EN 60086-5:2005

SLOVENSKI SIST EN 60086-5:2005

STANDARD
september 2005
Primarne baterije – 5. del: Varnost baterij z vodnim elektrolitom (IEC 60086-
5:2005)
Primary batteries – Part 5: Safety of batteries with aqueous electrolyte (IEC 60086-
5:2005)
ICS 29.220.10 Referenčna številka
©  Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno

EUROPEAN STANDARD EN 60086-5
NORME EUROPÉENNE
EUROPÄISCHE NORM May 2005
ICS 29.220.10 Supersedes EN 60086-5:2000

English version
Primary batteries
Part 5: Safety of batteries with aqueous electrolyte
(IEC 60086-5:2005)
Piles électriques Primärbatterien
Partie 5: Sécurité des piles Teil 5: Sicherheit von Batterien
à électrolyte aqueux mit wässrigem Elektrolyt
(CEI 60086-5:2005) (IEC 60086-5:2005)

This European Standard was approved by CENELEC on 2005-04-01. CENELEC members are bound to
comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration.

Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.

This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and
notified to the Central Secretariat has the same status as the official versions.

CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden,
Switzerland and United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2005 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. EN 60086-5:2005 E
Foreword
The text of document 35/1225/FDIS, future edition 2 of IEC 60086-5, prepared by IEC TC 35, Primary
cells and batteries, was submitted to the IEC-CENELEC parallel vote and was approved by CENELEC
as EN 60086-5 on 2005-04-01.
This European Standard supersedes EN 60086-5:2000.
It is the result of a reformatting initiative aimed at making it more user-friendly, less ambiguous and,
from a cross-reference point of view, fully harmonized with other parts of EN 60086. In addition, and
from a safety perspective, the standard contains further guidance for appliance designers with respect
to battery compartment design together with information regarding packaging, handling, warehousing
and transportation.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2006-02-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2008-04-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 60086-5:2005 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 60086-3 NOTE Harmonized as EN 60086-3:2005 (not modified).
IEC 60086-4 NOTE Harmonized as EN 60086-4:2000 (not modified).
IEC 60068-2-6 NOTE Harmonized as EN 60068-2-6:1995 (not modified).
IEC 60068-2-27 NOTE Harmonized as EN 60068-2-27:1993 (not modified).
IEC 60068-2-32 NOTE Harmonized as EN 60068-2-32:1993 (not modified).
__________
- 3 - EN 60086-5:2005
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
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.
NOTE Where an international publication has been modified by common modifications, indicated by (mod), the relevant
EN/HD applies.
Publication Year Title EN/HD Year
IEC 60050-482 2004 International Electrotechnical Vocabulary- -
Part 482: Primary and secondary cells
and batteries
IEC 60086-1 2000 Primary batteries EN 60086-1 2001
Part 1: General
IEC 60086-2 2000 Part 2: Physical and electrical EN 60086-2 2001
specifications
NORME CEI
INTERNATIONALE IEC
60086-5
INTERNATIONAL
Deuxième édition
STANDARD
Second edition
2005-04
Piles électriques –
Partie 5:
Sécurité des piles à électrolyte aqueux
Primary batteries –
Part 5:
Safety of batteries with aqueous electrolyte
© IEC 2005 Droits de reproduction réservés ⎯ Copyright - all rights reserved
Aucune partie de cette publication ne peut être reproduite ni No part of this publication may be reproduced or utilized in any
utilisée sous quelque forme que ce soit et par aucun procédé, form or by any means, electronic or mechanical, including
électronique ou mécanique, y compris la photocopie et les photocopying and microfilm, without permission in writing from
microfilms, sans l'accord écrit de l'éditeur. the publisher.
International Electrotechnical Commission, 3, rue de Varembé, PO Box 131, CH-1211 Geneva 20, Switzerland
Telephone: +41 22 919 02 11 Telefax: +41 22 919 03 00 E-mail: inmail@iec.ch Web: www.iec.ch
CODE PRIX
PRICE CODE V
Commission Electrotechnique Internationale
International Electrotechnical Commission
ɆɟɠɞɭɧɚɪɨɞɧɚɹɗɥɟɤɬɪɨɬɟɯɧɢɱɟɫɤɚɹɄɨɦɢɫɫɢɹ
Pour prix, voir catalogue en vigueur
For price, see current catalogue

60086-5 © IEC:2005 – 3 –
CONTENTS
FOREWORD.7
INTRODUCTION.11
1 Scope.13
2 Normative references .13
3 Terms and definitions .13
4 Requirements for safety .17
4.1 Design.17
4.1.1 General .17
4.1.2 Venting.17
4.1.3 Insulation resistance .17
4.2 Quality plan.17
5 Sampling .19
5.1 General .19
5.2 Sampling for type approval.19
6 Testing and requirements .21
6.1 General .21
6.1.1 Safety notice .23
6.1.2 Ambient temperature .23
6.2 Intended use .23
6.2.1 Intended use tests and requirements .23
6.2.2 Intended use test procedures .23
6.3 Reasonably foreseeable misuse .29
6.3.1 Reasonably foreseeable misuse tests and requirements.29
6.3.2 Reasonably foreseeable misuse test procedures.29
7 Information for safety.33
7.1 Safety precautions during handling of batteries .33
7.2 Packaging .37
7.3 Handling of battery cartons.39
7.4 Display and storage.39
7.5 Transportation.39
7.6 Disposal .39
8 Instructions for use.41
9 Marking .41
9.1 General .41
9.2 Small batteries .41
Annex A (informative) Additional information to Subclause 7.4.43
Annex B (informative) Battery compartment design guidelines .45
Bibliography.69

60086-5 © IEC:2005 – 5 –
Figure 1 – Sampling for type approval tests and number of batteries required.19
Figure 2 – Temperature cycling procedure .29
Figure 3 – Incorrect installation (four batteries in series).31
Figure 4 – External short circuit .31
Figure 5 – Overdischarge.33
Figure 6 – XYZ axes for free fall .33
Figure 7 – Ingestion gauge .37
Figure B.1 – Example of series connection with one battery reversed .45
Figure B.2 – Positive contact recessed between ribs .49
Figure B.3 – Positive contact recessed within surrounding insulation .49
Figure B.4 – Negative contact U-shaped to ensure no positive (+) battery contact .51
Figure B.5 – Design with respect to battery orientation .53
Figure B.6 – Example of the design of a positive contact of an appliance.55
Figure B.7 – Example of a short circuit, a switch is piercing the battery insulating jacket .57
Figure B.8 – Typical example of insulation to prevent short circuit .57
Figure B.9 – Insertion against spring (to be avoided) .59
Figure B.10 – Examples showing distorted springs .59
Figure B.11 – One example of protected insertion.59
Figure B.12 – Example of negative contacts .63
Figure B.13 – Example of series connection of batteries with voltage tapping .65
Table 1 – Test matrix .21
Table 2 – Intended use tests and requirements.23
Table 3 – Shock pulse .25
Table 4 – Test sequence.25
Table 5 – Test sequence.27
Table 6 – Reasonably foreseeable misuse tests and requirements .29
Table B.1 – Dimensions of battery terminals and recommended dimensions of the
positive contact of an appliance in Figure B.6 .55
Table B.2 – Minimum wire diameters .61
Table B.3 – Dimensions of the negative battery terminal.63

60086-5 © IEC:2005 – 7 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
PRIMARY BATTERIES –
Part 5: Safety of batteries with aqueous electrolyte
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with an IEC Publication.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60086-5 has been prepared by IEC technical committee 35:
Primary cells and batteries.
This second edition cancels and replaces the first edition published in 2000, and constitutes a
technical revision. It is the result of a reformatting initiative aimed at making it more user-
friendly, less ambiguous and, from a cross-reference point of view, fully harmonized with
other parts of IEC 60086. In addition, and from a safety perspective, the standard contains
further guidance for appliance designers with respect to battery compartment design together
with information regarding packaging, handling, warehousing and transportation.
The text of this standard is based on the following documents:
FDIS Report on voting
35/1225/FDIS 35/1228/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.

60086-5 © IEC:2005 – 9 –
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
IEC 60086 consists of the following parts, under the general title Primary batteries:
Part 1: General
Part 2: Physical and electrical specifications
Part 3: Watch batteries
Part 4: Safety of lithium batteries
Part 5: Safety of batteries with aqueous electrolyte
The committee has decided that the contents of this publication will remain unchanged until
the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in
the data related to the specific publication. At this date, the publication will be
• reconfirmed;
• withdrawn;
• replaced by a revised edition, or
• amended.
60086-5 © IEC:2005 – 11 –
INTRODUCTION
The concept of safety is closely related to safeguarding the integrity of people and property.
This part of IEC 60086 specifies requirements and tests for primary batteries with aqueous
electrolyte and has been prepared in accordance with ISO/IEC guidelines, taking into account
all relevant national and international standards which apply. Also included in this standard is
guidance for appliance designers with respect to battery compartments and information
regarding packaging, handling, warehousing and transportation.
Safety is a balance between freedom from risks of harm and other demands to be met by the
product. There can be no absolute safety. Even at the highest level of safety, the product can
only be relatively safe. In this respect, decision-making is based on risk evaluation and safety
judgement.
As safety will pose different problems, it is impossible to provide a set of precise provisions
and recommendations that will apply in every case. However, this standard, when followed on
a judicious "use when applicable" basis, will provide reasonably consistent standards for
safety.
60086-5 © IEC:2005 – 13 –
PRIMARY BATTERIES –
Part 5: Safety of batteries with aqueous electrolyte
1 Scope
This part of IEC 60086 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.
IEC 60050-482:2004, International Electrotechnical Vocabulary (IEV) – Part 482: Primary and
secondary cells and batteries
IEC 60086-1:2000, Primary batteries – Part 1: General
IEC 60086-2:2000, Primary batteries – Part 2: Physical and electrical specifications
3 Terms and definitions
For the purposes of this document, the definitions given in IEC 60050-482 and IEC 60086-1
(some of which are repeated below for convenience) apply, together with the following
definitions.
3.1
battery (primary)
one or more primary cells, including case, terminals and marking
3.2
button battery
small round battery, where the overall height is less than the diameter; batteries complying
with Figures 2, 3 and 4 of IEC 60086-2
3.3
cell (primary)
source of electrical energy obtained by the direct conversion of chemical energy that is not
designed to be charged by any other electrical source
3.4
cylindrical battery
primary battery with cylindrical geometry where the overall height is equal to or greater than
the diameter; batteries complying with Figures 1a and 1b of IEC 60086-2

60086-5 © IEC:2005 – 15 –
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 health of people, or damage to property or the environment
3.7
hazard
potential source of harm
NOTE The term hazard can be qualified in order to define its origin or the nature of the expected harm (e.g.
electric shock hazard, crushing hazard, cutting hazard, toxic hazard, fire hazard, drowning hazard).
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 battery
3.10
nominal voltage
suitable approximate value of voltage used to identify the voltage of a primary battery
3.11
prismatic battery
primary battery with non-round geometry; batteries complying with IEC 60086-2, Subclause
6.7, category 6
3.12
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
3.13
risk
combination of the probability of occurrence of a harm and the severity of that harm
3.14
safety
freedom from unacceptable risk
3.15
venting
release of excessive internal pressure from a battery in a manner intended by design to
preclude explosion
60086-5 © IEC:2005 – 17 –
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 and reasonable foreseeable misuse.
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 ± 20) V.
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.

60086-5 © IEC:2005 – 19 –
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 following number of samples are drawn for type approval.
Open circuit voltage (n = 70)
Dimensions (n = 70)
Intended uuse se
Reasonably
foreseeable
misuse
A B-1 B-2 C
Partial Transportation Transportation Climatic
use shock vibration (n = 5)
(n = 5) (n = 5) (n = 5)
D E F G
Incorrect External Over- Free
installation short discharge fall
see NOTE 1 circuit see NOTE 2
(n = 20) (n = 5) (n = 20) (n = 5)
IEC 929/2000
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

60086-5 © IEC:2005 – 21 –
6 Testing and requirements
6.1 General
Test methods and requirements are shown in Table 1.
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
Nominal Applicable tests
System Negative Positive voltage
Electrolyte
A B-1 C D E F G
letter electrode electrode
per cell
B-2
V
- Zinc Ammonium Manganese 1,5
R x x x x x x x
chloride dioxide
Zinc B NR
chloride
M x x x NR x x x
A Zinc Ammonium Oxygen 1,4
R x x x NR x x x
chloride
Zinc B NR
chloride
M x x x NR x x x
L Zinc Alkali metal Manganese 1,5
R x x x x x x x
hydroxide dioxide
B x x x NR x NR x
M x x x NR x NR x
P Zinc Alkali metal Oxygen 1,4
R NR
hydroxide
B NR x x NR x NR x
M NR
S Zinc Alkali metal Silver oxide 1,55
R x x x NR x NR x
hydroxide (Ag O)
B x x x NR x NR x
M NR
Test description:
Key
A: storage after partial use 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 M: multicell
D: incorrect installation
E: external short circuit
F: overdischarge
G: free fall
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.
Form
60086-5 © IEC:2005 – 23 –
6.1.1 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.
6.1.2 Ambient temperature
Unless otherwise specified, these tests shall be carried out at (20 ± 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 explosion (NE)
Environmental tests B-1 Transportation shock No leakage (NL)
No explosion (NE)
B-2 Transportation vibration No leakage (NL)
No explosion (NE)
Climatic-temperature C Climatic-temperature cycling 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 IEC 60086-2 until the service life falls by
50 % of the minimum average duration (MAD) value, followed by storage at 45 °C ± 5 °C
for 30 days.
c) Requirements
There shall be no leakage 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.

60086-5 © IEC:2005 – 25 –
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 given in Table 4.
Shock pulse – The shock pulse applied to the battery shall be as follows:
Table 3 – Shock pulse
Acceleration
Waveform
Minimum average acceleration Peak acceleration
first three milliseconds
75 g 125 g to 175 g Half sine
n n n
Table 4 – Test sequence
Step Storage time Battery orientation Number of shocks Visual examination
periods
1 – – – Pre-test
a
2 – 1 each –
a
3 – 1 each –
a
4 – 1 each –
–
5 1 h – –
6 Post-test
a
The shock shall be applied in each of three mutually perpendicular directions.
Step 1 Record open circuit.
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 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
given 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).

60086-5 © IEC:2005 – 27 –
Table 5 – Test sequence
Step Storage time Battery orientation Vibration time Visual examination periods
1 – – – Pre-test
a
2 – 90 min ± 5 min each –
a
3 – 90 min ± 5 min each –
a
4 – 90 min ± 5 min each –
–
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.
Steps 2 to 4 Apply the vibration specified in 6.2.2.3 and the sequence of Table 5.
Step 5 Rest battery for 1 h.
Step 6 Record examination results.
c) Requirements
There shall be no leakage and no explosion during this test.
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 below and/or Figure 2)
1) Place the batteries in a test chamber and raise the temperature of the chamber to
70 °C ± 5 °C within 30 min (t ).
2) Maintain the chamber at this temperature for 4 h (t ).
3) Reduce the temperature of the chamber to 20 °C ± 5 °C within 30 min (t ) and maintain
at this temperature for 2 h (t ).
4) Reduce the temperature of the chamber to –20 °C ± 5 °C within 30 min (t ) and
maintain at this temperature for 4 h (t ).
5) Raise the temperature of the chamber to 20 °C ± 5 °C within 30 min (t ).
6) Repeat the sequence for a further nine cycles.
th
7) After the 10 cycle, store the batteries for seven days prior to examination.

60086-5 © IEC:2005 – 29 –
70 °C
20 °C
–20 °C
t t t t tt t t
1 2 1 3 11 2 1
IEC  930/2000
t = 30 min
t = 4 h
t = 2 h
Figure 2 – Temperature cycling procedure
c) Requirements
There shall be 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 explosion (NE)*
E External short circuit No explosion (NE)
F Overdischarge No explosion (NE)
Environmental test G Free fall 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.

60086-5 © IEC:2005 – 31 –
B1
– + – + – + + –
IEC  931/2000
Figure 3 – 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 shall be clearly advised to install batteries correctly with regard to polarity (+ and –) to
avoid this hazard. (See 9.1g)).
c) Requirements
There shall be 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  932/2000
Figure 4 – External short circuit
c) Requirements
There shall be no explosion during this test.
6.3.2.3 Test F – Overdischarge
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 IEC 60086-2
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).

60086-5 © IEC:2005 – 33 –
The value of the resistor (R1) shall be approximately four times the lowest value from the
resistive load tests specified for that battery in IEC 60086-2. The final value of the resistor
(R1) shall be the nearest value to that prescribed in 6.4 of IEC 60086-1.
C1
– + – + – + – +
R1
IEC  933/2000
Figure 5 – Overdischarge
c) Requirements
There shall be 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 60068-2-32.
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
y
x
IEC  934/2000
Figure 6 – XYZ axes for free fall
c) Requirements
There shall be 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, if they are misused or abused, leakage or in extreme
cases explosion and/or possibly fire may result.

60086-5 © IEC:2005 – 35 –
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 and explosion and
may cause 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
with keys or coins can be short-circuited. This may result in venting, leakage and
explosion and may cause 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 and explosion and may cause 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 and explosion and may cause 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.
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.
60086-5 © IEC:2005 – 37 –
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.
+0,1
57,1
+0,1
25,4
+0,1
31,7
0 IEC  935/2000
Dimensions in millimetres
Figure 7 – Ingestion gauge
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. 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 and corrosion of the terminals. Protection
from inclement weather should be provided.

60086-5 © IEC:2005 – 39 –
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 and may cause personal
injury.
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.
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 ma
...