Compliance with UN R100 Revision 5 (Series 05) – Type approval of electric vehicle batteries
Conformité ECE R100 - Révision 5
Sécurité, performance et conformité réglementaire : une approche globale proposée au sein du Groupe Emitech
UN Regulation R100, Revision 5 (Amendment Series 05) represents a significant development in the requirements applicable to rechargeable energy storage systems (REESS) installed in electric vehicles. In addition to strengthening robustness testing, Rev. 5 introduces a system safety demonstration approach focused on controlling thermal runaway, as well as a new section dedicated to the approval of REESS installation in the vehicle.
The Emitech Group supports battery manufacturers, system integrators and vehicle manufacturers in achieving compliance with these new requirements, from defining the test strategy through to obtaining the E-mark.
What has changed in Rev. 5 compared to Rev. 3
Revision 3, which came into force in 2021, laid the initial foundations for thermal runaway management, notably by requiring a 5-minute warning period prior to a hazardous situation. Rev. 5 takes this a step further by formalising a comprehensive system safety assessment framework.
Note on Series 04: Series 04 of amendments, which came into force in January 2025, primarily introduced identification provisions for heavy-duty electric vehicles (buses, M3/N3 category lorries), in order to harmonise their marking with that of alternative-fuel vehicles (LPG, CNG, hydrogen). It does not substantially alter the REESS testing requirements. It is the Series 05 that constitutes the next major revision for battery manufacturers, integrators and vehicle manufacturers.
Why choose the Emitech Group for your UN R100 Rev.5 approval?
Full mastery of the new requirements of the 05 series
- Conducting tests under Part I
- Conducting tests under Part II
- Conducting tests under the revised versions of Annexes 9A to 9J
- Implementation of the new Annex 9K – Thermal Propagation Test, the centrepiece of Rev.5
- Coverage of the requirements of Part III: type-approval of the installation of an approved REESS as part of a vehicle type-approval
Support that goes beyond testing alone
- Definition of the compliance strategy: choice of test level (complete vehicle, battery pack, subsystem)...
- Compilation of the technical type-approval dossier, including elements subject to industrial confidentiality in accordance with the provisions of Rev.5
- Direct liaison with technical services (ALEE) to obtain the certificate of conformity
- Active monitoring of developments (retrofit, L categories, etc.)
The UN R100 Rev.5 tests
Annexe 9A - Vibrations
Annex 9B - Thermal shock / thermal cycling
Annex 9C - Mechanical shocks
Annex 9D - Mechanical crushing
Annex 9E - Fire resistance
Appendix 9F - External short-circuit protection
Annex 9G - Overload protection
Annex 9H - Protection against excessive discharge
Annex 9I - Overheating protection
Annex 9J - Overcurrent protection
Annexe 9K – Thermal Propagation Test (nouveau Rev.5)
The resources and expertise offered by the Emitech Group
In-house specialist testing facilities
- Battery cycling test benches up to 1000 V / 1000 A
- Fire testing laboratory (direct and indirect fire resistance, IR sensors, HD video)
- Secure climatic chambers for thermal cycling
- Vibration platforms, 100 kN mechanical crushing equipment
- Test facilities dedicated to thermal runaway, from cell, module and pack to vehicle level.
- High-resolution measurement systems and advanced safety devices for abuse testing
Additional services
- Exploratory pre-testing to optimise design and anticipate risks of non-compliance
- Design of fastening tools (in-house design office)
- Multi-standard testing programmes: UN R100, UN 38.3, IEC 62660, ISO 12405, UL 9540A…
- Abuse testing, mechanical safety, water resistance, corrosion, altitude
With the Emitech Group, benefit from comprehensive regulatory support
- Monitoring developments regarding UN R100 Rev.5, R136, GTR 20 and their current amendments
- Documentation preparation, risk analysis, functional diagrams
- Technical training courses on battery regulations and Rev.5
- Test reports recognised for E-marking (via ALEE / KBA)
Related Services
Needs
Discover a selection of additional resources that explore topics related to this page including regulatory contexts, technical articles, and specific areas of expertise. These materials provide further insight to help you better understand the key challenges and available solutions.
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Are you developing a high-voltage battery or integrating a REESS into an electric vehicle?
Our experts can support you every step of the way, from Rev.5 compliance strategy through to type approval. Contact us today.
