BUREAU OF INDIAN STANDARDS Manak Bhavan, 9 Bahadur Shah Zafar Marg New Delhi 110002 Phones 2323 0131 TeleFax +91 11 2323 1192 Website :www.bis.org.in 2323 3375 Extn 4284 email : [email protected]वयापक परिचालन मं मसौदे रलेख रेषण संञापन तकनीकी सममतत ईटी 10 ............................................................................................................................................ रȯषती : 1. ईटीडी 10 कȯ सभी सदस य 2. विय ु त तकनीकी विभाग परिषद कȯ सभी सदस य तथा 3. चि िखनȯ िालȯ अन य सभी ननकाय महȪदय, क ृ प या ननम नललखखत मसȫदȯ की एक रनत संलग न हȰ : रलȯख शीषषक ईटीडी 10 (10239) घडी की बȰटिी - विलशटट ईटीडी 10 ( 10240) षािीय मंगनीज डाइऑसाइड सȯल - विलशटट ईटीडी 10 (10242) राथलमक बȰटरियां - ललचथयम बȰटरिय की स ु िषा ईटीडी 10 (10244) राथलमक बȰटरियां - जलीय इलȯरȪलाइट कȯ साथ बȰटरिय की स ु िषा ईटीडी 10 (10245) षणदीप - विलशटट ईटीडी 10 (10307) राथलमक बȰटरियां - भȫनतक औि विध ु तीय अपȯषाएं क ृ प या इस मसȫदȯ का अिलȪकन किं औि अपनी समनतयाँ यह बतातȯ ह ु ए भȯजं कक अंतत यदद यȯ मानक कȯ प मȯ रकालशत हȪ जाए तȪ इस पि अमल किनȯ मं आपकȯ ि यिसाय अथिा कािȪबाि मं क या कदिनाइयाँ आ सकती हं । समनतयाँ भȯजनȯ की अंनतम तािीख: 20-07-2016. समनतयाँ यदद कȪई हȪ तȪ क ृ प या अगलȯ प ृ ष ि पि ददए पर मं अधȪहस ताषिी कȪ उपरिललखखत पतȯ पि भȯज दं । संदभ ददनाँक ईटीडी 10/ टी – 2, 5,6,8,9,13 20-05-2016
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NOTE Open boxes in the above matrix are not necessarily available for standardization due to the concept of overlapping tolerances.
a See Annex A .
Table2–Dimensions and size codes
Dimensions in millimetres
Diameter
d4
Height h1/h2
Codea
d1
Tolerance
Codea
12 16 20 25 30 32
Tolerances
0 –0,20b
0 –0,20b
0 –0,25b
0 –0,30b
0 –0,30b
0 –0,30b
16
16
0 –0,25
5,00
1,20
1,60
2,00
2,50
3,20
20
20
0
–0,25
8,00
1,20
1,60
2,00
2,50
3,20
23
23
0 –0,30
8,00
1,20
1,60
2,00
2,50
24
24,5
0
–0,30
8,00
1,20
1,60
3,00
NOTE Open boxes in the above matrix are not necessarily available for standardization due to the concept of over-lapping tolerances.
a See Annex A.
b To be reduced in the future.
4.2 Terminals
Negative contact (–): the negative contact (dimension d4) shall be in accordance with
Tables 1 and 2.This is not applied to those batteries with a two-step negative contact.
Positive contact (+): the cylindrical surface is connected to the positive terminal.
Positive contact should be made to the side of the battery but may
be made to the base.
4.3 Projection of the negative terminal (h5)
The dimension h5 shall be as follows:
h5≥0,02 for h1/h2≤1,65
h5≥0,06 for 1,65 < h1/h2 < 2,5
h5≥0,08 for h1/h2≥2,5
NOTE the negative contact should be the highest point of the battery.
4.4 Shape of negative terminal
The space requirements shall be contained within an angle of
45°(seeFigure2).The minimum values of l1,for different heights of
h1/h2,aregiveninTable3.
h1/h
2
l1
d1 45º
IEC 156/11
Figure 2–Shape of negative terminal
Table 3–Minimum values of l1
Dimensions in millimetres
h1/h2 l1 min
1<h1/h2≤1,90 0,20
1,90<h1/h2≤3,10 0,35
3,60≤h1/h2≤4,20 0,70
5,40≤h1/h2 0,90
4.5 Mechanical resistance to pressure
A force F(N),as specified in Table 4, applied for 10s through a steel ball of 1mm
diameter, at the centre of each contact area, shall not cause any deformation prejudicial
to the proper functioning of the battery, i.e. after this test, the battery shall pass the tests
specified inClause7.
Table4–Applied force F by battery dimensions
Battery dimensions Forc
e d1
mm
h1/h2
mm
F
N
<7,9 <3,0 5
≥3,0 10
≥7,9 <3,
0
10
≥3,0 10
4.6 Deformation
The dimensions of batteries shall conform with the relevant specified dimensions at all
times including discharge to the defined end-point voltage.
NOTE1 A battery height increase up to 0.25mm can occur in B, C, L and S systems, if discharged below this voltage.
NOTE2 A battery height decrease can occur in B and C systems as discharge continues.
4.7 Leakage Undischarged batteries and, if required, batteries tested according to 7.2.6 shall be
examined as stated in 7.3.The acceptable number of defects shall be agreed between the
manufacturer and the purchaser.
4.8 Marking
4.8.1 General The designation and the polarity shall be marked on the battery. All other markings
may be given on the packing instead of on the battery:
a) Designation according to normative Annex A, or common;
b) Expiration of are commended us age period or year and month or week of
manufacture;
The year and month or week of manufacture may be in code. The code is composed by
the last digit of the year and by a number indicating the month. October, November
and December should be represented by the letters O, Y and Z respectively.
EXAMPLE
41: January 2014;
4Y: November 2014.
c) polarity of the positive(+) terminal;
d) nominal voltage;
e) name or trade mark of the supplier;
f) cautionary advice;
g) caution for ingestion of swallowable batteries shall be given. Refer to Doc ETD
(10244)
NOTE1 Battery marking should not impede electrical contact.
NOTE2 Examples of the common designations can be found in Annex D of Doc ETD (10307).
4.8.2 Disposal Marking o f batteries with respect to the method of disposal shall be in accordance with
local legal requirements. 5 ELECTRICAL REQUIREMENTS
5.1 Electro chemical system, nominal voltage, end-point voltage and open-
circuit voltage The requirements concerning the electro chemical system, the nominal voltage, the end-
point voltage and the open-circuit voltage are given in Table 5.
Table 5–Standardised electro chemical systems
Letter
Negative electrode
Electrolyte
Positive electrode
Nominal
voltage
(Vn)
V
End-point
voltage
(EV)
V
Open-circuit voltage (UOC orOCV)
V
Max. Min.
B Lithium(Li) Organic electrolyte Carbon mono
fluoride
(CF)x
3,0 2,0 3,70 3,00
C Lithium(Li) Organic electrolyte Manganese di oxide
(MnO2)
3,0 2,0 3,70 3,00
L Zinc(Zn) Alkali metal
hydroxide
Manganese di oxide
(MnO2)
1,5 1,0 1,68 1,50
S Zinc(Zn) Alkali metal
hydroxide
Silver oxide(Ag2O) 1,55 1,2 1,63 1,57
5.2 Closed circuit voltage Ucc (CCV), internal resistance and impedance
Closed circuit voltage and internal resistance shall be measured according to 7.2.AC
impedance should be measured with an LCR meter.
Limit values shall be agreed between the manufacturer and the purchaser.
5.3 Capacity
The capacity shall be agreed between the manufacturer and the purchaser on the basis of
a continuous discharge test lasting approximately 30 days, according to 7.2.6.
5.4 Capacity retention
The capacity retention is the ratio between the capacities under the given discharge
conditions measured on fresh batteries and a sample of the same lot stored during 365
days at (27±2)°C and a relative humidity between 45% and 75%.
The ratio of capacity retention shall be agreed between the manufacturer and the
purchaser. The minimum value should be at least 80% for a period of 12 months. The
capacity measurement is carried out according to 7.2.6.
6 Sampling and quality assurance
6.1 General
The use of sampling plans or product quality indices may be agreed between manufacturer
and purchaser. Where no agreement is specified, the options in 6.2 and/or 6.3 are
recommended.
h1/h
2
6.2 Sampling
6.2.1 Testing by attributes
When testing by attributes is required, the sampling plan chosen shall be in accordance
with relevant Indian standard. The individual parameters to be tested and the acceptance
quality level (AQL) values shall be defined (a minimum of three batteries of the same type
shall be tested).
6.2.2 Testing by variables When testing by variables is required, the sampling plan chosen shall be in accordance with
the relevant Indian Standard. The individual parameters to be tested, the sample and the
acceptance quality level (AQL) shall be defined.
7 Test methods
7.1 Shape and dimensions
7.1.1 Shape requirement The shape of the negative contact is checked preferably by optical projection or by an open
gauge according to Figure 3.
The measurement method shall be agreed between the manufacturer and the purchaser.
l1
d1 45°
IEC 157/11
Figure 3– Shape requirement
7.2 Electrical characteristics
7.2.1 Environmental conditions Unless otherwise specified, the sample batteries shall be tested at a temperature of
(27±2)°C and a relative humidity between 45% and 75%.
During use, batteries maybe exposed to low temperatures; it is therefore recommended to
carry out complementary tests at (0±2)°C and at(–10±2)°C.
7.2.2 Equivalent circuit–effective internal resistance– DC method Resistance of any electrical component determined by calculating the ratio between the
voltage drop ΔU across this component and the range of current Δi passing through this
component and causing the voltage drop R = ΔU / Δi.
NOTE As an analogy, the internal d.c. resistance Ri of any electro chemical cell is defined by the following relation:
Ri()ΔU(V)
(1)
Δi(A)
U
U
U
U(t
)
U'
The internal d.c. resistance is illustrated by the schematic voltage transient as given
below in Figure 4.
U1(i1)
U2=f(i2,t)
U2(i2)
∆t ∆t' t
t1 t2 t3
Figure 4– Schematic voltage transient
As can be seen from this diagram, the voltage drop ∆U of the two components differs in
nature, as shown in the following relation:
∆U=∆UΩ+∆U(t) (2) The first component ∆UΩ for (t=t1) is independent of time (ohmic drop), and results from the increase in current ∆i according to the relation:
∆UΩ=∆i × RΩ (3)
In this relation, RΩ is a pure ohmic resistance. The second component ∆U (t) is time dependent and is of electro chemical origin (capacitive reactance).
7.2.3 Equipment The equipment used for the voltage measurements shall have the following specifications:
– accuracy: ≤0,25 %;
– precision: ≤ 50 % of last digit;
– internal resistance: ≥ 1MΩ
– measurement time: in the tests proposed in the following sub clauses, it is important
to make sure that the measurement is taken during the flat period
of the voltage transient (see Figure5 ). Otherwise, a measurement
error due to the capacitive reactance may occur (lower internal
resistance). The time t' necessary for the measurement shall be brief in comparison to t, and the
measurement equipment compatible with these criteria.
U
1
2
3
4
t
t
Key
1 open-circuit voltage Uoc (OCV)
2 effect of capacitive reactance
3 closed circuit voltage Ucc(CCV)
4 Δt'(measurement Ucc)
Figure 5–Curve:U=f(t)
7.2.4 Measurement of open-circuit voltage Uoc(OCV) and closed circuit voltage Ucc(CCV)(seeFigure6)
1 V
2
Key
1 Reading Ucc/Uoc
2 Rm resistance of measurement
Figure 6– Circuitry principle First measurement Uoc: The switch is left open while this measurement is being carried
out.
Next measurement Ucc: The battery being tested shall be connected to the load Rm.The switch shall be left closed during the duration ∆t according to Table 6.
Table 6–Test method for Ucc(CCV) measurement
Test method Battery with KOH electrolytea All other batteries
Rm Ω
t s
Rm Ω
t ms
Ab 150±0,5% 1±5% 1500±0,5% 10±5%
Bc 150±0,5% 0,5–2 470±0,5% 500–2000
Cd 200±0,5% 5±5% 2000±0,5% 7,8±5%
NOTE Rm should take into consideration the resistance of the connection lines of the battery being tested and the contact resistance of the switch. a Application with high peak current.
b Method A (recommended test): requires specialized test equipment.
c Method B: to be used in the absence of method A test equipment.
d Method C: to be used only by agreement between the manufacturer and the purchaser.
7.2.5 Calculation of the internal resistance Ri
The internal resistance may be determined by the following calculation:
U -U Ri=
oc cc
Ucc/ Rm
NOTE The relation Ucc/Rm corresponds to the current delivered through the discharge resistance
Rm(see7.2.4).
7.2.6 Measurement of the capacity
7.2.6.1 General
There are two methods for measuring capacity: – The recommended method is method A, which is more indicative of watch
requirements; method B is a more general method and is already specified in Doc ETD (6901)
and Doc ETD (10244).
When presenting capacity data, the manufacturer shall specify which test method was
used.
7.2.6.2 Method A
a) Circuitry principle(seeFigure7)
1 V 3
2
Key
1 Reading Ucc/U’oc
2 Rm resistance of measurement
3 Rd resistance of continuous discharge
Figure 7–Circuitry principle for method A
b) Procedure
The duration of the discharge test at the resistor Rd approximates to
30days.
Value of the resistance Rd: the value of the resistive load (specified in Table 8 )shall include all parts of the external circuit and shall be accurate to within ±0,5%.
c) Determination of the capacity
The measurements of the open-circuit voltage U'oc and that of the closed circuit
voltage Ucc are carried out at least once a day on the battery permanently connected
to Rd, until the first passage of the Uccunder the end-point voltage defined in Table 5 is obtained.
1) First measurement U'oc: the resistance Rd being much higher than Rm, U'oc approximates to Uoc.
The switch is left open while the measurement is being carried out.
2) Next measurement Ucc: the battery being tested is connected to Rm.The switch is left closed during the duration ∆t according to Table7.
Table 7–Test method A for Ucc(CCV)measurement
Batteries with KOH electrolyte All other batteries
R
m
Ω
∆t
s
Rm
Ω
∆t
ms
150±0,5% 1±5% 1500±0,5% 10±5%
NOTE1 The value of resistive loads (which includes all parts of the external circuit) should be as specified in Table 7 and Table 8.
3) Calculation of the capacity C : the capacity of the battery is obtained by adding the partial
capacity amounts Cp, calculated after each measurement with the following formula:
U'×t
Cp= oc i
Rd
Where ti is the time between two measurements
C=ƩCp
NOTE2 At the end of the discharge, it is recommended to carry out several measurements a day in order to obtain sufficient accuracy.
7.2.6.3 Method B
a) Circuitry principle (see Figure 8 )
1 V 2
Key
1 Reading Ucc
2 Rd resistance of continuous discharge
Figure 8– Circuitry principle for method B
b) See procedure in (7.2.6.2
b).
c) Determination of the capacity: when the on-load voltage of the battery under test
drops for the first time below the specified end point as specified in Table 5, the time t
is calculated and defined as service life.
The capacity is calculated by the following formula:
where
C is the capacity;
C= Ucc(average)
t
Rd
Ucc(average)is the average voltage value of Ucc during discharge duration time (0-t);
t is the service life. 7.2.7 Calculation of the internal resistance Ri during discharge in case of
method A (optional) After each measurement of U'oc and Uccis carried out according to the procedure described in 7.2.6,it is possible to calculate the internal resistance Riof the battery using the following formula:
Ri =
′oc − cccc/m
Table 8 – Discharge resistance (values)
Code number according to the
dimensions
Letter for electro chemical systems
Code number according to the
dimensions
Letter for electro chemical systems
L S C B
Discharge resistance
kΩ
Discharge resistance
kΩ
416 1212
421 1216
510 1220 62
512 1225
514 1612
516 150 1616
521 100 1620 47
527 68 1625
610 1632
612 2012
614 120 2016 30
616 100 2020 30
621 68 2025 15
626 47 2032
710 2312
712 100 2316
714 68 2320 15
716 68 2325
721 47 2412
726 33 2416
731 27 2430
736 22
754 15
910
912
914
916 47
920 33
927 22
936 15
1110
1112
1114
1116 39
1120 22
1126 15
1130 15
1136 15
1142 10
1154 6,8
NOTE Blank values under consideration.
7.3 Test methods for determining the resistance to leakage
7.3.1 Preconditioning and previous examination
Before carrying out the tests specified in 7.3.2 and 7.3.3, the batteries shall be submitted
to a visual examination according to the requirements stated in Clause 8.
For tests in 7.3.2.1 and 7.3.2.2, batteries shall be pre conditioned at the specified
temperature (40°C and 45°C respectively) for 2h to avoid condensation at elevated
humidity.
7.3.2 High temperature and humidity test
7.3.2.1 Recommended test
The battery shall be stored under the conditions specified in Table 9.
Table 9 – Storage conditions for the recommended test
Temperatu
re
°C
Relative
humidity
%
Test
time
day 40
2
90to95 30or90
NOTE The test time of 30 days may be used for an accelerated routine quality control test, whereas the
test time of 90 days applies to qualification testing of new batteries.
7.3.2.2 Optional test
After agreement between the manufacturer and purchaser, the following testing conditions
may be chosen (see Table10).
Table 10–Storage conditions for optional test
Temperature
°C
Relative humidity
%
Test time
day
45 2 90 to 95 20 or 60
NOTE The test time of 20 days may be used for an accelerated routine quality control test, whereas the test time of 60 day applies to qualification testing of new batteries.
7.3.3 Test by temperature cycles
The battery shall be submitted to 150 temperature cycles according to the schedule
inFigure 9:
1 cycle
(60 ±2)°C
Room temperature (-10 ± 2) °C
0,5 h 1h 1h 1 h 1h
Figure 9–Test by temperature cycles
The relative humidity shall be 50% to 60% at room temperature; it will subsequently
vary with the temperature variation.
8 Visual examination and acceptance conditions
8.1 Pre conditioning Before carrying out the previous visual examination or after the tests specified in Clause7,
the batteries shall be stored for at least 24h at room temperature and at a relative humidity
between 45% and 70%.
NOTE1 The leakage should, as a rule, be observed after crystallization of the electrolyte. The time of the storage of 24h can be prolonged if necessary.
NOTE2 This examination may be applied to new or used batteries, or to batteries which have been submitted to different tests.
8.2 Magnification The visual examination shall be carried out at a magnification of x10 to x15.The
magnification of x15 is necessary in order to detect small leaks.
8.3 Lighting The visual examination shall be carried out under a diffuse white light of 900 lx to 1100 lx
at the surface of the battery to be inspected.
8.4 Leakage levels and classification The leakage levels and classification are given in Table 11.
Table 11–Leakage levels and classification
Leakage levels
Diagram
Definition Classification Grade
Salting
S1
Little salting found near the gasket, affecting less than 10 % of the perimeter of the gasket, detected while observing at a magnification of x15. The leak Is not detectable with the naked eye
S2
Traces of salting near gasket can be detected with the naked eye. At a magnification of x15, it may be noted that these salts affect more than 10 % of the perimeter of the gasket
S3
Salt spreads on both sides of the gasket can be detected with the naked eye, but do not reach the flat of the negative contact
Table 11–Leakage levels and classification (continued)
Leakage levels
Diagram
Definition Classification Grade
Clouds
C1
Leaks spread in clouds on both sides of the gasket, do reach the flat of the negative contact but do not reach the central part of the flat negative contact
C2
Leaks spread in clouds, which reach the central part of the flat negative contact
Leaks
L1
The accumulation of crystallised liquid coming from the electrolyte swells up on part of the cloud spread, which covers the entire surface of the flat negative contact
L2
The accumulation of crystallised liquid coming from the electrolyte swells up on the entire cloud spread, which covers the entire surface of the flat negative contact
8.5 Acceptance conditions
The acceptable level, as well as the proportion of defective pieces, shall be agreed between
the manufacturer and the purchaser.
Fresh batteries, with a level of leakage exceeding S1, shall not be submitted for qualification.
The acceptance criteria may be less restrictive for batteries which have been tested according
to 7.3.2. If necessary, photographic references may be established..
Annex A
(normative)
Designation
Watch batteries manufactured with the express purpose of complying with this standard
should be designated by a system of coded letters and numbers as shown below. However,
the letter W is used to indicate compliance with IS 11675.
EXAMPLE: S R 7 21 S W
Electro chemical system letter
according to Table 4
Round cell: (Doc ETD (6901)
Dimension: diameter in millimetres
Dimension: height in tenths of millimetres
Electrolyte:
- S:SodiumhydroxideNaOH(optional)
- P:PotassiumhydroxideKOH(optional)
Letter P may be left out in the case of electro chemical system letter S
- Organic electrolyte: null
Letter W: compliance with Doc ETD (10242)
Doc: ETD 10(10240)
BUREAU OF INDIAN STANDARDS
DRAFT FOR COMMENTS ONLY
(Not to be reproduced without the permission of BIS or used as a STANDARD)
Draft Indian Standard
ALKALINE MANGANESEDIOXIDE CELLS
SPECIFICATION (First Revision of IS 15063)
Last date for receipt of comments is: 20-07-2016
0 Foreword
1 (Formal clauses will be added later)
1 SCOPE
This standard covers the dimensions, tests and the performance requirements of primary alkaline Manganese
a Pulse load for 1 s every 6 s for 5 min per day. Background load alternately and
continuously for 24 h per day
Table 3J : Initial Discharge Application Test Regime and Minimum Performance Requirements for 4LR61
Representative
application
Resistance/
power /current
drain
Discharge
schedule End Voltage Life initial
life after 12
months
1 2 3 4 5 6
Electric
equipment 0.33 kΩ 24 h 3.6 24 h 19.2 h
Service
output test 6.8 kΩ 24 h 3.6 700 h 560 pulses
Table 3K : Initial Discharge Application Test Regime and Minimum Performance Requirements for
4LR25X
Representative
application
Resistance/
power /current
drain
Discharge
schedule End Voltage Life initial
life after 12
months
1 2 3 4 5 6
Portable
Lighting 1 8.2 Ω 30 min 3.6 900 min 720 min
Portable
Lighting 2 9.1 Ω
30 min on, 30
min off for 8 h
per day
3.6 1020 min 816 min
Road
warning lamp 110 Ω 12 h 3.6 310 h 248 h
Table 3L : Initial Discharge Application Test Regime and Minimum Performance Requirements for
6LR61
Representative
application
Resistance/
power /current
drain
Discharge
schedule End Voltage Life initial
life after 12
months
1 3 4 5 6 6
Toy 270 Ω 1 h/day 5.4 12 h 9.6 h
Clock radio 620 Ω 2 h/day 5.4 33 h 26.4 h
Smoke detector*
Background: 10
kΩ Pulse: 0,62 kΩ
1s on, 3599 s off
for 24 h per
day#
7.5 16 days 12.8 days
1
Doc: ETD 10(10242)
BUREAU OF INDIAN STANDARDS
DRAFT FOR COMMENTS ONLY
(Not to be reproduced without the permission of BIS or used as a STANDARD)
Draft Indian Standard
PRIMARY BATTERIES – SAFETY OF LITHIUM BATTERIES
(First revision of IS 6303(Part 4))
Last date for receipt of comments is: 20-07-2016
0 Foreword
1 (Formal clauses will be added later)
1 SCOPE
This standard specifies tests and requirements for primary lithium batteries to ensure
their safe operation under intended use and reasonably foreseeable misuse.
NOTE Primary lithium batteries that are standardized and are expected to meet all applicable requirements herein.
It is understood that consideration of this standard might also be given to measuring and/or ensuring the safety of
non-standardized primary lithium batteries. In either case, no claim or warranty is made that compliance or non-
compliance with this standard will fulfill or not fulfill any of the user’s particular purposes or needs.
2 NORMATIVE REFERENCES
The following documents, in whole or in part, are normatively referenced in this
document and are indispensable for its application. For dated references, only the
edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
IS No. Title
6303: 2016 (Under Preparation Doc ETD
10 (6901))
PRIMARY BATTERIES –
General
3 TERMS AND DEFINITIONS
For the purposes of this document, the following terms and definitions apply.
3.1 Battery
One or more cells electrically connected and fitted in a case, with terminals,
markings and protective devices etc., as necessary for use
3.2 Coin Cell Coin Battery
Small round cell or battery where the overall height is less than the diameter
NOTE 1 to entry: In English, the term “coin (cell or battery)” is used for lithium batteries only while the term “button (cell or
battery)” is only used for non-lithium batteries. In languages other than English, the terms “coin” and “button” are often used
interchangeably, regardless of the electrochemical system.
NOTE “In practice terms, the term coin is used exclusively for non-aqueous lithium cells.” replaced with a different note)]
Cell basic functional unit, consisting of an assembly of electrodes, electrolyte, container,
terminals and usually separators, that is a source of electric energy obtained by direct
conversion of chemical energy
3.4 Component Cell
Cell contained in a battery
3.5 Cylindrical (cell or battery)
Round cell or battery in which the overall height is equal to or greater than the
diameter
3.6 Depth of Discharge DOD
Percentage of rated capacity discharged from a battery
3.7 Fully Discharged
State of charge of a cell or battery corresponding to 100 % depth of discharge
3.8 Harm
Physical injury or damage to health of people, or damage to property or the environment
3.9 Hazard
Potential source of harm
3.10 Intended Use
Use of a product, process or service in accordance with information provided by the
supplier , -
3.11 Large Battery
Battery with a gross mass of more than 12 kg
3.12 Large Cell
Cell with a gross mass of more than 500 g
3.13 Lithium Cell Cell containing a non-aqueous electrolyte and a negative electrode of lithium or
containing lithium
3.14 Nominal Voltage
Suitable approximate value of the voltage used to designate or identify a cell, a battery
or an electrochemical system
3.15 Open Circuit Voltage OCV, UOC, Off-Load Voltage
Voltage across the terminals of a cell or battery when no external current is flowing
3.16 Prismatic Cell Prismatic Battery
Qualifies a cell or a battery having the shape of a parallelepiped whose faces are
rectangular
3.17 Protective Devices Devices such as fuses, diodes or other electric or electronic current limiters designed to
interrupt the current flow, block the current flow in one direction or limit the current
flow in an electrical circuit
3.18 Rated Capacity
Capacity value of a cell or battery determined under specified conditions and declared
2
by the manufacturer
3.19 Reasonably Foreseeable Misuse
Use of a product, process or service in a way not intended by the supplier, but
which may result from readily predictable human behaviour
3.20 Risk
Combination of the probability of occurrence of harm and the severity of that harm
Safety freedom from unacceptable risk
3.22 Undischarged
State of charge of a primary cell or battery corresponding to 0 % depth of discharge
4 REQUIREMENTS FOR SAFETY
4.1 Design
Lithium batteries are categorized by their chemical composition (anode, cathode,
electrolyte), internal construction (bobbin, spiral) and are available in cylindrical, coin
and prismatic configurations. It is necessary to consider all relevant safety aspects at
the battery design stage, recognizing the fact that they can differ considerably,
depending on the specific lithium system, power capability and battery configuration.
The following design concepts for safety are common to all lithium batteries:
a) Abnormal temperature rise above the critical value defined by the manufacturer
shall be prevented by design.
b) Temperature increases in the battery shall be controlled by a design which limits
current flow.
c) Lithium cells and batteries shall be designed to relieve excessive internal pressure
or to preclude a violent rupture under conditions of transport, intended use and
reasonably foreseeable misuse.
See Annex A for guidelines for the achievement of safety of lithium batteries.
4.2 Quality Plan
The manufacturer shall prepare and implement a quality plan defining the procedures
for the inspection of materials, components, cells and batteries during the course of
manufacture, to be applied to the total process of producing a specific type of battery.
Manufacturers should understand their process capabilities and should institute the
necessary process controls as they relate to product safety.
5 SAMPLING
5.1 General
Samples should be drawn from production lots in accordance with accepted
statistical methods.
5.2 Test Samples
The number of test samples is given in Table 1. The same test cells and batteries are
used for tests A to E in sequence. New test cells and batteries are required for each of
3
tests F to M.
4
Table 1 – Number of test samples
Tests
Discharge state
Cells and
single cell
batteriesa
Multi-cell
batteries
Tests A to E
Undischarged 10 4
Fully discharged 10 4
Test F or G
Undischarged 5 5 component
cells
Fully discharged 5 5 component
cells
Test H Fully discharged 10 10 component
cells
Tests I to K Undischarged 5 5
Test L Undischarged 20 (see Note 1) n/a
Test M
50 % pre
discharged
20 (see Note 2) n/a
75 % pre
discharged
20 (see Note 3) n/a
a single cell batteries containing one tested component cell do not require re-
testing unless the change could result in a failure of any of the tests.
Key:
n/a: not applicable
NOTE 1 Four batteries connected in series with one of the four batteries
reversed (5 sets). NOTE 2 Four batteries connected in series, one of which is 50
% pre discharged (5 sets).
NOTE 3 Four batteries connected in series, one of which is 75 % pre discharged (5 sets).
6 TESTING AND REQUIREMENTS
6.1 General
6.1.1 Test Application Matrix
Applicability of test methods to test cells and batteries is shown in Table 2.
Table 2 – Test application matrix
Form
Applicable tests
A B C D E F G H I J K L M
s x x x x x x a x a x x x x x b x c
m x x x x x x a,
d
x a,
d
x d x x x n/a n/a
Test description: Key:
Intended use tests
A: Altitude
B: Thermal
cycling
C: Vibration
D: Shock
Reasonably foreseeable
misuse tests
E: External short-circuit
F: Impact
G: Crush
H: Forced discharge
I: Abnormal charging
J: Free fall
K: Thermal abuse
L: Incorrect installation
Form
s: cell or single cell
battery Applicability
x: applicable
n/a: not applicable
a Only one test shall be applied, test F or test G. b Only applicable to CR17345, CR15H270 and similar type batteries of a spiral
construction that could be installed incorrectly and charged. c Only applicable to CR17345, CR15H270 and similar type batteries of a spiral
construction that could be over discharged. d Test applies to the component cells.
6.1.2 Safety Notice
WARNING: These tests call for the use of procedures which can result in injury
if adequate precautions are not taken.
It has been assumed in the drafting of these tests that their execution is
undertaken by appropriately qualified and experienced technicians
using adequate protection.
6.1.3 Ambient Temperature
Unless otherwise specified, the tests shall be carried out at an ambient
temperature of 27 °C ± 2 °C.
6.1.4 Parameter Measurement Tolerances
The overall accuracy of controlled or measured values, relative to the specified or
actual parameters, shall be within the following tolerances:
a) ± 1 % for voltage;
b) ± 1 % for current;
c) ± 2 °C for
temperature; d) ± 0,1 % for time;
e) ± 1 % for dimensions;
6
f) ± 1 % for capacity.
These tolerances comprise the combined accuracy of the measuring
instruments, the measurement techniques used, and all other sources of error in the test
procedure.
6.1.5 Pre Discharge
Where a test requires pre discharge, the test cells or batteries shall be discharged to
the respective depth of discharge on a resistive load with which the rated capacity is
obtained or at a current specified by the manufacturer.
6.1.6 Additional Cells
Where additional cells are required to perform a test, they shall be of the same
type and, preferably, from the same production lot as the test cell.
6.2 Evaluation of Test Criteria
6.2.1 Short-Circuit
A short-circuit is considered to have occurred during a test if the open-circuit
voltage of the cell or battery immediately after the test is less than 90 % of its voltage
prior to the test. This requirement is not applicable to test cells and batteries in fully
discharged states.
6.2.2 Excessive Temperature Rise
An excessive temperature rise is considered to have occurred during a test if the
external case temperature of the test cell or battery rises above 170 °C.
6.2.3 Leakage
Leakage is considered to have occurred during a test if there is visible escape of
electrolyte or other material from the test cell or battery, or the loss of material
(except battery casing, handling devices or labels) from the test cell or battery such
that the mass loss exceeds the limits in Table 3.
In order to quantify mass loss ∆m / m, the following equation is provided:
Δm / m
=
m1
- m
2 × 100 %
Where
m1 is the mass before a test;
m2 is the mass after that test.
m1
Table 3 – Mass loss limits
Mass of cell or battery m
Mass loss limit ∆m / m
m < 1
g
0,5 %
1 g ≤ m ≤
75 g
0,2 %
m > 75
g
0,1 %
0,3
m
7
6.2.4 Venting
Venting is considered to have occurred if, during a test, an excessive build up of
internal gas pressure escapes from a cell or battery through a safety feature designed
for this purpose. This gas may include entrapped materials.
6.2.5 Fire
A fire is considered to have occurred if, during a test, flames are emitted from the test
cell or battery.
6.2.6 Rupture
A rupture is considered to have occurred if, during a test, a cell container or battery
case has mechanically failed, resulting in expulsion of gas, spillage of liquids, or
ejection of solid materials but no explosion.
6.2.7 Explosion
An explosion is considered to have occurred if, during a test, solid matter from any
part of a cell or battery has penetrated a wire mesh screen as shown in Figure 1,
centred over the cell or battery on the steel plate. The screen shall be made from
annealed aluminium wire with a diameter of 0,25 mm and a grid density of 6 to 7 wires
per cm.
0,6
m
2 1
IEC
NOTE The figure shows an aluminium wire mesh screen (1) of octagonal shape resting on a steel plate (2).
Figure 1 – Mesh screen
8
6.3 Tests and Requirements – Overview
This standard provides safety tests for intended use (tests A to D) and
reasonably foreseeable misuse (tests E to M).
Table 4 contains an overview of the tests and requirements for intended use and
reasonably foreseeable misuse.
Table 4 – Tests and requirements
Test number Designation Requirements
Intended use tests A Altitude N
L,
N
V,
N
C,
N
R,
N
E,
NF
B Thermal cycling NL, NV,
NC,
N
R,
N
E,
NF
C Vibration NL, NV,
NC,
N
R,
N
E,
NF
D Shock NL, NV,
NC,
N
R,
N
E,
NF
Reasonably
foreseeable
E External short-circuit N
T,
N
R,
N
E,
NF misuse tests
Impact N
T,
N
E,
NF
F G Crush N
T,
N
E,
NF
H Forced discharge N
E,
NF
I Abnormal charging N
E,
NF
J Free fall N
V,
N
E,
NF
K Thermal abuse N
E,
NF
L Incorrect installation N
E,
NF
M Over discharge N
E,
NF
Tests A through E shall be conducted in sequence on the same cell or battery.
Tests F and G are provided as alternatives. Only one of them shall be conducted. Key
NC: No short-
circuit NE: No
explosion
NF: No fire
NL: No
leakage NR:
No rupture
NT: No excessive
6.4 Tests for Intended Use
6.4.1 Test A: Altitude
a) Purpose
This test simulates air transport under low pressure conditions.
b) Test procedure
Test cells and batteries shall be stored at a pressure of 11,6 kPa or less for at least 6 h
at ambient temperature.
9
c) Requirements
There shall be no leakage, no venting, no short-circuit, no rupture, no explosion
and no fire during this test.
6.4.2 Test B: Thermal Cycling
a) Purpose
This test assesses cell and battery seal integrity and that of their internal
electrical connections. The test is conducted using temperature cycling.
b) Test procedure
Test cells and batteries shall be stored for at least 6 h at a test temperature of 72
°C, followed by storage for at least 6 h at a test temperature of –40 °C. The maximum
time for transfer to each temperature shall be 30 min. Each test cell and battery shall
undergo this procedure 10 times. This is then followed by storage for at least 24 h at
ambient temperature.
NOTE Figure 2 shows one of ten cycles.
For large cells and batteries the duration of exposure to the test temperatures shall
be at least 12 h instead of 6 h.
The test shall be conducted using the test cells and batteries previously subjected
to the altitude test.
+72 °C
–40 °C
t2 t1 t2 t1
IEC
Key
t1 ≤ 30 min
t2 ≥ 6 h (12 h for large cells and batteries)
Figure 2 – Thermal cycling procedure
c) Requirements
There shall be no leakage, no venting, no short-circuit, no rupture, no explosion
and no fire during this test.
10
6.4.3 Test C: Vibration
a) Purpose
This test simulates vibration during transport. The test condition is based on the
range of vibrations as given by ICAO [2].
b) Test procedure
Test cells and batteries shall be firmly secured to the platform of the vibration
machine without distorting them and in such a manner as to faithfully transmit the
vibration. Test cells and batteries shall be subjected to sinusoidal vibration
according to Table 5 which shows a different upper acceleration amplitude for
large batteries. This cycle shall be repeated 12 times for a total of 3 h for each
of three mutually perpendicular mounting positions. One of the directions shall be
perpendicular to the terminal face.
The test shall be conducted using the test cells and batteries previously subjected
to the thermal cycling test.
Table 5 – Vibration profile (sinusoidal)
Frequency range Amplitudes Duration of
logarithmic
sweep cycle
(7 Hz – 200 Hz – 7
Hz)
Axis Numb
er of
cycles From To
f1 = 7 Hz f2 a1 = 1 gn
15 min
X 12
f
2 f3 s = 0,8 mm Y 12
f
3 f4 = 200
Hz
a2 Z 12
and back to f1 = 7 Hz Total 36
NOTE Vibration amplitude is the maximum absolute value of displacement or
acceleration. For example, a displacement amplitude of 0,8 mm corresponds to a Key
f1, f4 lower and upper frequency
f2, f3 cross-over frequencies;
f2 ≈ 17,62 Hz; and
f3 ≈ 49,84 Hz, except for large batteries, where f3 ≈ 24,92 Hz
a1, a2 acceleration amplitude
a2 = 8 gn except for large batteries, where a2 = 2 gn
NOTE gn = 9,80665 m / s2
c) Requirements
There shall be no leakage, no venting, no short-circuit, no rupture, no explosion
and no fire during this test.
6.4.4 Test D: Shock
a) Purpose
This test simulates rough handling during transport.
11
b) Test procedure
Test cells and batteries shall be secured to the testing machine by means of a rigid
mount which will support all mounting surfaces of each test cell or battery. Each
test cell or battery shall be subjected to 3 shocks in each direction of three
mutually perpendicular mounting positions of the cell or battery for a total of 18
shocks. For each shock, the parameters given in Table 6 shall be applied.
Table 6 – Shock parameters
Waveform
Peak
acceleration
Pulse
duration
Number of
shocks per
half axis
Cells or batteries except
large ones
Half sine 150 gn 6 ms 3
Large cells or batteries Half sine 50 gn 11 ms 3
NOTE gn = 9,80665 m / s²
The test shall be conducted using the test cells and batteries previously subjected
to the vibration test.
c) Requirements
There shall be no leakage, no venting, no short-circuit, no rupture, no explosion
and no fire during this test.
6.5 Tests for Reasonably Foreseeable Misuse
6.5.1 Test E: External Short-Circuit
a) Purpose
This test simulates conditions resulting in an external short-
circuit.
b) Test procedure
The test cell or battery shall be stabilized at an external case temperature of 55 °C
and then subjected to a short-circuit condition with a total external resistance of
less than 0,1 Ω at 55 °C. This short-circuit condition is continued for at least 1 h
after the cell or battery external case temperature has returned to 55 °C.
The test sample shall be observed for a further 6 h.
The test shall be conducted using the test samples previously subjected to the shock
test.
c) Requirements
There shall be no excessive temperature rise, no rupture, no explosion and no fire
during this test and within the 6 h of observation.
12
6.5.2 Test F: Impact
a) Purpose
This test simulates mechanical abuse from an impact that can result in an internal
short circuit.
b) Test procedure
The impact test is applicable to cylindrical cells greater than 20 mm in
diameter.
The test cell or component cell is placed on a flat smooth surface. A stainless
steel bar (type 316 or equivalent) with a diameter of 15,8 mm ± 0,1 mm
and a length of at least 60 mm or of the longest dimension of the cell,
whichever is greater, is placed across the centre of the test sample. A
mass of 9,1 kg ± 0,1 kg is dropped from a height of 61 cm ± 2,5 cm at
the intersection of the bar and the test sample in a controlled manner using
a near frictionless, vertical sliding track or channel with minimal drag on the
falling mass. The vertical track or channel used to guide the falling mass
shall be oriented 90 degrees from the horizontal supporting surface.
The test sample is to be impacted with its longitudinal axis parallel to the flat
surface and perpendicular to the longitudinal axis of the stainless steel bar lying
across the centre of the test sample (see Figure 3).
5
4
3 2
1
IEC
NOTE The figure shows a flat smooth surface (1) and a stainless steel bar (2) which is placed across the centre of the
test sample (3). A mass (4) is dropped at the intersection in a controlled manner using a vertical sliding channel (5).
Figure 3 – Example of a test set-up for the impact test
Each test cell or component cell shall be subjected to one impact only. The test sample
shall be observed for a further 6 h.
The test shall be conducted using test cells or component cells that have not
been previously subjected to other tests.
c) Requirements
There shall be no excessive temperature rise, no explosion and no fire during this
test and within the 6 h of observation.
6.5.3 Test G: Crush
a) Purpose
This test simulates mechanical abuse from a crush that can result in an internal
short circuit.
b) Test procedure
The crush test is applicable to prismatic, flexible 2, coin cells and cylindrical cells not
more than 20 mm in diameter.
A cell or component cell is to be crushed between two flat surfaces. The crushing is
to be gradual with a speed of approximately 1,5 cm / s at the first point of contact.
The crushing is to be continued until one of the three conditions below is reached:
1) The applied force reaches 13 kN ± 0,78 kN;
Example: The force can be applied by a hydraulic ram with a 32 mm diameter
piston until a pressure of 17 MPa is reached on the hydraulic ram.
2) The voltage of the cell drops by at least 100 mV; or
3) The cell is deformed by 50 % or more of its original thickness.
As soon as one of the above conditions has been obtained, the pressure shall be
released. A prismatic or flexible cell shall be crushed by applying the force to the
side with the largest surface area. A coin cell shall be crushed by applying the force
on its flat surfaces.
For cylindrical cells, the crush force shall be applied perpendicular to the longitudinal
axis. See Figure 4.
4 4 4
2 2 2
3 3
1
1
IEC
3
1
IEC
IEC
13
a) Prismatic or flexible cell b) Coin cell c) Cylindrical cell
NOTE Figures 4a) to 4c) show two flat surfaces (1 and 2) with batteries (3) of different shapes placed between
them for crushing, using a piston (4).
Figure 4 – Examples of a test set-up for the crush test
Each test cell or component cell is to be subjected to one crush only. The test sample shall
be observed for a further 6 h.
The term “flexible cell” is used in this document in place of the term “pouch cell” which
is used in [19]. It is also used in place of the terms “cell with a laminate film case” and
“laminate film cell”.
The test shall be conducted using test cells or component cells that have not
previously been subjected to other tests.
c) Requirements
There shall be no excessive temperature rise, no explosion and no fire during this test
and within the 6 h of observation.
6.5.4 Test H: Forced Discharge
a) Purpose
This test evaluates the ability of a cell to withstand a forced discharge condition.
b) Test procedure
Each cell shall be force discharged at ambient temperature by connecting it in
series with a 12 V direct current power supply at an initial current equal to the
maximum continuous discharge current specified by the manufacturer.
The specified discharge current is obtained by connecting a resistive load of
appropriate size and rating in series with the test cell and the direct current power
supply. Each cell shall be force discharged for a time interval equal to its rated
capacity divided by the initial test current.
This test shall be conducted with fully discharged test cells or component cells
that have not previously been subjected to other tests.
c) Requirements
There shall be no explosion and no fire during this test and within 7 days after the
test.
6.5.5 Test I: Abnormal Charging
a) Purpose
This test simulates the condition when a battery is fitted within a device and is
exposed to a reverse voltage from an external power supply, for example memory
back-up equipment with a defective diode (see 7.1.2). The test condition is based
upon UL 1642 [17].
b) Test procedure
Each test battery shall be subjected to a charging current of three times the
abnormal charging current Ic specified by the battery manufacturer by connecting it
in opposition to a d.c. power supply. Unless the power supply allows for setting the
current, the specified charging current shall be obtained by connecting a resistor of
the appropriate size and rating in series with the battery.
The test duration shall be calculated using the formula:
td = 2,5 × Cn / (3 × Ic)
where
td is the test duration. In order to expedite the test, it is permitted to adjust the
test parameters such that td does not exceed 7 days;
Cn is the nominal capacity;
Ic is the abnormal charging current declared by the manufacturer for this test.
c) Requirements
There shall be no explosion and no fire during this test.
6.5.6 Test J: Free Fall
a) Purpose
This test simulates the situation when a battery is accidentally dropped. The test
condition is based upon IEC 60068-2-31 [7].
b) Test procedure
The test batteries shall be dropped from a height of 1 m onto a concrete surface.
Each test battery shall be dropped six times, a prismatic battery once from each of its
six faces, a round battery twice in each of the three axes shown in Figure 5. The test
batteries shall be stored for 1 h afterwards.
The test shall be conducted with undischarged test cells and batteries.
z
x y
IEC
Figure 5 – Axes for free fall
c) Requirements
There shall be no venting, no explosion and no fire during this test and within the
1 h of observation.
6.5.7 Test K: Thermal Abuse
a) Purpose
This test simulates the condition when a battery is exposed to an extremely high
temperature.
b) Test procedure
A test battery shall be placed in an oven and the temperature raised at a rate of 5
°C/min to a temperature of 130 °C at which the battery shall remain for 10 min.
c) Requirements
There shall be no explosion and no fire during this test.
6.5.8 Test L: Incorrect Installation
a) Purpose
This test simulates the condition when one single cell battery in a set is
reversed.
b) Test procedure
A test battery is connected in series with three undischarged additional single cell
batteries of the same brand and type in such a way that the terminals of the test
battery are connected in reverse. The resistance of the interconnecting circuit shall
be no greater than 0,1 Ω. The circuit shall be completed for 24 h or until the
battery case temperature has returned to ambient (see Figure 6).
+ – – + – + – +
B1 B2...B4
IEC
Key
B1 Test cell
B2…B4 Additional cells, undischarged
Figure 6 – Circuit diagram for incorrect installation
c) Requirements
There shall be no explosion and no fire during this test.
6.5.9 Test M: Over Discharge
a) Purpose
This test simulates the condition when one discharged single cell battery is
connected in series with other undischarged single cell batteries. The test further
simulates the use of batteries in motor powered appliances where, in general,
currents over 1 A are required.
NOTE CR17345 and CR15H270 batteries are widely used in motor powered appliances where currents over 1 A are
required. The current for non-standardized batteries may be different.
b) Test procedure
Each test battery shall be pre discharged to 50 % depth of discharge. It shall then be
connected in series with three undischarged additional single cell batteries of the
same type.
A resistive load R1 is connected in series with the assembly of batteries in Figure 7
where
R1 is taken from Table 7.
The test shall be continued for 24 h or until the battery case temperature has
returned to ambient.
The test shall be repeated with 75 % pre discharged test batteries.
Table 7 – Resistive load for over discharge
Battery
type
Resistive load R1
Ω CR17345 8,20
CR15H270 8,20
NOTE Table to be modified or expanded when additional
batteries of a spiral construction are standardized.
EXAMPLE When CR17345 and CR15H270 batteries were
standardized, R1 was determined from the end voltage of the
assembly in Figure 7, using the formula
R = 4 × 2,0 V / 1 A
where
2,0 V is the end voltage taken from the specification tables in
– + – +
– + – +
B1 B2...B4
R1 IEC
Key B1 Test battery, 50 % pre discharged and, in separate tests, 75 % pre discharged.
B2... B4 Additional batteries, undischarged
R1 Resistive load
Figure 7 – Circuit diagram for over discharge
c) Requirements
There shall be no explosion and no fire during this test.
6.6 Information to Be Given In the Relevant Specification
When this standard is referred to in a relevant specification, the parameters given in
Table 8 shall be given in so far as they are applicable:
Table 8 – Parameters to be specified
Item Parameters Clause
and/or
subclaus
e a) Pre discharge current or resistive load and end-point
voltage specified by the manufacturer
6.1.5
b) Shape: prismatic, flexible, coin or cylindrical;
Diameter: not more than 20 mm or greater than 20 mm.
6.5.2 and
6.5.3
c) Maximum continuous discharge current specified by the
manufacturer for test H
NOTE Forced discharge of a cell can occur when it is
connected in series with other cells and when it is not protected
with a bypass diode.
6.5.4
d) Rated capacity specified by the manufacturer for test H 6.5.4
e) Abnormal charging current declared by the manufacturer for test I
NOTE Abnormal charging of a cell can occur when it is
connected in series with other cells and one cell is reversed or
when it is connected in parallel with a power supply
and the protective devices do not operate correctly.
6.5.5
f) Normal reverse current declared by the manufacturer which
can be applied to the battery during its operating life
NOTE Normal reverse current flow through a cell can occur
when it is connected in parallel with a power supply and the
protective devices are operating properly.
7.1.2
6.7 Evaluation and Report
When a report is issued, the following list of items should be considered:
a) name and address of the test facility;
b) name and address of applicant (where appropriate);
c) a unique test report identification;
d) the date of the test report;
e) design characteristics of the test cells or batteries according to 4.1;
f) test descriptions and results, including the parameters according to 6.6;
g) type of the test sample(s): cell, component cell, battery or battery assembly;
h) weight of the test sample(s);
i) lithium content of the sample(s);
j) A signature with name and status of the signatory.
7 INFORMATION FOR SAFETY
7.1 Safety Precautions during Design of Equipment
7.1.1 General
See also Annex B for guidelines for designers of equipment using lithium batteries.
7.1.2 Charge protection
When incorporating a primary lithium battery into a circuit powered by an
independent main power source, protective devices shall be used in order to prevent
charging the primary battery from the main power source, for example
a) a blocking diode and a current limiting resistor (see Figure 8a);
b) two series blocking diodes (see Figure 8b);
c) circuits with a similar blocking function based on two or more independent
protective devices;
provided that the first protective device is capable of limiting the charging current
through the lithium battery to the normal reverse current specified by the
manufacturer which can be applied to the battery during its operating life, while the
second protective device is capable of limiting the charging current to the abnormal
charging current specified by the battery manufacturer and used for conduction of
test I, Abnormal charging. The circuit shall be so designed that at least one of
these protective devices remains operational when any one component of the circuit
fails.
RAM RAM
+ +
– –
IEC IEC
a) Diode and resistor b) Two diodes
Figure 8 – Examples of safety wiring for charge protection
7.1.3 Parallel connection
Parallel connection should be avoided when designing battery compartments.
However, if required, the battery manufacturer shall be contacted for advice.
7.2 Safety Precautions during Handling of Batteries
When used correctly, lithium batteries provide a safe and dependable source of power.
However, if they are misused or abused, leakage, venting or in extreme cases,
explosion and/or fire can result.
a) Keep batteries out of the reach of children
In particular, keep batteries which are considered swallowable out of the reach of
children, particularly those batteries fitting within the limits of the ingestion
gauge as defined in Figure 9. In case of ingestion of a cell or battery, seek medical
assistance promptly. Swallowing lithium coin cells or batteries can cause
chemical burns, perforation of soft tissue, and in severe cases can cause death.
They must be removed immediately if swallowed. See Figure 10 for an example of
appropriate warning text.
NOTE Refer to [14] for general information on hazards from batteries.
+0,1
25,4
0
+0,1
57,1
0
+0,1 ∅ 31,7 0
IEC
Dimensions in millimetres
NOTE This gauge defines a swallowable component and is defined in ISO 8124-1 [16].
WARNING
Figure 9 – Ingestion gauge
KEEP OUT OF REACH OF CHILDREN. Swallowing
can lead to chemical burns, perforation of soft tissue, and
death. Severe burns can occur within 2 hours of ingestion.
Seek medical attention immediately.
IEC
Figure 10 – Example for warning against swallowing,
particularly lithium coin cell batteries
b) Do not allow children to replace batteries without adult supervision
c) Always insert batteries correctly with regard to polarity (+ and –) marked on the
battery and the equipment
When batteries are inserted in reverse they might be short-circuited or charged.
This can cause overheating, leakage, venting, rupture, explosion, fire and personal
injury.
d) Do not short-circuit batteries
When the positive (+) and negative (–) terminals of a battery are in electrical
contact with each other, the battery becomes short-circuited. For example loose
batteries in a pocket with keys or coins, can be short-circuited. This can result in
venting, leakage, explosion, fire and personal injury.
e) Do not charge batteries
Attempting to charge a non-rechargeable (primary) battery can cause internal gas
and/or heat generation resulting in leakage, venting, explosion, fire and personal
injury.
f) Do not force discharge batteries
When batteries are force discharged by means of an external power source, the voltage
of the battery will be forced below its design capability and gases will be generated
inside the battery. This can result in leakage, venting, explosion, fire and personal injury.
g) Do not mix new and used batteries or batteries of different types or brands
When replacing batteries, replace all of them at the same time with new batteries
of the same brand and type. When batteries of different brand or type are used
together or new and used batteries are used together, some batteries might be
over-discharged / force discharged due to a difference of voltage or capacity. This
can result in leakage, venting, explosion or fire, and can cause personal injury.
h) Exhausted batteries should be immediately removed from equipment and
properly disposed of
When discharged batteries are kept in the equipment for a long time, electrolyte
leakage can occur causing damage to the equipment and/or personal injury.
i) Do not heat batteries
When a battery is exposed to heat, leakage, venting, explosion or fire can occur
and cause personal injury.
j) Do not weld or solder directly to batteries
The heat from welding or soldering directly to a battery can cause leakage, venting,
explosion or fire, and can cause personal injury.
k) Do not dismantle batteries
When a battery is dismantled or taken apart, contact with the components can be
harmful and can cause personal injury or fire.
l) Do not deform batteries
Batteries should not be crushed, punctured, or otherwise mutilated. Such abuse can
cause leakage, venting, explosion or fire, and can cause personal injury.
m) Do not dispose of batteries in fire
When batteries are disposed of in fire, the heat build-up can cause explosion
and/or fire and personal injury. Do not incinerate batteries except for approved
disposal in a controlled incinerator.
n) A lithium battery with a damaged container should not be exposed to water
Lithium metal in contact with water can produce hydrogen gas, fire, explosion
and/or cause personal injury.
o) Do not encapsulate and/or modify batteries
Encapsulation or any other modification to a battery can result in blockage of the
safety vent mechanism(s) and subsequent explosion and personal injury. Advice
from the battery manufacturer should be sought if it is considered necessary to make
any modification.
p) Store unused batteries in their original packaging away from metal objects. If
already unpacked, do not mix or jumble batteries
Unpacked batteries could get jumbled or get mixed with metal objects. This can
cause battery short-circuiting which can result in leakage, venting, explosion or fire,
and personal injury. One of the best ways to prevent this from happening is to store
unused batteries in their original packaging.
q) Remove batteries from equipment if it is not to be used for an extended period
of time unless it is for emergency purposes
It is advantageous to remove batteries immediately from equipment which has
ceased to function satisfactorily, or when a long period of disuse is anticipated
(e.g. camcorders, digital cameras, photoflash, etc.). Although most lithium batteries
on the market today are highly leak resistant, a battery that has been partially or
completely exhausted might be more prone to leak than one that is unused.
7.3 Packaging
The packaging shall be adequate to avoid mechanical damage during transport,
handling and stacking. The materials and packaging design shall be chosen so as to
prevent the development of unintentional electrical contact, short-circuit, shifting and
corrosion of the terminals, and afford some protection from the environment.
7.4 Handling of Battery Cartons
Battery cartons should be handled with care. Rough handling might result in batteries
being short-circuited or damaged. This can cause leakage, explosion, or fire.
7.5 Transport
7.5.1 General
Tests and requirements for the transport of lithium cells or batteries are
given in IEC 62281 [12].
Regulations concerning international transport of lithium batteries are based on
the UN Recommendations on the Transport of Dangerous Goods [18].
Regulations for transport are subject to change. For the transport of lithium
batteries, the latest editions of the following regulations should be consulted.
7.5.2 Air Transport
Regulations concerning air transport of lithium batteries are specified in the Technical
Instructions for the Safe Transport of Dangerous Goods by Air published by the
International Civil Aviation Organization (ICAO) [2] and in the Dangerous Goods
Regulations published by the International Air Transport Association (IATA) [1].
7.5.3 Sea Transport
Regulations concerning sea transport of lithium batteries are specified in the
International Maritime Dangerous Goods (IMDG) Code published by the
International Maritime Organization (IMO) [13].
7.5.4 Land Transport
Regulations concerning road and railroad transport are specified on a national or
multilateral basis. W hile an increasing number of regulators adopt the UN Model
Regulations [18], it is recommended that country-specific transport regulations be
consulted before shipping.
7.6 Display and Storage
a) Store batteries in well ventilated, dry and cool conditions
High temperature or high humidity can cause deterioration of the battery
performance and/or surface corrosion.
b) Do not stack battery cartons on top of each other exceeding a specified height
If too many battery cartons are stacked, batteries in the lowest cartons might be
deformed and electrolyte leakage can occur.
c) Avoid storing or displaying batteries in direct sun or in places where they get
exposed to rain
When batteries get wet, their insulation resistance might be impaired and self-
discharge and corrosion can occur. Heat can cause deterioration.
d) Store and display batteries in their original packing
When batteries are unpacked and mixed they can be short-circuited or
damaged. See Annex C for additional details.
7.7 Disposal
Batteries may be disposed of via communal refuse arrangements provided no local
rules to the contrary exist.
During transport, storage and handling for disposal, the following safety precautions
should be considered:
a) Do not dismantle batteries
Some ingredients of lithium batteries might be flammable or harmful. They can
cause injuries, fire, rupture or explosion.
b) Do not dispose of batteries in fire except under conditions of approved and
controlled incineration
Lithium burns violently. Lithium batteries can explode in a fire. Combustion
products from lithium batteries can be toxic and corrosive.
c) Store collected batteries in a clean and dry environment out of direct sunlight
and away from extreme heat
Dirt and wetness might cause short-circuits and heat. Heat might cause leakage of
flammable gas. This can result in fire, rupture or explosion.
d) Store collected batteries in a well-ventilated area
Used batteries might contain a residual charge. If they are short-circuited,
abnormally charged or force discharged, leakage of flammable gas might be
caused. This can result in fire, rupture or explosion.
e) Do not mix collected batteries with other materials
Used batteries might contain residual charge. If they are short-circuited,
abnormally charged or force discharged, the generated heat can ignite flammable
wastes such as oily rags, paper or wood and cause a fire.
f) Protect battery terminals
Protection of terminals should be considered by providing insulation, particularly
for those batteries with a high voltage. Unprotected terminals might cause short-
circuits, abnormal charging and forced discharge. This can result in leakage, fire,
rupture or explosion.
8 INSTRUCTIONS FOR USE
a) Always select the correct size and type of battery most suitable for the
intended use. Information provided with the equipment to assist correct battery
selection should be retained for reference.
b)
c) Replace all batteries of a set at the same time.
d) Clean the battery contacts and also those of the equipment prior to battery
installation.
e) Ensure that the batteries are installed correctly with regard to polarity (+ and –).
f) Remove exhausted batteries promptly.
9 MARKING
9.1 General
With the exception of small batteries (see 9.2), each battery shall be marked
with the following information:
a) designation, IEC or common;
b) Expiration of a recommended usage period or year and month or week of
manufacture. The year and month or week of manufacture may be in code;
c) polarity of the positive (+) terminal;
d) nominal voltage;
e) name or trade mark of the manufacturer or supplier;
f) cautionary advice;
g) Caution for ingestion of swallowable batteries, see also 7.2 a).
9.2 Small Batteries
For batteries that fit entirely within the Ingestion Gauge (Figure 9) the designation 9.1
a) and the polarity 9.1c) shall be marked on the battery, while all other markings
shown in 9.1 may be given on the immediate package. However, when batteries are
intended for direct sale in consumer-replaceable applications, caution for ingestion
9.1g) shall also be marked on the immediate package.
9.3 Safety Pictograms
Safety pictograms that could be considered for use as an alternative to written
cautionary advice are provided in Annex D.
Annex A (informative)
Guidelines for the achievement of safety of lithium batteries
The guidelines given in Figure A.1 were followed during the development of high power batteries for consumer use. They are given here for information.
Design Prevent abnormal temperature rise of the battery by incorporating a current
limitation
EXAMPLE
High current drain can result in a rapid temperature increase in the lithium battery. The designer should make sure that the current drain is controlled by design. One method that has been used successfully is the incorporation of a resettable PTC which activates rapidly when the battery is exposed to a current drain exceeding its design criteria.
Provide intrinsic current limitation In the design of the battery, the designer should make sure that the current flow is limited if the battery temperature rises above its design criteria. One method that has been used successfully is to incorporate a separator system whose ability to pass current is significantly reduced with excess temperature.
Prevent explosion of the battery by a means to release internal pressure when temperature rises excessively
Lithium batteries are tightly sealed to prevent leakage. Therefore, the design of the battery should provide a method to release excessive internal pressure. This should occur at a temperature range consistent with the battery’s design criteria
Pilot production
Confirm that actual batteries can be produced according to design quality
Establish necessary safety precautions
Mass production
Mass production of batteries according to design quality
Request equipment manufacturers to carefully observe the safety
precautions
Reject defects in the production process
Make this information available to end users
Inspection Confirm that batteries meet design quality
Reject defects by the inspection
IEC
Figure A.1 – Battery design guidelines
ANNEX B (informative)
GUIDELINES FOR DESIGNERS OF EQUIPMENT USING LITHIUM BATTERIES
Table B.1 sets out the guidelines to be used by designers of equipment which employs
lithium batteries (see also Doc ETD 10 (10244) ,Annex B, for guidelines for the
design of battery compartments).
Table B.1 – Equipment design guidelines (1 of 3)
Item Sub-item Recommendations Possible
consequences if
the (1) When a
lithium
battery is used
as main power
source
(1.1) Selection of
a suitable battery
Select most suitable
battery for the
equipment, taking note
of its electrical
characteristics
Battery might
overheat
(1.2) Number of
batteries (series
connection or
parallel
connection) to be
used and method of
use
a) Multi-cell
batteries (2CR5, CR-
P2, 2CR13252
and others); one
piece only
If the capacity of
batteries in series
connection is
different, the
battery with the
lower capacity will
be over
discharged. This
can result in
electrolyte
leakage,
overheating,
rupture, explosion
or fire
b) Cylindrical
batteries (CR17345
and others); less than
three pieces
c) Coin type batteri
es (CR2016, CR2025,
CR11108 and others);
less than three pieces
d) When more than
one battery is used,
different types should
not be used in the
same battery
compartment
e) When batteries
are
used in parallela
protection against
charging should be
provided
If the voltages of
batteries in parallel
connection are
different, the battery
with the lower
voltage will
become charged.
This can result in
electrolyte
leakage,
overheating,
rupture, explosion
or fire
(1.3) Design of
battery circuit
a) Battery circuit
shall be isolated from
any other
power source
Battery might be
charged.
This can result in
electrolyte leakage,
overheating,
rupture, explosion
or fire
b) Protective
devices such as
fuses shall be
incorporated in the
circuit
Short-circuiting a
battery can result in
electrolyte leakage,
overheating,
rupture, explosion
or fire
a See 7.1.3.
Table B.1 (2 of 3)
Ite
m
Sub-
Item
Recommendatio
ns
Possible
consequences if
the (2) When a lithium
battery is used as
back-up power
source
(2.1) Design of
battery circuit
The battery should
be
used in separate
circuit so that it is
not force
discharged or
charged by the main
power source
Battery might be
over- discharged
to reverse
polarity or charged.
This can result in
electrolyte leakage,
overheating,
rupture, explosion
or fire
(2.2) Design of
battery circuit for
memory back-up
application
When a battery is
connected to the
circuit of a main
power source with
the possibility of
being
charged, a
protective circuit
must be provided
with a combination
of
diode and resistor.
The accumulated
amount of
the leakage current
of the diode should
be below 2 %
of the battery
capacity
during expected life
time
Battery might be
charged.
This can result in
electrolyte leakage,
overheating,
rupture, explosion
or fire
(3) Battery holder and battery
compartment
a) Battery
compartments
should be designed
so that if a battery is
reversed,
open circuit is
achieved. Battery
compartments should
be clearly and
permanently marked
to show the correct
orientation of
batteries
Unless protection is
provided against
battery reversal,
damage to
equipment can
occur from
resultant
electrolyte
leakage,
overheating,
rupture, explosion
or fire
b) Battery
compartments
should be designed
so that batteries
other than the
specified size cannot
be inserted and make
contact
Equipment might
be
damaged or might
not operate
c) Battery
compartments
should be designed
to
allow generated
gases to escape
Battery
compartments might
be damaged when
internal pressure of
the
battery becomes too
high due to gas
generation
d) Battery
compartments
should be designed
to be water proof
e) Battery
compartments
should be designed
to be explosion
proof when
tightly sealed
f) Battery
compartments should
be isolated from
heat generated by
the equipment
Battery might be
deformed and leak
electrolyte due to
excessive heat
g) Battery
compartments
should be designed
so that they cannot
easily be
opened by children
Children might
remove batteries
from the
compartment and
swallow them
Table B.1 (3 of 3)
Ite
m
Sub-
Item
Recommendatio
ns
Possible
consequences if
the (4) Contacts and terminals a) Material and
shape of contacts
and terminals
should be selected
so that effective
electric contact is
maintained
Heat might generate
at the contact due to
insufficient
connection
b) Auxiliary circuit
should be designed
to prevent reverse
installation of
batteries
Equipment might
be
damaged or might
not operate
c) Contact and
terminal should be
designed to
prevent reverse
installation of
batteries
Equipment might
be
damaged. Battery
might cause
electrolyte leakage,
overheating, rupture,
explosion or fire
d) Direct soldering
or
welding to a battery
should be avoided
Battery might leak,
overheat, rupture,
explode or catch
fire
(5) Indication of
necessary
precautions
(5.1) On the
equipment
Orientation of
batteries
(polarity) should be
clearly indicated at
the battery
compartment
When a battery is
inserted reverse and
charged, it
can result in
electrolyte leakage,
overheating,
rupture, explosion
or fire
(5.2) In the
instruction manual
Precautions for the
proper handling of
batteries
should be indicated
Batteries might be
mishandled and
cause accidents
ANNEX C (informative)
ADDITIONAL INFORMATION ON DISPLAY AND STORAGE
This annex provides additional details concerning display and storage of lithium
batteries to those already given in 7.6.
The storage area should be clean, cool, dry, ventilated and weatherproof.
For normal storage, the temperature should be between +10 °C and +25 °C and should
never exceed +30 °C. Extremes of humidity (over 95 % and below 40 % relative
humidity) for sustained periods should be avoided since they are detrimental to
both batteries and packings. Batteries should therefore not be stored next to radiators
or boilers nor in direct sunlight.
Although the storage life of batteries at room temperature is excellent, storage is
improved at lower temperatures provided that special precautions are taken. The
batteries should be enclosed in special protective packing (such as sealed plastic bags
or variants) which should be retained to protect the batteries from condensation
during the time they are warming to ambient temperature. Accelerated warming is
harmful.
Batteries which have been cold-stored may be put into use after return to ambient
temperature.
Batteries may be stored fitted in equipment or packages, if determined suitable by the
battery manufacturer.
The height to which batteries may be stacked is clearly dependent on the strength
of the packaging. As a general rule, this height should not exceed 1,5 m for cardboard
packages or 3 m for wooden cases.
The above recommendations are equally valid for storage conditions during prolonged
transit. Thus, batteries should be stored away from ship engines and not left for long
periods in unventilated metal box cars (containers) during summer.
Batteries shall be dispatched promptly after manufacture and in rotation to distribution
centres and on to the users. In order that stock rotation (first in, first out) can be
practised, storage areas and displays should be properly designed and packs adequately
marked.
ANNEX D (informative)
SAFETY PICTOGRAMS
D.1 General
Cautionary advice to fulfill the marking requirements in this standard has, on a
historical basis, been in the form of written text. In recent years, there has been a
growing trend toward the use of pictograms as a complementary or alternative means
of product safety communication.
The objectives of this annex are: (1) to establish uniform pictogram recommendations
that are tied to long-used and specific written text, (2) to minimize the proliferation of
safety pictogram designs, and (3) to lay the foundation for the use of safety
pictograms instead of written text to communicate product safety and cautionary
statements.
D.2 Pictograms
The pictogram recommendations and cautionary advice are given in Table D.1.
Table D.1 – Safety pictograms (1 of 2)
Referen
ce
Pictogram Cautionary advice
A
DO NOT CHARGE
B
DO NOT DEFORM OR
DAMAGE
C
DO NOT DISPOSE OF IN
FIRE
D
DO NOT INSERT
INCORRECTLY
NOTE The grey shading highlights a white margin appearing when the pictogram
is printed on coloured or black background.
Table D.1 (2 of 2)
Referen
ce
Pictogram Cautionary advice
E
KEEP OUT OF REACH OF
CHILDREN
F
DO NOT MIX
DIFFERENT TYPES OR
BRANDS
G
DO NOT MIX NEW AND
USED
H
DO NOT OPEN OR
DISMANTLE
I
DO NOT SHORT CIRCUIT
J
INSERT CORRECTLY
NOTE The grey shading highlights a white margin appearing when the pictogram
is printed on coloured or black background.
D.3 Instruction for Use
The following instructions are provided for use of the pictograms.
a) Pictograms shall be clearly legible.
b) Whilst colours are permitted, they shall not detract from the information displayed.
If colours are used, the background of pictogram J should be blue and the circle
and diagonal bar of the other pictograms should be red.
c) Not all of the pictograms need to be used together for a particular type or brand of
battery.
In particular, pictogram D and J are meant as alternatives for a similar purpose.
Doc: ETD 10(10244)
BUREAU OF INDIAN STANDARDS
DRAFT FOR COMMENTS ONLY
(Not to be reproduced without the permission of BIS or used as a STANDARD)
Draft Indian Standard
PRIMARY BATTERIES – SAFETY OF BATTERIES WITH AQUEOUS ELECTROLYTE
Last date for receipt of comments is: 20-07-2016
0 Foreword
1 (Formal clauses will be added later)
1 SCOPE
This standard specifies tests and requirements for primary batteries with aqueous
electrolyte to ensure their safe operation under intended use and reasonably
foreseeable misuse.
2 NORMATIVE REFERENCES
The following referenced documents are indispensable for the application of this
document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
IS No.
Title
Doc ETD (6901) Primary batteries - General
Doc ETD (6902) Multipurpose dry batteries
Doc ETD (10240) Alkaline battery
Doc ETD (10239) Watch batteries
Doc ETD (10307): Primary Batteries: Physical and Electrical Specifications
IEC 60068-2-6
Environmental testing – Part 2-6: Tests – Test Fc :
Vibrations (sinusoidal)
IEC 60068-2-27
Environmental testing – Part 2-27: Tests – Test Ea and
guidance: Shock
IEC 60068-2-31
Environmental testing – Part 2-31: Tests – Test Ec: Rough
handling shocks, primarily for equipment-type specimens
3 TERMS AND DEFINITIONS
For the purpose of this document, the terms and definitions given in IS 6303 as well
as the following terms and definitions apply.
3.1 Battery
One or more cells electrically connected by permanent means, fitted in a case, with
terminals, markings and protective devices etc, as necessary for use
3.2 Button Battery
Small round battery, where the overall height is less than the diameter.
3.3 Cell Basic functional unit, consisting of an assembly of electrodes, electrolyte, container,
terminals and usually separators that is a source of electric energy obtained by direct
conversion of chemical energy
3.4 Cylindrical (Cell or Battery)
Cell or battery with a cylindrical shape in which the overall height is equal to or
greater than the diameter
3.5 Explosion (Battery Explosion)
An instantaneous release wherein solid matter from any part of the battery is
propelled to a distance greater than 25 cm away from the battery
3.6 Harm
Physical injury or damage to the health of people.
3.7 Hazard
Potential source of harm
3.8 Intended Use
Use of a product, process or service in accordance with information provided by the
supplier
3.9 Leakage
Unplanned escape of electrolyte, gas or other material from a cell or battery
3.10 Nominal Voltage (Of A Primary Battery)
Vn (symbol)
Suitable approximate value of the voltage used to designate or identify a cell, a battery
or an electrochemical system
3.11 Primary (Cell or Battery)
Cell or battery that is not designed to be electrically recharged
3.12 Prismatic (Cell or Battery)
Cell or battery having the shape of a parallelepiped whose faces are rectangular
3.13 Protective Device
device such as a fuse, a diode or other electric or electronic current limiter
designed to interrupt the current flow in an electrical circuit
3.1 Reasonably Foreseeable Misuse
Use of a product, process or service in a way not intended by the supplier, but which
may result from readily predictable human behavior.
0
3.15 Risk
Combination of the probability of occurrence of harm and the severity of that harm
3.16 Round (Cell or Battery)
Cell or battery with circular cross section
3.17 Safety
Freedom from unacceptable risk
3.18 Undischarged
State of charge of a primary cell or battery corresponding to 0 % depth of discharge
3.19 Venting
release of excessive internal pressure from a battery in a manner intended by
design to preclude explosion
4 REQUIREMENTS FOR SAFETY
4.1 Design
4.1.1 General
Batteries shall be so designed that they do not present a safety hazard under
conditions of normal (intended) use.
4.1.2 Venting
All batteries shall incorporate a pressure relief feature or shall be so constructed that
they will relieve excessive internal pressure at a value and rate which will preclude
explosion. If encapsulation is necessary to support cells within an outer case, the type
of encapsulant and the method of encapsulation shall not cause the battery to overheat
during normal operation nor inhibit the operation of the pressure relief feature.
The battery case material and/or its final assembly shall be so designed that, in the
event of one or more cells venting, the battery case does not present a hazard in its own
right.
4.1.3 Insulation resistance
The insulation resistance between externally exposed metal surfaces of the battery
excluding
electrical contact surfaces and either terminal shall be not less than 5 MΩ at 500
0+100V
4.2 Quality Plan
The manufacturer shall prepare a quality plan defining the procedures for the inspection
of materials, components, cells and batteries during the course of manufacture, to be
applied to the total process of producing a specific type of battery.
A Partial use
(n = 5)
B-1 Transportation-
shock (n = 5)
B-2 Transportation-
vibration (n = 5)
C Climatic (n = 5)
5 SAMPLING
5.1 General
Samples should be drawn from production lots in accordance with accepted
statistical methods.
5.2 Sampling for Type Approval
The number of samples drawn for type approval is given in Figure 1.
Open circuit voltage (n = 70) Dimensions (n = 70)
Intended
use
Reasonably
foreseeable
misuse
D
Incorrect
installati
on see
NOTE 1
(n = 20)
E
Exter
nal
short
circui
t (n =
5)
F
Over-
discharg
e see
NOTE 2
(n =
20)
G
Fre
e
fall
(n = 5)
NOTE 1 Four batteries connected in series with one of the four batteries reversed (5 sets).
NOTE 2 Four batteries connected in series, one of which is discharged (5 sets).
Figure 1 – Sampling for type approval tests and number of batteries required
6 TESTING AND REQUIREMENTS
6.1 General
6.1.1 Applicable safety tests
Applicable safety tests are shown in Table 1.
The tests described in Tables 2 and 6 are intended to simulate conditions which the
battery is likely to encounter during intended use and reasonably foreseeable misuse.
Table 1 – Test matrix
Syste
m
letter
Nega
tive
elect
Electrolyte
Positive
electrode
No
mi
nal
vol
Fo
rm
Applicable tests
A B-
1
C D E F G
No
letter
Zinc
(Zn)
Ammonium
chloride,
Zinc
chloride
Manganese
dioxide
(MnO2)
1,5 R NR
B N
R Pr x x x x x x x
M x x x N
R
x x x
A Zinc
(Zn)
Ammonium
chloride,
Zinc
chloride
Oxygen
(O2)
1,4 R x x x N
R
x x x
B N
R Pr x x x x x x x
M x x x N
R
x x x
L Zinc
(Zn)
Alkali metal
hydroxide
Manganese
dioxide
(MnO2)
1,5 R x x x x x x x
B x x x N
R
x N
R
x
Pr x x x x x x x
M x x x N
R
x N
R
x
P Zinc
(Zn)
Alkali metal
hydroxide
Oxygen air
(O2)
1,4 R NR
B N
R
x x N
R
x N
R
x
Pr x x x x x x x
M N
R S Zinc
(Zn)
Alkali metal
hydroxide
Silver
oxide
(Ag2O)
1,55 R x x x N
R
x N
R
x
B x x x N
R
x N
R
x
Pr x x x x x x x
M N
R Test description:
A: storage after partial use Key x: required
B-1: transportation-shock R: cylindrical (3.4) NR: Not required
B-2: transportation-vibration B: button (3.2)
C: climatic-temperature cycling Pr: prismatic
single cell
(3.12)
D: incorrect installation
M:Systems L and S button cells or batteries under 250 mAh capacity and system P button cells or
batteries under 700 mAh capacity are exempt from any testing.
6.1.2 Safety notice
WARNING
These tests call for the use of procedures which may result in injury if adequate precautions are
not taken.
It has been assumed in the drafting of these tests that their execution is undertaken by
appropriately qualified and experienced technicians using adequate protection.
6.1.3 Ambient temperature
Unless otherwise specified, these tests shall be carried out at (27 ±5) °C.
6.2 Intended Use
6.2.1 Intended Use Tests and Requirements
Table 2 – Intended use tests and requirements
Test Intended use simulation Requirements
Electrical test A Storage after partial use No leakage (NL)
No fire (NF)
No explosion (NE)
Environmental
tests
B-1 Transportation-shock No leakage (NL)
No fire (NF)
No explosion (NE)
B-2 Transportation-vibration No leakage (NL)
No fire (NF)
No explosion (NE)
Climatic-
temperature
C Climatic-temperature
cycling
No fire (NF)
No explosion (NE)
6.2.2 Intended Use Test Procedures
6.2.2.1 Test A – Storage after partial use
a) Purpose
This test simulates the situation when an appliance is switched off and the installed
batteries are partly discharged. These batteries may be left in the appliance for a
long time or they are removed from the appliance and stored for a long time.
b) Test procedure
An undischarged battery is discharged under an application/service output test
condition, with the lowest resistive load test as defined in Doc ETD
(10240) ,Doc ETD (10239) and Doc ETD (10307) until the service life falls
by 50 % of the minimum average duration (MAD) value, followed by storage at (45
±5) °C for 30 days.
c) Requirements
There shall be no leakage, no fire and no explosion during this test.
6.2.2.2 Test B-1 – Transportation-shock
a) Purpose
This test simulates the situation when an appliance is carelessly dropped with
batteries installed in it. This test condition is generally specified in IEC 60068-2-27.
b) Test procedure
An undischarged battery shall be tested as follows.
The shock test shall be carried out under the conditions defined in Table 3
and the sequence in Table 4.
Shock pulse – The shock pulse applied to the battery shall be as follows:
Table 3 – Shock pulse
Accelerat
ion
Waveform Minimum average
acceleration first
three milliseconds
Peak acceleration
75 gn 125 gn to 175 gn Half sine
NOTE gn = 9,80665 m/s².
Table 4 – Test
sequence
Step Storage time Battery
orientation
Number of
shocks
Visual
examination
periods
1 – – – Pre-test 2 – a 1
each
–
3 – a 1
each
–
4
–
a
1
– 5 1
h
– – –
6 – – – Post-test
a The shock shall be applied in each of three mutually perpendicular directions.
Step 1 Record open circuit voltage in accordance with 5.2.
Steps 2 to 4 Apply shock test specified in Table 3 and the sequence in Table 4.
Step 5 Rest battery for 1 h.
Step 6 Record examination results.
c) Requirements
There shall be no leakage, no fire and no explosion during this test.
6.2.2.3 Test B-2 – Transportation-vibration
a) Purpose
This test simulates vibration during transportation. This test condition is
generally specified in IEC 60068-2-6.
b) Test procedure
An undischarged battery shall be tested as follows.
The vibration test shall be carried out under the following test conditions and the
sequence in Table 5.
Vibration – A simple harmonic motion shall be applied to the battery having an
amplitude of 0,8 mm, with a total maximum excursion of 1,6 mm. The frequency
shall be varied at the rate of 1 Hz/min between the limits of 10 Hz and 55 Hz.
The entire range of frequencies (10 Hz to 55 Hz) and return (55 Hz to 10 Hz) shall
be traversed in (90 ±5) min for each mounting position (direction of vibration).
Table 5 – Test sequence
Step Storage
time
Battery
orientation
Vibration time Visual examination
periods
1 – – – Pre-test 2 – a (90 ±5) min each –
3 – a (90 ±5) min each –
4 – a
(90 5) min
–
5 1
h
–
–
–
6 – –
–
Post-test
a The vibration shall be applied in each of three mutually perpendicular directions.
Step 1 Record open circuit voltage in accordance with 5.2.
Steps 2 to 4 Apply the vibration specified in 6.2.2.3 in the sequence in Table 5.
Step 5 Rest battery for 1 h.
Step 6 Record examination results.
c) Requirements
There shall be no leakage, no fire and no explosion during this test.
t1
6.2.2.4 Test C – Climatic-temperature cycling
a) Purpose
This test assesses the integrity of the battery seal which may be impaired
after temperature cycling.
b) Test procedure
An undischarged battery shall be tested under the following procedure. Temperature
cycling procedure (see 1) to 7) below and/or Figure 2)
1) Place the batteries in a test chamber and raise the temperature of the chamber
to (70 ±5) °C within t1 = 30 min.
2) Maintain the chamber at this temperature for t2 = 4 h.
3) Reduce the temperature of the chamber to (20 ±5) °C within t1 = 30 min and
maintain at this temperature for t3 = 2 h.
4) Reduce the temperature of the chamber to (–20 ±5) °C within t1 = 30 min and
maintain at this temperature for t2 = 4 h.
5) Raise the temperature of the chamber to (20 ±5) °C within t1 = 30 min.
6) Repeat the sequence for a further nine cycles.
7) After the 10th cycle, store the batteries for seven days prior to examination.
70 °C
20 °C
–20 °C
t1
t1 = 30 min
t2 = 4 h
t3 = 2 h
t2
t
1
t3 t1 t2 t1
IEC 427/11
Figure 2 – Temperature cycling procedure
c) Requirements
There shall be no fire and no explosion during this test.
6.3 Reasonably Foreseeable Misuse
6.3.1 Reasonably Foreseeable Misuse Tests and Requirements
Table 6 – Reasonably foreseeable misuse tests and
requirements
Test Misuse simulation Requirements
Electrical tests D Incorrect installation No fire (NF)
No explosion (NE)*
E External short circuit No fire
(NF) No
explosion
(NE)
F Overdischarge No fire
(NF) No
explosion
(NE)
Environmental test G Free fall No fire
(NF) No
explosion
(NE)
* See NOTE 2 of 6.3.2.1b)
6.3.2 Reasonably Foreseeable Misuse Test Procedures
6.3.2.1 Test D – Incorrect installation (four batteries in series)
a) Purpose
This test simulates the condition when one battery in a set is reversed.
b) Test procedure
Four undischarged batteries of the same brand, type and origin shall be
connected in series with one reversed (B1) as shown in Figure 3. The circuit shall
be completed for 24 h or until the battery case temperature has returned to ambient.
The resistance of the inter-connecting circuitry shall not exceed 0.1 Ω.
B
1
– + – + – + + –
IEC 428/11
Figure 3 – Circuit diagram for incorrect installation (four batteries in series)
NOTE 1 The circuit in Figure 3 simulates a typical misuse condition.
NOTE 2 Primary batteries are not designed to be charged. However, reversed installation of a battery in a series
of three or more exposes the reversed battery to a charging condition. Although cylindrical batteries are designed to
relieve excessive internal pressure, in some instances an explosion may not be precluded. Therefore, the user should
be clearly advised to install batteries correctly with regard to polarity (+ and –) to avoid this hazard. (See 9.1f)).
c) Requirements
There shall be no fire and no explosion during this test (see NOTE 2 of 6.3.2.1b).
6.3.2.2 Test E – External short circuit
a) Purpose
This misuse may occur during daily handling of batteries.
b) Test procedure
An undischarged battery shall be connected as shown in Figure 4. The circuit
shall be completed for 24 h or until the battery case temperature has returned to
ambient. The resistance of the inter-connecting circuitry shall not exceed 0.1 Ω.
– +
IEC 429/11
Figure 4 – Circuit diagram for external short circuit
c) Requirements
There shall be no fire and no explosion during this test.
6.3.2.3 Test F – Over discharge
a) Purpose
This test simulates the condition when one (1) discharged battery is series-
connected with three (3) other undischarged batteries.
b) Test procedure
One undischarged battery (C1) is discharged under the application or service
output test condition, with the highest MAD value (expressed in time units), as
defined in IS 15063, IS 11675 and IS XXXX until the on-load voltage falls to (n x
0,6 V) where n is the number of cells in the battery. Then, three undischarged
batteries and one discharged battery (C1) of the same brand, type and origin shall
be connected in series as shown in Figure 5. The discharge shall be continued until
the total on-load voltage falls to four times (n x 0,6 V).
The value of the resistor (R1) shall be approximately four times the lowest value from the
resistive load tests specified for that battery in IS 15063, IS 11675 and IS XXXX. The final
value of the resistor (R1) shall be the nearest value to that prescribed in 6.4 of IS 6303.
C1
– + – + – + – + R1
IEC 430/11
Figure 5 – Circuit diagram for over discharge
c) Requirements
There shall be no fire and no explosion during this
test.
6.3.2.4 Test G – Free fall test
a) Purpose
This test simulates the situation when a battery is accidentally dropped. The test
condition is based upon IEC 60068-2-31.
b) Test procedure
Undischarged test batteries shall be dropped from a height of 1 m onto a concrete
surface. Each test battery shall be dropped six times, a prismatic battery once on
each of its six faces, a round battery twice in each of the three axes shown in Figure
6. The test batteries shall be stored for 1 h afterwards.
z
x y
IEC 431/11
Figure 6 – XYZ axes for free fall
c) Requirements
There shall be no fire and no explosion during this test.
7 Information for Safety
7.1 Safety Precautions during Handling Of Batteries
When used correctly, primary batteries with aqueous electrolyte provide a safe and
dependable source of power. However, battery misuse or abuse may result in leakage,
or in extreme cases, fire and/or explosion.
a) Always insert batteries correctly with regard to the polarities (+ and –) marked
on the battery and the equipment
Batteries which are incorrectly placed into equipment may be short-circuited, or
charged. This can result in a rapid temperature rise causing venting, leakage,
explosion and personal injury.
b) Do not short-circuit batteries
When the positive (+) and negative (–) terminals of a battery are in electrical
contact with each other, the battery becomes short-circuited. For example loose
batteries in a pocket and/or handbag with keys or coins can be short-circuited. This
may result in venting, leakage, explosion and personal injury.
c) Do not charge batteries
Attempting to charge a non-rechargeable (primary) battery may cause internal gas
and/or heat generation resulting in venting, leakage, explosion and personal injury.
d) Do not force discharge batteries
When batteries are force discharged with an external power source, the voltage
of the battery will be forced below its design capability and gases will be
generated inside the battery. This may result in venting, leakage, explosion and
personal injury.
e) Do not mix old and new batteries or batteries of different types or brands
When replacing batteries, replace all of them at the same time with new batteries
of the same brand and type.
When batteries of different brand or type are used together, or new and old
batteries are used together, some batteries may be over-discharged due to a
difference of voltage or capacity. This can result in venting, leakage and explosion
and may cause personal injury.
f) Exhausted batteries should be immediately removed from equipment and
properly disposed of
When discharged batteries are kept in the equipment for a long time, electrolyte
leakage may occur causing damage to the appliance and/or personal injury.
g) Do not heat batteries
When a battery is exposed to heat, venting, leakage and explosion may occur and
cause personal injury.
h) Do not weld or solder directly to batteries
The heat from welding or soldering directly to a battery may cause internal short-
circuiting resulting in venting, leakage and explosion and may cause personal injury.
i) Do not dismantle batteries
When a battery is dismantled or taken apart, contact with the components can be
harmful and may cause personal injury or possibly fire.
0
25,4
+0
,1
0
57,1
+0
,1
0
j) Do not deform batteries
Batteries should not be crushed, punctured, or otherwise mutilated. Such abuse may
result in venting, leakage and explosion and cause personal injury.
k) Do not dispose of batteries in fire
When batteries are disposed of in fire, the heat build-up may cause explosion and
personal injury. Do not incinerate batteries except for approved disposal in a
controlled incinerator.
l) Keep batteries out of the reach of children
Especially keep batteries which are considered swallowable out of the reach of
children, particularly those batteries fitting within the limits of the ingestion
gauge as defined in Figure 7. In case of ingestion of a cell or a battery, the person
involved should seek medical assistance promptly.
Dimensions in millimetres
∅ 31,7 +0,1
IEC 265/11
Figure 7 – Ingestion gauge (Inner dimensions)
m) Do not allow children to replace batteries without adult supervision
n) Do not encapsulate and/or modify batteries
Encapsulation, or any other modification to a battery, may result in blockage of the
safety vent mechanism(s) and subsequent explosion and personal injury. Advice
from the battery manufacturer should be sought if it is considered necessary to make
any modification.
o) Store unused batteries in their original packaging away from metal objects. If
already unpacked, do not mix or jumble batteries.
Unpacked batteries could get jumbled or get mixed with metal objects. This can
cause battery short-circuiting which may result in venting, leakage and explosion
and personal injury; one of the best ways to avoid this happening is to store
unused batteries in their original packaging.
p) Remove batteries from equipment if it is not to be used for an extended period
of time unless it is for emergency purposes.
It is advantageous to remove batteries immediately from equipment which has
ceased to function satisfactorily, or when a long period of disuse is anticipated
(e.g. still-cameras, photoflash, etc.). Although most batteries on the market today
are provided with protective jackets or other means to contain leakage, a battery
that has been partially or completely exhausted may be more prone to leak than one
that is unused.
7.2 Packaging
The packaging shall be adequate to avoid mechanical damage during transport,
handling and stacking. The materials and packaging design shall be chosen so as to
prevent the development of unintentional electrical contact, corrosion of the
terminals and some protection from the environment.
7.3 Handling of Battery Cartons
Rough handling of battery cartons may result in battery damage and impaired
electrical performance and may result in leakage, explosion, or possibly fire.
7.4 Display and Storage a) Batteries shall be stored in well-ventilated, dry and cool conditions
High temperature or high humidity may cause deterioration of the battery
performance or surface corrosion.
b) Battery cartons should not be piled up in several layers (or should not exceed a
specified height)
If too many battery cartons are piled up, batteries in the lowest cartons may be
deformed and electrolyte leakage may occur.
c) When batteries are stored in warehouses or displayed in retail stores, they should
not be exposed to direct sun rays for a long time or placed in areas where they get
wet by rain
When batteries get wet, their insulation resistance decreases, self-discharge may
occur and rust may be generated.
d) Do not mix unpacked batteries so as to avoid mechanical damage and/or short-
circuit among each other
When mixed together, batteries may be subjected to physical damage or overheating
resulting from external short circuit. Leakage and/or explosion may then occur.
To avoid these possible hazards, batteries should be kept in their packaging until
required for use.
e) See Annex A for additional details
7.5 Transportation
When loaded for transportation, battery packages should be so arranged to minimise
the risk of falling e.g. one from the top of another. They should not be stacked so high
that damage to the lower packages occurs. Protection from inclement weather should be
provided.
7.6 Disposal
a) Do not dismantle batteries.
b) Do not dispose of batteries in fire except under conditions of controlled incineration.
c) Primary batteries may be disposed of via the communal refuse arrangements,
provided that no local rules to the contrary exist.
d) Where there is provision for the collection of used batteries, the following
should be considered:
i. Store collected batteries in a non-conductive
container.
ii. Store collected batteries in a well-ventilated area. Since some used batteries
may still contain a residual charge, they could be short circuited, charged or
force discharged and thereby evolve hydrogen gas. If collection containers
and storage areas are not properly ventilated, hydrogen gas can build up and
explode in the presence of an ignition source.
iii. Do not mix collected batteries with other materials. Since some used batteries
may still contain a residual charge, they could be short circuited, charged or
force discharged. The subsequent possible heat generation can ignite
flammable wastes such as oily rags, paper or wood and can cause a fire.
iv. Consider protecting used battery terminals, particularly those batteries with
high voltage, to preclude short circuits, charging and force discharging, for
instance, by means of covering battery terminals with insulating tape.
v. Failure to observe these recommendations may result in leakage, fire, and/or
explosion.
8 Instructions for use
a) Always select the correct size and grade of battery most suitable for the
intended use. Information provided with the equipment to assist correct battery
selection should be retained for reference.
b) Replace all batteries of a set at the same time.
c) Clean the battery contacts and also those of the equipment prior to battery
installation.
d) Ensure that the batteries are installed correctly with regard to polarity (+ and –).
e) Remove batteries from equipment which is not to be used for an extended period of
time.
f) Remove exhausted batteries promptly.
9 MARKING
9.1 General (see Table 7)
With the exception of small batteries (see 9.2), each battery shall be marked
with the following information:
a) designation, IEC or common;
b) expiration of a recommended usage period or year and month or week of
manufacture. The year and month or week of manufacture may be in code;
c) polarity of the positive (+) terminal;
d) nominal voltage;
e) name or trade mark of the manufacturer or supplier;
f) cautionary advice.
NOTE The common designation can be found in Annex D of Doc ETD 10 (10307).
9.2 Marking Of Small Batteries (See Table 7)
a) Batteries designated in IEC as small, mainly category 3 and category 4 batteries
have a surface too small to accommodate all markings shown in 9.1. For these
batteries the designation 9.1a) and the polarity 9.1c) shall be marked on the battery.
All other markings shown in 9.1 may be given on the immediate packing instead of
on the battery.
b) For P-system batteries, 9.1a) may be on the battery, the sealing tab or the
immediate packing. 9.1c) may be marked on the sealing tab and/or on the battery.
9.1b), 9.1d) and 9.1e) may be given on the immediate packing instead of on the
battery.
c) Caution for ingestion of swallowable batteries shall be given. Refer to 7.1l) for
details.
Table 7 – Marking requirements
Marking
Batteries
with the
exception of
Small batteries
P-
system a) Designation, IEC or common A A C
b) Expiration of a recommended usage
period or year and month or week of
manufacture. The
year and month or week of
A
B
B
c) Polarity of the positive (+) terminal A A D
d) Nominal voltage A B B
e) Name or trade mark of the
manufacturer or supplier
A
B
B
f) Cautionary advice A Ba Ba
A: shall be marked on the battery.
B: may be marked on the immediate packing instead on the battery.
C: may be marked on the battery, the sealing tab or the
immediate packing. D: may be marked on the sealing tab
and/or on the battery.
a Caution for ingestion of swallowable batteries shall be given. Refer to
7.1 l).
ANNEX A (informative)
Additional Information To 7.4
The purpose of this annex is to describe these good practices in general terms and,
more specifically, to warn against procedures known from experience to be harmful.
It takes the form of advice to battery manufacturers, distributors, users, and equipment
designers.
Storage and stock rotation
a) For normal storage, the temperature should be between +10 °C and +35 °C and
should never exceed +40 °C. Extremes of humidity (over 95 % RH and below 40 %
RH) for sustained periods should be avoided since they are detrimental to both
batteries and packing. Batteries should therefore not be stored next to radiators or
boilers nor in direct sunlight.
b) Although the storage life of batteries at room temperature is good, storage is
improved at lower temperatures provided special precautions are taken. The
batteries should be enclosed in special protective packing (such as sealed plastic
bags or variants) which should be retained to protect them from condensation
during the time they are warming to ambient temperature. Accelerated warming is
harmful.
c) Batteries which have been cold-stored should be put into use as soon as possible
after return to ambient temperature.
d) Batteries may be stored fitted in equipment or packages if determined suitable
by the battery manufacturer.
e) The height to which batteries may be stacked is clearly dependent on the strength
of the pack. As a general guide, this height should not exceed 1,5 m for cardboard
packs or 3 m for wooden cases.
f) The above recommendations are equally valid for storage conditions during
prolonged transit. Thus, batteries should be stored away from ship engines and
not left for long periods in unventilated metal box cars (containers) during summer.
g) Batteries should be dispatched promptly after manufacture and in rotation to
distribution centres and on to the users. In order that stock rotation (first-in, first-
out) can be practised, storage areas and displays should be properly designed and
packs should be adequately marked.
ANNEX B (informative)
Battery Compartment Design Guidelines
B.1 Background
B.1.1 General
In order to meet the ever-growing advances in battery-powered equipment
technology, primary batteries have become more sophisticated in both chemistry and
construction with resultant improvements to both capacity and rate capability.
Resulting from these continuing developments and recognising the need for both
safety and optimum battery performance it was established that the majority of
reported battery failures resulted from electrical abuse generally arising from
consumer accidental misuse.
The following text and figures are intended to aid the battery-powered equipment
designer to significantly reduce or eliminate such battery failures.
B.1.2 Battery failures resulting from poor battery compartment design
Poor battery compartment design may lead to reversed battery installation or to
short- circuiting of the batteries.
B.1.3 Potential hazards resulting from battery reversal
If a battery is reversed in a circuit with three or more batteries in series as shown in
Figure B.1, the following potential hazards exist:
a) charging of the reversed battery;
NOTE The charging current limited by the external circuit/load.
b) gas generation within the reversed battery;
c) vent activation of the reversed battery;
d) leakage of electrolyte from the reversed battery.
NOTE Battery electrolytes are harmful to body tissues.
Reversed battery
IEC 432/11
Figure B.1 – Example of series connection with one battery reversed
B.1.4 Potential Hazards Resulting From A Short Circuit
a) Heat generation resulting from high current flow.
b) Gas generation.
c) Vent activation.
d) Electrolyte leakage.
e) Heat damage to insulating jackets (e.g. shrinkage).
NOTE Battery electrolytes are harmful to body tissues and generated heat can cause burns.
B.2 General Guidance for Appliance Design
B.2.1 Key Battery Factors to Be First Considered
These guidelines are essentially directed toward cylindrical batteries with sizes
ranging from R1 to R20. The battery systems involved are commonly referred to as
alkaline manganese and zinc carbon. Whilst the two systems are interchangeable they
should never be used in combination.
The following physical differences between the two systems and permitted design
features should be noted during the early phases of battery compartment design.
a) The positive terminal of the alkaline manganese battery is connected to the battery
case.
b) The positive terminal of the zinc carbon battery is insulated from the battery
case.
c) Both battery types have an outer insulated jacket. This may be of paper, plastic or
other non-conductive material. On occasion, the outer jacket may be metallic
(conductive); in such instances this is insulated from the basic unit.
d) When forming the negative contact it should be noted that the corresponding battery
terminal may be recessed. (For clarification refer to IS 6303). To ensure good
electrical contact, completely flat negative equipment contacts should be avoided.
e) Under no circumstances should battery connectors or any part of the equipment
circuitry come into contact with the battery jacket. Any design of battery
compartment permitting this, risks the possibility of a short circuit.
NOTE For example, helical (not parallel) springs used for negative connection should compress uniformly when the battery
is inserted and not bridge across to the battery jacket. (Spring connection to the positive terminal of a battery is not
recommended.)
B.2.2 Other Important Factors to Consider
a) It is recommended that companies producing battery-powered equipment should
maintain close liaison with the battery industry. The capabilities of existing
batteries should be taken into account at design inception. W henever possible, the
battery type selected should be one included in IS 8144 Doc ETD 10 (6902), IS
15063 Doc ETD 10 (10240), Doc ETD 10 (10242).
b) Design compartments so that batteries are easily inserted and do not fall out.
c) Design compartments to prevent easy access to the batteries by young children.
d) Dimensions should not be tied to a particular battery manufacturer as this can create
problems when replacements of different origin are installed. Only consider the
battery dimensions and tolerances defined within Doc ETD 10 (6902), Doc ETD
10 (10240), Doc ETD 10 (10242)when designing the battery compartment.
e) Clearly indicate the type of battery to use, the correct polarity alignment (+ and
–) and directions for insertion.
f) Although batteries are very much improved regarding their resistance to leakage,
it can still occasionally occur. When the battery compartment cannot be completely
isolated from the equipment, it should be positioned so as to minimise possible
equipment damage from battery leakage.
g) Design equipment circuitry such that equipment will not operate below 0,7 V per
battery (0,7 V x ns where ns is the number of batteries connected in series).
To continue discharging below this level may result in unfavourable chemical
reactions within the battery/batteries resulting in leakage.
B.3 Specific Measures Against Reversed Installation
B.3.1 General
To overcome the problems associated with the reversed placement of a battery,
consideration should be given at the design stage to ensure that batteries cannot be
installed incorrectly or, if so installed, will not make electrical contact.
B.3.2 Design Of The Positive Contact
Some suggestions for the R03, R1, R6, R14 and R20 size battery compartments are
illustrated in Figures B.2 and B.3 below. Provision should also be made to prevent
unnecessary movement of batteries within the battery compartment.
NOTE Battery contacts should be shielded to prevent contact during reverse
installation.
Insulated ribs hold the
negative terminal away
from contact
IEC 433/11
IEC 434/11
Figure B.2a – Correct insertion of the battery Figure B.2b – Incorrect
insertion of the battery
Figure B.2 – Positive contact recessed between ribs
Negative terminal contacts only the insulated surround
IEC 436/11
IEC 435/11
Figure B.3a – Correct insertion of the battery Figure B.3b – Incorrect
insertion of the battery
Figure B.3 – Positive contact recessed within surrounding insulation
B.3.3 Design of the Negative Contact
The following suggestion is given for R03, R1, R6, R14 and R20 size battery
compartments (see Figure B.4).
Positive terminal does not contact U-shaped negative contact but only
insulated centre
IEC 437/11
IEC 438/11
Figure B.4a – Correct insertion of the battery Figure B.4b – Incorrect
insertion of the battery
Figure B.4 – Negative contact U-shaped to ensure no positive (+) battery contact
B.3.4 Design With Respect To Battery Orientation
In order to avoid reverse insertion of batteries, it is recommended that all batteries
have the same orientation. Examples are shown in Figures B.5a and B.5b.
Figure B.5a shows the preferred battery arrangement inside a device while Figure B.5b
shows an alternative recommendation.
IEC 439/11
NOTE Protection of the positive contact should be as shown in Figures B.2 and B.3.
Figure B.5a – Preferred battery orientation
IEC 440/11
NOTE 1 Protection of the contacts should be as shown in Figures B.2 or B.3 for the positive and Figure B.4 for the
negative contact.
NOTE 2 This arrangement (Figure B.5b) is only considered practical for R14 and R20 size batteries due to the
small negative terminal area (dimension C of the relevant specification) of the other sizes.
Figure B.5b – Alternative recommendation for battery orientation
Figure B.5 – Design with respect to battery orientation
B.3.5 Dimensional Considerations
Table B.1 provides critical dimensional details relating to the battery terminals and
the recommended dimensions for the devices positive contact. By making reference to
Figure B.6, and designing in accordance with the dimensions shown in Table B.1,
subsequent reversal of a battery, such that its negative terminal is presented to the
devices positive contact, will result in a ‘fail safe’ situation, i.e. there will be no
electrical contact.
Table B.1 – Dimensions of battery terminals and recommended
dimensions of the positive contact of an appliance in Figure B.6
SAMPLING PLAN AND CRITERIA FOR CONFORMITY FOR FLASHLIGHTS
C-1 LOT
C-1.1 All the flashlights of the same type and size
manufactured by the same factory during the same
period, using the same materials and process shall
constitute a lot.
C-1.2 Sample shall be tested from each lot.
C -2 SCALE OF SAMPLING
C-2.1 The number of flashlights to be selected from
each lot shall depend upon the lot size and shall be in
accordance with col 1 and 2 of Table 1.
Table 1
Sample Size and Permissible Number of Defectives
( Clause C-2.1 )
Lot Size Sample Size Permissible No.
of Defectives
( N) (n) (a)
(1) (2) (3)
Up to 100 13 1
101 to 300 20 2
301 to 500 32 3
501 to 1000 50 5
1001 and above 80 7
NOTES:
Whenever the lot size is below 14 all the flashlights
shall be tested and no defective flashlight shall be
permissible.
The sampling plan is such that the lots with 4 percent
or less defectives would be accepted most of the time
C-2.2 Flashlights shall be selected at random. In order
to ensure the randomness of selection, suitable
Procedures as given in IS 4905 : 1968 shall be
adopted.
C-3 NUMBER OF TESTS AND CRITERIA FOR
CONFORMITY
C-3.1 All the flashlights selected in the sample shall be
subjected to the acceptance tests given in 8.2. A
flashlight shall be called a defective if it fails in any
one of the acceptance tests. The lot shall be considered
as conforming to the requirements of the acceptance
tests, if the num9ber of flashlight failing to satisfy in
any one or more of the acceptance tests does not
exceed the corresponding number of permissible
defective (see col 3 Table 1).
ANNEX D
( Annex A 3.2 )
SPECIFICATION OF LED AS LIGHT SOURCE OF FLASHLIGHT
D-1 LUMEN: Unit of flux. It is equal to the flux
emitted in a solid angle of one steradian by uniform
point source of one candela.
D-2 Rated Value — The quantitative value for the
characteristic of a LED under specific operating
conditions. The value and the conditions are assigned
by the manufacturer.
D-3 Test Voltage, Current or Power — Input voltage,
current or power at which tests are carried out.
D-4 Efficacy: Quotient of the luminous flux emitted
by the power consumed by the LED. LED efficacy
shall be calculated from the measured initial luminous
flux of the LED divided by the measured initial input
power of the same LED. Up to one watt the efficacy
shall be minimum 100 lumen/ watt at rated voltage
and rated current declared by the manufacturer
D-5: Lumen maintenance: Value of the luminous flux
at a given time in the life of a LED divided by the
initial value of the luminous flux of the LED and
expressed as a percentage of the initial luminous flux
value.
Lumen maintenance of LED shall have a minimum
value of initial luminous flux when subjected to 1000
hour test at rated current and rated voltage specified
by manufacturer as mentioned in the table D1A .
D-6:TESTS : Type Tests The following shall
constitute the type tests to be carried out on selected
sample of LED being drawn from regular production
lot.
For method of measurement refer to IS 16106.
Dimension of integrating sphere shall be
20 cm to 50 cm as per CIE 127.
TABLE : D1A
LED wattage Initial lumen
Minimum Lumen
after 1000Hr
<=0.4W 100% 50%
>0.4W & <=3W 100% 80%
Table D1 Sampling Sizes
(Annex D)
Sl
No
Ref of Clause Test Minimum Number of
Samples
1 Annex D ( D-4 ) Efficacy 5
2 Annex D ( D-5 ) Lumen maintenance 5
6
ANNEX E
COLOUR NOMENCLATURE, VARIATION AND RENDERING OF LED AS A LIGHT SOURCE
E.1 COLOUR NOMENCLATURE, VARIATION
AND RENDERING
E.1.1: CCT and Chromaticity Co-Ordinate: The
chromaticity of a LED is measured both initially and
maintained after an operation time of 1000 Hrs at rated
voltage and current. To comply with this standard, the
measured initial and maintained chromaticity values of
each LED in the sample shall be within the range as
mentioned in table E1 and colour tolerances shall fall
within the area on the chromaticity chart bounded by
straight lines joining the 12 points indicated for the
colours as specified in Table E2.
TABLE : E1
LED wattage Cool white(CCT)
Intermediate White
(CCT) Warm White(CCT)
<0.4W 5600K-23000K 4000K-5000K 2500K-3500K
>0.4W & <=3W 5600K-10000K 4000K-5000K 2500K-3500K
TABLE: E2
Cool white (5500K-23000K)
LED
wattage
<0.4W
X 0.32
5 0.313 0.301
0.272
5 0.251 0.223 0.242 0.281 0.314 0.34 0.359
0.37
3
Y 0.34
4 0.356 0.271 0.285 0.283 0.275 0.242 0.26 0.281
0.30
1 0.32
0.33
7
Cool white (5500K-10000K)
LED
wattage
>0.4W
& <=3W
X 0.33 0.33 0.33 0.314 0.315 0.287
5
0.291
7 0.279
0.287
5
0.29
8 0.309
0.31
7
Y 0.31
8
0.342
5 0.368 0.355 0.342
0.320
5 0.318 0.288 0.275
0.28
8 0.301
0.30
9
Intermediate white(4000-5000K)
LED
wattage
<0.4W &
<=3W
X 0.37
7
0.378
5
0.377
2
0.373
4
0.368
2
0.368
8 0.359
0.357
5
0.358
9
0.36
3
0.367
9
0.37
3
Y 0.38
4
0.350
3
0.374
3
0.367
2
0.361
2 0.358
0.358
1
0.361
7
0.367
7
0.37
5
0.380
7
0.38
4
Warm white(2500-3500K)
LED
wattage
<0.4W &
<=3W
X 0.44
6
0.447
9
0.446
8
0.443
5
0.438
5
0.433
5
0.429
6
0.428
1
0.429
1
0.43
3
0.437
5
0.44
3
Y 0.41
2
0.408
5
0.402
9 0.397
0.391
9
0.389
5 0.39
0.393
7
0.399
1
0.40
5
0.410
1
0.41
3
E.1.2 (colour rendering index ) CRI: Minimum CRI
value shall be greater than equal to (Ra) 40. Initial colour
rendering index of an LED shall be measured as is the
value after total operation of 1000hrs .To comply this
standard all measured Initial CRI values shall be greater
than or equal to the rated CRI Value(declared by
manufacturer) less than 3 points and all measured
maintained CRI values (at 1000 hrs) shall be greater than
or equal to rated CRI value(declared by manufacturer)
less 5 points
For method of measurement refer to IS 16106.
Dimension of integrating sphere will be 20cm to 50
cm.
(Annex E)
Table E1 Sampling Sizes
Sl
No
Ref of Clause Test Minimum Number of
Samples
1 Annex E ( E1.1 ) CCT and Chromaticity Co-Ordinate 5
2 Annex E ( E.1.2 ) colour rendering index(CRI) 5
Page No: 1
Doc: ETD 10(10307)
BUREAU OF INDIAN STANDARDS
DRAFT FOR COMMENTS ONLY
(Not to be reproduced without the permission of BIS or used as a STANDARD)
Draft Indian Standard
PRIMARY BATTERIES –
Part 2: Physical and electrical specifications
Last date for receipt of comments is: 16-07-2016
0 Foreword 1 (Formal clauses will be added later)
1 SCOPE
This part of IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901) is applicable to primary batteries based on standardized electro- chemical systems.
It specifies
– The physical dimensions,
– The discharge test conditions and discharge performance requirements.
2 Normative References
The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901) Primary batteries General
3 TERMS, DEFINITIONS, SYMBOLS AND ABBREVIATIONS
For the purposes of this document, the terms, definitions, symbols and abbreviations given in IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901) and the following apply. 3.1 Terms and Definitions 3.1.1 Application Test Simulation of the actual use of a battery in a specific application
3.1.2 CLOSED-CIRCUIT VOLTAGE CCV Voltage across the terminals of a battery when it is on discharge
Page No: 2
3.1.3 End-Point Voltage Ev
Specified voltage of a battery at which the battery discharge is terminated 3.1.4 Minimum Average Duration MAD
Minimum average time on discharge which is met by a sample of batteries
Note 1 to entry: The discharge test is carried out according to the specified methods or standards and designed to show conformity with the standard applicable to the battery types.
3.1.5 Nominal Voltage (Of A Primary Battery) Vn
Suitable approximate value of the voltage used to designate or identify a cell, a battery or an electrochemical system
3.1.6 Open-Circuit Voltage OCV
Voltage across the terminals of a cell or battery when it is off discharge
3.1.7 Primary (Cell or Battery)
Cell or battery that is not designed to be electrically recharged
3.1.8 Round (Cell or Battery) Cell or battery with circular cross section
3.1.9 Service Output (Of A Primary Battery)
Service life, or capacity, or energy output of a battery under specified conditions of discharge
3.1.10 Service Output Test
Test designed to measure the service output of a battery
Note 1 to entry: A service output test may be prescribed, for example, when
a. an application test is too complex to replicate. b. The duration of an application test would make it impractical for routine testing
purposes. 3.1.11 Storage Life
Duration under specified conditions at the end of which a battery retains its ability to perform a specified service output
3.1.12 Terminals (Of A Primary Battery) Conductive parts of a battery that provide connection to an external circuit
3.2 SYMBOLS AND ABBREVIATIONS
EV end-point voltage MAD minimum average duration OCV open-circuit voltage (off-load voltage)
Page No: 3
R load resistance Vn nominal voltage of a primary battery
Page No: 4
4 BATTERY DIMENSIONS, SYMBOLS The symbols used to denote the various dimensions are as follows:
h1 maximum overall height of the battery;
h2 minimum distance between the flats of the positive and negative contacts;
h3 minimum projection of the flat positive contact;
h4 maximum recess of the negative flat contact surface;
h5 minimum projection of the flat negative contact; d1 maximum and minimum diameters
of the battery; d2 minimum diameter of the flat positive contact;
d3 maximum diameter of the positive contact within the specified projection height;
d4 minimum diameter of the flat negative contact;
d5 maximum diameter of the negative contact within the specified projection height;
d6 minimum outer diameter of the negative flat contact surface;
d7 maximum inner diameter of the negative flat contact surface;
P concentricity of the positive contact.
Recesses are permitted in the negative flat contact surface defined by dimensions d6 and d7 for batteries having the shape shown in Figure 1a, provided that batteries placed end to end in series make electrical contact with each other and that the contact separation is an integral multiple of the contact separation for one battery. The following conditions shall be satisfied:
d6 > d3 d2 > d7 h3 > h4
5 CONSTITUTION OF THE BATTERY SPECIFICATION TABLES
5.1 Batteries Are Categorized Into Several Groups According To Their Shapes.
5.2 In each category, batteries having the same shape but belonging to a different electrochemical system are grouped together and shown in succession.
5.3 Batteries are always listed in ascending order of nominal voltage and, within each nominal voltage, in ascending order of volume.
5.4 One common shape drawing of these batteries which fall in the same group is exhibited.
5.5 Designation, nominal voltage, dimensions, discharge conditions, minimum average duration and application for these batteries which fall into the same group are summarized in one table.
5.6 When a drawing represents only one type of battery, the dimensions of the relevant battery may be directly shown on the drawing.
5.7 Batteries are categorized into the following groups:
a) Category 1 batteries
Page No: 5
FR10G445, FR14505
b) Category 2 batteries CR14250, CR15H270, CR17345, CR17450, BR17335
5.8 The specification drawings show the shape of the relevant batteries. Dimensions for each battery are shown in the tables of Clause 6.
NOTE See Annexes A, B and C for ease of locating battery sizes.
P
h2
h4
h
3
h6
h
4
h3
h
1
6 PHYSICAL AND ELECTRICAL SPECIFICATIONS
6.1 Category 1 Batteries
6.1.1 General
d
3 d
2
1 d3 2
3
d7
d
6 d
1
For the definition of the dimensions, see Clause 4. The cylindrical surface is insulated from the contacts. Terminals: flat/cap and base. For general information, see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)
Figure 1a: negative contact surface may not be flat over the whole area.
Figure 1b: negative contact surface shall be essentially flat over the whole surface area.
For batteries complying with Figures 1a and 1b, flat negative contact is not necessarily recessed.
When the flat negative contact surface forms the lower part of the battery, dimensions "h1" and "h2" are both measured from the surface and dimension "h4" is zero.
Dimensions "P" to be measured in
accordance with ISO 1101.
The profile over the dotted lines is not specified. 1: Positive contact 2: Optional pip (Dimension "h6" for
batteries having the pip is 0,4 mm max.)
3: Negative contact area
Page No: 6
P
h2
h4
h
3
h6
h
4
h3
h
1
Figure 1a
d3
1 2 d3
3
d6 d1
Figure 1b
Figure 1 – Dimensional
drawing: Category 1
P
h2
h
4
h3
h1
Dimensions FR14505
h1 max. 50,5
h2 min. 49,5
h3 min. 1,0
h4 max. 0,5
d1
max. 14,5
min. 13,7
d3 max. 5,5
d6 min. 7,0
P
max.
0,25
6.1.2 Category 1 – Specifications: FR14505
Dimensions in millimetres
d3
d6
d1
Figure 4 – Dimensional drawing:
FR14505
Electrochemical system letter F
IEC designation
FR14505 Common designation AA, FR6 Vn (V) 1,5
OCV max. (V) 1,83
Delayed discharge performance
after 12 months
95 Application
s Load Daily
Period EV
(V) MADa
(Initial) Digital still camera
1 500 mW 650 mW
b
1,05
370 pulses
Page No: 8
High Intensity lighting
1000 mW
4 min on, 11 min off for 8 h per day
1,0
120 min
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
b Repeat 10 times per hour: 1 500 mW for 2 s, then 650 mW for 28 s, then 0 mW for
P
h2
h
4
h3
h1
Dimensions
FR10G445
h1 max. 44,5
h2 min. 43,5
h3 min. 0,8
h4 max. 0,5
d1
max. 10,5
min. 9,8
d3 max. 3,8
d6 min. 4,3
P
max.
0,25
6.1.3 Category 1 – Specifications: FR10G445
Dimensions in millimetres
d3
d
6 d
1
Figure 5 – Dimensional drawing:
FR10G445
Electrochemical system letter F
IEC designation FR10G445 Common
designation AAA, FR03 Vn
(V)
1,5 OCV
max. (V) 1,83 Delayed discharge performance after 12 months
(% of MAD) 95
Applications Load Daily Period EV
(V) MADa
(Initial) Digital still camera
1 200 mW 650 mW
b
1,05
100 pulses
Digital audio
50 mA
1 h on, 11 hr off for 24 h
0,9
16 h
High Intensity lighting
400 mW
4 min on, 11 min off for 8 h per day
1,0
140 min
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
b Repeat 10 times per hour: 1 200 mW for 2 s, then 650 mW for 28 s, then 0 mW for
Clause 4. The cylindrical surface is insulated from the contacts. Terminals: flat/cap and base. For general information, see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
b A period of at least 10 min shall elapse between activation and commencement of electrical measurement.
c Equipment designers' attention is drawn to the importance of making positive
electrical contact on the side of the battery so that air access is not impeded for "P" system batteries.
d The pulse load alone shall be applied across the battery. It is the effective load. It is not added in series or parallel to the background load. See diagram in footnote f.
e f Six repeated cycles of the pulse load for 100 ms, followed by the background load
for 119 min, 59 s, 900 ms, then off for 12 h.
g Twelve repeated cycles of the pulse load for 15 min, followed by the background load for 45 min, then off for 12 h.
Delayed discharge performance after 12 months (% of MAD)
90
IEC designatio
n
Commo
n
designati
on
Test
Load
Dail
y
Peri
od
EV
(V)
MADa
(Initial)
SR62 SR516
Service output test
82 kΩ 24 h 1,2
390 h SR63 379, SR521 Service output
test 68 kΩ 24 h 1,
2 560
h SR65 SR616
Service output test
100 kΩ 24 h 1,2
810 h SR64 SR5
27 Service output test
56 kΩ 24 h 1,2
540 h SR60 363, 364,
SR621 Service output test
68 kΩ 24 h 1,2
685 h SR67 SR7
16 Service output test
68 kΩ 24 h 1,2
820 h SR66 376, 377,
SR626 Service output test
47 kΩ 24 h 1,2
680 h SR58 361, 362,
SR721 Service output test
47 kΩ 24 h 1,2
518 h SR68 373, SR916 Service output
test 47 kΩ 24 h 1,
2 680
h SR59 396, 397, SR726
Service output test
33 kΩ 24 h 1,2
530 h SR69 370, 371,
SR921 Service output test
33 kΩ 24 h 1,2
663 h SR41 384, 392 Service output
test 22 kΩ 24 h 1,
2 450
h SR57 395, 399, SR927
Service output test
22 kΩ 24 h 1,2
500 h SR55 381, 391 Service output
test 22 kΩ 24 h 1,
2 450
h SR48
309, 393
Hearing aid 1,5 kΩ 12 h 0,9
40 h
Service output test
15 kΩ 24 h 1,2
580 h SR54 389, 390,
SR1130 Service output test
15 kΩ 24 h 1,2
580 h SR42 344, 350, 387 Service output
test 15 kΩ 24 h 1,
2 670
h SR43 301, 386 Service output test
10 kΩ 24 h 1,2
620 h
SR44
303, 357
Service output test
6,8 kΩ 24 h 1,2
620 h
Accelerated application
test for
Pulse: 39 Ω
Β
Ω
b,c
0,9
450 h
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4,Initial discharge test).
b Pulse load for 1 s every 6 s for 5 min per day. Background load alternately and continuously for 24 h per day
c The pulse load alone shall be applied across the battery. It is the effective load. It is not added in series or parallel to the background load. See diagram below.
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
b Pulse load for 1 s every 6 s for 5 min per day. Background load alternately and continuously for 24 h per day
c The pulse load alone shall be applied across the battery. It is the effective load. It is not added in series or parallel to the background load. See diagram below.
Background load Background load Background load
Pulse load Pulse load Pulse load
Background discharge Pulse discharge No discharge IEC
6.5.2 Category 5 – Specifications: 5AR40
Dimensions in millimeters
–
Dimensions 5AR40
A max. 190,0
Ø max. 184,0
Terminals: Screw terminals. Terminals located on top surface.
Maximum terminal stud diameter: 4,2 mm. For general information, see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)
Electrochemical system letter A
IEC designation 5AR4
0a Common designation --
Vn (V) 7,0 OCV max. (V) 7,75 Delayed discharge performance after 12 months (% of
MAD) 80
Applications Load Daily
Period EV (V) MADb
(initial) Electric fence controller
240 Ω 24 h 4,5 120 days a Equipment designers' attention is drawn to the importance of ensuring that air
access is not impeded for "A" system batteries. b Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10
(6901)Table 4, Initial discharge test).
l 7
=
=
l 2
Dimensions 3R12P 3R12S
h1
max. 67,0 67,0
min. 63,0 63,0
l1
max. 62,0 62,0
min. 60,0 60,0
l2
max. 22,0 22,0
min. 20,0 20,0
l3
max. - -
min. 23,0 23,0
l4
max. - -
min. 16,0 16,0
l5
max. - -
min. 1,0 1,0
l6
max. - -
min. 3,0 3,0
l7
max. 7,0 7,0
min. 6,0 6,0
Terminals: spring clips.
For general information, see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)
6.6 CATEGORY 6 BATTERIES
6.6.1 Category 6 – Specifications: 3R12P, 3R12S
Dimensions in millimetres
l3
l5 l4
l6
(–) (+)
= = l
1
Figure 19 – Dimensional drawing: 3R12P,
3R12S
Electrochemical system letter No letter
No letter
IEC designation 3R12P
High
power
3R12S
Standard
Common
designation - -
Vn
(V)
4,5
4,5
OCV
max. (V) 5,19
5,19
Delayed discharge performance after 12 months
(% of MAD) 80 80
Applications Load Daily
Period EV
(V) MADa (Initial)
Portable lighting
20 Ω 1 h
2,7 5,5 h 3,5 h
Radio
220 Ω
4 h
2,7 96 h
96 h
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
l 5
l 6
l h
6
l h
1
Dimensions CR-P2
h1
max. 36,0
min. 34,5
h4
max. 1,5
min. 0,7
h6
max. 1,0
min. 0,1
l1
max. 35,0
min. 32,5
l2
max. 19,5
min. 18,5
l3 - 16,8
l4 - 8,4
l5
max. 16,2
min. 15,3
l6
max. 9,8
min. 9,2
l7
max. 8,7
min. 7,5
l8
max. -
min. 1,3
r1
max. 10,0
min. 7,4
Terminals: flat contacts.
contacts are recessed.
For general information, see IS 6303:2016
(under preparation)
h4
7
2
r
6.6.2 Category 6 – Specifications: CR-P2
Dimensions in millimetres
(–)
l1
1
(+)
l8 1
r1
l4
l3
Figure 21 – Dimensional drawing: CR-P2
Electrochemical system letter C
IEC designation CR-P2 Common
designation 223 Vn
(V)
6,0
OCV
max. (V) 7,4 Delayed discharge performance after 12 months (% of
MAD) 98 Applications Loa
d Daily Period EV
(V) MADa
(Initial) Photo
Current drain 900
3 s on, 27 s off for 24 h
3,
1 400 pulses
Service output test 200 Ω
24 h 4,0
40 h a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10
(6901)Table 4, Initial discharge test).
l 7
l 6
l
5 l 2
Dimensions 2CR5
h1
max. 45,0
min. 43,0
h6
max. 0,9
min. 0,1
h7
max. 4,5
min. 3,5
l1
max. 34,0
min. 32,5
l2
max. 17,0
min. 16,0
l3 - 16,0
l4 - 8,0
l5
max. 15,5
min. -
l6
max. 1,0
min. 0,2
l7
max. 4,5
min. 3,5
l8
max. 4,6
min. 3,5
r1
max. 9,0
min. 8,0
Terminals: flat contacts.
For general information, see IS 6303:2015.
6.6.3 Category 6 – Specifications: 2CR5
Dimensions in millimetres
l
1 r1
(–)
(+)
l8
l
4 l3
Figure 22 – Dimensional drawing: 2CR5
Electrochemical system letter C
IEC designation 2CR5
Common
designation 245 Vn
(V)
6,0 OCV
max. (V) 7,4 Delayed discharge performance after 12 months (% of
MAD) 98
Applications Loa
d Daily Period EV
(V) MADa
(Initial) Photo
Current drain 900
3 s on, 27 s off for 24 h
3,
1 400 pulses
Service output test 200 Ω
24 h 4,0
40 h a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10
(6901)Table 4, Initial discharge test).
l 2
Dimensions 4R25X
h1
max. 115
min. 108
h6
max. 102
min. 97
l1
max. 67
min. 65
l2
max. 67
min. 65
l3
max. 27
min. 23
- 45°
Terminals: spiral springs having at least three complete windings compressible to within 3 mm of the flat surface of the box.
This battery has rounded or bevelled corners and shall pass freely through a gauge having a diameter of 82,6 mm.
For general information, see IS
6303:2016 (under preparation)
1: Conical spiral wire spring terminals
6.6.4 Category 6 – Specifications: 4R25X
Dimensions in millimetres
h 1
h6
1
l3
(–)
(+)
l1
Figure 23 – Dimensional drawing:
4R25X
Electrochemical system letter No letter
IEC designation 4R25X
Vn
(V)
6,0 OCV
max. (V) 6,92 Delayed discharge performance after 12 months (%
of MAD) 80 Applications Load Daily Period EV
(V) MADa
(Initial) Portable Lighting 1
8,2 Ω 30 min 3,6 350 min
Portable Lighting
9,1 Ω
30 min on, 30 min off for 8 h
3,6
270 min
Road warning lamp
110 Ω 12 h
3,6
155 h a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION
Terminals: screw terminals (insulated or metallic nuts).
The maximum terminal stud diameter is 3,5 mm.
This battery has bevelled or rounded corners and shall pass freely through a gauge having a diameter of 82,6 mm.
For general information, see IS
6303:2016 (under preparation)
2
6.6.5 Category 6 – Specifications: 4R25Y
Dimensions in millimetres
l3
(–)
l1
(+)
Figure 24 – Dimensional drawing: 4R25Y
Electrochemical system letter No letter
IEC designation 4R25Y
Vn
(V)
6,0
OCV max. (V) 6,92
Delayed discharge performance after 12 months (% of MAD)
80
Applications Load Daily Period EV
(V) MADa
(Initial) Portable Lighting 1
8,2 Ω
30 min 3,6
350 min
Portable Lighting
9,1 Ω
30 min on, 30 min off for 8
3,
270 min
Road warning lamp
110 Ω 12 h 3,6 155 h
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
l h
6
h
1
Dimensions 4R25-2
h1
max. 127,0
min. -
h6
max. 114,0
min. 109,5
l1
max. 136,5
min. 132,5
l2
max. 73,0
min. 69,0
l3
max. 77,0
min. 75,2
r min. 14,0
Terminals: screw terminals (insulated nuts).
Maximum terminal stud diameter = 4,2 mm.
Minimum diameter of bearing surface of terminal = 6,3 mm.
For general information, see IS
6303:2016 (under preparation)
1: Insulated nuts
2
6.6.6 Category 6 – Specifications: 4R25-2
Dimensions in millimetres
1
(+) (–)
l3 r
l1
Figure 25 – Dimensional drawing:
4R25-2
Electrochemical system letter No letter
IEC designation 4R25-2
Vn
(V)
6,0
OCV
max. (V) 6,92
Delayed discharge performance after 12 months (% of MAD)
80
Applications Load Daily Period EV
(V) MADa (Initial)
Portable Lighting 1
8,2 Ω 30 min 3,6
900 min
Portable Lighting
9,1 Ω
30 min on, 30 min off for 8 h
3,6
696 min
Road warning lamp
110 Ω 12 h
3,6
200 h
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
l 2
Dimensions 6F22 6LP3146
h1
max. 48,5 48,5
min. 46,5 46,5
h6
max. 46,4 46,4
min. - -
l1
max. 26,5 26,5
min. 24,5 24,5
l2
max. 17,5 17,5
min. 15,5 15,5
l3
max. 12,95 12,95
min. 12,45 12,45
Terminals: miniature snap fasteners.
For general information, see IS 6303:2016 (under
preparation)
1: Socket
2: Stud
6.6.7 Category 6 – Specifications: 6F22,6LP3146
Dimensions in millimetres
1 2
(–) (+)
l
3 l
1
Figure 26 – Dimensional drawing:
6F22, 6LP3146
Electrochemical system letter No letter
L
IEC designation 6F22 6LP3146
Common
9V
9V, 6LF22
Vn (V) 9,0
9,0
OCV
max. (V) 10,4
10,1
Delayed discharge performance after 12 months
(% of MAD) 80 90
Applications Load Daily Period EV
(V) MADa (Initial)
Toy 270 Ω 1 h
5,4
7 h
12 h
Clock radio 620 Ω 2 h 5,4 24 h 33 h
Smoke
detectorb
Background: 10
kΩ Pulse:
Ω
1 s on, 3 599 s off for 24 h
per dayc
7,5
8 days
16 days
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test)
b This is an accelerated test
c The pulse load alone shall be applied across the battery. It is the effective load. It is not added in series or parallel to the background load. See diagram below.
Background load Background load Background load
Pulse load Pulse load Pulse load
h7
h8
Dimensions 6F22
6LP3146
h7
max. 3,10
min. 2,90
h8
max. (2,55)
min.
l4
max. 5,77
min. 5,67
l5
max. (5,38)
min.
r1
max. (0,8)
min.
r2
max. (0,4)
min.
6.6.8 Category 6 – Configurations: Stud for 6F22, 6LP3146
Dimensions in millimetres
l4
r1
r2
l5
Figure 27 – Dimensional drawing: Stud
l 2
h1
Dimensions 6AS4
h1 max. 114
l1 max. 168
l2 max. 113
Terminals: wire.
Minimum free length of connecting wires = 200 mm.
For general information, see IS 6303:2016 (under preparation)
1: Wire
6.6.9 Category 6 – Specifications: 6AS4
Dimensions in millimetres
1
(–)
(+)
l1
Figure 28 – Dimensional drawing: 6AS4
Electrochemical system letter A
IEC designation 6AS
4b Vn
(V)
8,4 OCV max. (V) 9,30
Delayed discharge performance after 12 months (% of MAD)
80
Applications Load Daily Period EV
(V) MADa
(Initial) Electric fence controller
300 Ω 24 h 5,4 80 days
a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10 (6901)Table 4, Initial discharge test).
l 2
h
1
Dimensions 6AS6
h1 max. 162
l1 max. 192
l2 max. 128
Terminals: wire.
Minimum free length of connecting wires = 200 mm.
The wire ends may be fitted with special terminals.
For general information, see IS 6303:2016 (under preparation)
1: Wire
6.6.10 Category 6 – Specifications: 6AS6
Dimensions in millimetres
1
(–)
(+)
l1
Figure 29 – Dimensional drawing: 6AS6
Electrochemical system letter A
IEC designation 6AS6b Vn
(V)
8,4 OCV max. (V) 9,30
Delayed discharge performance after 12 months (% of MAD)
80
Applications Load Daily Period EV
(V) MADa
(Initial) Electric fence controller
300 Ω 24 h 5,4 120 days a Standard conditions (see IS 6303 : 2016 UNDER PREPARATION DOC ETD 10
(6901)Table 4, Initial discharge test). b Equipment designers' attention is drawn to the importance of ensuring that air
access is not impeded for "A" system batteries.
Annex A
( informative)
Tabulation of batteries by application Each of the Tables A.1 to A.17 lists all the batteries for which there is a discharge test given in this specification for that application.
Within each table the batteries are listed in ascending order of nominal voltage and, within each nominal voltage, in ascending order of volume.
Table A.1 – Automatic camera
Designati
on Nominal voltage
V SR4
4 4SR44
1,55
6,2
Table A.2 – Digital
audio
Designati
on Nominal
voltage FR10G4
45 1,5
Table A.3 – Digital still camera
Designati
on Nominal
voltage FR14505 FR10G4
45
1,5
Table A.4 – Electric fence controller
Designati
on Nominal
voltage 5AR40
6AS
7,0
8,
Table A.5 – Electronic key
Designati
on Nominal
voltage CR202
5
3,0
3,0
Table A.6 – Hearing aid
Designati
on Nominal
voltage SR4
8
1,5
Table A.7 – Hearing aid high drain
Designati
on Nominal
voltage PR7
0
1,4
Table A.8 – Hearing aid standard
Designati
on Nominal
voltage PR7
0 1,4 PR4
1 1,4 PR4
8 1,4 PR4
4 1,4
Table A.9 – High intensity lighting
Designati
on Nominal
voltage FR10G4
45
1,5
1,5 Table A.10 – Photo
Designati
on Nominal
voltage CR15H
270 3,0 CR173
45 3,0 CR-
P2 6,0
2CR5
6,0
Table A.11 – Portable lighting (LED)
Designati
on Nominal
voltage 3R12
P 4,5
3R12S
4,5 4R25
X 6,0 4R25
Y 6,0 4R25-
2 6,0
Table A.12 – Radio
Designati
on Nominal
voltage 3R12
P 4,5 3R12
S 4,5
Table A.13 – Radio / Clock
Designati
on Nominal
voltage 6F2
2 9,0
6LP3146
9,0
NOTE The application for the 6F22 and 6LP3146 is Clock radio
Table A.14 – Road warning lamp
Designati
on Nominal
voltage 4R25
X 6,0 4R25
Y 6,0 4R25-
2 6,0
Table A.15 – Smoke detector
Designati
on Nominal
voltage 6F2
2
9,0
9,0
Table A.16 – Toy (motor)
Designati
on Nominal
voltage 6LP31
46 9,0
Table A.17 – Wireless streaming
Designati
on Nominal
voltage PR4
1
1,4
Annex B
(informative)
Cross-reference index Batteries having the same physical dimensions may belong to a different electrochemical system.
In order to allow physically interchangeable batteries from different electrochemical systems to be compared in terms of electrical performance, a cross-reference is given in Tables B.1 to B.6.
Batteries are ranked per category and in each category by chemistry and by shape/size. Batteries are always ranked by voltage and in each voltage by volume.
The index in Table C.1 provides for the relation between a particular battery and its physical dimensions and application/service output test requirements.
In this index, the batteries are ranked by increasing number of the numerical part after the alphabetical part of the designation. In the case where two batteries have the same numerical part, they are ranked alphabetically according to the alphabetical part of the designation. In the case where these two rules still do not allow a clear ranking, further distinction is made by the increasing numerical part before the alphabetical part of the designation.
Table C.1 – Index
Battery Pag
e Battery Pag
e Battery Page
CR-P2 21
PR41 10
CR15H270 8
2CR5 22
SR41 14
CR1025 16 FR10G445 7 SR42 1
4 CR1216 1
6 3R12P 22
SR43 14
CR1220 16 3R12S 2
2 PR44 1
0 BR1225 1
6 5AR40 21
SR44 14
CR1616 16 6AS4 2
8 4SR44 1
8 CR1620 1
6 6AS6 29
PR48 10
CR2012 16 6F22 2
6 SR48 1
4 BR2016 1
6 6LP3146 26
SR54 14
CR2016 16 4R25X 2
3 SR55 1
4 CR2025 1
6 4R25Y 24
SR57 14
CR2032 16 4R25-2 2
5 SR58 1
4 BR2320 1
6 SR59 14
CR2320 16 SR60 1
4 BR2325 1
6 SR62 14
CR2330 16 SR63 1
4 CR2354 1
6 SR64 14
CR2430 16 SR65 1
4 CR2450 1
6 SR66 14
BR3032 16 SR67 1
4 CR3032 1
6 SR68 14
CR11108 9 SR69 1
4 2CR13252 1
8 PR70 10
CR14250 8 FR14505 6 BR17335 8
CR17345 8 CR17450 8
Annex D
(informative)
Common designation
The index in Table D.1 provides a cross-reference for IEC and common designations of batteries for marking purposes.
Table D.1 – Index
IEC Designatio
Common
Designatio
IEC Designation
Common
Designation IEC
Designation Commo
n CR-P2 22
3 PR4
1 312
CR15H270
CR2 FR10G44
5 AAA, FR03
SR41
384, 392 CR1025 1025 2CR5 24
5 SR4
2 344, 350, 387 CR1216 121
6 FR14505 AA, FR6 SR43
301, 386 CR1220 1220 3R12P -
- PR4
4 675
BR1225 -- 3R12S -
- SR4
4 303, 357 CR1616 161
6 6F22
9V
4SR44 -- CR1620 1620 6LP3146 9V,
6LF22 PR4
8 13
CR2012 2012 4R25X -
- SR4
8 309, 393 BR2016 -
- 4R25Y --
SR54
389, 390, SR1130
CR2016 2016 4R25-2 -
- SR5
5 381, 391 CR2025 202
5 SR57
395, 399, SR927
CR2032 2032 SR5
8 361, 362, SR721
BR2320 -- SR5
9 396, 397, SR726
CR2320 2320 SR6
0 363, 364, SR621
BR2325 -- SR6
2 SR516
CR2330 2330 SR6
3 379, SR521 CR2354 235
4 SR64
SR527
CR2430 2430 SR6
5 SR616
CR2450 2450 SR6
6 376, 377, SR626
BR3032 -- SR6
7 SR716
CR3032 3032 SR6
8 373, SR916 CR11108 1/3
N SR69
370, 371, SR921
2CR13252 2CR-1/3N, 28L PR7
0 10, PR536 CR14250 CR-1/2AA
BR17335 BR-2/3A
CR17345 123, CR123A CR17450 CR-
A 5AR40 --
6AS4
-- 6AS
6 --
Batteries having a letter ‘W’ at the end of the common designation should comply with Doc ETD (10242), where more detailed dimensions and test conditions are specified.