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Battery Safety Testing Services

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Battery Safety Testing Services

Compatible Electronics performs battery safety testing for lithium-ion, lead-acid, NiMH, and other rechargeable battery systems — covering overcharge, short-circuit, crush, thermal runaway, and charge control verification — as part of NVLAP-accredited safety evaluations at our laboratory (Lab Code 200527-0).

NVLAP Lab Code 200527-0 ISO/IEC 17025:2017 IEC 62368-1 · IEC 60335-2-29 Li-ion · Lead-Acid · NiMH Lake Forest · Brea · Newbury Park

What is Battery Safety Testing?

Battery safety testing evaluates the behaviour of battery cells, packs, and charging systems under abnormal conditions that could cause fire, explosion, toxic gas release, or electrolyte leakage. As lithium-ion batteries are now found in virtually every product category — from consumer electronics and medical devices to power tools and EV charging infrastructure — battery safety testing has become one of the most critical aspects of product compliance.

Battery safety requirements appear throughout the CE scope accreditation — in IEC 62368-1 (PS2/PS3 power source classification), IEC 60335-2-29 (battery chargers), IEC 60601-1 (medical devices with batteries), IEC 61010-1 (laboratory equipment), and IEC 61851 (EV charging). Temperature rise testing is always performed alongside battery safety tests.

💡 IEC 62368-1 PS classification: Battery packs are classified as PS1 (not a fire hazard), PS2 (limited fire hazard), or PS3 (fire hazard). PS3 batteries require a fire enclosure — tested to V-1 minimum flammability rating. Our engineers advise on appropriate classification for your battery design.

Battery Safety Tests We Perform

  • Overcharge test — charging beyond rated voltage with failed charge control
  • Short-circuit test — external short across battery terminals
  • Over-discharge test — discharging beyond minimum voltage
  • Charge control circuit verification — cut-off and protection circuit function
  • Abnormal charging test — reverse polarity, incorrect charger
  • Temperature monitoring during charge/discharge — thermal runaway precursor detection
  • Hydrogen gas ignition test — lead-acid chargers per IEC 60335-2-29
  • Battery enclosure fire containment — V-1 flammability verification
  • Temperature rise — cells, pack, charger under normal and fault conditions
  • Dielectric strength — isolation between battery and chassis

Standards Covering Battery Safety

  • IEC 62368-1 — Annex M: Battery-powered equipment; PS classification
  • IEC 60335-2-29 — Battery charger overcharge and charge control tests
  • IEC 60601-1 — Clause 8.4.5: Internal electrical power sources (batteries)
  • IEC 61010-1 — Clause 14: Battery-operated equipment
  • IEC 61851 — EV charging battery interface safety
  • IEC 60335-1 — Clause 19: Abnormal operation including battery fault conditions
  • IEC 60335-2-82 — Amusement machine battery-powered features
  • UL 1642 / IEC 62133 — Cell-level battery safety (witness/reference testing)

Related Safety Tests

Temperature Rise Testing Dielectric Strength / Hi-Pot Testing Leakage Current Testing IEC 60335-2-29 Battery Chargers IEC 62368-1 Testing IEC 61851 EV Charging Pre-Compliance Safety Testing All Safety Testing Services

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Contact our safety engineers for a quote or to discuss your testing requirements.

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