10 Table 2 – Main dimensions of batteries of standard series LN with standard fastenings with 5 notches at length side and 3 notches at width side see Figures 4 and 5.... 15 Table 3 – Ma
Marking
Safety labelling
The batteries shall bear the six coloured safety symbols in accordance with EN 50342-1.
Marking of the polarity of terminals
The batteries shall be marked with signs for both polarities that have to be positioned near to or on the top face of the terminals
This marking shall take the form of the symbol ‘+’ either on the upper surface of the positive terminal or on the lid adjacent to the positive terminal
This marking shall take the form of the symbol "–" either on the upper surface of the negative terminal or on the lid adjacent to the negative terminal
4.1.2.3 Design and dimensions of marking of terminals
The symbols used for marking the terminals shall be in accordance with the IEC 60417, symbol 5005 a for the positive and symbol 5006 a for the negative polarity
The polarity symbols may be either indented or embossed by (0,4 ± 0,1) mm.
Recycling
Recycling of lead
The batteries shall be marked with the recycling symbol and the EC-Symbol of a crossed through roll out container, both in accordance with EN 61429.
Recycling of plastic material
The marking of plastic moulded parts has to be fixed in the tooling of the battery container e.g on the bottom or on one short wall side near the ledge
For the polypropylene-polyethylene copolymer the marking > PP < or > PP/PE < in accordance with
EN ISO 1043-1 is the minimum requirement
– the number 7 or 07 for PP/PE and
– the addition of “other" in case of additives to PP
The marking shall be achieved by moulding in relief The recommended thickness is (0,3 ± 0,1) mm The height of the marking characters shall be between 5 mm and 7 mm.
Dimensions and design
All dimensions are in millimetres
Details of the design that are not indicated in the generic drawings have to be chosen appropriately
The illustrations in this standard, especially those of the design of the lid, handles, ribs, ledges, vent caps and their locations are not mandatory
This clause aims to revise the previous standard by introducing updated versions of the LS and LBS models, now referred to as LN and LBN These new models are intended to replace the earlier versions, and for any new battery developments, only the LN and LBN series should be utilized.
– the main dimensions of starter batteries of the two preferred series LN and LBN;
– the location of the positive and negative terminals with respect to the fastening system;
– the dimensions of tapered terminals of starter batteries;
– the main dimensions and design of the ‘Semi Lid’ (SL);
– the top clamping area (M) for fastening on the upper part
The preferred series LN replaces LS and series LBN replaces LBS of 6.1.
Recommended types LN and LBN
Starter batteries in accordance with this part of the standard are marked with LN and LBN (N = new) Both battery series have the same width (L = large) but different height:
Of the two series, the model LN (large, standard height, new) shall be considered as the most preferred series.
Main dimensions of batteries
The battery dimensions are illustrated by symbols in the provided drawings, which do not include specific design details of the battery's top.
The dimensions corresponding to the symbols below shall be in accordance with Figure 3, Figure 4, Figure 5, Table 2 and Table 3
Symbols used: a1 = Overall length at the battery base with ledges a2 = Length at the battery base without ledges a3 = Length at battery lid
The overall height, denoted as H, encompasses the lid, plugs, and terminals The height of the upper surface M, which supports the hold-down device, is represented by h Additionally, a4 indicates the distance of the inside notches, while a5 measures the distance between the terminal and the edges of the lid on the short side.
Figures 4 and 5) a6 = Distance of the robotic-grips-segments (see Figure 13 and Table 4)
Handles
General
Batteries with a weight less than or equal to 20 kg can be designed with or without handles Batteries with a weight of more than 20 kg must have handles.
Handles, if any
If the batteries have handles, the handles must be integrated in the lid (see Figure 3)
The handle design illustrated throughout this standard is intended for informational purposes only It is the responsibility of the battery manufacturer to propose a design that aligns with this standard regarding overall dimensions.
Standard fastening on the bottom
Design of ledges
The ledge profiles must align with Figure 6, and the length of the ledges on the rear side of the battery should be shortened by 20 mm at both ends, as illustrated in Figure 3, in comparison to the front side.
Notches
The hold-down clamps of the support shall match with the ledges and the notches to provide secure fastening in either direction
For symmetrical rotation and secure fastening, the opposite ledges must feature an equal number of notches Specifically, the long sides should have 5 notches, while the short sides should contain 3 notches to ensure the correct positioning of the battery on the support.
Arrangement and dimensions of ledges and notches
The shape and dimensions of ledges and notches shall be in accordance with Figure 3, Figure 4, Figure 5 and Figure 6 (details ‘X’, ‘Y’ and ‘Z’).
General concerning permissible alternative fastening
Starter batteries in accordance with this part of the standard may be fixed to the vehicles either:
– by a bottom hold-down device of the long side,
– by a bottom hold-down device of the short side or
– by means of a hold-down device engaging with the upper part of the battery (for example, a metal frame), connected to the top clamping area ‘M’ (see 5.4.4.2)
In either case, such batteries shall have on the long sides top clamping areas ‘M’
5.4.4.1 Fastening by ledges at the short side
For fastening on the short sides, it is recommended to use batteries from this standard series due to their reduced length tolerances The shape and dimensions of the ledges and notches must align with Figure 6.
Safety note: The hold-down clamps of support shall match with the ledges and notches to provide secure fastening in both direction and height
5.4.4.2 Fastening by upper part of the battery
Batteries for fastening by the upper part (top clamping area ‘M’) shall be designed so that the lid provides appropriate support for the hold-down device, for instance a metal frame.
Terminals
The position of positive and negative terminals ‘P’ (see Figure 4 or Figure 5) with respect to the shortened ledge shall be in accordance with Figure 3
5.4.5.2.1 Dimensions of the positive terminal
The tapered positive terminal shall be in accordance with Figure 7 a)
5.4.5.2.2 Dimensions of the negative terminal
The tapered negative terminal shall be in accordance with Figure 7 b).
Marking of polarity and dimensions of corresponding symbols
Batteries must be marked twice near the terminals as specified in the standard, either as shown in Figure 3 or Figure 12, and this marking should be applied on the lid as outlined in section 4.1.2.
The symbol of the polarity and the dimension of the symbols shall be in accordance with 4.1.2.
Special features of lid
Semi bloc lid
The semi block lid is designed with terminals and vent plugs that are flush with the lid surface, ensuring a streamlined appearance A key feature of this lid is the top clamping area 'M', as illustrated in Figures 3 to 5.
Spray water proof
That means a flat surface and water sealed maintenance openings, if any.
Central degassing
That means a central degassing system with gas outlets ‘E’ at right angles to the faces of one or both of the short sides (Figure 10).
Recessed holes
That means recessed holes ‘K’ for optional terminal protection covers on both sides (Figure 11).
Removable cell plugs
That means, if removable cell plugs ‘V’ are present, they are relevant to the safety of the degassing systems (Figure 12).
Information for tooling the lid
For further developments of lid tooling the design should take into account the possible future need for sensor-holes ‘S’ of 28 mm maximum diameter (Figure 12)
– Position of alternatives is demonstrated in Figure 12 in conjunction with the dimensions of Table 1 – Details will be given by the battery makers
Table 1 – Position of sensor holes ‘S’ (see Figure 12)
Welded lid
The welded lid shall project beyond the sides of all four of the container walls by 2,5 mm or more.
Handling of starter batteries by robot-equipment
Car manufacturers are increasingly utilizing robotic units to install starter batteries into vehicle bodies, necessitating precise positioning tools for the robot arms on the battery containers.
This section outlines the specifications for the position and dimensions of grips on battery containers in the LN and LBN series, designed for handling by robotic assembly equipment These ledges can be requested based on an agreement between the car manufacturer and the battery manufacturer.
If robot grips are requested, they shall conform to the dimensions and positions shown in Figures 13 a),
– Figure 13 a) shall correspond to series LN;
– Figures 13 a) and 13 b) are alternative, both corresponding to series LBN
– Figure 13 c) shall correspond to both series LN and LBN
The robot grips shall be integral parts of the battery container
It is emphasised that - according to the detail drawing ‘U’ (see Figure 13 c)) - the robot grips shall not exceed dimensions of the battery lid
In all cases, they should conform to the dimensions given in this standard.
Reinforcement of battery side walls
The stiffness of battery side walls can be inadequate in flooded batteries at elevated temperatures and in VRLA batteries overall This deficiency leads to wall bulging, which diminishes both the functionality and longevity of the batteries due to reduced compression of the plate pack.
For those applications reinforcement by means of thicker walls (see Figure 8) or additional ribs (see Figure 9) for avoiding bulging can be chosen by the battery manufacturer
The maximum bulging shall not exceed the maximum tolerance of 5 mm as shown in Figure 20 In addition the maximum bulging shall not exceed 2 mm at 30 mm height
All dimensions are referring to new batteries at start of electrical testing according EN 50342-1 and not to aged batteries
Figure 3 – Main dimensions of batteries and arrangement of standard fastening system, the top clamping area ‘M’, the terminals, recessed holes ‘K’ and the integrated handles (if any)
E = Degassing outlet (see Detail ‘E’ in Figure 10)
M = Top clamping area (see Detail ‘M’ in Figure 3, Figure 4 and Figure 5)
P = Positive and negative terminal (see Figure 7)
U = Robotic grips (see Detail ‘U’ in Figure 13 c))
X = Notches on ledges (see Detail ‘X’ in Figure 6 a))
Y = Ledges (see Detail ‘Y’ in Figure 6 b))
Z = Ledges (see Detail ‘Z’ in Figure 6 c))
NOTE The datum ‘A’ shows that container and lid has to be positioned by process of welding with the given tolerance in accordance with EN ISO 1101
Holes for fixation of adapters in the notches of the ledges along all sides are permissible
Users should make provision for the possible deformation of the end walls of the battery container by keeping the spaces between a 1 and a 2 clear of other items
Figure 4 – Main dimensions of batteries and arrangement of standard fastening system
E = Degassing outlet (see Detail ‘E’ in Figure 10)
M = Top clamping area (see Detail ‘M’ in Figure 3, Figure 4 and Figure 5)
P = Positive and negative terminal (see Figure 7)
U = Robotic grips (see Detail ‘U’ in Figure 13 c))
X = Notches on ledges (see Detail ‘X’ in Figure 6 a))
Y = Ledges (see Detail ‘Y’ in Figure 6 b))
Z = Ledges (see Detail ‘Z’ in Figure 6 c))
NOTE The datum ‘A’ shows that container and lid has to be positioned by process of welding with the given tolerance in accordance with EN ISO 1101
Holes for fixation of adapters in the notches of the ledges along all sides are permissible
Users should make provision for the possible deformation of the end walls of the battery container by keeping the spaces between a 1 and a 2 clear of other items
Figure 5 – Main dimensions of batteries and arrangement of standard fastening system
Table 2 – Main dimensions of batteries of standard series LN with standard fastenings with 5 notches at length side and 3 notches at width side (see Figures 4 and 5)
Table 3 – Main dimensions of batteries of standard series LBN with standard fastenings with 5 notches at length side and 3 notches at width side (see Figures 4 and 5)
Holes for fixation of adapters in the hold down notches along all sides are permissible
Dimensions on the short sides.
Figure 6 b) – Detail ‘Y’ – Profile of ledges
Dimensions on the long sides.
Figure 6 c) – Detail ‘Z’ – Profile of ledges Figure 6 – Details of ledges
Figure 7 a) – Positive terminal Figure 7 b) – Negative terminal
The dimensions of the terminals ‘P’ (see Figures 4 and 5) must be in accordance with the Figures 7 a) and 7 b)
Figure 7 – Dimensions of positive and negative terminal ‘P’
Figure 8 – Reinforcement by thicker walls on short sides
Figure 9 – Reinforcement by additional ribs on short sides
Minimum depth of insertion of 10 mm in the degassing outlet has to be provided for
Attachments with connecting piece have to be gastight
Figure 11 – Recessed holes for terminal protection cover (Detail ‘K’)
Figure 12 – Plugs ‘V’ and position of sensor holes ‘S’
NOTE In Figure 13 a) the number of grips is 4 on each long side
NOTE The long sides in Figure 13 b) may have 2 or 4 grips respectively (4 grips like Figure 13 a))
Detail ‘U’ - Grips on long sides Detail ‘W’ - Grips on short sides, design optional
Figure 13 c) – For the position of Details ‘U’ and ‘W’ see Figures 13 a) + 13 b)
Figure 13 – Dimensions and positions of grips
Table 4 – Dimensions of grips in accordance with Figures 13 a) and 13 b)
13 b) a Measurements applies to the version with 4 grips only (Figure 13 a))
NOTE The following battery types shall not be used for new developments
The object of this clause is to specify
– the main dimensions of starter batteries of eight standard series;
– the location of the positive and negative terminals with respect to the fastening system;
– the dimensions of tapered terminals;
– the marking of the polarity.
Battery series
Wide series
The first four series have the same width (L = large) but different height:
LB/LBS = low height (H = 175 mm)
Narrow series
The last four series have the same width (E = narrow) but different height:
EB/EBS = low height (H = 205 mm)
Handles, if any
Batteries adhering to this standard may include handles, but the projection 'C' of these handles must not exceed specified limits Additionally, the handles should be designed to be foldable or removable to avoid interfering with other dimensions.
Standard fastening
Fastening by ledges at the long sides
All batteries in the L, LB, E, and EB series feature ledges or recesses on the lower part for secure fastening along the entire length of the long sides These ledges are an integral part of the battery container, enabling the battery to be securely fixed using the bottom of the container.
Notches
The hold-down clamps of the support shall match with the ledges and the notches to provide secure fastening in either direction
To ensure proper battery placement on the support, the terminal side should feature one notch on the ledge, while the opposite side should have two notches Additionally, having three or five notches on both sides is acceptable.
Dimensions of batteries
Main dimensions of series L, LB, E and EB
The dimensions represented by the symbols are defined in Figure 14 and Table 5 The symbols include: \( b \) for overall width above ledges, \( b_1 \) for width across ledges, \( l \) for overall length without handles, \( l_1 \) for length at the battery base, \( l_2 \) for length at the battery base with ledges, and \( c \) for additional length for handles.
H = Overall height including lid, plugs and terminals
Dimensions and arrangement of ledges and notches
The shape and dimensions of ledges and notches shall be in accordance with Detail ‘X’ (see Figure 16 a)) and Detail ‘Y’ (see Figure 16 b))
The positions of ledges and notches are indicated in the Figures 14 and 15.
Supplementary dimensions of batteries with permissible alternative fastening
6.4.3.1 General concerning permissible alternative fastening
Starter batteries of this part of the standard having the main dimensions of the standard series L, LB, E and
EB may, as alternatives to the standard fastening, be fixed to the vehicles either
– by additional ledges at the short sides (letter S added to the designation of the standard series LS, LBS,
A hold-down device, such as a metal frame, secures the upper part of the battery and is connected to the support platforms L, LS, LB, LBS, E, ES, EB, and EBS.
In either case, such batteries shall have on the long side ledges in accordance with Figure 19
6.4.3.2 Fastening by ledges at the short side
Batteries from the LS, LBS, ES, and EBS series are designed with ledges on the bottom of their short sides, which are integral to the battery container The shape and dimensions of these ledges must conform to the specifications outlined in Figures 16 a) and 16 b).
The hold-down clamps of support shall match with the ledges and notches to provide secure fastening in both directions and height
6.4.3.3 Fastening by upper part of the battery
6.4.3.3.1 Arrangement of the upper part of container
Batteries designed for fastening by the upper part, including series L, LS, LB, LBS, E, ES, EB, and EBS, must feature a lid that adequately supports the hold-down device, such as a metal frame.
6.4.3.3.2 Supplementary dimension of batteries with fastening by upper part of the container
The height (h) of the upper surface that supports the hold-down device for series L, LS, LB, LBS, E, ES, EB, and EBS must align with the specified values in Table 5, as illustrated in Figures 14 and 15.
Terminals
Location of terminals
The arrangement of positive and negative terminals with respect to the position of the notches shall be in accordance with Figure 14 or Figure 15.
Dimensions of terminals (‘P’)
6.5.2.1 Dimensions of the positive terminal
The tapered positive terminal shall be in accordance with Figure 17 a)
6.5.2.2 Dimensions of the negative terminal
The tapered negative terminal shall be in accordance with Figure 17 b).
Marking of polarity of batteries and dimensions of corresponding symbols
Batteries shall carry the marking of polarity in accordance with 4.1.2, at least of the positive terminal
If the negative terminal is also marked, the symbol used shall also be in accordance with 4.1.2.
Handling of starter batteries by robot-equipment
General
Car manufacturers are increasingly utilizing robotic units to install starter batteries into vehicle bodies, necessitating precise positioning tools for the robot arms on the battery containers.
This section outlines the positioning and dimensions of grips on battery containers in the L, LS, LB, and LBS series for compatibility with robotic assembly equipment The inclusion of these ledges can be arranged through mutual agreement between the car manufacturer and the battery manufacturer.
Position and dimensions of robot grips
If robot grips are requested, they shall conform to the dimensions and positions shown in Figures 18 a),
Figure 18 a) shall correspond to series L and LS
Figures 18 b) and 18 c) are alternative, both corresponding to series LB and LBS
The robot grips shall be integral parts of the battery container
It is emphasised that, according to the detail drawing X, the robot grips shall not exceed dimensions of the lid
When requesting robot grips, it is recommended to position them on the two long sides; however, they can also be placed on the two short sides or all four sides In every scenario, the grips must adhere to the dimensions specified in this standard.
A = Notches on ledges (see detail ‘X’ in Figure 16 a))
B = Ledges (see detail ‘Y’ in Figure 16 b))
Figure 14 – Main dimensions of batteries and arrangement of the standard fastening system
(ledges, notches) and of the terminals
Table 5 – Main dimensions of batteries with standard fastening (see Figure 14)
Series Type Length Width Height Handles l l 1 b b 1 H h C max +0 / -4 +0 / -4 +0 / -4 max
A = Notches on ledges (see detail ‘X’ in Figure 16 a))
B = Ledges (see detail ‘Y’ in Figure 16 b))
Figure 15 – Supplementary dimensions of batteries with permissible alternative fastening, arrangement of ledges, notches and terminals
Table 6 – Supplementary dimension I 2 additional to Table 5 see Figure 15 of batteries with permissible additive fastening by ledges on the short side of the container
Holes for fixation of adapters in the hold down notches along all sides are permissible.
Figure 16 a) – Detail ‘X’ – Notch Figure 16 b) – Detail ‘Y’ – Ledges
Figure 16 – Details of ledges and notches
Figure 17 a) – Positive terminal Figure 17 b) – Negative terminal
Figure 17 – Dimensions of positive and negative terminal ‘P’
Figure 18 a) – Robotic grips for series L and LS
Figure 18 b) – Robotic grips for series LB and LBS
Figure 18 c) – Robotic grips for series LB and LBS (alternative) Figure 18 – Position and dimensions of robotic grips
Figure 19 – Robotic grips, Detail ‘X’ (in Figure 18)
Table 7 – Dimension of grips in accordance with Figure 18
Figure 20 – Maximum allowed bulging on short sides
EN ISO 1101, Geometrical Product Specifications (GPS) Geometrical tolerancing Tolerances of form, orientation, location and run-out (ISO 1101)