먼저 갖춰야 할 것들
라벨에 리튬이온이라고 적혀 있다면, 서류에는 UN3480 또는 UN3481이라고 적혀 있어야 합니다. 이것이 핵심입니다. 나머지 모든 것은 이 판단에서 따라옵니다.
상자를 만지기 전에 세 가지를 준비하세요:
- 배터리 설계가 UN 38.3을 통과했다는 증거(시험 보고서)와 운송업체나 검사관에게 요청 시 즉시 제출할 수 있는 UN38.3 시험 요약서.
- 오늘 출하하는 셀이나 팩에 실제로 맞는 포장 자재 명세서, 작년 개정판이 아닙니다.
- 귀하의 운송 방식과 수량을 수용할 운송업체. 많은 통합업체가 항공 운송 시 UN3480에 대해 사전 승인을 요구합니다. 위험물 데스크에 전화하고, 담당자 이름을 기록하고, 조건을 기록하세요.
현재 SDS를 인쇄하세요. UN38.3 시험 요약서의 디지털 사본을 공유 드라이브에 넣으세요. 그런 다음 팩 리스트에 링크되는 QR 코드를 붙이세요. 램프 에이전트가 스캔하고, 고개를 끄덕이고, 팔레트를 이동시키길 원합니다.작업대 위의 도구:
- 교정된 저울. 각 포장 전에 영점 조절을 누르세요.
- 테이프 건과 3인치 감압 테이프. 손바닥으로 당기고 누르세요; 느슨한 가장자리가 없어야 합니다.
- 멀티미터. 충전 상태(SOC) 관리의 일환으로 전압을 점검하세요.
- 모서리 보호대, 정전기 방지 백, 비전도성 캡, 케이블 타이.
- 라벨 키트: 리튬 배터리 마크, Class 9 리튬 배터리 라벨, 화물 항공기 전용 라벨, 방향 화살표, OVERPACK 마크, 그리고 실제로 누군가 받는 전화번호 라벨.
“UN38.3 인증”에 관한 참고 사항. 정부 인증서는 없습니다. 오직 적합성만 있습니다: 셀/배터리 설계가 UN 시험 및 기준 매뉴얼, Part III, sub-section 38.3을 통과해야 하며, 요청 시 UN38.3 시험 요약서를 제공해야 합니다. 실험실이 보고서를 발급합니다. 귀하는 이를 보관하고 요약서를 공유합니다.미국 워크플로우, 단계별
- shipment 분류
사양서를 열고 화학 조성(Li-ion vs Li-metal), 정격 Wh, 구성(셀, 배터리, 또는 장비)을 적으세요. 적절한 운송 명칭과 UN 번호를 선택하세요:
- UN3480, 리튬이온 배터리(리튬이온 폴리머 포함) — 단독.
- UN3481, 장비에 내장된 리튬이온 배터리 — 기기에 설치됨.
- UN3481, 장비와 함께 포장된 리튬이온 배터리 — 같은 상자에 있지만 설치되지 않음.
항공기의 경우, shipment를 IATA 포장 지침(PI 965–967)에 맞추세요. 국내 육상의 경우, 49 CFR 173.185를 사용하세요. 해상의 경우, IMDG Code를 사용하세요.
- UN38.3 적합성 확인 및 시험 요약서 작성
셀 또는 팩 공급업체에 UN 시험 보고서와 UN38.3 시험 요약서를 요청하세요. 요약서에 다음이 명시되어 있는지 확인하세요:
- 제조사 및 연락처
- 셀/배터리 모델 및 설명
- 시험 표준 참조 및 판본
- T.1부터 T.8까지 각 시험 및 결과
- 보고서 날짜 및 책임자
PDF를 여세요. 모델 번호를 명판과 문자 하나하나 대조하세요. 팩 개정으로 BMS, 셀 유형, 또는 기계적 설계가 변경되었다면, 잠시 멈추고 38.3의 “유형” 정의에 따라 새 시험이 필요한지 확인하세요. 이메일 스레드를 파일의 일부로 만드세요.
- 와트시 및 SOC 측정 및 관리
와트시는 배터리에 표시되어야 합니다. 누락된 경우, Wh = 공칭 전압 × 정격 Ah를 계산하고 내구성 있는 라벨을 인쇄하세요. UN3480의 항공 shipment의 경우, 2026년 IATA 리튬 배터리 운송 규칙에 따라 SOC를 30% 이하로 설정하세요. BMS 도구 또는 제어된 방전을 사용하세요. 추측하지 마세요. 미터를 단자에 대고 판독값을 traveler에 기록하세요. - 위험과 비용에 따라 모드를 선택하세요
- 항공: 가장 빠르고, 가장 제한적. UN3480은 수량 제한, 전체 Class 9 리튬 배터리 라벨링, 그리고 shipper’s declaration이 있는 화물 항공기 전용입니다. 많은 운송업체가 일일 개수를 제한하거나 계약을 요구합니다.
- 육상(49 CFR 리튬 배터리 육상 운송): 더 유연합니다. 173.185(c)를 충족하는 소형 배터리는 리튬 배터리 마크로 이동할 수 있으며 위험물 등급 라벨이 필요하지 않습니다; 대형 팩은 완전히 규제됩니다. 운송업체 규칙은 여전히 적용됩니다.
- 해상: 무거운 ESS 및 산업용 팩에 적합합니다. IMDG 적재 및 분리를 따르세요. 일찍 예약하세요; DG 슬롯이 채워집니다.
- 패키지 구성
물리적 작업을 수행하세요:
- 단자를 캡으로 덮거나 테이프로 감으세요. 노출된 금속이 없어야 합니다. 단락될 방법이 없어야 합니다.
- 각 배터리를 비전도성 백에 감싸세요. 내부 포장 안에서 움직이지 않도록 완충재를 추가하세요.
- 튼튼한 외부 포장을 사용하세요. 완전히 규제되는 shipment는 내부 팩에 맞는 UN 성능 포장(예: 4G 섬유판, 4C1 목재)이 필요합니다. 시험된 대로 닫으세요: 올바른 테이프 패턴, 감는 횟수, 밀봉 방법. 즉흥적으로 하지 마세요.
- 포장된 상자를 흔드세요. 움직임이 들리면 다시 포장하세요.
- 올바른 조합으로 마크와 라벨을 부착하세요
상자를 저울 위에 세우세요. 필요한 경우 shipper’s declaration에 총 중량을 적으세요. 그런 다음 라벨을 붙이세요:
- UN 번호(UN3480 또는 UN3481)와 추가 정보를 위한 작동하는 전화번호가 있는 리튬 배터리 마크.
- 완전히 규제될 때 Class 9 리튬 배터리 위험 라벨(배터리 아이콘이 있는 것).
- 여객기에 실을 수 없는 UN3480 항공 shipment에 대한 화물 항공기 전용 라벨.
- Class 9 라벨 근처에 인쇄된 Proper Shipping Name 및 UN 번호.
- 액체가 들어 있는 섬유판 상자 또는 포장 표준이 요구할 때 방향 화살표.
- 여러 라벨이 붙은 상자를 함께 감싸거나 밴딩하는 경우 OVERPACK 마크; 최소 한 세트가 보이도록 필요한 라벨을 복제하세요.
각 라벨을 손바닥으로 평평하게 누르세요. 가장자리에 주름이 없어야 합니다. 다른 라벨을 덮는 라벨이 없어야 합니다.
- Prepare paperwork
- Air: IATA Shipper’s Declaration for Dangerous Goods for fully regulated shipments. Use the current edition. Fill quantity, net battery weight, packing instruction, and any special provisions. Attach SDS and the commercial invoice. Keep copies.
- Ground: Shipping papers per 49 CFR if fully regulated; include the proper shipping description and a 24‑hour emergency response number. If your shipment qualifies for the small battery exceptions in 173.185(c), you’ll apply the lithium battery mark and follow packaging rules; some carriers still ask for DG documentation—check your service guide.
- Ocean: IMDG dangerous goods declaration (DGD), packing certificate, and segregation plan if required.
- Overpack and palletize
Place labeled boxes on a clean pallet. Use corner boards. Stretch‑wrap tightly with at least three bottom wraps and three top wraps. If you cover labels, add a duplicate set on the outside of the stretch wrap or apply the OVERPACK mark. - Book and pre‑alert
Upload paperwork to the carrier portal. Include the UN38.3 test summary link if allowed. Email the acceptance checklist to your forwarder. Write “SOC ≤ 30%” in the booking notes for UN3480 by air to speed acceptance. - Handoff and retain records
At tender, hand the DG packet to the agent. Keep training records, declarations, and acceptance checklists for at least two years, or longer if your quality system requires.Mode Rules that Matter
Air (IATA DGR; ICAO TI governs)
- UN3480 is restricted to cargo aircraft, with package quantity limits and full Class 9 lithium battery hazard communication. SOC must be at or below 30%. Shipper’s Declaration is required.
- UN3481 shipments (contained in or packed with equipment) have different limits and documentation triggers. Check PI 966/967 for piece counts and inner packaging. Many consumer moves are possible but still need the lithium battery mark and sometimes the declaration, depending on configuration and quantity.
- Damaged, defective, or recalled lithium batteries are not accepted by air. Treat them as hazardous waste or non‑air modes under applicable approvals.
Ground (49 CFR) - 49 CFR 173.185 is your home base. Many small lithium‑ion shipments qualify for exceptions: strong outer packaging, lithium battery mark, and no Class 9 label or shipping paper. Larger packs and many industrial batteries are fully regulated Class 9.
- You need hazmat training under 49 CFR Subpart H if you offer fully regulated packages. Keep training certificates on file.
- Carriers (parcel and LTL) layer their own acceptance rules. Read the tariff. Call before you ship unusual sizes.
Ocean (IMDG Code) - Similar technical requirements to air/ground but with maritime stowage, segregation, and documentation.
- Very large containerized energy storage units may fall under UN 3536 (lithium batteries installed in cargo transport unit). Do not assume. Confirm the entry and packing instructions with your DG forwarder.
Technical Details That Trip Teams Up
UN38.3 “type” and design changes
- Swapping cell suppliers, changing the BMS, altering the enclosure, or adding parallel strings can push you into a new “type.” Ask your lab or safety engineer to decide whether a partial or full retest is needed. Put that decision in writing.
“Contained in” versus “packed with” - If the battery is installed in the equipment and connected, that’s “contained in equipment.” If it sits in the same box but is not installed, that’s “packed with equipment.” The limits and labels differ. Mixing them casually causes holds.
Small battery myths - Air “Section II” allowances for standalone UN3480 were removed years ago. Don’t rely on an old carve‑out from a forum post. Read the current IATA packing instruction.
SOC proof - A control plan beats an argument at the counter. Export a BMS report showing SOC. When that’s not possible, maintain a discharge‑to‑setpoint log signed by the operator. Clip the log to the pick list.
Watt‑hour marking - The battery itself must show watt‑hours. If your supplier left it off, you add a durable, legible label. Not the box—the battery.
Damaged or recalled batteries - Treat them as a different hazard class scenario with mode prohibitions. If a battery leaked, vented, or shows swelling, stop. Isolate the unit, take photos, and escalate to your EHS lead.
Troubleshooting: Why Carriers Put You on Hold
What goes wrong in the real world, and how to fix it fast:
- Missing or mismatched UN numbers on the lithium battery mark. Fix: print a new mark with UN3480 or UN3481 that matches your declaration.
- No phone number or a number that rings to nowhere. Fix: route to a trained person; test the line before pickup.
- SOC not controlled for UN3480 by air. Fix: discharge to ≤30%, update the note in your booking, re‑present.
- Reused UN box with the wrong closure. Fix: follow the closure instructions from the box’s test report—tape width, pattern, staples—and document it.
- Labels hidden by stretch wrap. Fix: apply duplicate labels to the outside of the wrap or use OVERPACK with replicated labels.
- UN38.3 test summary not available. Fix: email a PDF or provide a QR code immediately. Keep it in the shipment folder going forward.
- Mixing UN3480 and general cargo in the same overpack without marks. Fix: break down the overpack or add proper marks and replicated labels.
When a hold happens, don’t argue on the dock. Take the box back, rework on the bench, photograph each fix, and resubmit with a bullet list of corrections in your email to the DG desk.Worked Examples for LiFePO4 Packs
Example A — 10 kWh LiFePO4 residential ESS pack, domestic U.S.
- Classification: Li‑ion chemistry, UN3480, Lithium ion batteries. Watt‑hours far above small‑battery exceptions.
- Mode choice: air is technically possible only under very tight limits and carrier acceptance; cost and risk are high. Most teams choose ground (49 CFR) or ocean.
- Actions on the bench: discharge to shipping setpoint; cap the terminals; bag and cushion; build a UN 4G outer with blocking and bracing.
- Marks/labels: lithium battery mark (UN3480), Class 9 lithium battery label, proper shipping name and UN number. For ground, apply as fully regulated if above exception thresholds.
- Docs: shipping papers per 49 CFR with emergency number; SDS attached. Keep UN38.3 test summary ready.
- Pallet: corner boards, four straps, stretch‑wrap, OVERPACK mark with replicated labels.
- Risk control: request non‑stack handling from the carrier; photograph the loaded pallet.
Example B — 48 V, 400 Ah LiFePO4 forklift replacement battery (industrial truck) - Classification: UN3480 unless shipped installed in the truck. If the battery is shipped inside the powered industrial truck, 49 CFR has a vehicle rule—confirm applicability. As a standalone pack, treat as fully regulated Class 9.
- Mode: ground or ocean.
- Actions: verify UN38.3 type coverage for the exact BMS and cell set; torque terminal covers; add shock indicators on the crate; weigh and record gross weight on the bill.
- Marks/labels: lithium battery mark (UN3480), Class 9 lithium battery label, proper shipping name, UN number.
- Docs: shipping paper with net battery weight; emergency response number that connects to someone who can read the SDS.
- Note: lift‑truck batteries are heavy. Screw the crate to the pallet deck. No loose nails. No tilt.
Example C — 12 V, 100 Ah LiFePO4 RV/golf‑cart pack to a dealer - Classification: Standalone replacement pack is UN3480. If it ships installed in the RV or golf cart, different equipment/vehicle provisions may apply—confirm before you rely on them.
- Mode: many dealers prefer ground. Air is possible subject to carrier acceptance, SOC ≤30%, and IATA limits; some integrators will not accept it from non‑contract shippers.
- Actions: fit non‑conductive end caps; foam‑in‑place to stop movement; verify watt‑hour marking on the battery case; print the lithium battery mark with UN3480.
- Labels/documents: for air, add Class 9 lithium battery label, Cargo Aircraft Only if required, and Shipper’s Declaration citing the correct packing instruction. For ground, follow 49 CFR; use the exception only if the configuration qualifies.
- Tip: put a copy of the UN38.3 test summary in the box sleeve. The dealer will thank you when forwarding to an end customer.
These examples mirror what many OEM/ODM makers of LiFePO4 packs for energy storage, forklifts, RVs, and golf carts ship every week. The pattern does not change: classify, prove UN38.3, control SOC, package, mark, declare, and book with a carrier that actually wants the freight.Documentation and Labeling, Up Close
UN38.3 test summary essentials
Print or export a one‑page summary with: - Manufacturer, address, and contact
- Cell/battery model designation and description
- Reference to UN Manual of Tests and Criteria, Part III, sub‑section 38.3 (edition specified)
- Individual test outcomes (T.1–T.8)
- Report date and signatory
Store the full lab report in controlled documents. The summary travels; the report stays internal but must be available.
Shipper’s Declaration (air) - Use the current IATA format. Black ink. No corrections with white‑out.
- Enter the proper shipping name and UN number exactly as listed.
- Indicate packing instruction (PI 965/966/967 for lithium ion).
- Weigh the net battery content; don’t estimate. Put the box on the scale and read the number.
- Sign by a trained person. Training currency must be documented.
Lithium battery mark - Minimum size and border thickness matter. If the box is small, use the reduced‑size mark allowed by the rule.
- Include UN number and a telephone number that reaches knowledgeable staff. Test the line.
Carrier Acceptance: Winning the Ramp
Do three things the day before pickup:
- Email the forwarder a clean photo set: one shot of each label, one of the closed box, and one of the pallet.
- Attach the SDS, Shipper’s Declaration (if required), and a link to the UN38.3 test summary.
- Put your cell phone on. If the acceptance team calls, answer on the first ring.
At pickup, hand the packet to the driver or counter agent. Say “Class 9 lithium battery, UN3480/UN3481” out loud. People listen when they hear a hazard class.Quality Metrics and Cost Control
Track these on a whiteboard near the bench:
- Acceptance rate (no‑defect DG acceptance on first presentation)
- Rework count and causes (label, SOC, packaging, paperwork)
- Damage rate in transit
- Average door‑to‑door time by mode
- Packaging cost per shipped Wh
Run a monthly 15‑minute audit: - Pull three shipments at random. Open the photos and paperwork. Check for UN number mismatches, missing SOC notes, and unreadable labels.
- Read the latest regulatory bulletins from your carriers and from IATA/PHMSA/IMDG. Flag any changes to PI 965–967 or 49 CFR 173.185 for your work instructions.
- Refresh training for anyone who signs a declaration.
One hold at an airport can burn more money than a month of proper packaging. Acceptance is ROI.Common Edge Cases
- Prototypes and small production runs: If the design has not passed UN38.3, you need a competent authority approval to move by air. Most teams choose ground with special handling or wait for testing.
- Mixed chemistries in one box: Don’t. Separate shipments.
- Power banks and portable power stations: These are lithium‑ion batteries by another name. Treat them under UN3480 unless shipped “contained in equipment” per the relevant instruction.
- Containerized ESS: Ask your DG forwarder about UN 3536 versus UN3480 at the system level. The entry drives stowage, labeling, and paperwork.
- Returns and field failures: Create an RMA flow that assumes “damaged/defective” and routes to ground‑only carriers with special packaging.
A Bench‑Side Checklist You Can Use Today
Tape this where you work. Then follow it like a pilot.
- Identify: UN3480 or UN3481? Write it on the traveler.
- Verify: UN38.3 test summary matches model and revision. File link checked.
- Mark battery: Watt‑hours printed on the case. If missing, add a durable label.
- Control SOC: For UN3480 by air, discharge to ≤30%. Log the reading.
- Protect: Cap/tape terminals, bag, cushion. No movement.
- Pack: Use the specified inner and UN outer. Close exactly as tested.
- Label box: Lithium battery mark with UN number and phone; Class 9 lithium battery label if required; CAO label if required; proper shipping name and UN number; OVERPACK if used.
- Paper: SDS, shipper’s declaration or shipping paper as applicable, emergency number confirmed.
- Photo: Snap labels and pallet. Save to the job folder.
- Book: Pre‑alert carrier with docs and photos.
- Retain: Archive records and training certs.
Sources and Update Cadence
Work to the current editions:
- UN Manual of Tests and Criteria, Part III, sub‑section 38.3
- IATA Dangerous Goods Regulations (the current 2026 edition for air)
- 49 CFR Parts 171–180, especially 173.185 for lithium batteries (ground)
- IMDG Code for ocean shipments
- Individual carrier service guides and dangerous goods tariffs
Put a recurring calendar entry at the turn of each year to review IATA changes and mid‑year to check PHMSA and carrier updates. Then change your work instructions, not just the slide deck.
Move carefully, label cleanly, and keep your test summary within arm’s reach. That’s how UN38.3‑certified lithium battery shipping guidelines turn into shipments that load, fly, and arrive.
