UN38.3 Testing for Lithium Batteries

Secure your supply chain and pave the way to global markets

In today's logistics, time is the most valuable asset. Lithium-ion, lithium-metal, and sodium-ion batteries are classified as Class 9 dangerous goods. Attempting to transport them without the proper documentation is a direct path to cargo impoundment and severe financial penalties.

In our laboratory, we conduct testing in accordance with the UN Manual of Tests and Criteria (Section 38.3). This is the only legal basis that guarantees airlines, ocean carriers, and road transport operators will accept your product for transport without delays, enabling smooth and secure distribution across global markets.

What is Section 38.3 of the UN Manual and why does your battery need it?

The absence of UN38.3 certification acts as a physical barrier for your products. In accordance with the special provisions of the UN Model Regulations, all types of cells and batteries (including the increasingly popular sodium-ion cells) must undergo mandatory safety validation.

These tests are the definitive proof for your business partners, investors, and customs authorities that the equipment is ready for transport. Furthermore, you must remember that any significant change in design – such as a mass change of more than 20% for primary batteries, a nominal energy change of more than 20% for rechargeable batteries, or modifications to key components – classifies the product as a new type that requires re-testing.

With us, you can be certain that your documentation is always error free, up to date, and honored worldwide.

Testing Procedures and Pass Criteria: The 8 Tests of the UN38.3 Standard

During transport, batteries are exposed to vibrations, shocks, and extreme temperature fluctuations. In accordance with procedure 38.3.4, we conduct tests that simulate the harshest logistical conditions. Tests T.1 to T.5 are performed sequentially on the same sample, whereas T.6 and T.8 are conducted on new, previously untested units

Table 1: Scope of testing and pass criteria according to UN 38.3

Test

Test parameters and procedure (in accordance with 38.3.4)

Pass criteria

T.1: Altitude simulation

Storage at a pressure of 11.6 kPa or lower for a minimum of 6 hours at ambient temperature (20 ± 5 °C). Simulation of airplane cargo hold conditions.

No leakage (mass loss exceeding the limits in Table 38.3.1), no venting, no disassembly, no rupture, and no fire. Open circuit voltage of a minimum of 90% of its initial voltage.

T.2: Thermal test

Extreme temperature shocks: a minimum of 6 hours at 72 ± 2 °C, followed by a minimum of 6 hours at -40 ± 2 °C. Maximum transfer time: 30 min. 10 cycles. Large batteries: minimum exposure of 12 hours.

No leakage, no venting, no disassembly, no rupture, and no fire. Open circuit voltage after the test is a minimum of 90% of its initial voltage.

T.3: Vibration

Sinusoidal waveform, logarithmic sweep (7 Hz - 200 Hz - 7 Hz) over 15 minutes. Repeated for 3 hours for each of the 3 axes.

No leakage, no venting, no disassembly, no rupture, and no fire. Open circuit voltage immediately after the test is a minimum of 90%.

T.4: Shock

Half-sine wave. Small batteries: 150gn for 6 ms. Large batteries: 50gn for 11 ms. A total of 18 shocks (3 for each axis and direction).

No leakage, no venting, no disassembly, no rupture, and no fire. Open circuit voltage is a minimum of 90%.

T.5: External short circuit

Sample heated (casing to 57 ± 4 °C). Subjected to a short circuit with a total resistance of less than 0.1 ohm. The short circuit condition is maintained for at least 1 hour after the cell or battery case temperature returns to 57 ± 4 °C, or, in the case of large batteries, decreases by half of the maximum temperature increase observed during the test and remains below this value.

Maximum external temperature of 170°C. No disassembly, no rupture, and no fire during the test and for 6 hours after it.

T.6: Impact / Crush

Impact (cylindrical cells with a minimum diameter of 18.0 mm): A 9.1 kg mass dropped from 61 cm onto a 15.8 mm bar.

Crush (other cells): Crushing until reaching 13 kN, a voltage drop of 100 mV, or 50% deformation.

Maximum external temperature of 170°C. No disassembly, no rupture, and no fire during the test and for 6 hours after it.

T.7: Overcharge

(Rechargeable batteries). Application of a current equal to twice the maximum recommended current. Duration: 24 hours.

No disassembly and no fire during the test and within 7 days after its completion.

T.8: Forced discharge

Forced discharge at a current equal to the maximum discharge current.

No disassembly and no fire during the test and within 7 days after its completion.

*The voltage drop requirement does not apply to cells and batteries tested in a fully discharged state.

Schedule is key. How many samples do you need to provide?

Don't waste time deciphering the complexities of standards on your own. We do it for you. According to section 38.3.3.1 of the UN Manual, the exact number of samples depends, among other things, on whether we are testing a single cell or a finished battery/pack, as well as on the product's mass.

We verify the stability of your technology not only straight from the production line, but also by testing samples after 25 operating cycles.

Example breakdown for rechargeable batteries:

• Cells and single-cell batteries: In total, we require the delivery of several dozen units to be divided among tests T.1-T.5 (10 pcs), T.6 (10 pcs), and T.8 (20 pcs) in various states of charge.

• Small batteries up to 12 kg: Typically, 8 units subjected to the T.1-T.5 sequence are sufficient (half new, half after 25 cycles), which then proceed to test T.7.

• Large batteries over 12 kg: Due to their dimensions, the standard requires a smaller quantity – typically 4 units for the T.1-T.5 sequence and test T.7.

*This is a simplified model. We will prepare the exact material specification for sample shipping for you during a free consultation.

Batteries integrated into equipment

Does your product have a built-in battery that cannot be removed without damaging the casing? Contrary to appearances, the situation here is not complicated because, according to 38.3.2.1 of the UN Manual, cells or batteries that form an integral part of the equipment can be tested directly inside the device.

Contact DLP – we will analyze the design of your equipment and choose a procedure that will save you time and money.

Build a competitive advantage through fast certification.

Time is money, and every day spent waiting for a certificate means a delayed product launch and frozen capital.