RV Installation Guide

Recreational Vehicle Standards Update: Lithium Batteries

AS/NZS 3001.2:2022 has many new requirements relating to electrical safety in Recreational Vehicles (RV). It covers electrical wiring, inverters, batteries (both lead acid and lithium), amongst others. The updated standard has additions to protect against exposure to gases and fire during a potential catastrophic battery failure. It also calls for batteries to be AS IEC 62619:2023 compliant. REDARC’s LBAT12100, LBAT12100-HD and LBAT1200 batteries are AS IEC 62619:2023 compliant. This paper addresses the requirements specific to the installation of lithium batteries in RVs. The standard becomes effective from November 18, 2023. It applies to new RVs sold or registered from that date onwards. Additionally, it covers major upgrades, such as replacing AGM batteries with lithium batteries. In such cases, the installed batteries must comply with the new standard. The standard does not apply retrospectively, RVs built before AS/NZS 3001.2:2022 do not need to be changed.

Installation Locations:

Historically common RV battery installation locations included:
Toolbox on the drawbar (external)
Box attached to the chassis or A-frame (external)
Under the bed
Under the seat
Tunnel boot
Hatch
Cavity under the floor
In a cupboard

The standard now calls for Lithium batteries to “be installed externally, i.e. behind a wall or barrier that prevents the egress of gases into the habitable area and not enter the habitable area of the structure[1]”. While the standard does not provide a definition of “habitable area” it is generally assumed by the industry that all locations listed above are acceptable provided effective measures are taken to prevent battery vapours and fire from entering an area that people are inhabiting, i.e. sleeping, eating, living, etc. For locations that are not external to the RV, it is required to install lithium batteries in a vapour sealed box that is vented to the atmosphere outside the RV.

There are additional installation requirements about proximity of batteries to gas and diesel lines, etc. Installers should consult the Standard[1] for additional information.

Vapour management:

When locating batteries in locations that are not fully external to the RV, e.g. under the bed or seat they must be:

Installed in a vapour sealed enclosure that is vented to outside of the RV to ensure no gasses can enter the habitable area. The inside of the enclosure effectively becomes an uninhabitable area. The enclosure requires the following:
- It must be sealed to prevent gasses escaping into the habitable area.
- A sealed access port for installation and maintenance.
- Sealing integrity must be maintained, when in use, in storage, after maintenance, etc.
- A screwdriver or specialised tool must be required to access the enclosure.
- All cables passing through the enclosure must be vapour sealed (using suitable cable grommets).
- Batteries inside the enclosure and the enclosure itself must be suitably mechanically restrained to prevent faults, injury during travel and road accidents.
- The battery storage space and ventilation design requirements for lead acid and lithium batteries are different. Where the ventilation implementation is specific to only Lithium batteries, clearly visible warning labels should be attached to the enclosure spaces to identify that the space is only suitable for Lithium batteries and not lead acid chemistries.
Special attention to venting ports is recommended, including:
- Preventing water and road splash from entering the sealed enclosure. This may occur during river fording, driving through puddles, car wash, rain on the road or pressure washing. Moisture getting into the sealed enclosure could lead to condensation build-up, corrosion, etc. over time.
- It should be noted that the IP rating [4] is different from corrosion resistance. REDARC’s LBAT12100, LBAT12100-HD and LBAT1200 batteries are IP65 which means are dust tight and will survive a low pressure water jet for a short period of time. The IP rating does not address corrosion. Exposure to moisture, especially salt water, over a period of time could lead to corrosion of battery terminals, wiring, lugs, etc. and even the enclosure itself. It is recommended that venting solutions that prevent water ingress and moisture build-up but will release gases externally in the event of a battery outgassing event be used. Contact REDARC for recommendations on how to minimise exposure to moisture.
- Preventing gasses from outside an RV from entering the habitable area, e.g. exhaust fumes.
- There may be Federal, State and Territory vehicle design rules that regulate where vent ports can be located. Please consult the appropriate authorities.

Fire management:

It is recommended that the vapour sealed enclosure material be constructed of a fire-resistant material like steel or aluminium which will reduce the risk of fire spreading in the event of a battery fire.

In the unlikely event of a fire inside the box its surface could get hot enough to ignite materials in contact with it. The area surrounding the vapour sealed box should be designed to prevent all potentially flammable objects and materials like bedding, plastics and paper from coming into contact with the outside of the vapour sealed box. The area under the bed or bench must be designed and labelled to prevent users from storing potentially flammable items like bedding, clothing, flammable chemicals, etc. coming into contact with the enclosure (for example, some types of paper have a contact ignition temperature as low as 250°C).

Battery Specifications:

The standard requires that batteries be installed to operate within the manufacturer’s specifications, this includes charge and discharge current, temperature, environmental conditions, etc. Care must be taken to do design the overall electrical system and installation location that allows for this.

Installation Locations Examples:

Figure 1 (a): External battery box

Figure 1 (b): External battery box

Figure 2: Battery box under bed

Figure 3: Battery box under bench seat

Figure 4: Battery box under floor

Figure 4: Battery in tunnel

Monitoring device:

Each battery (or bank of batteries) must be monitored via a battery monitor that displays the state of charge (SoC) and may display voltage. REDARC’s Manager30 and BSEN500 provides this functionality.

References:

[1] AS/NZS 3001.2:2022, Electrical installations — Connectable electrical installations and supply arrangements, Part 2: Connectable electrical installations

[2] AS 60529, Degrees of protection provided by enclosures (IP Code)