Sheet1

Chapter MBN Proposed Test with Test with open

Reference Test
Isolation Unit LV123 Station closed cover cover
resistance
Withstand
LV amperage
(internal HV- EOL Test
voltage
when BMS is
wiring)
(internal HV- [MOhm] 10.5.6 Station
EOL Test x
sleeping
BMS software
1.3 LV
2.1 Safety wiring)
(contactors
Inlet/Outlet [mA] 10.5.7.2 Station x
version
All cell
Amperage open)
temperature
(without
voltages SW [mA] not covered x
No activein
Module
2.3 Error sensors:
Software range
flashing) max
2.4 errors in BMS 0/1
temperature
not covered x
memory difference
(incoming
error memory
Max cell
sensors:
(Temp. max 0/1 not covered x
value
voltage ofdiff.
all
2.5 difference
between [K] not covered x
cells V) ->
deviation min
Temperature UPack
sensors)
SoC Value of [K] not covered x
to max within
measurement
all Cells(before 0/1
module x
difference
Voltage
Isolation
balancing)
from sum of [mV]
measurement
x
monitor:
Isolation
cell fault
fromvoltages
all points [V]
detection
x
monitor: fault
2.8 Voltage are plausible 0/1
positive x
detection
HVIL break
terminal  0/1 x
negative
HVIL break EOL Test
detection at
2.9 Isolation detection
terminal at 0/1 10.6.1 Station x
LV Manual
HV Connector
Service 0/1 x
HVIL
HV break
connection
Disconnect
detection at 0/1 x
not possible
External BMS
LV connector
during 0/1 x
control HVIL
via EOL Test
2.10 HVIL failureby
CAN 0/1 10.5.15 Station
EOL Test x
Startup
Difference
Current
battery
Current sensor 0/1
tester
sensor not covered Station x
sequence
UPack to as EOL Test
calibration
calibration
intended 0/1 Station x
external
check: EOL Test
check: primary
3.1 BMS measurement
Battery
current sensor [V] Station
EOL Test x
secondary
capacity
(shunt) is [A] Station x
current sensors
Capacity EOL Test
minimum(full
3.3 Current (hall)
Capacity [A] Station x
nominal
Minimum pack
Check)
capacity EOL Test
voltage
Maximum during
@25°C
test [Ah] Station
EOL Test x
pack
Currentvoltage
sensor
All cell
(Umin±3%) [V] Station x
during correct
shows test EOL Test
voltages rise
(Umax±3%)
sign
Flow during [V] Station
EOL Test x
with equal gain
All cell
charging
resistance
during 0/1 Station
EOL Test x
temperatures
(pressure
charging loss: 0/1 Station x
rise during
Calculated EOL Test
inlet-outlet
charging
BMS signals 0/1
TBD teststand;
Station
EOL Test x
are plausible
@25°C @TBD 0/1 Station
EOL Test x
Inner cell
Lt/min) [kPa] Station x
resistance
Inner cell
HPPC
CHA deviation EOL Test
resistance DIS
is <10%
deviation is [%] Station
EOL Test x
Inner pack
<10%
resistance [%] Station
EOL Test x
CHA
Inner pack [mOhm] Station
EOL Test x
No
No cell
BMSvoltage
resistance
limit was DIS [mOhm] Station
EOL Test x
3.4 Combined interference
Mechanical
All cells in
violated
Electrical (no current
integrity
Battery (No is 0/1
SOC
Station
EOL Test x
balanced
Performance damage
limitation) 0/1 Station x
to
set to delivery EOL Test
condition (cell
sealing,
state (35%) [%] 10.5.18 Station x
voltage EOL Test
housing,
4.1 Delivery difference)
Isolation [mV] 10.5.18 Station
EOL Test x
connectors) -
4.2 Safety resistance
optical [Ohm] 10.5.6
10.5.14 Station x
4.3 Mechanical inspection 0/1 10.5.16 Assembly Line x

Page 1
 Sheet1
All labels are
4.4 Visual present 0/1 10.5.1 Assembly Line x

Page 2
operation
the rearpack-->on measured Test duration:
withstand
test bedtest
battery
the the against the parasitic
repair Each
min. 1cell
minute
voltage?
must be
temperature capacities
voltage:
possiibility
If not, test
checked. pack until stable
within module
Current
sensors
Measuring in the grounding 3.624
value ± 0.005
would
Both
modules have
HVIL
consumption and toin Both poles could damage
points towithbe point. and V (from
Internal
be
loopsdone
of BMS
the have
inlet andto (HV+
must BMUs.
Test
defined, The housing charging
resistance of
The
open
be cell
cover
tested
checked and
in HV-) for the Conditions
outlet
working of the
under ground All readingsand
direction) Sheet1
voltages
disconnected
individually
sleeping
Comments
cooling
may
andtest inverter
circuit Testing circuit measurement
Test voltage:
Acceptance
from module
Prior
voltage! to connection 3.606
that device: ± 0.005
deviate
BMS/BMU.
awake
procedure
must be
from
states, must be
interface 2150
The
Criteria V ≥DC
battery
temperature
10
electrical
Second
the incomingand is closest to the V
MΩ (from
1.
withActivation
checked.open measured Test
must
sensors duration:
react
andon
operation discharging
final
status.
Test
of
The Failure
contactors.To it5s against
isolation
time:
reference
measured
Tbd. by the Correct
Environmental
6 sec.
interrupted
BMS
coolant
Messages from
must
voltage
2. Read
be
resistance
detect cell test: circuit
build-
error pack must be direction)
software
temperature:
Environmental
HVIL loop.
Time
ensured for
temperature that Mahindra Sleeping: 
temperature
both battery
Difference
version: tbd.
See
BMS 4.2.
behaviour
up, 1s memory chosen. 23 ± 5 °Ctbd.
memory
setting
will
the beactual
BMS BMS to groundingElectric (asat
Available
conditions
Reactions
µA / NOK
sensors
CAN
between
OK
23
(inlet
lines
min-
must
changes,
testing
3. be time
Deactivate
sleep has cell
to be point
they provide No
± 5 active
°C
(sending
BMS a
Awake:
determined
software has CAN and
must
max
MEML outlet)
be to
cell
checked
voltage
failure
considered for Available
BMS at
system) errors
signal
tdb. mA should
viawithin
with
the
active a
most recent
errors communicatio
CAN must
available
voltages
define
be not
how
present differ
atinto
the
measurement
4.
To Delete
ensure Error
that CAN as well
calibrated
revision.  n from
test
module:
flashBMSbed.
the
software
prior
must to
Memory
system bevoltage communicatio the
as proper
reference
operation Available
n  at reference
After
max.
memory sending
25 mV
performed.
measurement interruption of
temperature CAN temperature
the
UPack signalto sum by
During
EOL
is working this
tester test
sensor close to communicatio BMS The
the
more battery
main
than 1 ±
of each cell: 
the main must
must
properly provide
the pack.  the n  5 V react on
contactors)
°C. 
Command the
contactors
the
value
In order must to be Available at provoked
must
battery bemust
Difference
must be with
functionality
compared to CAN isolation
assessed.
perform Available at follow
between
opened.
The
switch
the function
sum on/off
of all communicatio failures
automated tests CAN closing/openin
internal HV
of
HVILthe
cellthe
at pack
at LV
voltages
test bed, n, EOL tester properly,
For followingby
communicatio g procedure.
measurements:
internal
connector requires the detecting
sceanrios, and
the battery n  ± 2 VBMS the
The
isolation
must be function to sending
HVIL a
must
system voltage be
monitor
HV must
connection
operated apply isolation proper
interrupted:
measurement signal
be
to checked
be
remotely combinedvia fault. •via CAN.
Main
(BMS HV
Upack
withtest
the breakbed. connector:must
Reading) pull
measurement
detection
Already in connector
not differ for
from
one
Tests BMS
case
have (e.g. •more
LV-MSD
included
Covered into
by than 2 V
compared
HVIL
be break
combined to at E- LV Connector, connector: pull
CAN
activation at from the test
storage
HV connector)
with othertester tests LVCAN connector
communicatio
test bench, Connector, bed
measurement,
Reduced
At different
nsequently (e.g. CAN measurement.
startup-up
can be steps,
capacity check tbd. EE (0.1%
current
capacity
At different
procedure test)
included
(correlation
can
to save
be timein to on display
current steps,
2.1 
full cap)
to 2.9for
combined
and energy; with value?)
can be
every
capa
HPPC pack
check
testswith
combined
full capacity • During the
will
capaalso
check detect
can be done at
assembly test no voltage
regular
faiures limit
samples
(missing bolts) (minimum and
The HPPC maximum
Samples
power profile voltage limit
during ramp
refers to ISO on cell and
up:
12405 2 pack level)
1st 100
Section 7.3.packs: must be
every 5th
Procedure see pack reached
full capa
separate HV connector, (charge or
gradually
The
Shallcells
document be done are LV connector; discharge).
reduced
delivered • If derating
at the end at
(performance of coolant
The
30% fully
SOC,
testing) the occurs the
EOL testing to connector impact must
assembled
pack shall be
detect bad cells not affect the
pack
shipped must
after going at be35%
checked
SOC. for pulse height
through all
any damage
check,tests to • Cooling
other
the sealing,
charge/dischar systemBMS
Signal can
Test can beof
Repetition Maximum
housing,
ge, HPPC keep
Readingup with
deleted
isolation here?,
test to differencemust of
connectors,
should be the
No
be thermal
damage
within the
after cell
check whether signals
load
grounding
amost SOC and should
range ofbe33-37
voltage
widthstand test --> HV connector, DebugCAN:
vent
neutralplugs present that
pack
voltage in rework HV connector, %.
LV connector 5 mV (tbd by
prior to has will deteriorate
station?
causes LV connector MEML)
shipment. or limit system
damages.has to See 1.3
Worker See 1.3
performance or
check.  operation.

Page 3
assembled
pack must be
checked for
complete Label
labelling. specification:
Included in see battery
mechanical system spec. Sheet1
inspection, ev. Tbd. by
camera system MEML

Page 4