IEC 60086-5:2016

IEC 60086-5 ®
Edition 4.0 2016-07
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Primary batteries –
Part 5: Safety of batteries with aqueous electrolyte

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

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IEC 60086-5 ®
Edition 4.0 2016-07
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
INTERNATIONALE
ICS 29.220.10 ISBN 978-2-8322-3507-2

– 2 – IEC 60086-5:2016 © IEC 2016
CONTENTS
FOREWORD . 5
INTRODUCTION . 7
1 Scope . 8
2 Normative references. 8
3 Terms and definitions . 8
4 Requirements for safety . 10
4.1 Design . 10
4.1.1 General . 10
4.1.2 Venting . 10
4.1.3 Insulation resistance . 11
4.2 Quality plan. 11
5 Sampling . 11
5.1 General . 11
5.2 Sampling for type approval . 11
6 Testing and requirements . 12
6.1 General . 12
6.1.1 Applicable safety tests . 12
6.1.2 Cautionary notice . 13
6.1.3 Ambient temperature . 13
6.2 Intended use . 13
6.2.1 Intended use tests and requirements . 13
6.2.2 Intended use test procedures . 13
6.3 Reasonably foreseeable misuse . 16
6.3.1 Reasonably foreseeable misuse tests and requirements . 16
6.3.2 Reasonably foreseeable misuse test procedures . 16
7 Information for safety . 18
7.1 Precautions during handling of batteries . 18
7.2 Packaging . 20
7.3 Handling of battery cartons . 20
7.4 Display and storage . 20
7.5 Transportation . 21
7.6 Disposal . 21
8 Instructions for use . 21
9 Marking . 22
9.1 General (see Table 7) . 22
9.2 Marking of small batteries (see Table 7) . 22
9.3 Safety pictograms . 22
Annex A (informative) Additional information on display and storage . 23
Annex B (informative) Battery compartment design guidelines . 24
B.1 Background . 24
B.1.1 General . 24
B.1.2 Battery failures resulting from poor battery compartment design . 24
B.1.3 Potential hazards resulting from battery reversal . 24
B.1.4 Potential hazards resulting from a short circuit . 24
B.2 General guidance for appliance design . 25

B.2.1 Key battery factors to be first considered . 25
B.2.2 Other important factors to consider . 25
B.3 Specific measures against reversed installation . 26
B.3.1 General . 26
B.3.2 Design of the positive contact . 26
B.3.3 Design of the negative contact . 26
B.3.4 Design with respect to battery orientation . 27
B.3.5 Dimensional considerations . 28
B.4 Specific measures to prevent short-circuiting of batteries . 29
B.4.1 Measures to prevent short-circuiting due to battery jacket damage . 29
B.4.2 Measures to prevent external short-circuit of a battery caused when
coiled spring contacts are employed for battery connection . 30
B.5 Special considerations regarding recessed negative contacts . 31
B.6 Waterproof and non-vented devices . 32
B.7 Other design considerations . 32
Annex C (informative) Safety pictograms . 34
C.1 General . 34
C.2 Pictograms . 34
C.3 Recommendations for use . 36
Bibliography . 37

Figure 1 – Sampling for type approval tests and number of batteries required . 11
Figure 2 – Temperature cycling procedure . 16
Figure 3 – Circuit diagram for incorrect installation (four batteries in series) . 17
Figure 4 – Circuit diagram for external short circuit . 17
Figure 5 – Circuit diagram for overdischarge . 18
Figure 6 – XYZ axes for free fall . 18
Figure 7 – Ingestion gauge . 20
Figure B.1 – Example of series connection with one battery reversed . 24
Figure B.2 – Positive contact recessed between ribs . 26
Figure B.3 – Positive contact recessed within surrounding insulation . 26
Figure B.4 – Negative contact U-shaped to ensure no positive (+) battery contact . 27
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) . 30
Figure B.10 – Examples showing distorted springs . 30
Figure B.11 – One example of protected insertion . 30
Figure B.12 – Example of negative contacts . 32
Figure B.13 – Example of series connection of batteries with voltage tapping . 33

Table 1 – Test matrix . 12
Table 2 – Intended use tests and requirements . 13
Table 3 – Shock pulse . 14

– 4 – IEC 60086-5:2016 © IEC 2016
Table 4 – Test sequence . 14
Table 5 – Test sequence . 15
Table 6 – Reasonably foreseeable misuse tests and requirements . 16
Table 7 – Marking requirements . 22
Table B.1 – Dimensions of battery terminals and recommended dimensions of the
positive contact of an appliance in Figure B.6 . 28
Table B.2 – Minimum wire diameters . 31
Table B.3 – Dimensions of the negative battery terminal . 32
Table C.1 – Safety pictograms . 34

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 fourth edition cancels and replaces the third edition published in 2011. This edition
constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous
edition:
a) The definition of explosion was changed to suitable sentence in order to harmonize in
IEC 60086 series;
b) To prevent removal of hydrogen gas, we revised it to the suitable sentence,
c) To prevent misuse, the battery compartments with parallel connections were revised to the
suitable sentence.
d) To clarify the method to determine the insulation resistance.

– 6 – IEC 60086-5:2016 © IEC 2016
The text of this standard is based on the following documents:
FDIS Report on voting
35/1360/FDIS 35/1361/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.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all parts in the IEC 60086 series, published 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 website 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.
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.
– 8 – IEC 60086-5:2016 © IEC 2016
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 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.
IEC 60086-1, Primary batteries – Part 1: General
IEC 60086-2, Primary batteries – Part 2: Physical and electrical specifications
IEC 60068-2-6, Environmental testing – Part 2-6: Tests – Test Fc: Vibration (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 purposes of this document, the following terms and definitions apply.
NOTE Certain definitions taken from IEC 60050-482, IEC 60086-1, and IEC Guide 51 are repeated below for
convenience.
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
[SOURCE: IEC 60050-482:2004, 482-01-04, modified definition]
3.2
button (cell or battery)
small round cell or battery where the overall height is less than the diameter
Note 1 to entry: In English, the term "button (cell or battery)" is only used for non-lithium batteries while the term
"coin (cell or battery)" is used for lithium batteries only. In languages other than English, the terms "coin" and
"button" are often used interchangeably, regardless of the electrochemical system.

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
[SOURCE: IEC 60050-482:2004, 482-01-01]
3.4
component cell
cell contained in a battery
3.5
cylindrical (cell or battery)
round cell or battery with a cylindrical shape in which the overall height is equal to or greater
than the diameter
[SOURCE: IEC 60050-482:2004, 482-02-39, modified ("cell with a cylindrical shape" replaced
by "round cell or battery")]
3.6
explosion (battery explosion)
the cell or battery opens and solid components are forcibly expelled
3.7
fire
flames are emitted from the test cell or battery
3.8
intended use
use in accordance with information provided with a product or system, or, in the absence of
such information, by generally understood patterns of usage
[SOURCE: ISO/IEC Guide 51:2014, 3.6]
3.9
leakage
unplanned escape of electrolyte from a cell or battery
[SOURCE: IEC 60050-482:2004, 482-02-32]
3.10
nominal voltage (of a primary battery)
V
n
suitable approximate value of the voltage used to designate or identify a cell, a battery or an
electrochemical system
[SOURCE: IEC 60050-482:2004, 482-03-31, modified (addition of "(of a primary battery)" and
symbol V )]
n
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

– 10 – IEC 60086-5:2016 © IEC 2016
[SOURCE: IEC 60050-482:2004, 482-02-38, modified (deletion of "qualifies a")]
3.13
protective devices
devices such as fuses, diodes 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 or system in a way not intended by the supplier, but which can result from
readily predictable human behaviour
[SOURCE: ISO/IEC Guide 51:1999, 3.14, modified ("process or service" replaced by "or
system" and "may" replaced by "can" and deletion of the Note)]
3.15
round (cell or battery)
cell or battery with circular cross section
3.16
safety
freedom from risk which is not tolerable
[SOURCE: ISO/IEC Guide 51:2014, 3.14]
3.17
undischarged
state of charge of a primary cell or battery corresponding to 0 % depth of discharge
3.18
venting
release of excessive internal pressure from a cell or 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
+100 V
electrical contact surfaces and either terminal shall be not less than 5 MΩ at 500 V
– 0 V
applied for a minimum of 60 seconds.
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 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
A B-1 B-2 C
misuse
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
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

– 12 – IEC 60086-5:2016 © IEC 2016
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 1,55 R x x x NR x NR x
hydroxide oxide
B x x x NR x NR x
(Ag O)
Pr x x x x x x x
M NR
Test description: Key
A: storage after partial use R: cylindrical (3.5) x: required
B-1: transportation-shock
B: button (3.2) NR: Not required
B-2: transportation-vibration
Pr: prismatic single cell (3.12)
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
6.1.2 Cautionary 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, these tests shall be carried out at an ambient temperature of
20 °C ± 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 °C ± 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.

– 14 – IEC 60086-5:2016 © IEC 2016
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/s .
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).

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
70 °C ± 5 °C within t = 30 min.
2) Maintain the chamber at this temperature for t = 4 h.
3) Reduce the temperature of the chamber to 20 °C ± 5 °C within t = 30 min and
maintain at this temperature for t = 2 h.
4) Reduce the temperature of the chamber to –20 °C ± 5 °C within t = 30 min and
maintain at this temperature for t = 4 h.
5) Raise the temperature of the chamber to 20°C ± 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.

– 16 – IEC 60086-5:2016 © IEC 2016
70 °C
20 °C
–20 °C
t
t t t t t t
2 1 3 t1
1 2 1
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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.

B1
– + – + – + + –
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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.
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.
– +
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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 × 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 × 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 60086-1:2015.

– 18 – IEC 60086-5:2016 © IEC 2016
C1
– + – + – + – +
R1
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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
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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 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
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