Technical Bulletin

Testing of High Voltage
Electric Vehicles
Version 1.1

January 2022
TB 011

TitleTesting of High Voltage ElectricVehicles
1.1
TB011
S. Edmonds
January 2022
Rescue, Extrication & Safety Test andAssessment Protocol
TB011 Update to reflect latest vehicle
fleet
2022

VersionDocument Number
Main Author
Date
Related Documents
StatusApplication Date

2

Preface
DISCLAIMER: Euro NCAP has taken all reasonable care to ensure that the information
published in this document is accurate and reflects the technical decisions taken by theorganisation. In the unlikely event that this protocol contains a typographical error or
any other inaccuracy, Euro NCAP reserves the right to make corrections and determine
the assessment and subsequent result of the affected requirement(s).

3ContentsPreface............................................................................................................................ 3
1. Introduction ................................................................................................................ 5
2. OEM Pre-test Information ......................................................................................... 5
3. HV vehicle assessment .............................................................................................. 6
Annex 1 .......................................................................................................................... 8
Annex 2 ........................................................................................................................ 134

1. Introduction
TB011 Testing of Electric Vehicles was first released in 2010. Since then, there havebeen numerous new vehicle propulsion systems coming to the market. For vehicles
other than traditional ICE additional preparations and precautions are required to ensure
safety before, during and after crash-testing for all persons involved. This bulletin now
includes requirements on:
1. Information that OEM needs to provide to the test laboratory.
2. Checks the test laboratory needs to perform on the vehicle pre, during and posttest.

2. OEM Pre-test Information
In order to achieve the safe and timely testing of vehicles the following items andinformation should be provided (at the latest upon vehicle delivery to the lab) by theOEM completing the HV vehicle questionnaire (Annex 1) covering the following:•••••

The location of the service plug (if applicable).
Diagram/drawing/photos and guidelines to show the location of HVconnection*.
The minimum State of Charge (SoC) of the Rechargeable Electrical
Energy Storage System (REESS) to any state which allows the normal
operation of the powertrain.
Instructions on how to put the vehicle in the correct state to be tested(restraint system deploys as normal as it would on the road, ADL, eCalletc functioning “as normal”).
Pre & Post test: Instructions on how to move the vehicle in order not todamage the HV system (for Pre) and not to create additional risk (forPost).

*If possible, break-out leads from HV and relevant adaptor to DAU may be fitted by
OEM personnel at test lab during the vehicle crash preparation phase (ideally oneweek in advance from the crash test date).
From 2023 onwards, if the OEM does not provide the completed questionnaire with therelevant information, the -1pt penalty of the ‘EV and hybrid vehicle compliance withECE regulations regarding electrical vehicle safety’ assessment (Rescue, Extrication& Safety Test and Assessment Protocol) will be applied automatically, irrespectiveof the post-crash compliance checks.
The HV questionnaire must be supplied to the test laboratory at the same time as theEmergency Response Guide (ERG). These documents must be delivered to the lab atleast 2 weeks before the first crash test.

53. HV Vehicle Assessment
Euro NCAP requires laboratories to measure the voltage of the HV battery during thefull-scale crash test. UNECE R94, R95, R135 and R137 have requirements which coverprotection against electrical shock. Four test options are allowed to verify the protection
against electrical shock:
1. Absence of high voltage
2. Low electrical energy
3. Physical protection
4. Isolation resistance
The laboratories are required to record and complete the post-test HV assessment ofprotection against electrical shock, see Annex 2 for assessment table in accordance withthe flow chart process.
3.1 HV Status
Euro NCAP tests can be carried out with a minimum state of charge (SoC) as per thequestionnaire in Annex 1.
Pre-testTo indicate the risk of >30v AC/60v DC post-test, an exterior LED indicator lightshould be mounted to show the status. The OEM is asked to provide guidance formounting the LED lights.
Post-test
After the crash test, extreme care needs to be taken to ensure that there is no exposure
to high voltage before any person touches the vehicle. After all the verifications withan active HV system have been done the HV system must be deactivated following theOEM instructions supplied within the Annex 1 questionnaire.
In the case of non-compliance of protection of electrical shock post-test, all post-test
activities will be halted, the laboratory must activate their relevant Emergency Plan andthe OEM shall be contacted immediately to instruct on the safe isolation of the HVsystem.
For storage, inspection and viewing the OEM or Laboratory should remove thebattery pack post test.
3.2 Thermal Event
Post-crash
The HV battery temperature and battery temperature rise rate should be monitored. The
method of monitoring the battery temperature (e.g. thermocouple, CAN data) is at thediscretion of the test laboratory. Any and all audio and visual warnings provided by
the vehicle of a potential thermal event will be noted. In the case of a thermal event
occurring and no warning being provided by the vehicle this will also be noted withEuro NCAP Secretariat being informed.
In order to aid the test laboratories when checking a high voltage vehicle the following
process flow chart indicates the preparation and assessment process:67Annex 1
OEM Vehicle Questionnaire8Information required from OEM regarding their High Voltage vehicle
The following section should be completed by OEM prior to any testing and sentdirectly to the test laboratory.

Manufacturer Specified Information – General Information

Information

Answer by OEM

Name of the car
Vehicle type (PHEV, HEV, EV, H2EV/ FCEV,etc)
1. SD Switch position. Is it mechanical or is it anelectric device? If there is no SD switch pleaseprovide instructions on a physical way todeactivate the HV system (emergency button).
2. Technical documents about how to deactivate
HV system to work safely. Procedure?
3. Technical documents about how to remove HVbattery to work safely Post test. Procedure?
4. Vehicle specific tool (lid, pad lock or other), incase there is one, to block the access to the SD
switch area once it is unplugged and/or preventthe high voltage system reconnection.
5. In case of post-test absence of HV not
complying, OEM to explain how HV system canbe deactivated without contact to, ormanipulation of, the vehicle.
e.g. if necessary by installation pre-test of
external emergency switch to service
disconnect.
6. OEM to provide diagram or pictures of thepoints where Test Facility must measure thevoltage of the powertrain buses after thedisconnection relay.
If disconnection relay is external to HVbattery, diagram to include measurements tothat location.
9Manufacturer Specified Information – General Information

Information

Answer by OEM

7. OEM to declare connector type / requirement tothe external HV vehicle break-out box.
OEM to provide all relevant information.
8. OEM to explain the powertrain bus type /condition and limit values for isolation
resistance measurement (separated or combined
AC or DC buses, or confirmation of IPXXB isfulfilled).
9. OEM to provide document and pictures of safe
handling of HV battery, in case of direct contact
and / or removal of the HV battery.
10. Nominal voltage requirement of the HV battery
for normal vehicle operation
11. Minimum state of charge (SoC) of the HV
battery to allow electric drive to perform thecrash
12. OEM to provide details of electrolyte (colour,smell etc)
13. OEM to provide details of how to pre-test
operate the vehicle with the HV disconnected,
and identify care points to prevent damage anderrors to the vehicle ECUs.
14. OEM to provide details of restrictions to pre-test/ post-test movement of the vehicle, without
damaging the regenerating system.
15. OEM to declare risk of regenerating energy
during vehicle movement.
16. OEM to supply and demonstrate values ofcondenser X and Y.

10Manufacturer Specified Information – General Information

Information

Answer by OEM

Additional item for BEV / PHEV:
17. OEM to provide battery charger and declarerecharge method for BEV and PHEV.
Additional items for HEV:
18. OEM to provide information how to attainelectric drive.
19. OEM to explain how the electric drive can be
maintained without combustion engine
operation. e.g. disabling of combustion engine
mode.
20. OEM to explain how to charge the HV battery
without moving or driving the vehicle.
Additional items for FCEV:
21. Helium is recommended to be used for test.
OEM to provide details of limitations to use
helium as substitute to hydrogen.
22. OEM to provide information of minimumhydrogen tank pressure to allow electric drive.
23. OEM to provide details of how the Test Facility
can install sensors to monitor and record the tankpressure and temperature.
24. OEM to support with supervision and guidanceon the installation of the sensors, within 1 weekprior to day of test.
Definitions of terms used in questionnaire:--

HV: “High Voltage” is considered at the automotive industry circuits with morethan 60 Volts.
BEV: “Battery Electric Vehicle”, a vehicle driven only by one or more electricmotors. The EV also contains a high voltage battery and the battery has external
charging.
PHEV: “Plug-in Hybrid Electric Vehicle”, it is a vehicle driven by an internal
combustion engine and one or several electric motors, at the same time orindependently. The vehicle also contains a high voltage battery and the battery
has external charging.
HEV: “Hybrid Electric Vehicle”, it is a vehicle driven by an internal
combustion engine and one or several electric motors, at the same time or11

--

independently. The vehicle also contains a high voltage battery but the battery
cannot be charged with external charger.
FCEV: “Fuel Cell Electric Vehicle”, is an electric vehicle that uses a fuel cell,sometimes in combination with a small battery or supercapacitor, to power its
onboard electric motor. Fuel cells in vehicles generate electricity generallyusing oxygen from the air and compressed hydrogen.
SD Switch: “Service Disconnect Switch”, mechanical or electric device that isused to disconnect the HV battery avoiding the output of power to thepowertrain or additional circuits.

12Annex 2
Post-test HV assessment of protection against electrical shock13

Post-test HV assessment of protection against electrical shock for each full scale crashtest vehicle to be used in combination with the Flow Chart
Test Facility
Vehicle Make / Model
Test / Assessment Date

Post-Test HV Check*
Absence of High VoltageRecorded values graph
Vb

Graph

V1

Graph

V2

Graph

Measured values

Status(OK, Not OK,N/A)

Status(OK, Not OK,N/A)

Vb
V1
V2
V1’
V2’
Ri/ Nominal
voltage* Relevant checks to be completed as per each lab’s internal requirements following
the flow chart process.
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Post-Test HV Check*
Isolation ResistanceDirect measurement withexternal DC power supply

Status(OK, Not OK,N/A)

Ri+ /NominalvoltageRi- / Nominal
voltage
Voltage measurement +calculations

Status(OK, Not OK,N/A)

V1 > V2
V2 > V1
Ri+/Nominalvoltage
Ri-/Nominal
voltage
Low Electrical Energy

Measured value or calculated
value

Status(OK, Not OK,N/A)

TE
TE1
TE2
Physical Protection

Measured value for all exposed
conductive parts

Status(OK, Not OK,N/A)

Indirect
Direct* Relevant checks to be completed as per each lab’s internal requirements following
the flow chart process.
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