SPECIFICATION NO PEAC
Techtronic Industries North America, Inc.
OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
General Information
Model Number: OP4026 (TTI #:130186006)
Description: Ryobi 40V 10S2P Lithium Ion Battery Pack
Test Procedure: New Product Qualification Procedure No. 105 Rev. 06
Nameplate Voltage: 40V
Scope: This PEAC is for the qualification of the OP4026 battery pack. It is intended to evaluate the product’s
compatibility with existing tools and chargers that are approved for use with this product. This revision serves to
test initial version of the product utilizing Samsung 13Q cells that was initially designed for European markets.
Thus, some references to 40V products may use 36V product test data as qualification data.
Compatible Chargers:
Model #
OP400
TTI Part #
140181001
Description:
UL version of EMEA Charger for 120V
Product Test Specifications:
I: Performance Testing
I.A: Battery Pack Discharge Test
Test to be conducted on each of (5) samples. Recharge battery packs using charger OP400.
1. Discharge samples at 1A. Plot discharge voltage, capacity (in Watt Hours), and pack temperature.
2. Repeat step 1 at 10A, and 20A for all (5) samples. Record same information from step 1.
3. Place each sample in 50°C chamber and allow temperature to stabilize. Connect pack to electronic
load outside of chamber (equipment at room temperature) and discharge pack at 20Amps. Record
same information from step 1, and conduct test on all (5) samples.
4. Repeat step 3 at 10°C, 0°C, and -10°C, for all (5) samples. Record same information from step 1.
5. Repeat step 3 at 1A for 0°C and -10°C for all (5) samples. Record same information from step 1.
Averaged measured voltages within 200ms after full discharge current has been applied must meet the
following minimum values.
Minimum Pack Voltage (V)
Discharge Temperature (ºC)
50ºC
Discharge Rate
(A)
1A
41.0
10A
38.7
20A
WRITTEN
REISSUED
22ºC
38.4
BY
10ºC
37.5
APPROVED
35.5
0ºC
-10ºC
40.5
40.1
33.5
32.6
SUPERSEDES
BY Stuart Miller
ISSUED:
PAGE
1
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NO. PEAC OP4026
ENG061.F
R01
Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
I.B: Pack Temperature Operating Range
1. On Tool Temperature Tests – N/A
2. Pack Charging Hysteresis Test: Temperature Hysteresis Tests are to be conducted with each
charger in “Compatible Chargers” section.
a. Each of (3) samples shall not initiate charge below 0°C.
b. Each of (3) samples shall initiate charge above 0°C and below 5°C
c. Each of (3) samples shall not initiate charge above 50°C.
d. Each of (3) samples shall initiate charge above 45°C and below 50°C
I.C: Pack Cycle Life Test
1. Each of (5) battery pack samples must maintain 1.80 Ah capacity following 150 cycles when
discharged according to LTP 97 until pack terminates discharge.
2. Recharge (5) battery pack samples using charger OP400. Discharge each sample for 150 cycles at
15A constant current until pack terminates discharge measuring pack DCIR for initial and final cycle.
Each sample shall complete final cycle delivering 2.48Ah and 89Wh or greater with DCIR not
increasing by more than 5% of original values.
I.D: Pack Capacity
Perform complete pack discharge of (3) freshly charged samples at each discharge rate specified below until
pack terminates discharge. The minimum capacity measured for each discharge rate must meet or exceed
the minimum capacity specified in the table below.
Discharge
Current
(A)
1C
10A
20A
Minimum
Current
Capacity (Ah)
2.60
2.50
2.50
I.E: Charger Compatibility – N/A
I.F: Low Voltage Pack Aging – N/A
I.G: Pack Self Discharge Storage Test – N/A
II: Functional Testing
II.A: Fuel Gauge Cycling
Each of (3) samples shall complete 2,000 cycles without loss of function, safety, or illumination. Each switch
cycle shall consist of a single button press and release, followed by a pause until timer extinguishes LEDs.
Lights must extinguish before proceeding to next cycle.
II.B: Fuel Gauge Operation
1. Gauge Set Point Test: LED fuel gauge shall indicate internal battery charge according to the
following set points:
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R01
Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
a. 1 Green LED on = 0% - 25% charged
b. 2 Green LEDs on = 25% - 50% charged
c. 3 Green LEDs on = 50% - 75% charged
d. 4 Green LEDs on = 75% - 100% charged
*Transitional accuracy of LED charge indication shall be +/- 10% of internal voltage set points.
2. Stuck Button Protection: Samples shall extinguish display within 15 seconds of initial button press.
While keeping button depressed, conduct Section 2.E Sleep Mode tests to ensure PCBA does not
drain cells. Each sample shall meet requirements defined in Section 2.E.
3. Pulse Mode Test: – N/A
II.C: Latch Performance (5 samples)
1. Latch Actuation Force: Force required to fully depress each latch shall be > 2lbs and < 8lbs.
2. Single Latch Push Off Force: For each of the following tools, each pack sample shall remain
latched while subjected to 50lbs push-off force.
 RY40100 Mower
 RY40200 String Trimmer
 RY40600 Hedge Trimmer
 RY40400 Blower
 RY40500 Chain Saw
II.D: Battery Terminal Engagement
1. On Tool Insertion Test: Each of (3) samples shall complete 50 cycles on RY40600 Hedge Trimmer
without loss of function or safety.
2. Terminal Connection Sequence Test: Each of (3) samples shall complete all 24 test sequences on
each charger in “Compatible Chargers” section without loss of function or safety.
3. Pack Engagement Cycling: Each of (3) samples shall complete 5,000 cycles without loss of function
or safety while waiting 10 seconds before installing or removing pack from charger. Following cycle
tests, each sample shall complete one full charge and discharge cycle at 1C rate without loss of
function or safety.
II.E: Sleep Mode
Each of (5) pack samples shall not have measured discharge rates of internal cells that exceed the
following values for the specified States of Charge (SOC).
Pack
SOC
(%)
100
50
0
Pack
Voltage (V)
Max sustained current after 60
seconds of sleep mode (μA)
> 39.6
38.0
(+/- 0.25)
< 35.5
4.00
4.00
4.00
II.F: Exposure to UV Environment – N/A
III: Safety Testing
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R01
Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
III.A: Drop Tests
1. On Tool Drop Test – To be performed at 4 feet with all tools and as indicated below. Tool damage
does not constitute battery pack failure.
Test
Tool #
1
2
3
4
With Tool
RY40200 String Trimmer
RY40600 Hedge Trimmer
RY40500 Chain Saw
RY40400 Blower
Drop
Height
4(ft)
4(ft)
4(ft)
4(ft)
Drop
Temperature
22°C
22°C
22°C
22°C
# Pack
Samples
3
3
3
3
2. Pack Only Drop Test – To be performed at 4 (ft) height onto concrete surface for each of (3)
samples at room temperature in the most vulnerable orientation.
For all drop tests:
Electrical safety, functionality, and structural integrity must be maintained after each drop.
Seam gaps in excess of 0.063-inch and excessive deformation are not allowed.
Battery must not expose any cells or internal wires.
Battery latches should not fracture when dropped with a tool.
Battery charge indicator must remain functional.
III.B: Locked Rotor
Each tool listed below shall be tested with (3) pack samples. Pack electronics are not to be bypassed for
this test. Each test is to be conducted at 100% SOC and then repeated at 50% SOC with new samples.
Charring or burning of the gauze is not allowed and charring is considered to be blackening of the gauze
caused by combustion. Record and report discharge current plot for each test.





RY40100 Mower
RY40200 String Trimmer
RY40600 Hedge Trimmer
RY40400 Blower
RY40500 Chain Saw
III.C: Shorted Pack – Pack electronics are not to be bypassed for these tests unless directly specified.
Complete each test at 100% SOC and again at 50% SOC (using separate samples for each test)
1. Shorted Pack Terminal Test – Each sample shall complete a direct short of the output terminals
without loss of safety and without ignition of cheesecloth.
2. Shorted Motor Terminal Test – Each sample shall complete a direct short of the motor terminals on
products shown below without loss of safety and without ignition of cheesecloth.




RY40100 Mower
RY40200 String Trimmer
RY40600 Hedge Trimmer
RY40400 Blower
Page 4 of 7
R01
Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA

RY40500 Chain Saw
3. Shorted Pack Terminal Test (Bypassed PCBA) – Each sample shall complete a direct short of the
output terminals without loss of safety and without ignition of cheesecloth. Fuse link opening is
acceptable. Samples are permitted to be damaged beyond function as result of this test. Pack
electronics ARE to be bypassed for this test in order to confirm function of fuse link in pack.
For all Shorted Pack Tests:
Record observations and note if pack electronics function properly upon application of terminal short.
Electronics may terminate discharge, but pack should be able to be reset upon load removal and function
normally after test unless PCBA has been bypassed. Graph current, voltage and temperature of cells
during test.
III.D: Vibration
1. On Tool Vibration Test – Each of (3) samples shall complete 15 discharges on RY40600 Hedge
Trimmer without loss of function or safety.
2. Mixer Drum Test – Each of (3) samples shall complete 60 minutes in mixer test without loss of
safety or function. Test each unit separately in mixer drum. Each sample must complete (2) 1C
discharge / OP400 charge cycles without failure following mixer test.
III.E: Humidity Testing
1. Humid Resistance Test – Each test sample shall remain safe and functional and have an average
resistance of 5MΩ or greater as a result of test.
III.F: Transportation
1. Shaker Table Test – Each sample shall meet United Nations 14th edition 2005 Section 38.3.4.3 Test
(T3 Vibration). Tests shall be completed without loss of function or safety. Passing results obtained
from an official test lab can be used in place of internal test results.
III.G: Compatibility Testing
1. On Tool Compatibility Test – Test battery packs with the tools listed below. Each Compatibility
Test section (A through E) shall be completed using 3 samples (minimum) of the tool models listed
and 2 separate battery packs for each individual tool model tested. Each battery pack sample shall
complete the number of discharge cycles defined in each of the following test sections. Recharge
packs using charger OP400. For each section, use a sufficient quantity of tool samples to complete
the specified testing. Tool failures shall not constitute pack failure and shall be evaluated on an
individual basis. Testing shall result in no safety hazards to the user from the tools tested or the
battery pack.
A. String Trimmer Compatibility Test (To be completed on RY40200) – Conduct the use tests by
discharging each pack sample by trimming grass or some media that simulates trimming grass
continuously until pack is fully discharged. After each charge, each pack shall complete a 15
minute rest period before resuming discharge on tool sample. Continue testing for 13 discharge
cycles. Packs shall be cooled via fan while charging.
B. Hedge Trimmer Compatibility Test (To be completed on RY40600) – Conduct the use tests by
discharging each pack sample by trimming hedges or shrubs or some media that simulates
Page 5 of 7
R01
Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
hedges or shrubs continuously until pack is fully discharged. After each charge, each pack shall
complete a 15 minute rest period before resuming discharge on tool sample. Continue testing
for 13 discharge cycles. Packs shall be cooled via fan while charging.
C. Mower Compatibility Test (To be completed on RY40100) – Conduct the use tests by
discharging each pack sample by cutting grass continuously until pack is fully discharged. After
each charge, each pack shall complete a 15 minute rest period before resuming discharge on
tool sample. Continue testing for 25 discharge cycles. Packs shall be cooled via fan while
charging.
D. Blower Compatibility Test (To be completed on RY40400) – Conduct the use tests by
discharging each pack sample by blowing leaves continuously until pack is fully discharged.
After each charge, each pack shall complete a 15 minute rest period before resuming discharge
on tool sample. Continue testing for 13 discharge cycles. Packs shall be cooled via fan while
charging.
E. Chain Saw Compatibility Test (To be completed on RY40500) – Conduct the use tests by
discharging each pack sample by cross cutting 4” x 4” pine lumber continuously until pack is fully
discharged. After each charge, each pack shall complete a 15 minute rest period before
resuming discharge on tool sample. Continue testing for 25 discharge cycles. Packs shall be
cooled via fan while charging.
2. Low Discharge Sleep Mode Compatibility
A. Low Discharge Interruption Test: – N/A
B. On Tool Sleep Mode Test: (2) Pack samples complete Section 2.E: Sleep Mode tests while
connected to the products listed below with switches in “ON” position. Allow packs to fully
discharge on product and terminate discharge once depleted. Pack samples shall remain
connected to products and product switches shall remain in “ON” position. After pack reaches
end of discharge, conduct tests as indicated in Section 2.E: Sleep Mode, monitoring cell
discharge rates. Each sample shall have individual cell discharge rates (measure every cell)
that does not exceed the limits defined for 0% SOC





RY40100 Mower
RY40200 String Trimmer
RY40600 Hedge Trimmer
RY40400 Blower
RY40500 Chain Saw
C. On Charger Sleep Mode Test: (2) Pack samples shall be connected to a sample of each
charger listed in “Compatible Chargers” section while the charger is unplugged. While
connected to unplugged chargers, complete Section 2.E: Sleep Mode tests on battery packs to
determine the standby current for each cell in the pack. Each sample shall meet the
requirements of Section 2.E: Sleep Mode.
III.H: Temperature
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Techtronic Industries North America, Inc.
SPECIFICATION NO. PEAC OP4026
PRODUCT EVALUATION AND ACCEPTANCE CRITERIA
1. (1) Sample of each tool listed below shall complete temperature test (per tool PEAC procedure) using
(2) pack samples for each tool. All tests shall result in completion of test procedure for each tool.
Each test shall not present safety hazards to the user from the tools tested or the battery pack. Each
sample must pass UL test for surfaces normally contacted in use and the temperature limits defined
in the PEAC for that specific tool.





RY40100 Mower
RY40200 String Trimmer
RY40600 Hedge Trimmer
RY40400 Blower
RY40500 Chain Saw
III.I: Charger 7 Day Storage Tests
1. (1) Sample of each charger listed in “Compatible Chargers” section shall be tested with (1) sample
battery pack. Each set shall complete a full charge cycle and charger shall remain powered for
duration of test. While pack remains connected to battery charger, monitor individual cell voltages on
pack for 7 days. Each pack sample shall complete 7 day storage tests without any cell voltages in
pack decreasing to 90% SOC or lower in any of the cells. Each sample shall remain safe throughout
and following the test.
2. (1) Sample of each charger listed in “Compatible Chargers” section shall be tested with (1) sample
battery pack. Each sample shall complete a full charge cycle and then have the power cord to
charger unplugged while pack remains connected to battery charger. Monitor individual cell voltages
on pack while connected to unplugged charger for 7 days. Each sample shall complete 7 day storage
tests without cell voltages in pack decreasing to 90% SOC or lower in any of the cells. Each sample
shall remain safe throughout and following the test.
For both tests, report output voltage of each cell using data-logger to generate plots that show voltage
change for the 7 day period.
III.J: Charging Characteristics
(1) Sample pack shall be fully discharged to pack shutdown. Each pack shall then be installed into (1)
sample charger from “compatible charger” section and allowed to fully charge while having pack voltage,
current, and temperature monitored. Use (1) pack sample for each charger sample. Allow each sample
combination to remain on charge for at least 9 hours while continuing to monitor and record voltage,
current, and temperature. Provide plots for each combination showing the information recorded.
IV. Packaging – N/A
Note: These tests are conducted to obtain insight into safety, quality, and durability of the product.
These tests will gather valuable information that helps fulfill acceptance requirements. Any failure on
these tests must be evaluated by the product team to determine the necessary corrective action.
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