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UL 9540 Thermal Runaway Testing

Applied Technical Services (ATS)
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UL 9540 Thermal Runaway Testing
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Applied Technical Services (ATS)
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UL 9540 Thermal Runaway Testing

UL 9540 Thermal Runaway Testing

UL 9540 Thermal Runaway in ESS Testing and Certification

The Applied Technical Services Family of Companies offers UL 9540 thermal runaway in ESS testing and certification to help manufacturers verify the safety and industry compliance of their energy storage systems.

Thermal Runaway Testing in Energy Storage Systems
Energy storage systems (ESS) are crucial components in the integration of renewable energy sources and the stabilization of electrical grids. The recent increase in ESS demand makes their safety and reliability integral to their continued widespread implementation. One of the most critical safety concerns for ESS is thermal runaway, a phenomenon that can lead to catastrophic battery failure, fires, and explosions. UL 9540 is an ESS thermal runaway standard established by the Underwriters Laboratories that requires extensive, exhaustive testing.
What Causes Thermal Runaway?
Thermal runaway occurs in lithium-ion batteries when a localized exothermic reaction causes the battery to heat up uncontrollably, resulting in an increase in temperature that further accelerates the reaction. This cascade effect can lead to the release of flammable gases, the breach of battery cells, and eventually fires or explosions. Thermal runaway can be triggered by a variety of factors, including overcharging, over-discharging, mechanical abuse, or manufacturing defects. Mitigating thermal runaway risks is of utmost importance to ensure the safe operation of energy storage systems.
UL 9540 Testing Criteria
UL 9540 is specifically designed to address the risks associated with thermal runaway in ESS. The standard outlines a comprehensive testing and evaluation process to assess the safety of these systems under various conditions and to identify potential vulnerabilities. This process includes:

Thermal Management Testing: Thermal management involves the use of cooling mechanisms to dissipate excess heat from the battery. The UL 9540 standard requires manufacturers to subject the ESS to extreme temperature conditions to assess how effectively the thermal management system handles potential thermal runaway scenarios. By conducting these tests, manufacturers can identify weaknesses in the thermal management system and make necessary improvements to enhance safety.

Electrical Testing: Electrical testing is an essential part of UL 9540 certification. This involves evaluating the electrical performance of the ESS, such as charging and discharging characteristics. Proper electrical system testing ensures that the system operates within safe parameters and reduces the risk of triggering thermal runaway due to electrical factors.

Mechanical Testing: Our highly trained technicians perform mechanical testing to evaluate the structural integrity of the ESS and verify its resistance to physically induced failure. Impacts and vibrations are both commonly experienced in an ESS’ standard operating environment and can cause damage to battery cells that increase the risk of thermal runaway. Comprehensive mechanical testing allows manufacturers to identify potential weak points and improve the overall resilience of their electrical storage system.

UL 9540 Certification
The certification process under UL 9540 requires that ESS thermal runaway testing be conducted by accredited testing laboratories specializing in energy storage system testing, such as Applied Technical Services. We thoroughly evaluate electrical storage systems against the specified requirements, certifying systems that pass all necessary tests and meet safety criteria. In the event that an ESS does not pass, we provide thorough, detailed reporting to give clients an in-depth understanding of the changes and improvements that need to be made.
Applied Technical Services
Applied Technical Services features an expansive service network comprised of laboratories and testing facilities located throughout the continental United States. All ATS Family of Companies (FOC) facilities are staffed by experts with years of experience who are committed to providing exceptional service quality. Get in touch with our team today at 1 (888) 287-5227 or submit a request form on this page for additional information or a free quote on UL 9540 thermal runaway in ESS testing and certification services.

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