Component Level) for EV Scooter

Columns: Test Name | Test Purpose | Test Standard (reference) | Test Conditions |
Acceptance Criteria

Test Name Test Test Test Acceptance

Purpose Stand Conditi Criteria
ard ons
(refer
ence)

1. Power-On Verify BMS Internal Apply POST passes

Self Test boots spec / nominal without
(POST) / correctly, ISO battery errors; all
Function runs 26262 voltage monitored
al self-chec (softw (e.g., 36 parameter
Startup ks and are V s valid;
enters aspect nominal fault
normal s) )→ LED/logs
operatio cycle only if real
n power fault
50 present;
times; recovery
observe time ≤
startup specified
under (e.g., 2 s)
cold
(−20°C),
room
(25°C),
hot
(+85°C)
2. Ensure BMS IEC Gradually Charger
Over-vol clamps/i 62133 increase disabled or
tage solates (batter charge balancing
Protectio charging y voltage engaged
n when safety) to +10% before cell
(Charge) cell/pack , above over-voltag
voltage Intern max e; no cell >
exceeds al pack max_volta
limit protect voltage; ge +
ion repeat tolerance;
spec at no
−20°C, damage;
25°C, automatic
+60°C resume
only after
condition
cleared

3. Prevent Internal Discharge Load

Under-v over-dis spec pack disconnect
oltage charge under ed at or
Protectio of cells; controlle above
n gracefull d load specified
(Dischar y to the cutoff
ge) disconne under-v (±2%);
ct load oltage SOC
threshol reporting
d at accurate;
0°C, no
25°C, permanent
+45°C cell
damage

4. Protect pack ISO Apply BMS trips

Over-cur and 26262 over-cur within
rent / wiring (syste rent specified
Short-cir from m step time vs
cuit excessiv safety) (e.g., current
Protectio e current , IEC 2–10× curve; no
n and 60721 rated fire/smoke;
(Dischar short (enviro current) component
ge) circuits nment and s intact;
al for bolted safe
 testing short for recovery
) specifie path
d defined
duration
s

5. Charge Protect IEC Simulate Charger

Over-cur against 61851 charger disconnect
rent / charger- (EV short-cir or disable
Charger side chargi cuit and within
Short faults ng), surge spec; no
IEC currents damage to
62196 per BMS or
(conne spec HV paths
ctors),
interna
l
charge
r spec

6. Thermal Prevent IEC Ramp Thermal cutoff

Protectio operatio 60068 ambient triggers at
n n -2-2/1 from defined
(Over-te beyond (temp −40°C thresholds;
mp) safe eratur to graceful
temperat e +125°C shutdown
ure tests) while if
limits; monitori exceeded;
trigger ng PCB no
cooling/f and cell permanent
ail-safe temps; damage
forced-h after
eating returning
of PCB to normal
compon temp
ents

7. Verify IEC 40°C, 93% No corrosion

Tempera operatio 60068 RH for affecting
ture n/aging -2-78 240 function;
Humidity under (damp hours no short
high heat (or OEM circuits;
humidity require functional
 (Damp and steady ment) performan
Heat) temperat state) with ce within
ure power spec; no
applied memory
and corruption
cycling

8. Thermal Assess IEC Cycle No solder

Cycling / mechani 60068 −40°C cracks;
Thermal cal and -2-14 ↔ connectors
Shock solder/joi (therm +85°C and
nt al (number mechanica
reliability shock) of l fixings
under , IEC cycles intact;
temperat 60068 per function
ure -2-1/2 spec, unchanged
swings e.g.,
10–30
cycles)

9. Vibration Verify ISO Random No component

(Rando mechani 16750 vibration looseness
m / Sine) cal -3 profile or
robustne (vibrati represe electrical
ss on on) / ntative failure; no
scooter IEC of intermittent
chassis 60068 scooter function;
-2-64 ride for communic
e.g., 3 ation
hrs axis errors ≤
each allowed
(X/Y/Z), rate
plus
sweep
sine test

10. Ensure BMS ISO Mechanical No mechanical

Mechani survives 16750 shocks failure;
cal impacts -3 / (e.g., 50 connectors
Shock and road IEC g, intact;
(Drop / shocks 60068 half-sine functionalit
Bump) -2-27 11 ms)
and
 drop y
tests maintained
per
packagi
ng spec

11. Ingress Ensure BMS IEC IP67/IP68 No ingress

Protectio enclosur 60529 tests: affecting
n (IP) / e resists (IP dust electrical
Water dust/wat rating) chambe function;
Immersi er r; device
on ingress immersi operates
on 1 m normally
for 30 after test
min or
per
product
spec

12. ESD Immunity to IEC Contact ±4 No loss of

Immunit electrost 61000 kV, Air function;
y atic -4-2 ±8 kV no
discharg (or as permanent
e required damage;
) at any
multiple transient
points faults must
clear and
be logged

13. Immunity to IEC 10 V/m (or No

Radiated radio-fre 61000 OEM degradatio
Immunit quency -4-3 level) 80 n of critical
y (RF) electrom MHz–1 functions
agnetic GHz, 3 (charging/
fields V/m discharge
above 1 control,
GHz; communic
modulati ation); no
on per uncontrolle
standar d
d shutdowns
14. Immunity to IEC Inject No
Conduct conduct 61000 conduct malfunctio
ed ed RF -4-6, ed n;
Immunit and ISO disturba communic
y& power-b 7637- nces ations
Power orne 2 onto intact; safe
Disturba disturba power operation
nce nces and maintained
signal
lines per
levels

15. Surge / Handle ISO Simulate No destructive

Transien automoti 7637- surge / failure;
t ve 2, IEC load-du surge
Immunit transient 61000 mp suppresse
y (Load s and -4-5 impulse d; system
Dump) load levels remains
dumps (e.g., safe; logs
from ±100 V fault if
alternato for necessary
r/charger specifie
d
duration
)

16. Isolation Verify HV IEC Insulation Resistance >

/ isolation 60950 resistan specified
Insulatio between / IEC ce MΩ (e.g.,
n pack 62133 measur >100 MΩ);
Resistan and (as ement no
ce chassis / releva at 500 V breakdown
user nt) DC (or
accessib per
le parts spec)
and
megger
test
17. Confirm IEC Apply AC No flashover,
Dielectri dielectric 60601 hipot no
c strength / between breakdown
Withstan of produc HV +/− , leakage
d (Hipot) insulatio t-speci and current
n fic HV chassis within
safety at limits
tests specifie
d
voltage
(e.g.,
1000 V
AC for 1
min)

18. CAN / Verify ISO 11898 Inject CAN BMS handles

Commu messag (CAN) errors, errors per
nication e / ISO messag spec; no
Function integrity, 14229 e loss, uncontrolle
al Test timing, (UDS high d outputs;
and diagno traffic, diagnostic
handling stics) and s logged;
of faults malform communic
ed ation
frames; recovers
test at within
operatin defined
g time
tempera
tures

19. CAN Verify ISO Simulate Correct

Bus wake/sle 11898, bus wake/slee
Robustn ep interna wake-up p
ess behavior l , transitions;
(Wake, of BMS power CAN-bu no
Sleep, on bus manag s stuck excessive
Arbitratio events ement domina current in
n) spec nt, high sleep; no
bus load bus-lock
condition
20. Software Ensure safe ISO Induce CPU Safe state
Fault behavior 26262 exceptio achieved
Injection on SW (softw n, (disable
/ exceptio are memory outputs,
Watchdo ns and safety) corrupti isolate
g MCU on, charger);
resets stack persistent
overflow logs or
, and counters
watchdo increment;
g reset restart
behavior
verified

21. Power Verify Internal Rapid No corruption

Cycling graceful spec / power of
& behavior IEC cycles non-volatil
Brown-o under 60068 (e.g., e data;
ut repeated -2-27 1000 reliable
power cycles) restart; no
on/off and permanent
and brown-o failure
brown-o ut
ut conditio
ns (drop
to
0.5×Vin)

22. Verify Internal Measure Quiescent

Sleep/Q low-pow vehicl current current ≤
uiescent er draw e spec in specified
Current when sleep/st (e.g., <100
inactive andby µA or per
to meet for scooter
vehicle 24–720 spec); no
standby hours at drain
requirem ambient anomalies
ents temp
and
after
temp
 extreme
s

23. Validate IEC Cycle pack BMS

Charge/ BMS 62660 through maintains
Discharg and cell (cells) defined balancing,
e manage / DoD accurate
Cycling ment interna (e.g., SOC/SOH
(Acceler over life l cycle 0–100% tracking
ated test or within
Aging) 10–90% tolerance;
) for N no safety
cycles incidents;
(e.g., capacity
500–20 fade within
00 expected
cycles) bounds
at
controlle
d temp

24. SOC Verify SOC Internal Run known SOC error

Accurac estimatio spec / charge/ within ±5%
y and n SAE discharg (or per
Calibrati accuracy J2344 e product
on against (SOC profiles spec) over
coulomb metho and 10 cycles
counting ds) compar across
/ground e SOC temperatur
truth estimate es
vs
measur
ed

25. Cell Verify Internal Force cell Cells

Balancin active/pa spec imbalan equalized
g ssive ce (e.g., within
Operatio balancin ±100 specified
n g mV) and delta (e.g.,
operates observe ≤10 mV)
correctly balancin within
g defined
behavio time; no
 r during overheatin
charge/ g
discharg
e

26. Reverse Protect IEC Connect No

Polarity system 62133 pack catastrophi
Protectio from / with c damage;
n reversed interna reverse protective
battery l spec d device
connecti polarity operates;
on for no
specifie propagatio
d time n to other
(with systems
fuse
removal
if
required
)

27. Inrush Ensure IEC Measure Inrush ≤

Current / inrush 60068 inrush allowed
Connect does not series during limits; no
or cause / connecti connector
Mating damage conne on and wear
and ctor power-o causing
connect OEM n; failures; no
ors specs mate/un fusing
survive mate unless
cycles cycles specified
(e.g.,
1000
cycles)

28. Validate Internal Force System

Watchdo recovery spec brown-o restarts
g& after ut, into
Recover complet remove defined
y (Cold e power main safe state;
Reset) loss/har power, NVM data
d reset and intact or
reapply; handled
 monitor gracefully;
NVM diagnostic
integrity s available

29. Thermal Verify BMS IEC Simulate BMS isolates

Runawa detectio 62619 failing affected
y n of cell (secon cell string,
Detectio thermal dary (temper disables
n& runaway cells), ature charging,
Contain precurso UN rise, raises
ment rs and 38.3 voltage alarms;
Test safe (trans collapse physical
isolation port) ) and containme
guidan observe nt
ce BMS assessed
reaction (test in
controlled
lab)

30. Verify Local Review All labels

Regulato marking regulat compon present;
ry / s, ions / ents manuals
Safety warnings UN and include
Labeling , and R100 / manuals warnings
& docume nation against and
Docume ntation al checklis service
ntation complet vehicl t instruction
Check eness e regs s per law

Notes & Recommendations

●​ Standards references above are typical. Use specific OEM/regulatory standards
applicable to your market (e.g., Indian AIS, UNECE R100, or local homologation
rules) where required.
●​ For each test include: test equipment list, measurement points, instrument calibration
due dates, pass/fail log template, and safety precautions (especially for high-voltage
& thermal runaway tests).
●​ For software-related tests, keep firmware versions, configuration files, and
reproducible test scripts in version control.
●​ Where destructive or hazardous tests (hipot, thermal runaway) are required, perform
them in certified labs with appro
●​