IEC 60086-5:2011

Primary batteries - Part 5: Safety of batteries with aqueous electrolyte

IEC 60086-5:2011 specifies tests and requirements for primary batteries with aqueous electrolyte to ensure their safe operation under intended use and reasonably foreseeable misuse. 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.

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

La CEI 60086-5:2011 spécifie des essais et des exigences pour les piles électriques à électrolyte aqueux pour assurer leur fonctionnement sûr dans des conditions d'utilisation prévue et d'utilisation impropre prévisible. Les principales modifications techniques par rapport à l'édition précédente sont les exigences relatives aux essais et l'harmonisation de l'article sur le marquage avec les autres normes de la série CEI 60086. En outre, le tableau du programme de sécurité a été ajouté comme Annexe C.

General Information

• Status: Published
• Publication Date: 07-Mar-2011
• ICS: 29.220.10 - Primary cells and batteries
• Technical Committee: TC 35 - Primary cells and batteries
• Drafting Committee: MT 16 - TC 35/MT 16
• Current Stage: DELPUB - Deleted Publication
• Completion Date: 13-Jul-2016

Relations

• Revised: IEC 60086-5:2016 - Primary batteries - Part 5: Safety of batteries with aqueous electrolyte
• Effective Date: 05-Sep-2023

Standards Content (Sample)

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

IEC 60086-5:2011

---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
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

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale

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– 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

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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

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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
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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.

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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.

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– 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.

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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]

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– 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]

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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.

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– 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.
0
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

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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 )
2
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 )
2
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 )
2

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 )
2
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)
2
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

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– 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
...