UL Subject 1012(0501)1.doc

Subject 1012May 1, 2009SUMMARY OF TOPICSThe following changes in requirements to the Standard for Power Units Other Than Class 2, UL1012, are being proposed:1. New requirements for batteries with integral chargers2. New requirements for power units for installation in air-handling spacesSTP BALLOTS & COMMENTS DUE: JUNE 15, 2009For your convenience in review, proposed additions to existing requirements are shown underlined andproposed deletions are shown lined-out.1. New requirements for batteries with integral chargersRATIONALEProposal submitted by: Kent Donohue, Underwriters LaboratoriesUL proposes new requirements for batteries with integral chargers. The proposal clarifies requirements applicable to batteries with integral chargers, and includes new requirements applicable to units witha solar cell feature.PROPOSALRECHARGEABLE BATTERIES WITH INTEGRAL CHARGERS92 Scope92.1 These requirements supplement and in some cases modify the requirements of Sections 7 61. These requirements apply to indoor use, household, and commercial rechargeable battery packs (RBPs)of the alternating current supplied type, solar cell supplied type, or combination supplied type.92.2 These requirements do not apply to a rechargeable battery for recharging from a separable batterycharger. Requirements for this type of rechargeable battery are specified in the Standard for Householdand Commercial Batteries, UL 2054.92.3 These requirements do not apply to a rechargeable battery intended for use in uninterruptible powersupply applications. Requirements for this type of rechargeable battery are specified in the Standard forUninterruptible Power Supply Equipment, UL 1778.SUBJECT 1012-2-MAY 1, 200992.4 These requirements do not apply to a rechargeable battery with an integral load, such as arechargeable night light, rechargeable flashlight, a rechargeable shaver, a rechargeable screwdriver, andthe like. Requirements for these types of products are specified in other Standards appropriate to theintended use.93 Glossary93.1 For the purpose of the requirements in Sections 92 98, the following definitions apply.93.2 ALTERNATING CURRENT SUPPLIED During recharge, the RBP is connected to a nominal120 or 240 V, 15 or 20 A branch circuit receptacle. The RBP may be either direct plug-in or cord- andplug-connected.93.3 COMBINATION SUPPLIED A direct plug-in or cord- and plug-connected RBP that also employsa solar cell integral to the RBP enclosure. During recharge, the RBP receives energy from either analternating current supply, from sunlight, or from both sources.93.4 RECHARGEABLE BATTERY PACK (RBP) A unit with an enclosure housing a battery chargercircuit, a rechargeable battery, control circuitry, and a polarized output connector integral to theenclosure or terminating on an output cord. During recharge the energy source is via an alternatingcurrent supply, or a solar cell. During discharge the output is connected to the load equipment.93.5 SOLAR CELL A photovoltaic assembly that converts sunlight directly into electricity.93.6 SOLAR CELL SUPPLIED During recharge, the RBP receives energy via a solar cell integral tothe RBP enclosure.94 General94.1 The RBP shall comply with the applicable requirements of Sections 7 61, modified by theconstruction and performance requirements for secondary battery packs specified in the Standard forHousehold and Commercial Batteries, UL 2054.95 Construction95.1 Enclosure95.1.1 Polymeric enclosure materials of a solar cell or combination supplied RBP shall comply with theultraviolet light exposure requirements of the Standard for Polymeric Material Use in ElectricalEquipment Evaluations, UL 746C.SUBJECT 1012-3-MAY 1, 200995.2 Battery95.2.1 A battery intended for installation and replacement by other than trained technicians shall employa rigid mechanical enclosure that complies with the enclosure construction and test requirements of theStandard for Household and Commercial Batteries, UL 2054.95.2.2 A RBP with a battery intended for installation and replacement by other than trained techniciansshall:a) Be designed to prevent misaligment, reverse polarity, damage upon connection, andaccessiblity of uninsulated parts during use; andb) Provide a battery securement means to prevent inadvertent disconnection or damage duringuse.95.3 RBPs with a lithium battery95.3.1 Compatibility between a lithium-ion battery and the charging system shall be verified anddocumented by the RBP manufacturer. Verification documentation shall include:a) The battery manufacturers specifications noted in 95.3.2; andb) Failure modes and effects analysis determining that the battery manufacturers specificationsnoted in 95.3.2 are not exceeded.95.3.2 The RBP manufacturer shall address in the product design the following specifications from thelithium-ion cell manufacturer:a) Rated charging current, charging voltage and cutoff current, with compliance verified in theRBP under normal and single fault conditions within the system;b) Rated discharge current/rate and endpoint voltage, with compliance verified in the RBPunder normal and single fault conditions within the system;c) Maximum charging current and charging voltage limit (established as part of the batteryabnormal charging test), with compliance verified in the RBP under double fault conditionswithin the system; andd) The upper and lower ambient temperature ranges for charging and discharging, withcompliance verified in the RBP.SUBJECT 1012-4-MAY 1, 200995.4 Supply connections95.4.1 The supply cord of a combination supplied RBP shall comply with the outdoor use requirements ofthe Standard for Cord Sets and Power Supply Cords, UL 817.95.4.2 Polymeric materials of the appliance inlet of a combination supplied RBP intended for use with adetachable power supply cord shall comply with the ultraviolet light exposure requirements of theStandard for Polymeric Material Use in Electrical Equipment Evaluations, UL 746C. The appliance inletshall also comply with the Standard for Attachment Plugs and Receptacles, UL 498.95.5 Solar cell protection95.5.1 Means for protecting the solar cell from reverse current shall be provided under normal and singlefault conditions, and the overall construction shall comply with the solar cell reverse current overload testof 96.3.96 Performance96.1 Power input test96.1.1 The RBP shall comply with Section 40, Power Input Test, when tested in accordance with 96.1.2.96.1.2 Prior to the test, the RBP is to be discharged in accordance with 40.3 40.5. The RBP is to thenbe connected to the alternating current supply and, if the construction permits, the RBP output is to beresistively loaded to deliver the maximum rated output current. The input current is to be measured whentemperatures peak.96.2 Normal temperature test96.2.1 The RBP is to be operated under the most severe normal conditions through two complete cyclesof charging and discharging in accordance with (a) (d). The temperature measurements are to be madeat the least favorable ambient temperature within the specified operating range for the RBP. Temperaturesshall not exceed the limits specified in Section 40, Power Input Test, and the temperature of the batteryat any time under conditions of charging and discharging shall not exceed the value specified in Table96.1.a) Prior to the test, the RBP is to be discharged in accordance with 40.3 40.5.b) During the charging cycles the RBP output is to be resistively loaded, if the constructionpermits, to deliver the maximum rated output current.c) During the discharge cycles the RBP is to be discharged with the resistive load initiallyadjusted to draw the maximum rated output current. Without further load adjustment, the RBP isto be discharged until temperatures peak.d) During the first charge cycle, the RBP is to be operated until temperatures peak. The RBP isto then be disconnected from the supply source (alternating current supply or solar cell supply)and discharged until temperatures peak. The RBP is then subjected to the second charge/discharge cycle. The test is terminated when temperatures peak or temperatures stabilize,whichever occurs first during the second cycle.SUBJECT 1012-5-MAY 1, 2009 Table 96.1Battery case temperature limitsBattery location or useTemperature limitUser accessible battery, intended for user contact 1The least of notes 2, 4, and 5User accessible battery, not intended for contact in normal useThe least of notes 3, 4, and 5Battery that is not-user accessible or subject to casual contactThe lesser of notes 4 and 5 1 Example: separable battery pack intended for handling by the user to facilitate recharge after use of battery operated product. 2 Enclosure surface temperature limit for parts intended to be grasped. 3 Enclosure surface temperature limit for parts subject to casual contact. 4 Pack enclosure material relative thermal index. 5 Cell manufacturers temperature specification.96.3 Solar cell reverse current overload test96.3.1 There shall not be flaming or charring of the cheesecloth in contact with the solar cell when areverse current under normal and single fault conditions is caused to flow through the solar cell.96.3.2 The RBP solar cell is to be draped with a single layer of cheesecloth. The cheesecloth is to beuntreated cotton cloth running 14 15 square yards/lb (26 28 m2/kg) and having what is known to thetrade as a count of 32 by 28.96.3.3 The RBP is to be operated under normal and single component fault conditions that result inmaximum reverse current through the solar cell due to a fully charged battery.a) If an overcurrent protective device operates, the test is to be repeated with a reverse currentat 135 percent of the overcurrent protective device rating.b) If a thermal or positive temperature coefficient resistor protector operates, the test is to berepeated with the protector bypassed and a reverse current adjusted to result in the protectorbody temperature at the trip point measured during the maximum reverse current test.96.3.4 For a combination supplied RBP, test conditions are to include operation with the alternatingcurrent supply connected, and operation with the alternating current supply disconnected.96.3.5 Each test is to be conducted in an area free of drafts, and the irradiance on the solar cell is to beless than 5 mW/cm2.96.3.6 Each test is to be continued for 2 hours or until ultimate results are known, whichever occurs first.SUBJECT 1012-6-MAY 1, 200996.4 Mechanical strength tests96.4.1 The applicable tests of Section 44, Mechanical Strength Tests for Metal Enclosures, and Section68, Performance, shall not result in any of the following:a) Breaking of the enclosure resulting in exposure of cells or circuitry;b) Damage to internal protective components and circuitry;c) Damage to the securement means of the pack or the external connectors that could result ina short circuit or other hazardous condition;d) Chemical leaks caused by cracking, rupturing or bursting of the cell casing or packenclosure;e) Explosion resulting in a cell casing or battery pack enclosure violently opening orcomponents of the cell or battery pack being forcibly expelled; norf) Emission of flame or expulsion of molten metal.97 Markings97.1 The enclosure of a solar cell or combination supplied RBP shall be marked where readily visible withthe following: “CAUTION Do Not Expose To Rain. Store indoors when not in use.”97.2 The enclosure of an alternating current supplied RBP shall be marked as specified in 60.1.4.97.3 A RBP provided with a user replaceable battery shall be marked with the following statement orequivalent in a location readily visible during battery replacement: “CAUTION Replace Battery with(responsible company name and battery designation) Only. Use of Another Battery May Present a Risk ofFire or Explosion. See instruction manual.”98 Instructions98.1 The operating instructions shall provide appropriate information regarding use and storagetemperature limits.98.2 The operating instructions of a RBP employing a battery intended for replacement and installationby the user shall include complete details for safe replacement and disposal of a used battery. Theinstructions shall include the marking specified in 97.3 and the following or equivalent: “Do not incinerate.”98.3 The operating instructions of a RBP with a non-user replaceable battery shall include details for thesafe disposal of the RBP. The instructions shall include the following or equivalent: “CAUTION Do notincinerate.”98.4 The instructions for a RBP that employs a battery intended for replacement or servicing only by atrained technician shall include the following or equivalent: “Servicing to be performed only bymanufacturers qualified personnel”.SUBJECT 1012-7-MAY 1, 20092. New requirements for power units for installation in air-handling spacesRATIONALEProposal submitted by: Kent Donohue, Underwriters LaboratoriesUL proposes new requirements applicable to units specified for plenum installation. These requirements apply only to permanently connected equipment since the National Electrical Code Article 400.8(5)does not permit flexible cords to be concealed by floors or ceilings. Units with integral batteries are not permitted due to concerns with battery servicing and substitution with batteries for which UL 2043 compliance is undetermined.PROPOSALPOWER UNITS FOR INSTALLATION IN AIR-HANDLING SPACES99 Scope99.1 These supplemental requirements apply to a power unit intended for installation in air handlingspaces, such as above suspended ceilings or below floors.100 General100.1 A power unit shall be a permanently connected type for input and output connections.100.2 A power unit shall not employ an integral battery.100.3 A power unit shall comply with the