EV Battery Testing Lab in India and Why AIS 156 and BIS Certificates Are Not the Same Thing
Manufacturers sometimes assume that EV battery testing services involve one certificate for the entire battery, from individual cells to the finished pack. In practice, cells, traction battery packs and some portable lithium cells follow different regulatory routes. Understanding these differences early can help avoid delays during product testing and approval.
An EV battery testing lab in India can determine which route applies before samples are shipped anywhere. Traction battery packs are generally approved through the automotive route as per AIS 156 or AIS 038 Rev 2, cells are tested under IS 16893 Parts 2 and 3 through an accredited laboratory and applicable portable lithium cells are covered under IS 16046 Part 2. They are distinct frameworks, not different phases of a single certificate.
Which Approval Does an EV Battery Actually Need in India?
The first question is not what certificate do I need but what am I really testing. The requirements for a standalone cell and a traction battery pack of many cells with a BMS are different from a portable lithium cell for consumer use.
At the cell level, testing is related to electrical and safety performance of the individual cells. Battery Pack Testing tests the assembled pack as mounted in a vehicle, and includes areas that cell-level testing does not. That pack that is installed in the vehicle has to meet automotive approval requirements, whereas BIS requirements for applicable lithium cells is a separate route. So correctly identifying the product type avoids testing to the wrong standard because you cannot just replace one certificate with another.
Cell-Level Testing Under IS 16893 Parts 2 and 3
Cell Level Testing IS 16893 specifies cell level testing. Part 2 and 3 specify different aspects of cell performance and safety. Cell manufacturers and importers should identify which part applies and confirm the requirements prior to submission as this depends on cell chemistry and intended use.
IS 16893 cell testing should be performed by an NABL accreditation testing lab with the relevant accredited scope for the specific tests required, and not on the assumption that general accreditation covers all parameters. Before sending the cells for testing, it is reasonable to cross check the exact standard and clause required against the NABL accredited testing scope of the laboratory.
Pack-Level Safety Tests Under AIS 156 and AIS 038 Rev 2
Traction battery packs are subject to varying assessments under the relevant automotive requirements, which typically deal with thermal propagation, electrical safety, short circuit behaviour, mechanical and vibration testing, environmental conditions and safety aspects of the battery management system. An EV battery test laboratory can help manufacturers identify the applicable test requirements based on the vehicle category and battery configuration.
The exact test parameters, sample quantities and acceptance criteria will depend on the vehicle category and the current revision of the applicable standard and should be confirmed directly rather than assumed.
● Thermal Propagation and Short Circuit Checks
Thermal propagation testing is critical for occupant safety as it examines how a fault in one cell will impact the rest of the pack. An EV battery testing lab in India can assess the applicable test requirements, while short circuit checks are made to see how the pack behaves in the case of an internal or external fault condition. The exact test setup for both is determined by the automotive standard in effect, so be sure to check the latest test plan with your laboratory.
● Ingress Protection and Vibration
Pack-level evaluation may include environmental and mechanical tests such as ingress protection against dust and moisture and vibration testing simulating vehicle operating conditions, depending on the applicable requirement. A BIS testing lab can help manufacturers identify the relevant testing requirements and confirm the applicable test scope before evaluation.
Where BIS IS 16046 Part 2 Still Applies to Lithium Cells
Portable lithium cells that are applicable, separate from EV traction battery packs, may be subject to IS 16046 Part 2, a separate compliance pathway from automotive pack approval. The two are not substitutes of each other and a battery testing services in India working both requirements can help clarify which route applies before testing begins.
What to Prepare Before Sending Cells and Packs to a Testing Lab
Manufacturers normally need the following information prior to submission: product details, cell or pack specifications, rated voltage and capacity, BMS information if applicable, drawings, circuit diagrams, datasheets, previous test reports, photographs, sample quantity and configuration.
● Sample, BMS Data and Drawing Requirements
The samples and documentation required quantities are dependent on the standard and scope of the test and should be confirmed with the laboratory prior to shipment.
Why Choose ACE Test Labs for EV Battery Testing?
ACE Test Labs & Metrology Pvt. Ltd. is a NABL Accredited Testing Laboratory in India. Our testing laboratory operates in accordance with ISO/IEC 17025:2017. As an EV battery testing lab in India, we support EV manufacturers through product and standard review, test planning based on the applicable requirement, testing capabilities within its current accredited scope, and technical documentation and reporting for manufacturers, importers and OEMs.
The accredited scope can differ by standard and test method. Before booking EV battery testing services, manufacturers should check the laboratory's current NABL accreditation scope for the exact parameter, method and product.
Planning Your EV Battery Testing Timeline
Before sending samples, identify the appropriate regulatory route, as timescales are determined by the standard, sample setup, test order and laboratory availability. An environmental testing laboratory in India may be part of the plan for packs or cells requiring environmental evaluation.
FAQs
1. Is EV battery certification mandatory in India?
Product types have different requirements. Traction battery packs, individual cells and portable lithium cells are under different routes so check which requirement applies to your specific product.
2. Is AIS 156 the same as BIS certification?
No. AIS 156 and AIS 038 Rev 2 are for approval of automotive traction battery packs whereas BIS requirements under IS 16046 Part 2 are for some portable lithium cells.
3. Which lab can test EV cells under IS 16893?
A lab with the correct NABL-accredited scope for IS 16893 Parts 2 and 3 can test cells against those requirements. Confirm the accredited scope before sending samples.
4. How long does EV battery testing take?
The time involved varies with the product, standard, test sequence, sample availability and laboratory schedule. There’s no set timeline for each submission.
About the Author: Dimpy Narang, is a writer and testing expert on EV batteries, safety standards, BIS requirements, certification & regulatory updates.