battery monitoring system, central de-gassing system, battery
connectors (plugs and sockets), thermal management system, etc

3.18
charging room
a room or closed area intended specifically for recharging batteries. The room may also be used for battery
maintenance

3.19
charging area
an open area designated and made suitable for recharging batteries. The area may also be used for battery
maintenance

4 Protection against electric shock

Measures shall be taken on batteries and in
contact and indirect contact, or against both
in detail in IEC 60364-4-41 specifying the
1 000 V a.c. or 1 500 V d.c. The following
traction batteries in electrical vehicles.
battery charging installations for protection against direct
direct or indirect contact. These measures are described
protection against electric shock on installations up to
clauses describe the typical measures to be taken for

4.1 Protection against both direct and indirect contact

Protection against direct and indirect contact is simultaneously met by the use of safety extra low
voltage (SELV) (24 V d.c.) or protective extra low voltage (PELV) (24 V d.c.), as long as the whole
installation corresponds to the conditions for SELV or PELV.
 -7- EN 50272-3:2002

For protection against direct contact the following protective measures apply:
- protection by insulation of live parts;
- protection by barriers or enclosures;
- protection by obstacles.
(see IEC 60364-4-41,412.1 to 412.3).

For protection against indirect contact the following measures can be selected:
- protection by automatic disconnection or signalling;
- protection by protective insulation;
- protection by earth-free local equipotential bonding;
- protective electrical separation.

4.2 Protection against direct and indirect contact when discharging the traction battery on
the vehicle (battery disconnected from charger / mains)

4.2.1 Batteries with nominal voltages up to and including 60 V d.c. do not require protection against
electric shock caused by direct contact, as long as the whole installation corresponds to the conditions
for SELV and PELV.

However, for other reasons, e.g. short circuits, mechanical damage, all batteries in electrical vehicles
require protection against direct contact of live parts, even if the battery nominal voltage is 60 V d.c. or
less.

4.2.2 Batteries with nominal voltages from above 60 V d.c. and up to and including 120 V d.c. require
protective measures against direct contact.

NOTE Batteries with nominal voltages up to and including 120 V d.c. are regarded as safe power sources for SELV-systems
(safety extra low voltage) or PELV-systems (protective extra low voltage) (see IEC 60364-4-41,411.1).

The following protective measures apply:

a) insulation of live parts;
b) barriers or enclosures;
c) obstacles or placing out of reach.

If the protection against direct contact of live parts is ensured only by obstacles or placing out of reach,
the battery accommodation shall have access restricted to trained and authorized personnel only, and
shall be marked by warning labels

Batteries having nominal voltages exceeding 120 V d.c. require protective measures against both
direct and indirect contact.

Battery compartments with batteries having nominal voltages exceeding 120 V d.c. shall be locked and
have restricted access for trained and authorized personnel only and shall be marked by warning
labels (see Clause 11).

For batteries with nominal voltages exceeding 120 V d.c. the following protective measures against
indirect contact can be selected:
- protective electrical insulation;
- protection by earth-free equipotential bonding;
- protection by automatic disconnection or signalling.
EN 50272-3:2002 -8-

4.3 Protection against direct and indirect contact when charging the traction battery

If battery chargers with safe separation from the feeding mains are used (in accordance to EN 61140),
the protective measures SELV or PELV are applicable. If the nominal voltage of the battery does not
exceed 60 V d.c. protection against direct contact is not required, as long as the total installation
corresponds with the conditions of SELV or PELV

When the battery charger does not comply with these requirements, the protective measures against
direct and indirect contact apply (see IEC 60364-4-41).

However, for other reasons, e.g. short circuits, mechanical damage, all batteries in electrical vehicles
(see also EN 1175-1) require protection against direct contact of live parts, even if the battery nominal
voltage is 60 V d.c. or less.

5 Prevention of short circuits and protection from other effects of electric current

5.1 Cables and cell connectors

Cables and cell connectors shall be insulated to prevent short circuits.

Protection against short circuits cannot be provided by overcurrent protection devices for battery-specific
reasons, therefore connecting cables between charger, respective battery fuse, and battery, and between
battery and vehicle must be protected against short circuit and earth fault.

For these cables EN 60204-1 applies.

Where trailing cable is used, the protection against short circuits shall be improved by the use of single core
cable generally equal to EN 60204-1. However where the battery nominal voltage is less or equal to 120 V
d.c. the trailing cables may be of grade H01ND2 minimum (see HD 22.1 S3) because of higher flexibility.

The battery terminal cables shall be fixed in a manner that prevents tensile/torsional strain on the battery
terminals.

Insulation shall be resistant to the effects of ambient influences such as temperature, electrolyte, water, dust,
commonly occurring chemicals, gasses, steam and mechanical stress.

5.2 Protective measures during maintenance

When working on live equipment, the use of appropriate procedures will reduce the risk of injury.

The regulations according to EN 60900 apply. Only insulated tools shall be used.

During maintenance operation where people work close to an exposed battery system the risk of injury shall
be minimized.

To minimize the risk of injury, the following measures shall be observed:

- batteries shall not be connected or disconnected without first isolating the circuit;
- battery terminal and connector covers shall be provided which allow routine maintenance whilst
minimising exposure of energized conductive parts;
- all metallic personal objects shall be removed from the hands, wrists and neck before starting work;
- for battery systems where the nominal voltage is above 120 V d.c., insulated protective clothing and/or
local insulated coverings will be required to prevent personnel making contact with the floor or parts
bonded to earth.

NOTE For maintenance purposes, batteries having a nominal voltage above 120 V d.c. should be divided into sections consisting of
120 V d.c. (nominal) or less.
 -9- EN 50272-3:2002

5.3 Battery insulation

5.3.1 A new battery shall have a minimum insulation resistance of 1 MΩ when measured between a
battery terminal and metallic tray, vehicle frame or other conductive supporting structure. Where the battery
is fitted into more than one container, this test shall be carried out with the sections (including metal battery
containers) electrically connected.

5.3.2 The insulation resistance of a disconnected battery taken out of service, when measured between a
battery terminal and metallic tray, vehicle frame or other conductive supporting structure, shall be at least
50 Ω multiplied by the nominal battery voltage and not less than 1 kΩ.

Where the battery is fitted into more than one container, this test shall be carried out with the sections
(including metal battery containers) electrically connected.

5.3.3 Test voltage - The insulation resistance of the vehicle and traction battery shall be checked
separately. The test voltage for the battery shall be greater than the nominal voltage, which is minimum the
open circuit voltage of the battery, but not more than 100 V d.c. or three times the nominal voltage
(see EN 1175-1).

For test procedure see EN 1987-1, subclause 6.2.1.

6 Provisions against explosion hazards by ventilation

6.1 Gas generation

During charge, gases are evolved from all secondary cells and batteries using aqueous electrolytes. This is a
result of the electrolysis of the water by the charging current.

Gases produced are hydrogen and oxygen.

When emitted into the ambient atmosphere an explosive mixture may be created if the hydrogen
concentration exceeds 4 % hydrogen by volume in air.

NOTE When a cell reaches its fully charged state water electrolysis occurs according to Faraday's law. Under standard conditions
1)
(N.T.P.) :
- 1 Ah decomposes H2O into: 0,42 l H2+ 0,21 l O2,
- decomposition of 1 cm3 (1g) H2O requires : 3 Ah
- 26,8 Ah decomposes H2O into: 1g H2+ 8g O2

When the operation of the charge equipment is stopped, the emission of gas from the cells will substantially
subside within one hour. However, precautions are still necessary after this time, as gas trapped within the
cells can be released suddenly due to movement of the battery when it is refitted to the vehicle or when the
vehicle moves in service.

6.2 Ventilation requirements

Whether the battery is charged on or off the vehicle, the ventilation requirements of this subclause shall be
met.

The purpose of ventilating a battery location or enclosure is to maintain the hydrogen concentration below
the 4 % hydrogen threshold. Battery accommodation rooms are to be considered as safe from explosions,
when by natural or artificial ventilation the concentration of hydrogen is kept below this safe limit.

1)
N.T.P.= Normal Temperature and Pressure, T=273 K, P=1 013 hPa.
EN 50272-3:2002 - 10 -

The necessary ventilation airflow for a battery location or compartment shall be calculated by the following
formula:
3
Q = v ⋅ q ⋅ s ⋅ n ⋅ Igas ⋅ Cn / 100 [m /h]

where
3
Q = ventilation air flow [m /h];
v = necessary hydrogen dilution factor = 24;
-3 3
q = 0,42 ⋅ 10 [m /Ah] generated hydrogen;
s = safety factor = 5;
n = number of cells;
Igas = current producing gas during the gassing phase of charge [A/100Ah] (see Table 1)
Cn = nominal capacity [Ah]

The ventilation formula can be resolved into the following:

-3 3
Q = 24 ⋅ 0,42 ⋅ 10 ⋅ 5 ⋅ n ⋅ Igas ⋅ Cn / 100 [m /h]
3
Q = 0,05 ⋅ n ⋅ Igas ⋅ Cn / 100 [m /h]

Where standard chargers are used and no detailed information regarding the charge characteristic is
provided, Igas ⋅ Cn / 100 shall be calculated as 25 % minimum of the rated charger output current.

For detailed calculation of the required ventilation air flow use the value of the gas producing current Igas
given in Table 1, which corresponds with the end of charge current for different charger types expressed in
A/100 Ah rated capacity.

Where a so-called ‘fast charger’ is used, a specific value for Igas should be obtained from the manufacturer.

When charging more than one battery in the same room the ventilation must be calculated as the sum of the
individual ventilation air flow.

Table 1 - Gas producing current Igas respectively typical end of charge current
in A per 100 Ah rated capacity, when charging with IU, IUI, or taper chargers

Charger Igas for lead-acid battery Igas for lead-acid battery a

Igas for NiCd battery
characteristic vented cells valve regulated cells
(voltage limit 2,4 V/c) (voltage limit 2,4 V/c) (voltage limit 1,55 V/c)
IU charging b b b
2 1 5
rd rd rd
current in 3 charging current in 3 charging current in 3 charging
IUI charging step step step
max. 6 max. 1,5 max. 5
minimum 25 % of nominal
charger current at 2,6 V/c, d d
Taper charging
typical values are in the
c
range of 5 to 7
a
For NiCd gas recombination type cells, consult the manufacturer.
b
Because of the large variations which can exist in battery design and installation, consult the manufacturer.
c
For simple taper charger without change-over of characteristic.
d
Taper charging is not typical for these batteries. For application consult the battery manufacturer.

The specified values are typical for worst case conditions to ensure that ventilation is adequate to all kinds of
vented or valve-regulated batteries. During the first few cycles of operation the recombination process in
VRLA batteries may not be completely established, and batteries may behave similar to vented batteries in
terms of gassing.
 - 11 - EN 50272-3:2002

6.3 Natural ventilation

The required air flow shall preferably be ensured by natural ventilation, otherwise by forced (artificial)
ventilation.

Battery rooms, areas and enclosures require an air inlet and outlet, each with a minimum free area of
opening calculated by the following formula:
2
A = 28 ⋅ Q [cm ]
3
where Q = ventilation air flow [m /h]

NOTE For the purpose of this calculation the air velocity is assumed to be 0,1 m/s.

In open air, in large halls and in well ventilated rooms an air velocity of ≥ 0,1 m/s can be assumed and
adequate air ventilation is ensured.
3
Well ventilated rooms shall have a free volume of at least 2,5 ⋅ Q [m ].

The air inlet and outlet shall be in the best possible location for the exchange of air, i.e.
- openings on opposite walls,
- minimum distance apart of 2 m when openings in the same wall.

The air extracted from the charging area/room shall be exhausted to the atmosphere outside the building.

6.4 Forced ventilation

Where the airflow Q can not be obtained with natural ventilation, forced ventilation shall be used to secure
the required exchange of air for the mode of operation. Interlocking of chargers and ventilation fans shall be
considered.

The air extracted from the charging area/room shall be exhausted to the atmosphere outside the building.

6.5 Close vicinity to the battery

In the close vicinity of the battery the dilution of explosive gases is not always secured, therefore a safety
distance of minimum 0,5 m through the air without flames, sparks, arcs or glowing devices (max. surface
temperature 300 °C) must be observed.

6.6 Ventilation of battery compartment

6.6.1 Where removable covers are provided for the battery and when appropriate, the covers shall be
removed prior to charging in order to ventilate gas produced and aid battery cooling

6.6.2 Suitable ventilation openings shall be provided in the battery container, compartment or cover so that
during discharge or rest periods, dangerous accumulations of gas do not occur when the equipment is used
in accordance with manufacturer's instructions.

The ventilation opening area shall be at least:

2
A = 0,005 ⋅ n ⋅ C5 [cm ]

where
2
A = total cross-sectional area of ventilation holes required [cm ]
n = number of cells in battery
C5 = capacity of battery at the 5h rate [Ah]
EN 50272-3:2002 - 12 -

7 Provision against electrolyte hazard

7.1 Electrolyte and water

Electrolyte used in lead-acid batteries is an aqueous solution of sulphuric acid. Electrolyte used in NiCd
batteries is an aqueous solution of potassium hydroxide. Distilled or demineralized water is used for topping
up the cells.

7.2 Protective clothing

In order to avoid personal injury from electrolyte splashes, when handling electrolyte and / or vented cells or
batteries, protective clothing shall be worn, such as
- protective glasses (see EN 166) or masks for eyes or face,
- protective gloves and aprons for skin protection.

In the case of valve-regulated or gastight batteries at least protective glasses and gloves shall be worn.

7.3 Accidental contact , "First Aid"

Both electrolytes cause burns to eyes and skin.

7.3.1 Eye contact

In the event of accidental contact with electrolyte immediately flood the eyes with large quantities of water for
an extended period of time of at least 15 min. In all cases get immediate medical attention !

7.3.2 Skin contact

In the event of accidental contact with electrolyte, wash the affected parts with large quantities of water or
with neutralising aqueous solutions, such as soap water for sulphuric acid or a mild acidic solution for
alkaline electrolyte. If irritation of skin persists obtain medical attention.

7.4 Battery accessories and maintenance tools

Materials used for battery trays, battery accessories and components inside battery charging rooms shall be
resistant to or protected from the chemical effects of the electrolyte.

In the event of electrolyte spillage remove the liquids with absorbing material; neutralising material is
preferred.

Maintenance tools, such as funnels, hydrometers, thermometers, etc, which are in contact with electrolyte
shall be separately dedicated to the lead-acid or NiCd-batteries and shall not be used for any other purpose.

8 Battery containers and enclosures

8.1 The battery accommodation, trays, crates and compartments shall have adequate mechanical
strength and be constructed either of electrolyte resistant materials or be protected against the damaging
effects of electrolyte leakage and spillage.

8.2 Provision shall be made to prevent the spillage of electrolyte on to underlying

equipment/components or the ground.

8.3 It shall be made possible to remove any accumulation of spilled electrolyte or water from the battery
tray.

NOTE Waste electrolyte from maintenance work on batteries shall be disposed of in accordance with local regulations.
 - 13 - EN 50272-3:2002

9 Accommodation for charging / maintenance

9.1 Charging areas shall be clearly defined by permanent marking of the floor area.

(Not required for electric equipment for domestic use, e.g. wheel chairs, lawn movers, etc.).

9.2 The charging area shall be adequately spaced from materials which may constitute a hazard such as
inflammable or explosive goods.

9.3 Except during essential battery maintenance/repair, the charging area shall not be subjected to any
sources of ignition such as sparks or sources of high temperature. The exception is where high temperature
equipment is required for work on the battery and this shall be in the control of trained and authorized
personnel who shall take all necessary precautions.

9.4 Prevention of electrostatic discharges when working with batteries: care shall be taken not to wear
clothes and footwear which may build up electrostatic charge.

Absorbent cloth for battery cleaning shall be antistatic and used moistened only with water without cleaning
agents.

9.5 When the battery is being charged or serviced, a space 0,8 m wide shall be provided on those sides
required for access.

9.6 When charging batteries on or off the vehicle the ventilation requirements of Clause 6 shall be met.

9.7 The charger shall be mounted, such that it is not vulnerable to damage by movement of the vehicle.

9.8 The charging area shall not be vulnerable to falling objects, drip water or liquids that could leak from
fractured pipes.

10 Battery peripheral equipment/accessories

10.1 Battery monitoring system

When applying battery monitoring the recommendations of Technical Report IEC/TR3 61431 should be
observed.

A battery monitoring system shall be designed and installed in such a way, that no hazard will occur during
use and operation, for example
- measuring cables installed on top of the battery shall be protected against short circuit by use of fuses,
double insulation or high impedance,
- cable installation shall follow the potential of the series connected cells to avoid leakage currents, e.g. by
means of accumulated dirt or electrolyte contamination,
- shunt cables or other measuring equipment shall be carefully fixed to the battery.

10.2 Central water filling system

10.2.1 General

During service of vented type traction batteries, water is lost mainly due to its electrolysis occurring towards
the end of charge which generates hydrogen and oxygen. This water must be periodically replaced in the
battery cells to restore the electrolyte level and specific gravity.

This can be done by the use of a "central" or "single point" topping up installation.
EN 50272-3:2002 - 14 -

The plugs of each cell are connected in series or series/parallel through a piping system. Water is fed to the
cells from a central reservoir either by gravity, vacuum or under pressure according to the plug design. Once
the electrolyte level in the cell achieves the prescribed level water is prevented from further entering into the
cell. This is accomplished in different ways according to the plug design.

“Float” design
The plug is fitted with a float which closes a water inlet valve once the electrolyte achieves the required level.
The gases are vented from each cell through an opening in the plug.

“Air-lock” design
The plug has no float or other moving parts; once the electrolyte achieves the prescribed level an
overpressure is generated in the cell space above the electrolyte or within the plug itself sufficient to prevent
the water from further entering into the cell. The gases are vented from the cell through the same piping used
for the water topping-up.

10.2.2 Safety aspects

In any battery where the cells are interconnected by pipes, this may be a gas mono-venting system or a
water filling system, precautions should be taken to minimize any risk of electrical tracking or the propagation
of battery explosions between cells.

The following precautions shall be followed:

- the risk of electrical tracking is reduced if the piping system follows the potential of the electrical circuit;
- the risks of both electrical tracking and the propagation of explosions is reduced if the number of cells
connected in a piped series circuit is reduced;
- the maximum number of cells which is to be connected in a series piped branch, is to be specified by the
manufacturer based on the system design.

NOTE In order to prevent an explosion occurring within an individual cell from propagating into the contiguous ones, the plugs may be
fitted with a built-in safety feature such as a water trap that prevents hydrogen from entering into the water piping circuit.

10.3 Central degassing systems

Central degassing systems are used to vent the battery gases outside the battery compartment. In many
cases they are associated with central water filling systems.

In the case of central water filling of the float type plug (see 10.2) the cell plugs have a double piping system
one for watering and the other for venting the gases. The safety requirements in this case are the same as in
10.2.2. With central degassing systems the gas venting outlets shall be located outside the battery
compartment and protected with flame arrestors against the risk of explosions caused by sources of ignition
close to the gas outlets.

Where during charging individual degassing circuits are coupled to a forced ventilation system which
exhausts the entire gas evolved to the outside of the charging area, the ventilation requirements of the
system shall be in accordance with 6.2 and 6.4.

Provided that all batteries being charged have a central degassing system that exhausts to the outside, the
room will have no special ventilation requirements.

10.4 Thermal management systems

Where thermal management systems are installed, care must be taken that no hazard is caused by sources
of ignition, leakage currents, electrolyte flooding, etc.

10.5 Electrolyte agitation system

Lead-acid traction batteries may be equipped with an electrolyte agitation system to eliminate stratification
and reduce charging factor. Mixing of the electrolyte is achieved by means of a continuous or intermittent air
stream released near the bottom, inside of the cell containers. The air is fed through flexible tubes by an air
pump to an air inlet on each cell.
 - 15 - EN 50272-3:2002

Provision shall be made to avoid confusion between air and water filling pipe systems.

The piping system shall follow the potential of the electrical circuit.
The maximum number of cells with peripheral accessories connected in series in a section shall be specified
by the battery manufacturer based on experience on his design

10.6 Catalyst vent plugs

For the reduction of water consumption and the extension of topping up intervals catalyst vent plugs may be
used. Catalyst vent pugs recombine hydrogen and oxygen generated mainly during the recharge process,
forming water which drops back into the cell.

The following hazards must be considered:

- due to the exothermal recombination reaction heat is generated and must be dissipated into the ambient
air (hot surface areas);
- the recombination reaction takes place only with certain efficiency depending on the relationship of
catalyst size to charge current and ageing of catalyst. Surplus charging gasses, which are not
recombined, will be released from the catalyst vent plugs.

The ventilation requirements according to 6.2 shall be observed, despite the use of catalyst vent plugs. To
avoid drying out of the battery, regular checks of the function of the catalyst and of the electrolyte level are
required.

10.7 Connectors (plugs/sockets)

Plugs and sockets for use with traction batteries shall be in accordance with the requirements of EN 1175-1,
Annex A.

For voltages higher than 240 V d.c. refer to manufacturers information.

11 Identification labels, warning notices and instructions for use, installation and
maintenance

11.1 Safety labels

The following safety labels shall be used to inform and warn of risks associated with batteries and battery
installations. At the minimum the standardized IEC symbols shall be indicated at the battery
- follow the instructions (iInformation sign),
- use protective cloths and goggles (command sign),
- dangerous voltage (when 60 V d.c. is exceeded) (warning sign),
- prohibition of naked flame (warning sign),
- warning sign - battery hazard (warning sign),
- electrolyte is highly corrosive (warning sign),
- explosion hazard (warning sign).

11.2 Identification label

The following information shall be indelibly marked on each battery assembly unit:
- name of battery manufacturer or supplier;
- battery type reference;
- battery serial number;
- nominal battery voltage (within one battery unit);
- battery capacity with time rating;
2)
- service mass , including ballast if used.

2)
Not required for individual monobloc batteries.
EN 50272-3:2002 - 16 -

11.3 Other labels

According to the European battery directives EC 93/86 and EC 91/157 traction batteries shall be marked with
the crossed-through roll-out container.

In addition marking with the recycling symbol ISO 7000-1135 with reference to the chemical system of the
battery according to EN 61429 is required.

Traction batteries exceeding a nominal voltage of 75 V d.c. shall be marked with the CE mark according to
the European low voltage directives EC 73/23 and EC 93/68.

12 Transportation, storage, disposal and environmental aspects

12.1 Packing and transport

The packing and transport of secondary batteries is covered in various national and international regulations.
The following international regulations for transport, safe packing and carriage of dangerous goods apply:

Road:
European Agreement for the International Carriage of Dangerous Goods by Road (ADR)

Rail (international):
International Convention concerning the carriage of Goods by Rail (CIM), Annex A: International regulations
concerning the carriage of dangerous goods by rail (RID)

Sea:
International Maritime Organisation, Dangerous Goods Code
IMDG Code 8 Class 8 corrosive

Air:
International Air Transport Association (IATA), Dangerous Goods Regulations

12.2 Disassembly, disposal, and recycling of batteries

Only competent personnel shall undertake disassembly and disposal of batteries.

The following EC-directives must be followed:

− 91/157 (EEC, council directive)
”Batteries and accumulators containing certain dangerous substances”
− 93/86 (EEC, commission directive)
”Adapting to technical progress Council Directive 91/157/EEC on batteries and accumulators containing
certain dangerous substances”

13 Inspection and monitoring

To secure the safe operation of a traction battery regular inspection is required. Any signs of deterioration
shall be noted and be subject to repair, specifically in the case of electrolyte leakage and insulation failures.

The inspection of the battery can be incorporated into the regular maintenance routine of the battery, such as
during the topping-up procedure.

Inspection and monitoring of batteries in service shall be in accordance with battery manufacturer's
instructions.
blank
BS EN
50272-3:2002
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