IEC 62368-1 is the global safety standard for Audio/Video (AV) and Information & Communication Technology (ICT) equipment. It fully replaced IEC 60950-1 (for IT equipment) and IEC 62301 (for AV equipment) in 2020. All lithium battery-powered products such as laptops, wireless routers, smart home devices and portable storage devices must comply with this standard. This article elaborates on its core hazard classification framework, lithium battery safety requirements and global market application rules.

1. Standard Migration Background

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2. Three-Tier Energy Hazard Framework of IEC 62368-1

IEC 62368-1 adopts a pain-based three-level classification system (PS1/PS2/PS3) to manage six types of energy hazards, including electrical, thermal and chemical risks. Clause 5.4 for battery safety is a key inspection item for all products equipped with lithium batteries.

• PS1 (No pain risk): Energy level poses no injury hazard under normal use conditions.
• PS2 (Noticeable pain risk): Moderate energy hazard. Warning labels and protective design are required to prevent general user access.
• PS3 (Severe injury risk): High energy hazard. Dual protection including warning marks and physical safeguards shall be implemented.

3. Core Battery Safety Test Items (Clause 5.4)

1. Battery airtightness test: No gas leakage; total content loss ≤ 0.1 g.
2. Overcharge protection test: Protection circuit shall activate when charging voltage exceeds 4.35 V.
3. External short circuit test: Under internal short circuit condition, surface temperature of battery enclosure shall be below 70 °C.
4. Overheating test: Place the battery in an environment of 70±2 °C for 4 hours; no fire or explosion is allowed.
5. Compression test: Apply a force of no less than 13 kN in specified directions; no fire or explosion occurs.
6. Forced discharge test: Discharge at 0.2C to cut-off voltage, then verify recharge reversibility.
7. Overcharge protection failure simulation: Backup safety mechanism shall work properly when the primary protection circuit fails.
8. Battery pack mechanical integrity test: No seal breakage, internal barrier failure or leakage for packs assembled with small cells.

4. Global Market Adoption & Corresponding Standards

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5. 6-Step Certification Application Process

Step 1: Product classification Confirm the product belongs to AV/ICT category and identify applicable clauses of IEC 62368-1.

Step 2: Feasibility assessment Evaluate battery type and capacity, and define required test items under Clause 5.4.

Step 3: Sample testing Submit samples to IECEE CB, NRTL or other accredited third-party labs for full testing against IEC 62368-1.

Step 4: Supplementary battery tests For lithium battery-powered devices, conduct additional tests per IEC 62133-2 / IEC 62619, or reuse existing CB test data.

Step 5: Report & certificate issuance Obtain compliance reports and apply for CE, UL, KC or other regional certificates.

Step 6: Continuous surveillance Undergo annual Follow-Up Service (FUS); surveillance cycles vary across different markets.

6. Five Key Compliance Notes

1. End of transition period: Major global markets no longer accept new applications based on obsolete IEC 60950-1 and IEC 62301.
2. Standard version selection: EN IEC 62368-1:2020 and :2023 are available; the 2023 edition is recommended for the UK market. Confirm the laboratory can issue reports for the latest version.
3. CB certificate reuse for batteries: Existing IEC 62133-2 CB certificates can be attached to the main unit CB report to streamline battery-related testing.
4. Combined testing with EMC: Apply for IEC 62368-1 (safety) and CISPR 32 (radiated & conducted EMC) in one batch to improve efficiency.
5. Attention to IEC 62368-3: This supporting standard specifies high-frequency safety limits for wired and wireless interfaces of AV/ICT devices.

7. Frequently Asked Questions

Q: Is IEC 62368-1 mandatory for lithium battery-powered laptops and routers? A: Yes. All AV/ICT devices with lithium batteries must comply with IEC 62368-1:2018, including combined testing of batteries and complete products.

Q: What is the difference between IEC 62368-1 and IEC 62133-2? A: IEC 62133-2 applies to standalone lithium cells and packs, while IEC 62368-1 is a full-product safety standard containing dedicated battery requirements under Clause 5.4. In most cases, both standards are required during testing.

Q: Do I need to upgrade existing CE certificates based on IEC 60950-1? A: Yes. The EU phased out EN 60950-1 in 2020. Current CE marking must be based on EN IEC 62368-1:2020 or newer versions. Certificate upgrade is highly recommended.

Q: Do laptop batteries need separate testing to IEC 62133-2? A: It is recommended. Inspectors will strictly review battery safety data during full-product testing. Holding a valid third-party CB certificate for batteries can accelerate the whole process.

Q: What about testing cycle and cost? A: General IEC 62368-1 testing takes 4–6 weeks. Total cost depends on test items and target regions. It is advised to arrange pre-evaluation in advance.

Feel free to contact Guangdong Energy Storage Testing Technology Co., Ltd. for customized IEC 62368-1 compliance solutions.

Disclaimer This article is for reference only and does not constitute certification commitment or legal advice. All operations shall comply with the latest official standards and regulations.