Knowledge Transfer

The essential components of a rechargeable cell are its two electrodes and an electrolyte.
The electrodes are called the cathode and anode and are separated both spatially and electrically by a separator.
It is very important that the separator is permeable to ions so that the electrochemical reaction within the cell can proceed without hindrance.

Batteries can be powered by different systems:

Ni-MH = nickel metal hydride
Li-Ion = lithium ion
LiFePo4 = lithium iron phosphate battery
Li-Po = lithium polymer

A pre-assembled battery pack consists of several arrangements of individual cells.
The exact arrangement of the cells depends on the desired voltage and capacity.

The higher the number of cells, the higher the energy density of the interconnected cell system (especially in a Li-ion system).
The cell system must be connected to a battery management system (= protective electronics), as this is the crucial interface between the battery and external communication. It also enables the software to be adapted to the relevant safety measures and ensures safe operation of the battery system.

Charging means that voltage equalisation takes place between two systems.

When a battery system is discharged, its nominal voltage also drops.

This can be balanced again with the help of a charger by charging the nominal voltage of the system back up to the maximum nominal voltage that the battery can achieve.
The voltage is balanced by what is known as charge transport (= current flow) when the voltage potential of the charger is higher than that of the respective consumer.
In this case, a battery is the consumer that can store the charge.
The current determines the capacity depending on the time.
As a result, battery packs with a higher capacity have longer or shorter charging times depending on the current.
In order to achieve a longer service life, we charge the batteries throughout the charging cycles with the gentlest possible charging current (0.2% of the charging capacity).

We offer intelligent fast charging systems for battery systems and individual cells, which are developed in-house by us.

There are a few things to keep in mind when handling Li-ion cells correctly. That’s why we’ve put together a few tips to help you avoid accidents caused by damaged batteries:

• Short circuit: One of the first and most important rules for lithium-ion systems is that short circuits must be avoided at all costs, as the high energy density could cause irreparable damage to the battery system, resulting in high temperatures and ultimately a fire hazard.
• Deep discharge: Both deep discharge and overcharging can damage the chemical system of a battery cell. Deep discharge of a single cell voltage below 2.5V can, for example, cause a polarity reversal and also damage the separator. This would cause a short circuit of the electrodes, which in turn would cause the temperature to rise and ultimately trigger a fire.
• Overcharging: If a system is overcharged, the heat generated can trigger a thermal reaction inside the battery. This reaction is also known as ‘thermal runaway’ and causes the cell to ‘go haywire’. It then exhibits an intensified chemical reaction and toxic gases are produced. If the system continues to be overcharged, self-reinforcing heat build-up occurs inside the battery, which can cause the core of the battery to melt. The result is a fire or even an explosion of the cells. That is why modern cells have an overpressure valve in their design to prevent an explosion. When this valve is triggered, toxic gases and the liquid electrolyte can escape from the cell, but extreme caution is required here!

Our battery systems are protected by our proprietary battery management systems (BMS), which are individually tailored to the respective application.

Li-ion = lithium ion
NiCd = nickel cadmium
LiPo = lithium polymer
LiFePO4 = lithium iron phosphat
LiMn = lithium manganese
NiMH = nickel metal hydride oxide
LTO bzw. Li4Ti5O12 = lithium titanate oxide
Li-SOCI2 = lithium thionyl chloride

SoC = State of Charge
Ah = Ampere­-hours
mAh = Milli­am­pe­re­-hours
Wh = Watt­-hours
V = Voltage
A = Ampere
PCM = Protec­tion Circuit Module (protective electronics)

The designations refer to the arrangement of the cells
S = Serial
P = Parallel

The number refers to the quantity.

6S1P = 6 cells in series and 1 cell in parallel.
7S10P = 7 cells in series and 10 cells in parallel.

A rechargeable battery can be recharged.
A battery cannot be recharged.

Primary cells are non-rechargeable (batteries).
Secondary cells are rechargeable (rechargeable batteries).

Cylindrical cells are particularly robust and are therefore widely used. They consist of a cylindrically wound cell with a hard casing (hard case).

Since 2017, NiCd batteries may only be used in emergency systems, emergency lighting and medical devices. Only stocks already in the EU may be sold. NiCd batteries can be replaced by identical NiMh (nickel-metal hydride) batteries with the same specifications. Old chargers can still be used for NiMh batteries.

The warranty period for batteries and rechargeable batteries is 6 months.

Yes, but laboratory measuring equipment is required for this.

When the battery can no longer supply sufficient energy for its intended use (e.g. e-bike, golf trolley) to ensure proper operation.
However, the environmental aspect should always be taken into consideration here. Disposing of batteries is relatively costly for the sake of the environment.
Before disposing of a battery, everyone should therefore consider whether it is really necessary.

However, there are other reasons that should lead to immediate but proper disposal.
For example, it can be dangerous if the battery has been mechanically damaged, e.g. if it has been dropped.
Even if the battery becomes noticeably warm during operation, it is advisable to have it checked. You can have this done by a specialist battery company.
Lithium-polymer batteries can also swell up. Cells in this condition are often subject to very high pressure, which can be very dangerous.
These batteries should also be disposed of properly as soon as possible.

It is best to dispose of your batteries at your specialist dealer or at the appropriate hazardous waste collection points.
If you want to dispose of individual cells, there are now many shops that offer battery collection boxes for disposal.

Once a large number of batteries have been collected in the collection boxes, it is safer to tape over the terminals before disposal to avoid the risk of a short circuit.

More detailed information on proper disposal can be found in the following document:

AUVA information sheet on handling lithium-ion batteries.

A charging cycle describes the charging of a battery from the lowest charge level to 100%.

The voltage of an electrical device or voltage circuit during normal operation. This value is usually specified by the manufacturer. For example, a lithium-ion cell has a nominal voltage of approximately 3.6 volts. The nominal voltage of a battery can be found in the technical data sheet.

The voltage required to operate an electrical circuit and thus a device.

In general, everyone should ensure that their battery is not used improperly or exposed to unfavourable or even dangerous conditions.
The enclosed information sheet describes in detail how to use the battery correctly, or you can find the necessary information on the homepage.
However, should an unfavourable situation arise for the battery, the protective electronics ensure that the battery interrupts operation, thus avoiding a potentially dangerous situation. These include circumstances such as:

• Protection against overcharging
• Protection against discharge into the deep discharge range
• Protection against excessive currents (e.g. in the event of a short circuit)
• Protection against excessive temperatures Dispose of.

Deep discharge of an accumulator refers to the state after power has been drawn until the capacity is almost completely exhausted or until the voltage falls below a certain level.

The extent of self-discharge can depend on many factors. The rate of self-discharge depends, among other things, on the storage time. As a rule, it decreases asymptotically with increasing storage time. Self-discharge is highly temperature-dependent; its rate increases with higher temperatures. As a rule of thumb, a temperature increase of 10°C doubles the rate of self-discharge. Approximately, self-discharge at 5°C is assumed to be about 1 to 2% per month, and at over 20°C about 3 to 7% per month. However, these are only estimates based on practical experience, as cell manufacturers do not disclose this type of information.

In the case of batteries with protective electronics, the energy consumption of the protective electronics is added to the self-discharge of the cells. For this reason, a battery should generally be recharged to 50 to 80% every 4-6 months, depending on the cell type and battery pack configuration.

Yes, because even when the device is switched off, a small amount of current may still flow, which can lead to deep discharge after a long period of time.

The abbreviation PEMS stands for Portable Emission Measurement System.
It is a mobile device for measuring exhaust emissions from a motor vehicle during actual road use.

The memory effect: If NiCd batteries are not fully discharged before recharging, this point becomes their full operating capacity. The battery ‘remembers’ how far it has been discharged and can no longer be used afterwards. The same memory effect occurs to a lesser extent with NiMH batteries. This is caused by a change in the crystals on the electrodes in the battery.

ACCUPOWER IQ chargers use two different charging methods. Which one is selected depends on which battery is inserted into the charger.
While the -dV/dt charging method is used for NiCd and NiMH batteries, the charger uses the CCCV charging method for Li-ion batteries.

The ACCUPOWER IQ chargers IQ338, IQ338XL and IQ328+ display ‘zero’ on the display when no battery cell is inserted in the charger.

Yes, they can. However, this is more likely to result in ignition than an explosion, and for that to happen, something would have to go seriously wrong during handling.
In general, it is important to ensure that a suitable charger specifically designed for Li-ion batteries is always used. This charger should also meet certain quality standards, so please do not purchase batteries and chargers from unknown sources. When purchasing your battery, ask whether it is equipped with protective electronics (usually also called PCM) with integrated balancing. These electronics monitor the battery and protect it from all unauthorised events. If one of these events occurs, the battery switches off and goes into self-protection mode, which you can reset yourself in most cases. By following these points, you can be sure that you are using Li-ion technology safely and can enjoy the enormous power of these batteries without any risk.

Spare batteries may only be stored in hand luggage and must be individually wrapped and protected to prevent short circuits.
Only rechargeable batteries for personal use may be carried.
There are no standard rules for this, so the regulations of the respective airline always apply!

No, only with a suitable lithium-ion charger.
In general, it is important to ensure that a charger specifically designed for Li-ion batteries is always used. This charger should also meet certain quality standards, so please do not purchase batteries and chargers from unknown sources. When purchasing your battery, ask whether it is equipped with protective electronics (usually also called PCM) with integrated balancing. These electronics monitor the battery and protect it from all unauthorised events. If one of these events occurs, the battery switches off and goes into self-protection mode, which you can reset yourself in most cases. By following these points, you can be sure that you are using Li-ion technology safely and can enjoy the enormous power of these batteries without any risk.

In principle, yes, if you have received the appropriate training or instruction for dangerous goods.
This is the only way to ensure that you are familiar with the regulations.

In principle, yes. Only after inspecting the battery can it be determined whether individual cells can be replaced.

No, because batteries must not be left unattended while charging.

In the SDB / MSDS (Material Safety Data Sheet / Safety Data Sheet) under point 14.

The Material Safety Data Sheet or Safety Data Sheet is required for the transport of dangerous goods.
The certificate is part of the UN38.3 test.

Safety data sheets, also known as material safety data sheets, are used to convey safety-related information about substances and mixtures.

Items or substances that may pose a risk to health, safety, property or the environment. e.g.: UN3480 Lithium-ion batteries.

Lithium batteries (battery = battery pack):
” Battery” means two or more cells that are electrically connected and equipped with devices necessary for use, e.g.: battery housing, battery terminals, marking and protective devices.

Lithium cells:
A single lithium battery is considered a ‘cell’ and must be tested in accordance with the test requirements for a ‘cell’ for the purposes of these regulations and the requirements of subsection 38.3 of the UN Manual of Tests and Criteria.

UN3480 is the UN number for lithium-ion batteries.

Yes, but only in sea freight (IMDG).
In air freight, there is an exception A199 (special provision).
By road/rail, it is not subject to dangerous goods regulations, so it is not classified as dangerous goods by road or rail.

ISO 9001 is an international quality management standard. It describes the requirements that the management system of an organisation – be it a company or a public authority – must meet in order to comply with a certain standard in the implementation of quality management.

The international environmental management standard ISO 14001 sets out globally recognised requirements for an environmental management system and is part of a family of standards.

The UN number is a four-digit number used to identify substances or objects in accordance with UN recommendations for the transport of dangerous goods. Every dangerous good is assigned a UN number in the dangerous goods lists of the regulations for all modes of transport.

UN3480 is the UN number for lithium-ion batteries.

UN3481 is the UN number for packaged lithium ion batteries or lithium ion batteries in equipment.

UN3090 is the UN number for lithium metal batteries.

UN3091 is the UN number for packaged lithium metal batteries or lithium metal batteries in equipment.

UN3496 is the UN number for nickel metal hydride batteries.

The UN38.3 test is a transport and safety test for lithium batteries and cells.
In principle, all lithium cells and battery packs must be tested in accordance with UN Manual 38.3 UN. As part of this UN test, you also receive the MSDS / SDB (Material Safety Data Sheet / Safety Data Sheet), which all transport companies check in advance to determine whether they will accept these goods for transport.

Manufacturers and subsequent distributors of cells or batteries manufactured after 30 June 2003 must provide the test summary specified in UN Manual of Tests and Criteria Part III, subsection 38.3, paragraph 38.3.5.

IEC 62133 is one of the most important safety standards for rechargeable lithium-ion batteries used in consumer goods, IT devices, tools, laboratory, household and medical equipment.

International Electrotechnical Commission; private international standardisation body for standards in the field of electrical engineering and electronics; based in Geneva.

ADR stands for ‘Accord européen relatif au transport international des marchandises dangereuses par route’. In English, this means ‘European Agreement concerning the International Carriage of Dangerous Goods by Road’.

The IMDG Code (International Maritime Dangerous Goods Code) is the transport regulation for dangerous goods in maritime transport.

The International Civil Aviation Organisation International Civil Aviation Organisation is a specialised agency of the United Nations with headquarters in Montreal, Canada.

The International Air Transport Association was founded as the umbrella organisation for airlines in Cuba.

The European Agreement concerning the International Carriage of Dangerous Goods by Inland Waterways (abbreviation ADN, from Accord européen relatif au transport international des marchandises dangereuses par voie de navigation intérieure).

Dangerous goods declaration is the shipper’s declaration for the shipment of dangerous goods by air.

Dangerous Goods Regulations (DGR) (IATA dangerous goods regulations) is a set of rules for the transport of dangerous goods by air under IATA.

International Maritime Organisation, i.e. International Maritime Organisation based in London.

An IMO declaration is the transport document for the transport of dangerous goods by sea (English: IMO Declaration).

IP = International Protection
Describes a type of protection that indicates the suitability of electrical equipment for various environmental conditions, as well as the protection of people against potential hazards during use. Protection classes range from IP00 to IP69K.

The letters IP, which are always present in the protection class designation, are followed by two digits (generally without a space). These indicate the extent of protection a housing offers with regard to contact or foreign bodies (first digit) and moisture or water (second digit).

These are international trade rules. International Commercial Terms.

Regulation (EC) No. 1907/2006 is an EU chemicals regulation that came into force on 1 June 2007. REACH stands for Registration, Evaluation, Authorisation and Restriction of Chemicals.

EU Directive 2011/65/EU serves to restrict the use of certain hazardous substances in electrical and electronic equipment. It regulates the use and marketing of hazardous substances in electrical equipment and electronic components.

Dual use describes the fundamental usability of goods for both civilian and military purposes. This includes, in particular, goods from the fields of sensitive electronics, telecommunications, IT technology, but also data processing programmes and other technologies.

The supplier’s declaration is a document that is normally only applicable in the European Union. It serves as proof when applying for or issuing a proof of origin. It can also be used to apply for a certificate of origin (e.g. EUR. 1).

A supplier’s declaration is proof of the preferential origin of imported goods. It is required by the exporter as proof for the issuance and application of a preferential certificate.

Companies need a customs tariff number, also known as a commodity code, to process their foreign trade transactions. The customs tariff number is the numerical code for a product. Determining the customs tariff number is called tariff classification or classification of the product in the customs tariff of the European Union.

This is the weight of a battery without packaging, for example.

This is the weight of, for example, a battery with packaging.