IECEE TEST REPORT FORM TEMPLATE - Code Authorities · 2020. 10. 22. · outdoor ground mounted, indoor floor mounted, outdoor wall mounted, indoor wall mounted, roof top, open garage

UL 9540A Report Ed.4 Unit Report 2020-04-21

UNIT TEST REPORT UL 9540A

Test Method for Evaluating Thermal Runaway Fire Propagation in Battery Energy Storage Systems (AACD)

Project Number. ............................. : 12345678 Date of issue ................................... : July 1, 2020 Total number of pages .................. : 43 UL Report Office ............................ : UL LLC, Northbrook, IL 60062 USA

Applicant’s name ........................... : ACME Energy Storage Address ........................................... : Anywhere USA

Test specification: 4th Edition, Section 7, November 12, 2019

Standard .......................................... : UL 9540A, Test Method for Evaluating Thermal Runaway Fire Propagation in Battery Energy Storage Systems

Test procedure ............................... : 9.1 – 9.8

Non-standard test method ........... : N/A

Copyright © 2020 UL LLC All Rights Reserved.

General disclaimer: The test results presented in this report relate only to the sample tested. UL LLC did not select the sample(s), determine whether the sample(s) was representative of production samples, witness the production of the test sample(s), nor were we provided with information relative to the formulation or identification of component materials used in the test sample(s). The issuance of this report in no way implies Listing, Classification or Recognition by UL and does not authorize the use of UL Listing, Classification or Recognition Marks or any other reference to UL on the product or system. UL LLC authorizes the above named company to reproduce this Report provided it is reproduced in its entirety. UL's name or marks cannot be used in any packaging, advertising, promotion or marketing relating to the data in this Report, without UL's prior written permission. UL LLC, its employees, and its agents shall not be responsible to anyone for the use or non-use of the information contained in this Report, and shall not incur any obligation or liability for damages, including consequential damages, arising out of or in connection with the use of, or inability to use, the information contained in this Report. This is a sample report to demonstrate the content provided in a UL 9540A unit level test report. This sample report contains real measurements taken from UL 9540A testing of a non-proprietary example product fabricated by UL for the purposes of creating demonstration data. This report has been created for the purposes of demonstrating a minimum level of information and data that should be provided for a UL 9540A unit level test report.

Page 2 of 43 Project No. Error! Reference source not found.

UL 9540A, Edition 4

Test item description ….…………...:

BESS Intended Installation Non Residential: outdoor ground mounted, indoor floor mounted, outdoor wall mounted, indoor wall mounted, roof top, open garage Residential: Outdoor ground mounted, indoor floor mounted, outdoor wall mounted, indoor wall mounted

Non residential – Indoor floor mounted

Residential Indoor Use: Smallest volume room installations specified.

N/A

BESS module configuration 9 S/1 P module configuration

Number of modules in BESS 9 modules

Module Manufacturer/Model No.: Top Cell Manufacturer/ Model XYZ Module

Module cell configuration (xS/yP) …...: 14 S/4 P cell configuration

Number of cells in module.: 56 cells

Cells in Module: Manufacturer Name Part Number Chemistry Format

Top Cell Manufacturer

Model ABC

NMC (Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO2))

Prismatic

BESS dimensions (X x Y x Z (mm))……………….: 370 mm wide x 610 mm deep x 1485 mm high

BESS weight (kgs)………………………. : 2300kg

BESS enclosure material……………….. : The systems were an open rack design with enclosures provided at the individual module level

Original Equipment Manufacturer (OEM): ACME Energy Storage

Branding Manufacturer (if not OEM): N/A

Model No ........................................... : Powersource ABC

Ratings ............................................. : 480Vac, 355 A output current, 170 KVA max power output, 1,350Ah max output energy output

Test item certified? ………………………….: Yes

Standard test item certified to ……….…..: UL 9540

Organization that certified test item …….: UL LLC

Organization that certified BESS: UL LLC

Testing Laboratory and testing location(s):

Testing Laboratory: UL LLC

Testing location/ address ............................ : 333 Pfingsten Road Northbrook, IL 60062, USA

Tested by (name, signature) ........................ : Sam Jones Sam Jones


UL 9540A, Edition 4

Witnessed by (for 3rd Party Lab Test Location) (name, signature) ......................................... :

N/A N/A

Project Handler (name, signature) .............. : John Smith John Smith

Reviewer (name, signature) …………………: Joe Adams Joe Adams

List of Attachments (including a total number of pages in each attachment): Attachment A: Sample Charging, OCV and SOC Measurement Profiles - (Pages 29 through 29) Attachment B: BESS (including module and any integral fire detection and suppression systems) Construction Photos/Diagrams - (Pages 30 through 31) Attachment C: BESS and Equipment Instrumentation and Test Installation Layout Photos/Diagrams - (Pages 32 through 32) Attachment D: Temperature Profiles and Heat Flux Measurements During Testing (Initiating Cell and Module, Target Modules, Wall Surfaces, etc. - (Pages 33 through 38) Attachment E: BESS Unit Testing and Post Testing Photos - (Pages 39 through 41) Attachment F: BESS Unit Test Datasheets - (Pages 42 through 42) Attachment G: BESS Unit Gas Flow Rate and Heat Release and Smoke Release Profiles – (Pages 43 through 43)

Summary of cell testing:

Cell failure test method performed (summary of method and test clause): External heating using thin film with 4°C to 7°C thermal ramp. Nail Penetration Overcharge External short circuit (X Ω external resistance) Others

Description of method used to fail cells if other than external thin film heater with thermal ramp, : N/A

Test Results from Cell Level Test:

Average cell surface temperature at gas venting, °C: Average cell surface temperature at thermal runaway, °C:

159°C (318°F)

201°C (394°F)

Test Results from Module Level Test

No of initiating cells failed to establish propagation at the module level

one

Flaming external to module, Location Yes, from the top of the module

Peak Heat Release Rate: 81 kW

Gas Composition Pre-Flaming: CO2 (1 L); CO (1 L); THC (43 L); H2 (0 L)

Gas Composition After Flaming: CO2 (259L); CO (181 L); THC (157 L); H2 (56 L)

Description of components employed within the BESS unit that serve to suppress propagation (fire protection features). : N/A Summary of BESS Unit Test Results


UL 9540A, Edition 4

Thermal Runaway Propagation: Propagation through all modules in the initiating unit External Flaming from BESS: External flames were visible Location(s) of Flame Venting: Flames were visible from the vent opening of the

initiating unit Maximum Target BESS Temperature, °C 800°C on the target adjacent to the BESS Maximum Wall Surface Temperature, °C 820°C at the wall surface above the initiating BESS Peak Chemical Heat Release Rate, kW 1170 Peak Convective Heat Release Rate, kW 490 Smoke Heat Release Rate, m2/s 12 Maximum Heat Flux on Target Modules, kW/m2 41 Maximum Heat Flux of Egress Path, kW/m2 26 Flying Debris: No evidence of flying debris Re-ignitions: No re-ignitions Gas Composition Pre-Flaming: CO, CO2, THC Gas Composition After Flaming: CO, CO2, THC

Gas Analysis: Flame ionization detection (FID) Non-Dispersive Infrared Spectrometer (NDIR) Fourier-Transform infrared Spectrometer Hydrogen Sensor (palladium-nickel, thin-film solid state sensor) White light source with photo detector (smoke release rate)

Summary of Gas Analysis Data:

• Gas Composition & Volume for Each Compound (Pre-flaming and After flame):

Gas Compound

Gas Type Pre-Flaming (L)

Flaming (L)

Total Hydro-carbons (Propane

Equi-valent)

Hydro-carbons 1,370 2,450

Carbon Dioxide

Carbon Contain-

ing 1,000 24,250

Carbon Monoxide

Carbon Contain-

ing 1,200 1,250

Hydrogen - 0 0

• Smoke Release Rate (m2/s) 12

• Total Smoke Released: (m2) 20

• Peak Chemical Heat Release Rate: (kW): 1170


UL 9540A, Edition 4

Performance Criteria met in accordance with Clause 9.8: Not compliant with unit level performance criteria


UL 9540A, Edition 4

Photo(s) of BESS unit:

Test Item Charge/Discharge Module Specifications:

• Charge current, A: 58.5 • Maximum charge voltage, Vdc: 75.6 • Charge temperature range, °C: -30~60 • End of charge current, A: 24 • Discharge current, A: 58.5 • End of discharge voltage, Vdc: 60 • Discharge temperature range, °C: -30~60


UL 9540A, Edition 4

Test item particulars .................................................. : Powersource ABC

Possible test case verdicts:

- test case does not apply to the test object ........... : N/A

- test object does meet the requirement .................. : P (Pass)

- test object does not meet the requirement ........... : F (Fail)

Testing .......................................................................... :

Date of receipt of test item ........................................ : 2020-05-11

Date (s) of performance of tests ............................... : 2020-05-14

General remarks:

"(See Enclosure #)" refers to additional information appended to the report. "(See appended table)" refers to a table appended to the report.

Manufacturer’s Declaration of samples submitted for test:

The applicant for this report includes samples from more than one factory location and a declaration from the Manufacturer stating that the sample(s) submitted for evaluation is (are) representative of the products from each factory has been provided ........................... :

Yes Not applicable

Name and address of factory (ies) .......................... : Anywhere in China

General product information and other remarks: Details of Construction of BESS provided in Test Item Description above and Attachment B.

Page 8 of 43 Report No. Error! Reference source not found.

UL 9540A, Edition 4,

Clause Requirement + Test Result - Remark Verdict

UL 9540A, Edition 4

5.0 CONSTRUCTION Verdict

5.3 Battery energy storage system unit Construction —

5.3.1, 5.3.2 Construction information See Test Item Description at the beginning of this report (page 2)

—

5.3.2 General layout of BESS unit contents See Attachment B —

5.3.3 Details of integral fire suppression system NA —

5.3.1 BESS certified to UL 9540 P

Organization that certified BESS: UL LLC —

6.0 PERFORMANCE Verdict

6.1 General

9.1 Sample and test configuration

9.1.1 The unit level test conducted with BESS units installed as described in the manufacturer's instructions.

See Attachment C for test installations Installation type:

P

9.1.2 The unit level test required one initiating BESS unit in which an internal fire condition in accordance with the module level test is initiated and target adjacent BESS units representative of an installation.

See Attachment C for test installations

P

Tests conducted for indoor floor mounted installations are representative of both indoor floor mounted and outdoor ground mounted installations.

Intended for indoor use only N/A

Tests conducted indoors with fire propagation hazards and separation distances between initiating and target units representative of the installation.

P

Testing conducted outdoors for outdoor only installations with following in place:

a) Wind screens with wind speed of ≤ 12 mph; b) Temperature range is 10°C to 40°C (50°F to 104°F); c) Humidity is < 90% RH; d) Sufficient light to observe the testing; e) There is no precipitation; f) There is control of vegetation and combustibles in the test area; and g) There are protection mechanisms in place to prevent inadvertent access by unauthorized persons in the test area.

N/A




UL 9540A, Edition 4

9.1.3 Testing to determine fire characterization was done at the battery system level rather than a complete BESS

N/A

9.1.4 The initiating BESS contained components representative of a BESS unit in a complete installation.

P

Combustible components that interconnect the initiating and target BESS units was included.

P

9.1.5 Target BESS units include the outer cabinet (if part of the design), racking, module enclosures, and components that retain cells components.

P

9.1.6 The initiating BESS was at the maximum operating state of charge (MOSOC).

See Table 2 and Attachment A P

After charging and prior to testing, the initiating BESS was at rest for a maximum period of 8 hours at room ambient.

See Table 2 P

9.1.7 The BESS unit included an integral fire suppression system.

No fire suppression system was employed.

N/A

9.1.8 Electronics and software controls such as the battery management system (BMS) are not relied upon for this testing.

P

Included a fire suppression control in accordance with UL 864 that is external to the BESS.

N/A

9.2 Test method – Indoor floor mounted BESS units

9.2.1 Test room ambient temperature within 10°C (50°F) to 32°C (90°F).

See Table 2

P

9.2.2 Access door(s) or panels on the initiating BESS unit and adjacent target BESS units were closed, latched and locked duration of the test.

P

9.2.3 The initiating BESS unit was positioned adjacent to two instrumented wall sections.

Attachment C P

9.2.4 Instrumented wall sections extend not less than 0.49 m (1.6 ft) horizontally beyond the exterior of target BESS units.

the width of the instrumented wall was 3000mm - Depth of one unit : 610mm - Distance between the

target 3 and the initiating unit : 915mm

P

9.2.5 Instrumented wall sections were at least 0.61-m (2-ft) taller than the BESS unit height, but not less than 3.66 m (12 ft) in height above the bottom surface of the unit.

Height of the tested units was 1485mm and the instrumented wall was 2100mm high

P




UL 9540A, Edition 4

9.2.6 The surface of the instrumented wall sections were covered with 16-mm (5/8-in) gypsum wall board and painted flat black.

See Attachment C P

9.2.7 The initiating BESS unit was centered underneath an appropriately sized smoke collection hood of an oxygen consumption calorimeter.

P

9.2.8 The light transmission in the calorimeter's exhaust duct was measured using a white light source and photo detector. The smoke release rate was calculated.

See Table 12 See Attachment G

P

9.2.9 The chemical and convective heat release rates were measured for the duration of the test.


P

9.2.10 The heat release rate measurement system was calibrated using an atomized heptane diffusion burner. The calibration was performed using flows of 3.8, 7.6, 11.4 and 15.2 L/min (1, 2, 3 and 4 gpm) of heptane.

P

9.2.11 The chemical heat release rate was measured using the following equipment:

Paramagnetic oxygen analyzer Non-dispersive infrared carbon dioxide and carbon monoxide analyzer Velocity probe Type K thermocouple

P

9.2.12 The chemical heat release rate at each of the flows was calculated.

P

9.2.13 The physical spacing between BESS units (both initiating and target) and adjacent walls was representative of the intended installation.

See Attachment C P

9.2.14 Separation distances were specified by the manufacturer for distance between:

a) The BESS units and the instrumented wall sections; and b) Adjacent BESS units.

See Attachment C P

9.2.15 Wall surface temperature measurements were collected

See Table 6 See Attachment D

P

The intended installation is composed completely of non-combustible construction

P




UL 9540A, Edition 4

9.2.16 Wall surface temperatures were measured in vertical array(s) at 152-mm (6-in) intervals for the full height of the instrumented wall sections using No. 24-gauge or smaller, Type-K exposed junction thermocouples.

P

The thermocouples for measuring the temperature on wall surfaces were horizontally positioned in the wall locations to receive greatest thermal exposure from the initiating BESS unit.

P

9.2.17 Thermocouples were secured to gypsum surfaces and the thermocouple tip was depressed into the gypsum so as to be flush with the gypsum surface at the point of measurement .

P

9.2.18 Heat flux was measured with at least two water-cooled Schmidt-Boelter gauges at the surface of each instrumented wall:

a) Both are collinear with the vertical thermocouple array; b) One is positioned to receive the greatest heat from the initiating module; and c) One is positioned to receive the greatest heat flux during potential propagation within the initiating BESS unit.

Due to the location of Target 2, which was in the path of heat flux from the initiating unit to the gauge, the sidewall was not instrumented with a heat flux gauge.

P

9.2.19 Heat flux was measured with 2 water-cooled Schmidt-Boelter gauges at the surface of each adjacent target BESS units facing initiating BESS unit:

a) One is positioned at the elevation estimated to receive the greatest heat flux from the initiating module; and b) One is positioned at the elevation estimated to receive the greatest surface heat flux due to initiating BESS.

Only one heat flux gauge was installed in each target unit at the elevation estimated to receive the greatest heat flux due to the thermal runaway of the initiating module. No secondary heat flux was installed because the distance between each target unit and the initiating unit is 0mm and based upon the engineering discretion the flame was expected near the initiating module and the right next to the initiating module was assumed to experience the greatest surface heat flux even in the thermal runaway of the initiating BESS

P

9.2.20 Heat flux was measured with the sensing element of at least one water-cooled Schmidt-Boelter gauge positioned in the center of the accessible means of egress.

P




UL 9540A, Edition 4

9.2.21 No. 24-gauge or smaller, Type-K exposed junction thermocouples were installed to measure the temperature of the surface proximate to the cells and between the cells and exposed face of the initiating module.

See Attachment C P

Each non-initiating module enclosure within the initiating BESS unit was instrumented with at least one No. 24-gauge or smaller Type-K thermocouple(s) within non-initiating modules.

See Attachment C P

Additional thermocouples were placed to account for convoluted geometries.

N/A

9.2.22 For residential use, the DUT was covered with a single layer of cheese cloth ignition indicator. The cheesecloth was untreated cotton cloth running 26 – 28 m2/kg with a count of 28 – 32 threads in either direction within a 6.45 cm2 (1 in2) area.

Non residential application N/A

9.2.23 An internal fire condition in accordance with the module level test was created within a single module in the initiating BESS unit:

a) The position selected to present the greatest thermal exposure to adjacent modules; and b) The setup was the same as that used to initiate and propagate thermal runaway within the module level test.

See Attachment C P

9.2.24 The composition, velocity and temperature of the initiating BESS unit vent gases was measured within the calorimeter's exhaust duct. Composition, velocity and temperature instrumentation shall be collocated with heat release rate calorimetry instrumentation.

P

Hydrogen gas shall be measured with a palladium-nickel thin-film solid state sensor.

P

The hydrocarbon content of the vent gas may also be measured using a Fourier-Transform Infrared Spectrometer with a minimum resolution of 1 cm-1 and a path length of at least 2 m (6.6 ft), or equivalent gas analyzer.

P

9.2.25 The hydrocarbon content of the vent gas was measured using flame ionization detection.

See Tables 8, 9, 10 and 11 P

9.3 Test method – Outdoor ground mounted units N/A




UL 9540A, Edition 4

9.3.1 Outdoor ground mounted non-residential use BESS for installation: test method described in Section 9.2 was used.

N/A

Outdoor use only installations: the smoke release rate, the convective and chemical heat release rate and content, velocity and temperature of the released vent gases were not be measured.

N/A

9.3.2 Outdoor ground mounted residential use BESS: The test method described in Section 9.2 except as noted in 9.3.3 and 9.3.4.

N/A

Heat flux measurements for the accessible means of egress were measured in accordance with 9.2.20.

N/A

Outdoor use only installations: the smoke release rate, the convective and chemical heat release rate and content, velocity and temperature of the released vent gases were not be measured.

N/A

9.3.3 Test samples were installed as shown in Figure 9.2 in proximity to an instrumented wall section that is 3.66-m (12-ft) tall with a 0.3-m (1-ft) wide horizontal soffit (under surface of the eave shown in Figure 9.2).

N/A

The sample was mounted on a support substrate and spaced from the wall in accordance with the minimum separation distances. The wall and soffit were constructed with 19.05-mm (3/4-in) plywood installed on wood studs and painted flat black.

N/A

The instrumented wall extended not less than 0.49-m (1.6-ft) horizontally beyond the exterior of the target BESS units.

N/A

If the manufacturer requires installation against non-flammable material, the test setup may include manufacturer recommended backing material between the unit and plywood wall.

N/A

The No. 24-gauge or smaller, Type-K exposed junction thermocouple array on the walls extended to the surface of the soffit.

N/A

9.3.4 Target BESS were installed on each side of the initiating BESS in accordance with installation specifications. The physical spacing between BESS units (both initiating and target) were the minimum separation distances specified.

N/A




UL 9540A, Edition 4

9.4 Test Method – Indoor wall mounted units N/A

9.4.1 Testing of indoor wall mounted BESS were in accordance with Section 9.2, except as modified in section 9.4.

N/A

9.4.2 The test was conducted in a standard NFPA 286 fire test room, 3.66 × 2.44 × 2.44-m (12 × 8 × 8-ft) high, with a 0.76 × 2.13-m (2-1/2 × 7-ft) high opening.

N/A

The room was constructed with 16-mm (5/8-in) gypsum wall board installed on wood studs and painted flat black.

N/A

9.4.3 The initiating BESS unit was positioned on the wall opposite of the door opening, with the center located 1.22-m (4-ft) above the floor, and halfway between adjacent walls.

N/A

9.4.4 Target BESS was installed on the wall on each side of the initiating BESS, at the same height above the floor as the initiating BESS. The physical spacing between BESS units (both initiating and target) were the minimum separation distances.

N/A

9.4.5 The wall on which the initiating and target BESS units were mounted were instrumented in accordance with Section 9.2.

N/A

9.4.6 The gas collection methods were in accordance with 9.2.

N/A

For residential use systems, the gas collection data gathered in 9.2 was compared to the smallest room installation specified by the manufacturer to determine if the flammable gas collected exceeds 25% LFL in air.

N/A

9.4.7 For residential use BESS, the DUT was covered with a single layer of cheese cloth ignition indicator. The cheesecloth was untreated cotton cloth running 26 – 28 m2/kg with a count of 28 – 32 threads in either direction within a 6.45 cm2 (1 in2) area.

N/A

9.5 Test Method – Outdoor wall mounted units N/A

9.5.1 Testing of outdoor wall mounted BESS were in accordance with Section 9.2, except as modified in section 9.5.

N/A




UL 9540A, Edition 4

Intended for outdoor use only wall mount installations: the smoke release rate, the convective and chemical heat release rate; and the content, velocity and temperature of the released vent gases were not be measured.

N/A

9.5.2 Test samples were mounted on an instrumented wall section that is 3.66-m (12-ft) tall with a 0.3-m (1-ft) wide horizontal soffit. The wall and soffit were constructed with 19.05-mm (3/4-in) plywood installed on wood studs and painted flat black.

N/A

The instrumented wall extended not less than 0.49-m (1.6-ft) horizontally beyond the exterior of the target BESS units.

N/A

No. 24-gauge or smaller, Type-K exposed junction thermocouple array on the walls extended to the surface of the soffit.

N/A

9.5.3 The initiating BESS unit was positioned on the instrumented wall, with its center located 1.22-m (4-ft) above the floor, and halfway between wall edges.

N/A

9.5.4 Target BESS was installed on the wall on each side of the initiating BESS at the same height. The physical spacing between BESS units (both initiating and target) are the minimum separation distances specified.

N/A

9.5.5 The wall on which the initiating and target BESS units are mounted was instrumented in accordance with Section 9.2.

N/A

9.5.6 For residential use BESS: the DUT was covered with a single layer of cheese cloth ignition indicator. The cheesecloth was untreated cotton cloth running 26 – 28 m2/kg with a count of 28 – 32 threads in either direction within a 6.45 cm2 (1 in2) area .

N/A

9.6 Rooftop and open garage installations N/A

9.6.1 Testing of BESS intended for non-residential use rooftop or open garage installations were in accordance with 9.2.

N/A

9.6.2 Intended for rooftop and open garage use only installations: the smoke release rate, the convective and chemical heat release rate and content, velocity and temperature of the released vent gases were not measured.

N/A




UL 9540A, Edition 4

9.7 Unit level test report 9.7.1 Installation type tested: Non-residential Indoor floor

mounted P

9.7.2 Testing is intended to represent more than one installation type.

See Test Item Description in beginning of this report.

9.7.3 a. Unit manufacturer name and model number (and whether UL 9540 compliant);

Manufacturer : ACME Energy Storage Model Number : Powersource ABC UL 9540A Compliant

b. Number of modules in the initiating BESS unit 72 modules c. BESS construction features; See Attachment C

See Critical Components Table See Also “Description of components employed within the module that impact propagation (fire protection features)” at the beginning of this report.

d. Fire protection features/ detection/ suppression systems within unit

Not applicable

e. Module voltages corresponding to the tested SOC;

See Attachment D

f. Thermal runaway initiation method used; See Attachment C g. Location of the initiating module within the

BESS unit; See Attachment C

h. Diagram and dimensions of the test setup including mounting location of the initiating and target BESS units, and the locations of walls, ceilings, and soffits;

See Attachment C

i. Observation of any flaming outside the initiating BESS enclosure and the maximum flame extension;

See Table 15

j. Chemical and convective heat release rate versus time data;


k. Separation distances from the initiating BESS unit to target walls

See Attachment C

l. Separation distances from the initiating BESS unit to target BESS units

See Attachment C

m. The maximum wall surface and target BESS temperatures achieved during the test and the location of the measuring thermocouple;

See Tables 5 and 6




UL 9540A, Edition 4

n. The maximum ceiling or soffit surface temperatures achieved during the indoor or outdoor wall mounted test and the location of the measuring thermocouple;

See Table 6

o) The maximum incident heat flux on target wall surfaces and target BESS units;

See Table 7

p) The maximum incident heat flux on target ceiling or soffit surfaces achieved during the indoor or outdoor wall mounted test;

See Table 7

q. Flammable gas generation and composition data;

See Attachment G See Tables 7, 8, 9, and 10

r. Peak smoke release rate and total smoke release data.


s. Indication of the activation of integral fire protection systems and if activated the time into the test at which activation occurred;

Table 13

t. Observation(s) of flying debris or explosive discharge of gases;

See Table 15

u. Observation of re-ignition(s) from thermal runaway events

See Table 16

v. Observation(s) of sparks, electrical arcs, or other electrical events;

See Table 15

w. Observations of the damage to: 1) The initiating BESS unit; 2) Target BESS units; 3) Adjacent walls, ceilings, or soffits;

See Table 16

x. Video of the test. Provided to the client 9.8 Performance at Unit level testing F

9.8.1 Installation level testing in Section 10 was not required if the following performance conditions outlined in Table 9.1 are met during the unit level test.

Non-Residential Installations – Indoor floor mounted:

a) Flaming outside the initiating BESS unit is not observed;

Flaming outside the initiating BESS unit was observed;

F

b) Surface temperatures of modules within target BESS units do not exceed the cell venting temperature;

The maximum temperature on the surface of modules within target BESS units was 800°C and the vent temperature at the cell level was 159°C

F




UL 9540A, Edition 4

c) For BESS units intended for installation in locations with combustible constructions, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) rise above ambient;

The maximum surface temperature measurements on wall surfaces was 820°C

F

d) Explosion hazards are not observed, including deflagration, detonation or accumulation (to within the flammability limits in an amount that can cause a deflagration) of battery vent gases; and

P

e) Heat flux in the center of the accessible means of egress did not exceed 1.3 kW/m2.

Heat flux in the center of the accessible means of egress was 26kW/m2

F

Non-Residential Installations – Outdoor ground mounted:

a) If flaming outside of the unit is observed, separation distances to exposures were determined by greatest flame extension observed during test.


c) For BESS units intended for installation in locations near combustible construction, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) rise above ambient;



N/A




UL 9540A, Edition 4

Non-Residential Installations – Indoor Wall Mounted:






N/A

Non-Residential Installations – Outdoor Wall Mounted:






N/A




UL 9540A, Edition 4

Non-Residential Installations – Rooftop and Open Garages:

a) If flaming outside of the unit is observed, separation distances to exposures were determined by greatest flame extension observed during test.


c) For BESS units intended for installation in locations near combustible construction, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) rise above ambient;



N/A

Residential Installations – Indoor floor mounted: a) Flaming outside the initiating BESS unit is not

observed as demonstrated by no flaming or charring of the cheesecloth indicator;

b) Surface temperatures of modules within the target BESS units adjacent to the initiating BESS unit do not exceed cell venting temperature;

c) BESS units intended for installation in locations with combustible construction, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) of temperature rise above ambient;


e) The concentration of flammable gas does not exceed 25% LFL in air for the smallest specified room installation size.

N/A




UL 9540A, Edition 4

Residential Installations – Outdoor ground mounted:

a) If flaming outside the unit is observed, separation distances to exposures shall be determined by greatest flame extension observed during test.

b) Surface temperatures of modules within the target BESS units adjacent to the initiating BESS unit do not exceed the cell venting temperature;

c) BESS units intended for near exposures, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) of temperature rise above ambient;


e) Heat flux in the center of the accessible means of egress2) shall not exceed 1.3 kW/m2.

N/A

Residential Installations – Indoor Wall Mounted: a) Flaming outside the initiating BESS unit is not

observed as demonstrated by no flaming or charring of the cheesecloth indicator;

b) Surface temperatures of modules within the target BESS units adjacent to the initiating BESS unit do not exceed cell venting temperature;

c) BESS units intended for installation in locations near combustible construction, surface temperature measurements on wall surfaces do not exceed 97°C (175°F) rise above ambient;


e) The concentration of flammable gas does not exceed 25% LFL in air for the smallest specified room installation size.

N/A




UL 9540A, Edition 4

Residential Installations – Outdoor Wall Mounted:





N/A

TEST RESULT TABLES:

Table 1 – Specified Module charging and discharging parameters

Charging: Discharging: Current (CC), A 58.5 Current (CC), A 58.5 Max Charge Voltage (CV), Vdc

75.6 End of discharge voltage, Vdc 60

End of charge current, A 24 Discharging Test Ambient, °C 25 Refer to Attachment A for charge/discharge profiles.

Table 2 - Test Initiation Details

Test Date 2020-05-14 Test Start Time (HH:MM:SS) 11:24 AM Initial Lab Temperature, °C 19°C Initial Relative Humidity % RH 50 ± 25% Module OCV at Start of Test, Vdc 75.0




UL 9540A, Edition 4

Table 3 – Approximate time of thermal runaway propagation through module Initiating Cell(s) Numbers

5 1 4 2 6 7

Thermal Runaway Time (HH:MM:SS)

0:24:30 0:30:34 0:30:54 0:31:13 0:41:48 0:50:03




UL 9540A, Edition 4

Table 4 – Test overview timeline

Time (HH:MM:SS) Event Description 00:00:00 Test Start Heater energized for cell. 00:24:30 Thermal runaway of

initiating cell Cell at 111°C, gas venting observed from front vent.

00:24:30-00:57:49 Propagation through initiating module

Propagation through initiating module, observed through cell temperatures, gas release.

00:35:00 Ignition of vent gases Ignition observed in vent gases in the vicinity of the initiating module.

00:40:00 Propagation to Module 9 Propagation to target Module 9 in the initiating rack. 00:40:30 Propagation to Module 8 Propagation to target Module 8 in the initiating rack. 00:41:45 Propagation to Module 7 Propagation to target Module 7 in the initiating rack. 00:42:00 Propagation to Module 6 Propagation to target Module 6 in the initiating rack. 00:42:05 Ignition of gas cloud Ignition of battery gas plume. 00:48:00 Propagation to Module 4 Propagation to live Module 4 in the initiating rack. 00:55:45 Propagation to Module 1 Propagation to target Module 1 in the initiating rack. 00:58:30 Propagation to Module 5 Propagation to live Module 5 in the initiating rack. 1:04:15 Propagation to Module 2 Propagation to live Module 2 in the initiating rack. 1:43:00 Test termination Manual suppression of fire with water. Data

collection stopped.




UL 9540A, Edition 4

Table 5 - Maximum Temperatures in Target Units Cell vent temperature from cell test data, °C 98°C

Target Unit 1 Target Unit 2 Target Unit 3 Module

Location No. Temper-ature (°C)

Module Location No.

Temper-ature (°C)

Module Location No.

Temper-ature (°C)

Module 1 437 Module 1 346 Module 1 151 Module 2 603 Module 2 513 Module 2 218 Module 3 645 Module 3 808 Module 3 211 Module 4 800 Module 4 690 Module 4 281 Module 5 789 Module 5 742 Module 5 312 Module 6 455 Module 6 801 Module 6 301 Module 7 179 Module 7 780 Module 7 300 Module 8 156 Module 8 787 Module 8 300 Module 9 148 Module 9 785 Module 9 300

Table 6 - Maximum Temperatures on Instrumented Wall Ambient Temperature: 19 °C UL 9540A performance criteria, Ambient + 97°C: 116 °C Height, mm

Maximum Temperature (°C)

Height, mm

Maximum Temperature (°C)

Height Maximum

Temperature (°C) 6 in. 542 54 in. 808 102 in. 523 12 in. 469 60 in. 796 108 in. 784 18 in. 792 66 in. 804 114 in. 761 24 in. 760 72 in. 756 120 in. 761 30 in. 750 78 in. 748 126 in. 813 36 in. 813 84 in. 740 132 in. 818 42 in. 820 90 in. 738 138 in. 761 48 in. 755 96 in. 754 - -

Note: Temperatures are measured constantly and then averaged every 60-seconds




UL 9540A, Edition 4

Table 7 – Heat Flux Measurements Summary of maximum heat flux in target units Summary of maximum heat flux

measured on instrumented wall Maximum Heat Flux, kW/m2 Target Module 1.: 24 Heat Flux Gauge No. kW/m2 Target Module 2.: 41 1 38 Target Module 3.: 9 2 33 Egress path measurement: 28

Table 8 – Gases measured and measurement methods used in unit level testing#

Measurement Method Gases Measured Chemical Formula Gas Type

Flame Ionization Detection (FID) Non-dispersive infrared spectroscopy (NDIR) Solid-state Hydrogen Sensor Fourier-Transform Infrared Spectrometer (FTIR)

Acetylene C2H2 Hydrocarbons Ethylene C2H4 Hydrocarbons Methane CH4 Hydrocarbons Methanol CH3OH Hydrocarbons

Propane C3H8 Hydrocarbons

Formaldehyde CH2O Hydrocarbons (Aldehydes)

Hydrogen Bromide HBr Hydrogen Halides

Hydrogen Chloride HCl Hydrogen Halides

Hydrogen Fluoride HF Hydrogen Halides

Carbon Dioxide CO2 Carbon Containing

Carbon Monoxide CO Carbon Containing

Ammonia NH3 Nitrogen Containing

Hydrogen Cyanide HCN Nitrogen Containing

Total Hydrocarbons - Hydrocarbons

Hydrogen H2 -

# - This table was modified to reflect the gases measured during testing.




UL 9540A, Edition 4

Table 9 - Gas generation periods

Time Condition 00:24:30 to 00:34:58 Pre-Flaming 00:34:58 to 01:43:00 Flaming

External Flaming of Gas Condition Duration (minutes)

External Flaming of Vent Gases: 68

Table 10 – Summary of battery gas volumes identified during thermal runaway in unit test

Gas Component Gas Type During Pre-flaming (L) During Flaming (L)

Carbon Dioxide Carbon Containing 1,000 24,250 Carbon Monoxide Carbon Containing 1,200 1,250

Ethylene Hydrocarbons 1,100 875 Methane Hydrocarbons 1,000 875

Table 11 – Summary of battery gas volumes for deflagration hazard calculations

Gas Component Gas Type During Pre-flaming (L)

During Flaming (L)

Total Hydrocarbons (Propane Equivalent)

Hydrocarbons 1,370 2,450

Carbon Dioxide Carbon Containing 1,000 24,250

Carbon Monoxide Carbon Containing 1,200 1,250

Hydrogen Hydrogen 0 0

Table 12 – Smoke and heat release rate Heat Release Rate (HRR) Smoke Release Rate (SRR)

Peak Chemical HRR (kW) 1170 kW Maximum SRR (m2/s) 12 Peak Convective HRR, (kW) 490 kW Total Smoke Released (m2) 20




UL 9540A, Edition 4

Table 13 – Integral Fire suppression system Details of Operation Time of operation of Sprinklers/Suppression System:

Time of Operation Start (HH:MM:SS)

Length of Operation (HH:MM:SS)

Sprinkler No. 1 Sprinkler No. 2 Sprinkler No. 3 Sprinkler No. 4 Fire Suppression System Operation

Note : Integral fire suppression system was not employed for the product under test.

Table 14 -Module OCV voltage measurement comparison before and after testing

Module Location In Rack OCV Prior to Test (V) 1 75.66 2 75.70 3 75.70 4 75.28 5 75.60 6 75.58 7 75.59 8 75.19 9 75.64

Table 15 – Other Observations during Unit test

Observed, Yes/No

Comments/Location

Flaming outside of Unit Yes Length of flame: Not determined as no flaming was allowed for indoor use.

Flying debris Yes Explosive discharge of gas Yes Sparks or electrical arcs Yes

Table 16 - Post Test Observations Thermal runaway behavior Re-ignitions No re-ignition Explosions No explosion Other Observations




UL 9540A, Edition 4

TABLE: Critical components information

Object / Part No.

Manufacturer/ trademark

Type / model Technical data Standard Mark(s) of conformity1)

Cell Top Cell Manufacturer

ABC 80Ah, 3.8V UL1642 UL

Module Top Cell Manufacturer

XYZ 320Ah, 53.2V UL1973 UL

Battery Management System (BMS)

Top Cell Manufacturer

UVW 320 V, 355 A, 12 V, 20A

UL 1973. (UL 991, 1998)

UL

Unit Enclosure UnitE Co. GHI SUS304, 4mm thickness

UL1973 UL

Rack Assembly RakAssy.Ltd JKL Carbon Steel UL50E UL

Internal Wiring Wirewire LLC MNO 18AWG UL62 UL

Thermal Insulating Materials

TIM Inc PQR 3mm thickness UL 746C UL


UL 9540A, Edition 4

List of test equipment used: A completed list of used test equipment shall be provided in the Test Reports when a Customer’s/Third Party Testing Facility has been used.

Clause Measurement / testing

Testing / measuring equipment / material used,

(Equipment ID) Range used Last Calibration

date Calibration due date

Note: Testing was done at the UL facility located in 333 Pfingsten Rd Northbrook Illinois, United States of America. Equipment specification and calibration information are maintained on UL’s Laboratory Equipment Record System (LERS) database, which is subjected controls in accordance with ISO 17025.


UL 9540A, Edition 4

Attachment A: Sample Charging, OCV and SOC Measurement Profiles - (Pages 29 through 29)

Figure 1 – Plot of module 1 – 6 charge data. Modules connected in series

Figure 2 – Plot of module 7 – 9 charge data. Modules connected in series


UL 9540A, Edition 4

Attachment B: BESS (including module and any integral fire detection and suppression systems) Construction Photos/Diagrams - (Pages 30 through 31)

Figure 3 – Photo of the cell

Figure 4 – Photo of the module


UL 9540A, Edition 4

Figure 5 – Photo of the unit


UL 9540A, Edition 4

Attachment C: : BESS and Equipment Instrumentation and Test Installation Layout Photos/Diagrams - (Pages 32 through 32)

Figure 6 – Test configuration and unit spacing

Figure 7 - Equipment Instrumentation


UL 9540A, Edition 4

Attachment D: Temperature Profiles and Heat Flux Measurements During Testing (Initiating Cell and Module, Target Modules, Wall Surfaces, etc. - (Pages 33 through 38)

Figure 8 – Surface temperature measured on the initiating cell during the unit level test

Figure 9 - Temperature measurements in the initiating module describing cell-to-cell propagation


UL 9540A, Edition 4

Figure 10 - Temperature measurements in the initiating unit


UL 9540A, Edition 4

Figure 11 – Target Unit 1 Module temperature

Figure 12 - Target Unit 2 Module temperature


UL 9540A, Edition 4

Figure 13 – Target 3 module temperature

Figure 14 – Heat flux measurements for target units


UL 9540A, Edition 4

Figure 15 – Heat flux measurements on the instrumented wall


UL 9540A, Edition 4

Figure 16 – Heat flux measurements for the egress path

Figure 17 – Temperatures on the target wall, presented with a 60 second running average (6 to 72 inches)


UL 9540A, Edition 4

Figure 18 - Temperatures on the target wall, presented with a 60 second running average

(78 to 138 inches)


UL 9540A, Edition 4

Attachment E: BESS Unit Testing and Post Testing Photos - (Pages 39 through 41)

(a) Test start

[00:00:00] (b) Thermal runaway of initiating cell and

propagating through module [00:26:51]

(c) Ignition of Vent gases near module

[00:35:00] (d) Propagation to Module 9

[00:40:00]

(e) Propagation to Module 8

[00:40:30] (f) Propagation to Module 7

[00:41:45]

(g) Propagation to Module 6 (h) Ignition of gas cloud


UL 9540A, Edition 4

[00:42:00] [00:42:05]

(i) Propagation to Module 4

[00:48:00] (j) Propagation to Module 1

[00:55:45]

(k) Propagation to Module 5

[00:58:30] (l) Propagation to Module 2

[01:04:15]

(m) Test termination [01:43:00]

Figure 19 – Test highlights


UL 9540A, Edition 4

Target Unit 1 Target Unit 2 Target Unit 3

Figure 20 – Photos of damage to target units after the test

Figure 21 – Condition of instrumented target walls after the test


UL 9540A, Edition 4

Attachment F: BESS Unit Test Datasheets - (Pages 42 through 42)

Datasheets associated with this project are stored on UL’s online project database


UL 9540A, Edition 4

Attachment G: BESS Unit Gas Flow Rate and Heat Release and Smoke Release Profiles - (Pages 43 through 44)

Figure 22 – Volumetric flow rates of gases over the duration of the unit test

Figure 23 – Chemical and convective heat release rate

Documents

IECEE TEST REPORT FORM TEMPLATE - Code Authorities · 2020. 10. 22. · outdoor ground mounted, indoor floor mounted, outdoor wall mounted, indoor wall mounted, roof top, open garage