F/CMVSS 305: Electrolyte Spillage and Electrical Shock Protection

As more electric vehicles (EVs) make their way into the roadway population, one safety standard OEMs address with lighter vehicles is Federal/Canadian Motor Vehicle Safety Standard (F/CMVSS) 305: Electrolyte Spillage and Electrical Shock Protection. This standard is similar in its purpose and application to F/CMVSS 301 for fuel system integrity. In this case, the fuel is the electrical charge and electrolytes (battery chemicals) for the energy storage, and it’s important for upfitters to become familiar with the requirements of the standard in maintaining OEM pass-through compliance. F/CMVSS 305 applies to MPVs, trucks and buses with a 10,000-pound or less gross vehicle weight rating (GVWR) “that use electrical propulsion components with working voltages more than 60 volts direct current (VDC) or 30 volts alternating current (VAC), and whose speed attainable over a distance of 1.6 km on a paved level surface is more than 40 km/h.” The voltage and speed conditions in the application distinguish what might otherwise be considered low-speed vehicles, which have separate requirements under FMVSS 500. The standard also applies to all vehicles designated with the vehicle type of “passenger car,” regardless of GVWR, and additionally to every three-wheeled vehicle in the Canadian standard. It’s also important to note this is not a new standard. It took effect in 2001 and has applied not just to EVs, but hybrid electric vehicles, as well. Chassis OEMs have critical crash test performance requirements of the standard when they launch new vehicle platforms or as changes are made to vehicles to which the standard applies. What you need to know Commercial vehicle industry chassis OEMs that manufacture vehicles with 10,000-pound or less GVWR — such as pickups with a box delete option and chassis-cabs and cutaways — are challenged to provide the second-stage manufacturer with guidance for F/CMVSS 305 compliance given the wide variety of body applications that may be installed. Each OEM bases guidance on analysis and testing. Similar to liquid fuel systems, this standard includes frontal, side and rear impact tests and a post-test static rollover (also referred to as a spit test due to the manner in which the vehicle is rotated on a horizontal support). To provide pass-through compliance rationale based on the specific vehicle and test performance, this guidance may include strict limitations for body mounting, such as attachments, body weight and body center of gravity position. Other elements will typically address structural modifications to the chassis, especially those that could affect support for the batteries, high-voltage cables, inverter, traction motors and any associated spatial clearance requirements. Some unique elements to OEM guidance, compared to that of liquid fuels, can include prohibitions on any modifications that could affect defined ground paths. The standard’s electrical safety aspect adds another dimension of complexity to ensure that vehicles with electrified propulsion systems can be upfit in a way to carry over the successful dynamic test performance of the base vehicle. Reviewing chassis OEM incomplete vehicle documents and body builder books is a critical part of preparing to work on these vehicles. Likewise, before working on new incomplete EV platforms, it’s vital to ensure OEMs have met their federal obligation to provide incomplete vehicle documents with their chassis products, along with associated body builder information, as new market entrants go into production. New and existing body builder materials can be found on OEM websites, which will highlight new material, so a routine check can help you connect with new EV upfitting guidance. However, it’s important to note that currently, there are no box removal programs authorized for new EV pickup truck models, which is not surprising given this and other F/CMVSS that must be addressed before an OEM can offer these modifications. Therefore, to manage end-user expectations regarding box removal of EV pickups, do not assume otherwise until OEMs publish specific guidance with pass-through compliance. Modification of a tested vehicle poses a challenge to chassis OEMs in determining how to allow pickup trucks and other vehicles to be modified while maintaining FMVSS 305 compliance, so this standard will continue to be a compliance challenge for the OEMs’ abilities to offer pickup box delete or box removal guidance on vehicles with electric powertrains. The strict requirements within these documents must be followed; otherwise, the company modifying the vehicles would be responsible for proof of compliance through successful results of the dynamic tests. The difficulty and expense associated with performing such tests, with no guarantee of success, discourages body and equipment final-stage manufacturers and alterers from completing or modifying vehicles outside OEM guidance.

F/CMVSS 305: Electrolyte Spillage and Electrical Shock Protection

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