EN 60086-5:2011

SLOVENSKI STANDARD
01-junij-2011
1DGRPHãþD
SIST EN 60086-5:2005
Primarne baterije - 5. del: Varnost baterij z vodnim elektrolitom (IEC 60086-5:2011)
Primary batteries - Part 5: Safety of batteries with aqueous electrolyte (IEC 60086-
5:2011)
Primärbatterien - Teil 5: Sicherheit von Batterien mit wässrigem Elektrolyt (IEC 60086-
5:2011)
Piles électriques - Partie 5: Sécurité des piles à électrolyte aqueux (CEI 60086-5:2011)
Ta slovenski standard je istoveten z: EN 60086-5:2011
ICS:
29.220.10 3ULPDUQLþOHQLLQEDWHULMH Primary cells and batteries
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD
EN 60086-5
NORME EUROPÉENNE
April 2011
EUROPÄISCHE NORM
ICS 29.220.10 Supersedes EN 60086-5:2005

English version
Primary batteries -
Part 5: Safety of batteries with aqueous electrolyte
(IEC 60086-5:2011)
Piles électriques - Primärbatterien -
Partie 5: Sécurité des piles à électrolyte Teil 5: Sicherheit von Batterien mit
aqueux wässrigem Elektrolyt
(CEI 60086-5:2011) (IEC 60086-5:2011)

This European Standard was approved by CENELEC on 2011-04-12. 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, Bulgaria, Croatia, Cyprus,
the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,
Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia,
Spain, Sweden, Switzerland and the United Kingdom.

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

Management Centre: Avenue Marnix 17, B - 1000 Brussels

© 2011 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. EN 60086-5:2011 E
Foreword
The text of document 35/1273/CDV, future edition 3 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 2011-04-12.
This European Standard supersedes EN 60086-5:2005.
The major technical changes with respect to EN 60086-5:2005 are the test requirements and the
harmonization of the marking clause with the other standards of the EN 60086 series. Moreover, the table
of safety pictograms was added as Annex C.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN and CENELEC shall not be held responsible for identifying any or all such patent
rights.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
(dop) 2012-01-12
national standard or by endorsement
– latest date by which the national standards conflicting
(dow) 2014-04-12
with the EN have to be withdrawn
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 60086-5:2011 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.
IEC 60086-4 NOTE  Harmonized as EN 60086-4.
__________
- 3 - EN 60086-5:2011
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  When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD
applies.
Publication Year Title EN/HD Year

IEC 60068-2-6 - Environmental testing - EN 60068-2-6 -
Part 2-6: Tests - Test Fc: Vibration
(sinusoidal)
IEC 60068-2-27 - Environmental testing - EN 60068-2-27 -
Part 2-27: Tests - Test Ea and guidance:
Shock
IEC 60068-2-31 - Environmental testing - EN 60068-2-31 -
Part 2-31: Tests - Test Ec: Rough handling
shocks, primarily for equipment-type
specimens
IEC 60086-1 2011 Primary batteries - EN 60086-1 2011
Part 1: General
IEC 60086-2 2011 Primary batteries - EN 60086-2 2011
Part 2: Physical and electrical specifications

IEC 60086-5 ®
Edition 3.0 2011-03
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Primary batteries –
Part 5: Safety of batteries with aqueous electrolyte

Piles électriques –
Partie 5: Sécurité des piles à électrolyte aqueux

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX W
ICS 29.220.10 ISBN 978-2-88912-386-5

– 2 – 60086-5  IEC:2011
CONTENTS
FOREWORD . 4
INTRODUCTION . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 7
4 Requirements for safety . 9
4.1 Design . 9
4.1.1 General . 9
4.1.2 Venting . 9
4.1.3 Insulation resistance . 10
4.2 Quality plan . 10
5 Sampling . 10
5.1 General . 10
5.2 Sampling for type approval . 10
6 Testing and requirements . 11
6.1 General . 11
6.1.1 Safety notice . 12
6.1.2 Ambient temperature . 12
6.2 Intended use . 12
6.2.1 Intended use tests and requirements . 12
6.2.2 Intended use test procedures . 12
6.3 Reasonably foreseeable misuse . 15
6.3.1 Reasonably foreseeable misuse tests and requirements . 15
6.3.2 Reasonably foreseeable misuse test procedures . 15
7 Information for safety. 17
7.1 Safety precautions during handling of batteries . 17
7.2 Packaging . 19
7.3 Handling of battery cartons . 19
7.4 Display and storage . 19
7.5 Transportation . 20
7.6 Disposal . 20
8 Instructions for use . 20
9 Marking . 21
9.1 General . 21
9.2 Marking of small batteries . 21
Annex A (informative) Additional information to 7.4 . 22
Annex B (informative) Battery compartment design guidelines . 23
Annex C (informative) Safety pictograms . 34
Bibliography . 36

Figure 1 – Sampling for type approval tests and number of batteries required . 10
Figure 2 – Temperature cycling procedure . 15
Figure 3 – Circuit diagram for incorrect installation (four batteries in series) . 16
Figure 4 – Circuit diagram for external short circuit . 16

60086-5  IEC:2011 – 3 –
Figure 5 – Circuit diagram for overdischarge . 17
Figure 6 – XYZ axes for free fall . 17
Figure 7 – Ingestion gauge (Inner dimensions) . 19
Figure B.1 – Example of series connection with one battery reversed . 23
Figure B.2 – Positive contact recessed between ribs . 25
Figure B.3 – Positive contact recessed within surrounding insulation . 25
Figure B.4 – Negative contact U-shaped to ensure no positive (+) battery contact . 26
Figure B.5 – Design with respect to battery orientation . 27
Figure B.6 – Example of the design of a positive contact of an appliance . 28
Figure B.7 – Example of a short circuit, a switch is piercing the battery insulating jacket . 29
Figure B.8 – Typical example of insulation to prevent short circuit . 29
Figure B.9 – Insertion against spring (to be avoided) . 29
Figure B.10 – Examples showing distorted springs . 30
Figure B.11 – One example of protected insertion . 30
Figure B.12 – Example of negative contacts . 31
Figure B.13 – Example of series connection of batteries with voltage tapping . 33

Table 1 – Test matrix . 11
Table 2 – Intended use tests and requirements . 12
Table 3 – Shock pulse . 13
Table 4 – Test sequence . 13
Table 5 – Test sequence . 14
Table 6 – Reasonably foreseeable misuse tests and requirements . 15
Table 7 – Marking requirements . 21
Table B.1 – Dimensions of battery terminals and recommended dimensions of the
positive contact of an appliance in Figure B.6 . 27
Table B.2 – Minimum wire diameters . 30
Table B.3 – Dimensions of the negative battery terminal . 31
Table C.1 – Safety pictograms . 34

– 4 – 60086-5  IEC:2011
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 itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
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 third edition cancels and replaces the second edition (2005) and constitutes a technical
revision.
The major technical changes with respect to the previous edition are the test requirements
and the harmonization of the marking clause with the other standards of the IEC 60086 series.
Moreover, the table of safety pictograms was added as Annex C.

60086-5  IEC:2011 – 5 –
The text of this standard is based on the following documents:
CDV Report on voting
35/1273/CDV 35/1276/RVC
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 60086 series, under the general title Primary batteries, can be
found on the IEC website.
The committee has decided that the contents of this publication will remain unchanged until
the stability 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.
– 6 – 60086-5  IEC:2011
INTRODUCTION
The concept of safety is closely related to safeguarding the integrity of people and property.
This part of IEC 60086 specifies tests and requirements 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:2011 – 7 –
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 60086-1:2011, Primary batteries – Part 1: General
IEC 60086-2:2011, Primary batteries – Part 2: 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 IEC 60086-1 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
[IEC 60050-482: 2004, 482-01-04, modified]
3.2
button battery
small round battery, where the overall height is less than the diameter; batteries complying
with Figures 3 and 4 of IEC 60086-2
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
[IEC 60050-482: 2004, 482-01-01]

– 8 – 60086-5  IEC:2011
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
[IEC 60050-482: 2004, 482-02-39, modified]
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.
[ISO/IEC Guide 51:1999, 3.3]
3.7
hazard
potential source of harm
[ISO/IEC Guide 51:1999, 3.5]
3.8
intended use
use of a product, process or service in accordance with information provided by the supplier
[ISO/IEC Guide 51:1999, 3.13]
3.9
leakage
unplanned escape of electrolyte, gas or other material from a cell or battery
[IEC 60050-482: 2004, 482-02-32]
3.10
nominal voltage (of a primary battery)
(symbol)
V
n
suitable approximate value of the voltage used to designate or identify a cell, a battery or an
electrochemical system
[IEC 60050-482: 2004, 482-03-31, modified]
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
[IEC 60050-482: 2004, 482-02-38, modified]

60086-5  IEC:2011 – 9 –
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
3.14
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
[ISO/IEC Guide 51:1999, 3.14]
3.15
risk
combination of the probability of occurrence of harm and the severity of that harm
[ISO/IEC Guide 51:1999, 3.2]
3.16
round (cell or battery)
cell or battery with circular cross section
3.17
safety
freedom from unacceptable risk
[ISO/IEC Guide 51:1999, 3.1]
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.

– 10 – 60086-5  IEC:2011
4.1.3 Insulation resistance
The insulation resistance between externally exposed metal surfaces of the battery excluding
+100
electrical contact surfaces and either terminal shall be not less than 5 MΩ at 500    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.
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 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  426/11
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:2011 – 11 –
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
Nominal Applicable tests
System Negative Positive voltage
Electrolyte
A B-1 C D E F G
letter electrode electrode per cell
B-2
V
No letter Zinc (Zn) Ammonium Manganese 1,5 R x x x x x x x
chloride, dioxide
B NR
Zinc (MnO )
chloride
Pr x x x x x x x
M x x x NR x x x
A Zinc (Zn) Ammonium Oxygen 1,4 R x x x NR x x x
chloride, (O )
B NR
Zinc
chloride
Pr x x x x x x x
M x x x NR x x x
L Zinc (Zn) Alkali metal Manganese 1,5 R x x x x x x x
hydroxide dioxide
B x x x NR x NR x
(MnO )
Pr x x x x x x x
M x x x NR x NR x
P Zinc (Zn) Alkali metal Oxygen air 1,4 R NR
hydroxide (O )
B NR x x NR x NR x
Pr x x x x x x x
M NR
S Zinc (Zn) 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
Pr x x x x x x x
M NR
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: multicell
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
– 12 – 60086-5  IEC:2011
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 (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 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 IEC 60086-2 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
60086-5  IEC:2011 – 13 –
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
Acceleration
Waveform
Minimum average acceleration Peak acceleration
first three milliseconds
75 g 125 g to 175 g Half sine
n n n
NOTE g = 9,80665 m/s².
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 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).

– 14 – 60086-5  IEC:2011
Table 5 – Test sequence
Step Storage time Battery orientation Vibration time Visual examination periods
1 – – – Pre-test
a
2 – (90 ± 5) min each –
a
3 – –
(90 ± 5) min each
a
4 – –
(90 ± 5) min each
–
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.
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
= 30 min.
(70 ± 5) °C within t
2) Maintain the chamber at this temperature for t = 4 h.
3) Reduce the temperature of the chamber to (20 ± 5) °C within t = 30 min and maintain
at this temperature for t = 2 h.
4) Reduce the temperature of the chamber to (–20 ± 5) °C within t = 30 min and maintain
at this temperature for t = 4 h.
5) Raise the temperature of the chamber to (20 ± 5) °C within t = 30 min.
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:2011 – 15 –
70 °C
20 °C
–20 °C
t t t t tt t t
1 2 1 3 11 2 1
IEC  427/11
t = 30 min
t = 4 h
t = 2 h
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.

– 16 – 60086-5  IEC:2011
B1
– + – + – + + –
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 – 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).
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.

60086-5  IEC:2011 – 17 –
C1
– + – + – + – +
R1
IEC  430/11
Figure 5 – Circuit diagram for overdischarge
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
y
x
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.
– 18 – 60086-5  IEC:2011
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.
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.
60086-5  IEC:2011 – 19 –
Dimensions in millimetres
+0,1
∅ 31,7
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
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