HV Battery Component Certificate (ECE R100) Final Report - 15560-23-Ec3

TÜV RHEINLAND GROUP
Test Report No.: 89-R100 Part II-15560/23

Applicant : PCA Automobiles India Private Limited
Test object(s) : Rechargeable Electrical Energy Storage System (REESS)
TEST REPORT
for
Part II: Safety requirements with respect to the Rechargeable Electrical Energy
Storage System (REESS), of road vehicles of categories M and N equipped with
electric power train, excluding vehicles permanently connected to the grid.
according to
UN Regulation No. 100
03 series of amendments
Supplement 2
Structure of the Test Report: 1. General information

2. Test Information
3. List of appendices
4. Statement of conformity
The Test Report shall be reproduced and published in full by the client only. It shall however be
reproduced partially with the written permission of the Testing Laboratory only.
TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 1 of 24

TÜV Rheinland (India) Pvt. Ltd.
"Sai-Icon", Plot No. 10, Near Sakal Nagar,
Baner Road, Aundh, Pune - 411007, India.

1. General Information
1.1. Name and address of the applicant : PCA Automobiles India Private Limited
Adhigattur Village, Kadambathur P.O, Thiruvallur,
Tamilnadu-631203
1.2. Name and address of the battery : Taizhou Division of SVOLT Energy Technology
pack manufacturer Co., Ltd
No. 666-1 Tongjiang East Road, Gaogang District,
Taizhou City, Jiangsu Province, P.R.China
1.3. Address of Manufacturing Plant : Taizhou Division of SVOLT Energy Technology
Co., Ltd
No. 666-1 Tongjiang East Road, Gaogang District,
Taizhou City, Jiangsu Province, P.R.China
1.4. Make of component cell : SVOLT
2. Test information
2.1. Details of battery pack
2.1.1 Make : SVOLT

2.1.2. Type : Lithium-ion traction battery packs
2.1.3. Model : PB301097A
2.1.4. Gross mass : (275±8.25) kg
2.1.5. Cell configuration : 94 Series 1 Parallel
2.1.6. Overall dimensions (LxWxD) : (1156±3) mm * (1552.8±5) mm * (231.8±3) mm
2.1.7. Nominal voltage : 300.8 V
2.1.8. Rated capacity : 97 Ah
2.1.9. Max operating range (voltage) : 343.1 V
2.1.10. BMS Make : SVOLT
2.1.11. BMS model number : FBMSG1.6
2.1.12 BMS type : Integrated & centralized
2.1.13 BMS version : ME10BV01BCU


2.2. Details of component cell
2.2.1. Type : Rechargeable small cell

2.2.2. Make : SVOLT
2.2.3. Model : CB52E8B2A
2.2.4. Gross mass : (1.9±0.02) Kg
2.2.5. Shape : Prismatic
2.2.6. Dimensions (D x L x H) : (52±1) mm * (148±1) mm * (112±1) mm
2.2.7. Nominal voltage : 3.2 V
2.2.8. Voltage range : 2.5 V to 3.65 V
2.2.9. Rated capacity : 97 Ah
2.3. Test location : 1. The Automotive Research Association of
India.
Plot No. E-1/1, MIDC Chakan Industrial Area,
Phase-III, Taluka Khed, Pune-410 501, India.
2. CATARC Automotive Test Center (Tianjin)

Co. Ltd.
2.4. Test dates : See below table
2.5. List of the tests performed : See below table
Sr. Tests performed Test dates Test results

1 Vibration test August 30, 2022 Pass
2 Thermal shock and cycling test August 30, 2022 Pass
3 Mechanical shock August 30, 2022 Pass
4 Fire resistance August 30, 2022 Pass
5 External short circuit August 30, 2022 Pass
6 Over-charge protection July 10, 2023 Pass
7 Over-discharge protection August 30, 2022 Pass
8 Over-temperature protection July 10, 2023 Pass
9 Over-Current protection August 30, 2022 Pass
10 Mechanical Integrity July 10, 2023 Pass


3. List of Appendices
Sr. Appendix details Page no.
1 Vibration test : 06
2 Thermal shock and cycling test : 07 to 08
3 Mechanical shock : 09 to 10
4 Fire resistance : 11 to 12
5 External short circuit : 13 to 14
6 Over-charge protection : 15 to 16
7 Over-discharge protection : 17 to 18
8 Over-temperature protection : 19 to 20
9 Over-current protection : 21 to 22
10 Mechanical Integrity : 23 to 24


4. Statement of conformity
The ‘Rechargeable Electrical Energy Storage System (REESS)’ submitted by PCA Automobiles India
Private Limited were tested as per UN Regulation No. 100.
That satisfactorily meets all the applicable requirements, The test results in this report refer to the
object(s) described under section 2.1. and 2.2. with regards to the required level of performance to be
achieved.
The test report (including appendices 1 to 10) consists of total 24 pages and shall not be reproduced
except in full without the written approval of the TÜV Rheinland (India) Pvt. Ltd.
Place / Date
Pune / 2023-07-19
Hemant N. Lohar
Expert Technical Service


Test results for Vibration Test Appendix 1

Clause Requirement Remark
6.2. General test conditions: : Complies with requirements.

and At the end of test, no electrolyte leakage,
(a) The test shall be conducted at an ambient
Annex no rupture, no fire, and no explosion
temperature of 22 ± 5 °C.
9A were observed from tested device.
(b) At the beginning of the test, the SOC shall Standard cycle applicable and performed
be adjusted in accordance with Annex 9, successfully.
Appendix 2.
Isolation resistance measurement after
(c) At the beginning of the test, all protection the test was greater than 100 Ω/V.
devices which affect the function(s) of the
Tested-Device that are relevant to the outcome
of the test shall be operational.
Requirement:
During the test, there shall be no evidence of
(a) Electrolyte leakage
(b) Rupture
(c) Fire
(d) Explosion
Evidence of electrolyte leakage shall be verified
by visual inspection without disassembling any
part of the tested device.
Test Photographs:


Test results for Thermal Shock and Cycling Appendix 2
6.3. Test conditions: : Complies with requirements.

and (a) The SOC shall be adjusted in accordance At the end of test, no electrolyte leakage,
Annex with Annex 9, Appendix 2. no rupture, no fire, and no explosion
9B were observed from tested device.
(b) All protection devices, which would affect
the function of the Tested-Device, and which Standard cycle applicable and performed
are relevant to the outcome of the test shall be successfully.
operational. Isolation resistance measurement after
Test procedure: The tested device shall be the test was greater than 100 Ω/V.
stored for at least six hours at a test temperature
equal to 60 °C ± 2 °C or higher if requested by
the manufacturer, followed by storage for at
least six hours at a test temperature equal to
-40 °C ± 2 °C or lower if requested by the
manufacturer. The maximum time interval
between test temperature extremes shall be 30
minutes. This procedure shall be repeated until
a minimum of 5 total cycles are completed,
after which the tested device shall be stored for
24 hours at an ambient temperature of 20°C ±
10 °C. After the storage for 24 hours, a standard
cycle as described in Annex 9, Appendix 1 shall
be conducted, if not inhibited by the tested
device. The test shall end with an observation
period of 1 h at the ambient temperature
conditions of the test environment.
Test Requirement: During the test, there shall
be no evidence of Electrolyte leakage, Rupture
(applicable to high voltage REESS(s) only),
Fire, Explosion.


Test Photographs:


Test results for Mechanical Shock Test Appendix 3
6.4.1. Test conditions: : Complies with requirements.

and a) The test shall be conducted at an ambient At the end of test, no electrolyte leakage,
Annex temperature of 20 ± 10 °C, no rupture, no fire, and no explosion
9C were observed from tested device.
(b) At the beginning of the test, the SOC shall
Standard cycle applicable and performed
be adjusted in accordance with Annex 9,
successfully. Isolation resistance
Appendix 2.
measurement is applicable.
(c) At the beginning of the test, all protection
devices which affect the function of the Tested-
Device, and which are relevant to the outcome
of the test, shall be operational.
Test procedure:
The Tested-Device shall be decelerated or
accelerated in compliance with the acceleration
corridors which are specified in Tables 1 to 3.
The manufacturer shall decide whether the tests
shall be conducted in either the positive or
negative direction or both.
For each of the test pulses specified, a separate
Tested-Device may be used.
The test pulse shall be within the minimum and
maximum value as specified in Tables 1 to 3. A
higher shock level and /or longer duration as
described in the maximum value in Tables 1 to
3 can be applied to the Tested-Device if
recommended by the manufacturer.
The test shall end with an observation period of
1 hour at the ambient temperature conditions of
the test environment.


The test shall end with an observation period of : Complies with requirements.
1 h at the ambient temperature conditions of the At the end of test, no electrolyte leakage,
test environment. The tested-device shall be no rupture, no fire, and no explosion
secured to the testing machine by means of a were observed from tested device.
rigid mount which will support all mounting Standard cycle applicable and performed
surfaces of the tested-device. successfully.
Test Requirement: During the test, there shall Isolation resistance measurement after
be no evidence of Electrolyte leakage, Rupture the test was greater than 100 Ω/V.
(applicable to high voltage REESS(s) only),
Fire, Explosion.
Test Photographs:


Test results for Fire Resistance Test Appendix 4
6.5. and This test applies for vehicles with a passenger : Complies with requirements.
Annex compartment only. At the end of test, no explosion was
9E (a) The test shall be conducted at a temperature observed from tested device.
of at least 0 °C.
(b) At the beginning of the test, the SOC shall
be adjusted in accordance with Annex 9,
Appendix 2.
(c) At the beginning of the test, all protection
devices which affect the function of the Tested-
Device and are relevant for the outcome of the
test shall be operational.
Test Requirement: During the test, the tested
device shall exhibit no evidence of explosion.
Test Parameter
Parameter Parameter
During Test
Fuel Pan Distance from 3m

DUT
Pre-Heating Duration 60 s
(Phase-A)
Duration of DUT Direct 70 s

exposure to flame
(Phase-B)
Duration of DUT 60 s
Indirect exposure to
flame (Phase-C)
Observation time 3 hours


Test Photographs:
Before Test After test


Test results External Short Circuit Protection Test Appendix 5

6.6. and Test conditions: : Complies with requirements.

Annex (a) The test shall be conducted at an ambient At the end of test, no electrolyte
9F temperature of 20 ± 10 °C or at higher leakage, no rupture, no fire, and no
temperature if requested by the manufacturer. explosion were observed from tested
(b) At the beginning of the test, the SOC shall be device. Standard cycle applicable and
adjusted in accordance with Annex 9, Appendix 2. performed successfully. Isolation
(c) At the beginning of the test, all protection resistance measurement is applicable.
devices which would affect the function of the
Tested-Device, and which are relevant to the
outcome of the test shall be operational.
(d) For testing with a complete vehicle, a breakout
harness is connected to the manufacturer specified
location and vehicle protection systems relevant to
the outcome of the test shall be operational.
Test procedure:
At the start of the test all relevant main contactors
for charging and discharging shall be closed to
represent the active driving possible mode as well
as the mode to enable external charging. If this
cannot be completed in a single test, then two or
more tests shall be conducted.
For testing with a complete REESS or REESS
subsystem(s), the positive and negative terminals
of the Tested-Device shall be connected to each
other to produce a short circuit. The connection
used for this purpose shall have a resistance not
exceeding 5 mΩ.
For testing with a complete vehicle, the short
circuit is applied through the breakout harness.
The connection used for creating the short circuit
(including the cabling) shall have a resistance not
exceeding 5 mΩ. environment.
The short circuit condition shall be continued until
the protection function operation of the REESS
terminate the short circuit current is confirmed, or
for at least one hour after the temperature
measured on the casing of the Tested-Device has
stabilised, such that the temperature gradient
varies by a less than 4 °C through 2 hours.


6.6. and Test Requirement: : Complies with requirements.

Annex During the test, there shall be no evidence of At the end of test, no electrolyte
9F Electrolyte leakage, Rupture (applicable to high leakage, no rupture, no fire, and no
voltage REESS(s) only), Fire, Explosion. explosion were observed from tested
Evidence of electrolyte leakage shall be verified device. Standard cycle applicable and
by visual inspection without disassembling any performed successfully.
part of the tested device. Isolation resistance measurement
after the test was greater than 100
Ω/V.
Test Photographs:


Test results for Overcharge Protection Test Appendix 6
6.7 and Test conditions: : Complies with requirements.

Annex (a) The test shall be conducted at an ambient The tested device interrupted the
9G temperature of 20 ± 10 °C or at higher charging at 327.7 V.
temperature if requested by the manufacturer.
(b) The SOC of REESS shall be adjusted around At the end of test, no electrolyte leakage,
the middle of normal operating range by normal no rupture, no fire, and no explosion
operation recommended by the manufacturer were observed from tested device.
such as driving the vehicle or using an external Standard cycle applicable and performed
charger. The accurate adjustment is not required successfully.
if the normal operation of the REESS is Isolation resistance measurement is
enabled. applicable.
(c) For vehicle-based test of vehicles with on-
board energy conversion systems (e.g., internal
combustion engine, fuel cell, etc.), fill the fuel
to allow the operation of such energy
conversion systems.
(d) At the beginning of the test, all protection
Tested-Device, and which are relevant to the
outcome of the test shall be operational. All
relevant main contactors for charging shall be
closed.
Test procedure:
Test was carried out on battery at an ambient
temperature of 20°C ± 10°C. Battery pack was
around 50% SOC before the test. Battery pack
was charged at 97A (1C) until 100% SOC
thereafter continued with charging with 97A, as
declared by the manufacturer. The charging was
terminated when the REESS overcharge
protection control terminated the REESS charge
current.


6.7 and Test Requirement: : Complies with requirements.

Annex During the test there shall be no evidence of At the end of test, no electrolyte leakage,
9G electrolyte leakage; rupture (applicable to high no rupture, no fire, and no explosion
voltage REESS(s) only); fire; explosion. were observed from tested device.
Evidence of electrolyte leakage shall be verified Standard cycle applicable and performed
by visual inspection without disassembling any successfully.
the test was greater than 100 Ω/V.
Test Photographs:


Test results Over-Discharge Protection Pest Appendix 7
6.8. Test conditions: : Complies with requirements.

and (a) The test shall be conducted at an ambient Battery pack was discharged at 97 A
Annex temperature of 20 ± 10 °C or at higher (1C), as declared by the manufacturer.
9H temperature if requested by the manufacturer.
The tested device interrupted the
(b) The SOC of REESS shall be adjusted at the discharging when the lowest cell voltage
low level, but within normal operating range, by reached at 2.3 V.
normal operation recommended by the At the end of test, no electrolyte leakage,
manufacturer, such as driving the vehicle or no rupture, no fire, and no explosion
using an external charger. Accurate adjustment were observed from tested device.
is not required as long as the normal operation
of the REESS is enabled. Isolation resistance measurement after
(c) For vehicle-based test of vehicles with on-
board energy conversion systems (e.g., internal
combustion engine, fuel cell, etc.), reduce the
electrical energy from such on-board energy
conversion systems, for example by adjusting
the fuel level to nearly empty but enough so that
the vehicle can enter into active driving possible
mode.
(d) At the beginning of the test, all protection
Tested-Device, and which are relevant for the
outcome of the test shall be operational.
Test Procedure: This procedure is applicable to
component-based test:
(a) All relevant main contactors shall be closed.
The external charge-discharge shall be
connected to the main terminals of the Tested-
Device.
(b) A discharge shall be performed with a stable
current within the normal operating range as
specified by the manufacturer.
(c) The discharging shall be continued until the
Tested-Device (automatically) terminates
REESS discharge current, or the temperature of
the Tested-Device is stabilized such that the
temperature varies by a gradient of less than 4
°C through 2 hours.


Where an automatic interrupt function fails to

operate, or if there is no such function, then the
discharging shall be continued until the Tested-
Device is discharged to 25 per cent of its
nominal voltage level.
(d) Immediately after the termination of the
discharging, one standard charge followed by a
standard discharge as described in Annex 9,
Appendix 1 shall be conducted if not inhibited
by the Tested-Device. After the over discharge
test, a standard cycle shall be conducted, if not
inhibited by the tested device. The test ended
with an observation period of 1 h at the ambient
temperature conditions of the test environment.
Test Photographs:


Test results Over-Temperature Protection Test Appendix 8
6.9 Test Procedure: : Complies with requirements.

and The tested-device with all protection devices The tested device inhibited charging at
Annex which would affect the function(s) of the tested- 56º C and discharging at 56º C.
9I device that are relevant to the outcome of the
test shall be operational except At the end of test, no electrolyte leakage,
cooling function and where the REESS will no rupture, no fire, and no explosion
remain functional without a cooling function were observed from tested device.
system being operational, the cooling system Standard cycle applicable and performed
were deactivated for the test. successfully.
During the test, the tested device was
continuously charged and discharged with a the test was greater than 100 Ω/V.
steady current that will increase the temperature
of cells as rapidly as possible within the range
of normal operation as defined by the
manufacturer.
The tested device with protective measure
against internal overheating was placed in a
convective oven or climatic chamber. The
temperature of the chamber or oven was
gradually increased until it reaches the
temperature defined by the manufacturer as
being the operational temperature threshold for
such protective measures. The test was
continued till the tested device inhibits and / or
limits the charge and / or discharge to prevent
the temperature increase or the temperature of
the battery pack was stabilized, which means
that the temperature varies by a gradient of less
than 4 °C through 2 hours.
Test Requirement: During the test there shall
be no evidence of Electrolyte leakage, Rupture,
Fire, Explosion.


Test Photographs:


Test results Over-Current Protection Test Appendix 9
6.10 Test Procedure: : Complies with requirements.

and (a) The test shall be conducted at an ambient
Annex temperature of 20 ± 10 °C. Battery pack was initiated at the highest
9J normal charge 97A, further the charge
(b) The SOC of REESS shall be adjusted around
current was increased from the highest
the middle of normal operating range by normal
normal charge current to over current
operation recommended by the manufacturer
176A.
such as driving the vehicle or using an external
charger. The accurate adjustment is not required
At the end of test, no electrolyte leakage,
if the normal operation of the REESS is
no rupture, no fire, and no explosion
enabled.
were observed from tested device.
(c) The overcurrent level (assuming failure of Standard cycle applicable and performed
external DC electricity supply equipment) and successfully.
maximum voltage (within normal range) that Isolation resistance measurement after
can be applied shall be determined, if necessary, the test was greater than 100 Ω/V.
through consultation with the manufacturer.
3. The overcurrent test shall be conducted in
accordance with paragraph 4. or paragraph 5., as
applicable and in accordance with manufacturer
information.
Fire, Explosion.


Test Photographs:


Test results Mechanical Integrity Test Appendix 10
6.4.2 Test Procedure: : Complies with requirements.

and The tested-device at ambient temperature of 20 At the end of test, no electrolyte leakage,
Annex ± 10 °C was having SOC in upper ≥95% of no rupture, no fire, and no explosion
9D normal operating SOC range with all protection were observed from tested device.
devices which would affect the function(s) of Standard cycle applicable and performed
the tested-device that are relevant to the successfully.
outcome of the test were operational. Isolation resistance measurement after
The Tested-Device shall be crushed between a
resistance and a crush plate as described in
Figure 1 with a force of at least 100 kN, but not
exceeding 105 kN, unless otherwise in this
Standard, with an onset time less than 3 minutes
and a hold time of at least 100 ms but not
exceeding 10 s.
A higher crush force, a longer onset time, a
longer hold time, or a combination of these,
may be applied at the request of the
manufacturer. The application of the force shall
be decided by the manufacturer having
consideration to the direction of travel of the
REESS relative to its installation in the vehicle.
The application force being applied horizontally
and perpendicular to the direction of travel of
the REESS. The test shall end with an
observation period of 1 h at the ambient
temperature conditions of the test environment.
Fire, Explosion.


Test Photographs:


HV Battery Component Certificate (ECE R100) Final Report - 15560-23-Ec3

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TÜV RHEINLAND GROUP

Test Report No.: 89-R100 Part II-15560/23

UN Regulation No. 100

Structure of the Test Report: 1. General information

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 1 of 24

Test Report No.: 89-R100 Part II-15560/23

2.1.1 Make : SVOLT

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 2 of 24

Test Report No.: 89-R100 Part II-15560/23

2.2. Details of component cell

2.2.1. Type : Rechargeable small cell

2. CATARC Automotive Test Center (Tianjin)

Sr. Tests performed Test dates Test results

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 3 of 24

Test Report No.: 89-R100 Part II-15560/23

Sr. Appendix details Page no.

2 Thermal shock and cycling test : 07 to 08

5 External short circuit : 13 to 14

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 4 of 24

Test Report No.: 89-R100 Part II-15560/23

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 5 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results for Vibration Test Appendix 1

6.2. General test conditions: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 6 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results for Thermal Shock and Cycling Appendix 2

Clause Requirement Remark

6.3. Test conditions: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 7 of 24

Test Report No.: 89-R100 Part II-15560/23

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 8 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results for Mechanical Shock Test Appendix 3

Clause Requirement Remark

6.4.1. Test conditions: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 9 of 24

Test Report No.: 89-R100 Part II-15560/23

Clause Requirement Remark

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 10 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results for Fire Resistance Test Appendix 4

Clause Requirement Remark

Fuel Pan Distance from 3m

Duration of DUT Direct 70 s

Observation time 3 hours

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 11 of 24

Test Report No.: 89-R100 Part II-15560/23

Before Test After test

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 12 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results External Short Circuit Protection Test Appendix 5

6.6. and Test conditions: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 13 of 24

Test Report No.: 89-R100 Part II-15560/23

Clause Requirement Remark

6.6. and Test Requirement: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 14 of 24

Test Report No.: 89-R100 Part II-15560/23

Test results for Overcharge Protection Test Appendix 6

Clause Requirement Remark

6.7 and Test conditions: : Complies with requirements.

TÜV Rheinland (India) Pvt. Ltd Engineering Centre: Page 15 of 24