APPENDIX A

GENERIC TEST PLAN OUTLINE

FOR
USABC BATTERY TESTING

Rev.

USABC TEST PLAN NUMBER

Date
APPROVAL:
USABC Program Manager

Date

USABC Test Manager

Date

Test Lab Representative

Date

APPROVAL:

ACKNOWLEDGEMENT:

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GENERIC TEST PLAN OUTLINE FOR USABC BATTERY TESTING

1.0

Purpose and Applicability

This test plan defines a series of tests to characterize aspects of the performance or life cycle
behavior of a battery for electric vehicle applications. These tests may be applied to single cells,
battery modules, full-size battery packs or complete battery systems (all of which are referred to as
batteries in this plan). It may also be used to specify testing for multiple identical batteries
subjected to the same or different test regimes (see Section 5.0.)

2.0

References
(To be as required by manufacturer or USABC Program Manager)

3.0

Equipment
Power, voltage, and current capabilities for the electronic loads and power supplies are to be
specified. Special test equipment required for the conduct of this test plan (if any) is specified in
the individual test procedures.

4.0

Prerequisites and Pre-Test Preparation

In addition to any prerequisites defined in individual test procedures, the following actions shall be
performed by the testing organization prior to testing a battery under control of this test plan:
4.1

The USABC identification number for the battery shall be determined and affixed to the
battery (if this has not been done by the manufacturer.) (See Appendix D for numbering
system.)

4.2

The battery or battery modules shall be examined to determine that damage has not
occurred during shipping or handling, and that the type and configuration (e.g. number and
interconnection of modules) are correct and agree with the assigned identification number.

4.3

The battery's physical dimensions and weight shall be measured. For battery packs
containing multiple subunits (modules or cells) interconnected by lab personnel after
receipt, the modules will be weighed individually; in other cases, the entire battery may be
weighed as a unit to avoid disassembling it (see Appendix E Worksheet).

4.4

Actual power levels (kW) and capacities (kWh or Ah) shall be established for those
planned tests specified in Section 7.0 where the procedures do not specify these levels.
These values should be derived from the ratings specified in Section 5.0 of this plan, based
on the manufacturers worksheet (Appendix E) and the measured weight or other
characteristics of the battery. If these are based on values other than manufacturer's
ratings or a fixed percentage of the USABC Mid Term or Long Term goals, the basis shall
be noted in the test plan and the battery log and subsequently reported.

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5.0

Ratings, Test Limitations and Other Test Information to be provided

Battery ID Number
NOTE: If more than one battery is covered by this test plan, provide table of ID numbers. If a
group of otherwise identical batteries is to be subjected to different sets of performance tests,
multiple copies of Tables 7.3 and 7.4 may be used.
(Information only)

Development/Testing Phase
5.1

RATINGS (DISCHARGE)
NOTE: All ratings are at Beginning of Life. A worksheet summarizing information to be
supplied by the manufacturer for each battery is included as Appendix E.
Rated Capacity
Ampere Hour Capacity:

(Ah)
3-hour (C/3) rate
2-hour (C/2) rate
1-hour (C/1) rate

Rated Energy Capacity

(Ah)
(Ah)
(Ah)

(kWh at 3-hour C/3 rate)

Test Unit Peak Power (rating at 2/3 OCV and 80% DOD at beginning of life)
(W or kW) (Nominal)
Peak Discharge Power to be applied on DST or FUDS testing
(W or kW)
Maximum Allowable (Peak) Currents to be applied during Reference Performance Cycle
or Peak Power Tests:
Discharge
(Amperes)
Regen
(Amperes)
Percent of capacity at top of charge where regen should not be applied (if applicable)
(%)

5.2

TEST TERMINATION CONDITIONS (applicable to planned tests)

DISCHARGE LIMITATIONS

VALUE

UNITS

Minimum Discharge Voltage

V/cell etc. *

Discharge Temperature Limit(s)

EC

Other (e.g. Max Current etc.)

* Specify load conditions if rate-sensitive. (If a value less than Discharge Voltage Limit is
specified, the DVL will be used for the Peak Power Test. DVL will also be used for DST or
FUDS tests unless a specific exemption is included in the test plan.)

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END OF LIFE TEST CONDITION(S):

5.3

OPERATING TEMPERATURE (Initial and limits for testing)

5.4

CHARGING
Procedure:

CHARGE LIMITATIONS

VALUE

UNITS/DEFAULT

Maximum Voltage on Charge

V/cell and/or battery

Maximum Charge Temperature

EC

Maximum Charge Rate

Amperes, watts, time

Open Circuit Time After Charge

(Default 1-24 hrs)

5.5

OTHER INFORMATION (Attachments can be referenced here)

Test laboratory Readiness Review requirements:
Thermal enclosure or other battery management system handling instructions (if
applicable):
Commissioning Instructions:
Battery Configuration Description:

6.0

Safety Concerns and Precautions

(To be included or attached as applicable.) NOTE: any conditions requiring safety-related
monitoring provisions and/or action shall be identified and described here.

7.0

Number and Types of Tests to be Performed Under this Test Plan

7.1 TEST CONTINUATION CRITERIA
Any ratings or required test results that constitute acceptance for testing (i.e. further testing should
not be performed unless these criteria are met) should be identified here or noted in the tables.
Normally, the capacity of the unit must be no less than 95% of rated, as determined either during

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commissioning or the C/3 constant current discharge specified in Section 7.2.

7.2 CORE PERFORMANCE TESTS (REQUIRED)

NOTE: Core Performance Tests are to be performed on all test units unless specifically
exempted in writing by the USABC Program Manager, in which case the reason for
exemption should be documented. If an adequate charge procedure is not furnished or
available, Test Procedure #11 from Table 7.4 should be performed prior to initiating the
Core Performance Test series.

TEST PROCEDURE

MINIMUM REPS

OTHER INFORMATION

2. Constant Current

@ 3-hour discharge rate

3. Peak Power

Single discharge

5. Variable Power

Default is DST, FUDS optional

4. Constant Power

@ Rate required to remove

75% of energy in 1 hour (may
be done for only 1 hour)

7.3 GENERAL PERFORMANCE TESTS (OPTIONAL)

TEST PROCEDURE

NO. REQ'D

OTHER INFORMATION

2. Constant Current

Default for procedure is 12

charge/discharge cycles at C/3, C/2,
C/1, C/3 discharge rates

4. Constant Power

Default power values are those

required to remove 75%, 50%, 25%
of battery energy in one hour.
(Discharge to rated capacity or
termination limits)

5. Variable Power

Regime (FUDS or DST) not

performed as part of Core
Performance

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7.4 SPECIAL PERFORMANCE TESTS (OPTIONAL)

TEST PROCEDURE

NO. REQ'D

OTHER INFORMATION

6. Partial Discharge

Specify partial DOD value

(Default 50%)

7. Stand

Specify stand period

(default 48 hrs midterm,
30 days long term)

8. Sustained Hill Climb

9. Thermal Performance

Specify matrix of temperatures

& discharge/charge cycles

10. Battery Vibration

Specify random or swept sine

wave excitation, normal or accel

11. Charge Optimization

Specify only if charge procedure

not furnished in Section 5.4

12. Fast Charge

Specify initial rate (default 2

times normal)

7.5 SAFETY/ABUSE TESTS (under development; following table is only an example)

TEST PROCEDURE

SELECTED
BATTERY ID NO.

MECHANICAL
13A. Impact (drop)
13B. Deformation (bend)
13C. Intrusion (spike)
13D. Turnover
ENVIRONMENTAL EXPOSURE
13E. Fire
13F. Immersion
ELECTRICAL
13G. Over-Charge
13H. Short-Circuit
13J. Reversal

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OTHER INFO

7.5 LIFE CYCLE TESTING REGIME (OPTIONAL)

TEST PROCEDURE

8.0

TEST UNIT ID No.

OTHER INFO

14A. Accelerated Aging

Use test matrix

to specify one
or more test
regimes &
accelerating
factors

14B. Actual-Use Simulation

FUDS-based;
specify
ambient
temperature
regime

14D. Baseline Life Cycle

80% DOD
DST discharge
at nominal
environmental
conditions

Special Measurement Requirements

Identify or attach number/location of temperature measurements:

Identify or attach number/location of voltage and current measurements (other than overall):

Specify any special monitoring (not already identified) required to assure that abnormal battery
conditions are detected:

9.0

Post-Test Examination and Analysis

Identify or attach requirements for post-test examination and/or any teardown and subsequent
analysis after completion of testing:

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