Battery Testing for Electric Bicycles and Other Light Electric Vehicles (LEVs)

Lithium-ion batteries in electric bicycles, scooters, cargo bikes, and L1e-B scooters constitute a crucial component that determines the safety and reliability of these vehicles. As the market for light electric vehicles grows, the importance of rigorous battery testing increases—both to meet formal requirements and to ensure failure-free operation in daily use. The BOSMAL Institute, equipped with modern laboratory facilities and an experienced team of experts, offers comprehensive testing for traction batteries used in e-bikes and other light EVs, assisting manufacturers and importers in meeting all safety requirements before a product is launched.

The most critical standards and regulations in the field of light electric vehicles include, among others: EN 50604-1 (safety of lithium-ion batteries for light vehicles), UN 38.3 requirements (transport tests for lithium batteries), and UN homologation regulations (e.g., UN Regulation No. 136 for L-category vehicles).

From May 2026, EN 50604-1 will become the de facto mandatory standard for batteries in electric bicycles (EPACs) in the European Union – as the sole battery safety criterion within the revised standard EN 15194:2017+A1:2023. It is already recognised as a key safety benchmark across the light e-mobility industry. Equally important is compliance with transport requirements – without successfully passing UN 38.3 tests, carriers will not accept shipments containing lithium batteries.

In response to these needs, BOSMAL offers a full range of battery testing services, from safety and transport tests to the homologation trials required for vehicles subject to registration.

EN 50604-1 is a European standard defining safety requirements for lithium-ion batteries used in Light Electric Vehicles (LEVs), including electric bicycles and electric scooters. BOSMAL carries out comprehensive battery compliance testing to EN 50604-1, which from May 2026 will be the sole battery safety criterion for EPAC electric bicycles (motor assistance up to 250 W, speed up to 25 km/h) sold in the EU. The scope of these tests covers the battery under the most demanding conditions, in order to minimise the risk of failure or accidents during use.

Our laboratory performs the full suite of EN 50604-1 tests, including:

• Electrical and Electronic Testing – Simulation of overload, overcharging, and external short circuits in a fully charged battery. We verify whether the Battery Management System (BMS) and battery safeguards react correctly, cutting off power in a fraction of a second to prevent overheating or cell ignition. Overload and short-circuit tests confirm that the battery operates safely even under extreme current and voltage deviations.
• Thermal Testing (Resistance to Extreme Temperatures) – We subject batteries to rapid cooling and heating cycles (e.g., from -40°C to +72°C) over multiple repetitions to simulate the impact of frost and heat on performance. This thermal shock test reveals potential casing leaks, material issues, and the chemical stability of cells under extreme temperature conditions. Using BOSMAL’s climatic chambers, we can verify if the battery maintains full functionality and safety across a wide operating temperature range (e.g., from -30°C to +65°C, as required by many manufacturer specifications).
• Mechanical Durability: Vibrations and Shocks – The battery is subjected to prolonged vibrations across all axes and sudden shocks/impacts, imitating years of use on uneven roads, sudden bumps, or drops during transport. BOSMAL utilizes vibration tables capable of shaking the battery for hours across a wide frequency range, as well as shock testing equipment. We verify, among other things, whether connections between cells remain intact, mounting bolts do not loosen, and the battery structure remains undamaged. Shock tests check resistance to sudden loads—simulating a dropped package or an impact during a collision—to ensure cells are not damaged and do not cause internal short circuits.
• Crush and Impact Testing – These are among the most severe safety trials. We simulate a situation where the battery is crushed or punctured (e.g., during a serious accident where the bicycle frame or scooter casing deforms and crushes the battery). The casing and internal cells must withstand such pressure without ignition or explosion. The drop test assesses whether the battery survives an impact against a hard surface from a specified height while maintaining tightness and mechanical integrity.
• BMS and Safety System Functionality Tests – EN 50604-1 requires every removable lithium battery in a light vehicle to be equipped with a BMS to oversee its safe operation. At BOSMAL, we verify the correct operation of the BMS: reactions to exceeding permissible parameters (cell temperature, charge/discharge current, voltage), cell balancing effectiveness, and emergency battery disconnection. These tests ensure that the management system meets required standards and enhances the overall safety of the pack.
• Aging and Cyclic Testing – To verify the long-term durability and reliability of the batteries, we conduct accelerated charge/discharge cycle tests and aging studies. We simulate years of battery use in a shorter timeframe, evaluating capacity fade, changes in internal resistance, and the overall condition of the cells after a specified number of cycles. This allows us to confirm that the battery will maintain its declared parameters throughout its intended lifespan and identify potential degradation mechanisms before the product hits the market.

Completing the full EN 50604-1 test programme confirms that a battery meets the highest safety standards applicable to light electric vehicles. For the manufacturer, this represents a quality assurance; for the end user, it provides confidence that the battery has been comprehensively evaluated for fire risk, failure, and performance loss. EN 50604-1 has been designed to be considerably more rigorous than general consumer electronics standards, particularly with regard to mechanical robustness. As a result, using a battery tested to this standard translates directly into greater safety of the electric vehicle in everyday use.

Every lithium-ion battery, before entering the market or being shipped to a customer, must pass a series of transport safety tests defined by UN 38.3 regulations. These requirements are applied globally to ensure that batteries do not pose a hazard during transport by air, sea, or land.

The BOSMAL laboratory performs the full range of UN 38.3 tests for cells, modules, and complete battery packs, in accordance with the current guidelines of the UN Manual of Tests and Criteria.

This includes eight specific tests simulating extreme transport and handling conditions:

• T1 – Altitude Simulation: The battery is placed in a low-pressure chamber where the pressure is reduced to 11.6 kPa (simulating an altitude of approximately 15,000 m). This checks the seal and stability of the cells in a highly rarefied atmosphere, such as in an aircraft cargo hold.
• T2 – Thermal Test (Thermal Cycling): The battery is subjected to rapid temperature changes from extreme cold to heat (e.g., cycles from -40°C to +72°C, 10 cycles). This rigorous test evaluates the integrity of seals and the battery’s chemical resistance to temperature fluctuations.
• T3 – Vibration: The battery undergoes several hours of vibration in all directions across various frequencies and accelerations, simulating long-term exposure during transport (e.g., in a truck or sea container) and operation.
• T4 – Shock: The battery is subjected to a series of violent mechanical shocks. We simulate the effects of sudden impacts that may occur if a package is dropped or during a transport collision.
• T5 – External Short Circuit: In controlled conditions, we cause a direct short circuit of the terminals on a fully charged battery. The BMS must immediately detect the surge and disconnect the battery to prevent thermal runaway.
• T6 – Impact / Crush: This primarily concerns cells and smaller batteries—— we check resistance to severe impact or crushing of the battery element. It is required that no cell explodes or ignites as a result of this trial.
• T7 – Overcharge: We examine the battery’s behavior when charged beyond its recommended limit (both voltage and current). The battery must demonstrate resistance to overcharging without resulting in fire or explosion.
• T8 – Forced Discharge: Applies to cells (both primary and secondary) — for complete multi‑cell Li‑ion packs this test is not normally required; however, BOSMAL can perform it at the customer’s request.

Passing the T1–T8 test sequence indicates that the battery design is safe for transport and normal handling. For manufacturers and distributors, this is a mandatory condition for shipping batteries—without it, courier companies and airlines may refuse to carry the product. .  

The development of light electric mobility requires not only innovative design, but also full compliance with type-approval requirements. In the case of electric L-category vehicles — such as e-mopeds, e-scooters or selected speed pedelecs — placing a product on the market requires completion of the EU type-approval process in accordance with Regulation (EU) No 168/2013 and the relevant UN Regulations. In the area of traction battery safety, UN Regulation No. 136 is of key importance, as it defines the requirements for the electric powertrain and REESS in L-category vehicles.

BOSMAL supports manufacturers and suppliers in the preparation and execution of type-approval test programmes for traction batteries intended for L-category vehicles. Our competencies cover both electric vehicle battery testing and a wide range of electrical, environmental, mechanical and IP tests relevant to safety, durability and regulatory compliance. BOSMAL’s scope of authorisation also includes the type approval of electric L-category vehicles.

Our services in this area may include, in particular:

• Vibration testing – verification of the REESS resistance to prolonged dynamic loads corresponding to vehicle operating conditions. UN Regulation No. 136 provides a dedicated vibration test procedure for REESS.
• Thermal shock and temperature cycling tests – assessment of battery behaviour under rapid temperature changes and repeated thermal load cycles. In this respect, R136 provides for a separate “thermal shock and cycling test” procedure.
• Mechanical testing of the REESS – depending on the system design, this may include, among others, a drop test for a removable REESS and a mechanical shock test. The purpose is to confirm the battery’s resistance to mechanical loads relevant to its intended application.
• Fire resistance testing – where applicable to a given configuration, the test programme may also include the fire resistance test provided for in R136.

• Electrical protection and functional safety testing – in particular with regard to protection against external short circuit, overcharge, over-discharge and overheating. UN Regulation No. 136 provides separate procedures and acceptance criteria for these aspects.

• Vehicle-level electrical safety testing – as a complement to REESS testing itself, and depending on the type-approval route, vehicle-level tests relating to the high-voltage system may also be required, including the withstand voltage test and protection against ingress of water.

• Assessment of requirements related to thermal propagation – more recent amendments to Regulation No. 136 also introduce requirements relating to thermal propagation. Where applicable to a given project, these should be taken into account in the testing strategy and type-approval documentation.

The scope of testing should always be tailored to the specific vehicle category, battery architecture, REESS installation method and the applicable series of regulatory amendments. In practice, the type-approval programme may be carried out at the level of the complete REESS, relevant subsystems or — where provided for by the regulations — supplemented by vehicle-level testing. The resulting test evidence and reports form part of the type-approval documentation. Thanks to a properly defined and executed test programme, the manufacturer can demonstrate that the traction battery complies with the safety requirements applicable to L-category vehicles and proceed efficiently through the type-approval process.