Manak Bhavan, 9 Bahadur Shah Zafar Marg New Delhi TeleFax Website : :

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1 BUREAU OF INDIAN STANDARDS Phones Extn 484 Manak Bhavan, 9 Bahadur Shah Zafar Marg New Delhi TeleFax Website : eetd@bis.org.in व य पक पर च लन म मस द रल ख र षण स ञ पन स द भ ईट ड / ट, 5,6,8,9,3 ददन क -5-6 तकन क सममतत ईट... रषत :. ईट ड क सभ सदस य. व य त तकन क व भ ग पर षद क सभ सदस य तथ 3. च खन ल अन य सभ ननक य मह दय, क प य ननम नललखखत मस द क एक रनत स लग न ह : रलख श षषक ईट ड (39) घड क बट - व लश टट ईट ड ( 4) ष य म गन ज ड इऑ स इड सल - व लश टट ईट ड (4) र थलमक बटर य - ललचथयम बटर य क स ष ईट ड (44) र थलमक बटर य - जल य इल र ल इट क स थ बटर य क स ष ईट ड (37) र थलमक बटर य - भ नतक औ व धत य अपष ए ईट ड (45) षणद प - व लश टट क प य इस मस द क अ ल कन क औ अपन स मनतय यह बत त ह ए भज कक अ तत यदद य म नक क प म रक लशत ह ज ए त इस प अमल क न म आपक य स य अथ क ब म क य कद न इय आ सकत ह स मनतय भजन क अ नतम त ख: स मनतय यदद क ई ह त क प य अगल पष प ददए पर म अध हस त ष क उपर ललखखत पत प भज द

2 यदद क ई सम मनत र प त नह ह त अथ सममनत म क ल भ ष स ब ध रद ट ह ई त उप कत रलख क यथ त अनत म प ददय ज एग यदद क ई सम मनत तकन क रक नत क ह ई त व षय सलमनत क अधयष क प मशष स अथ उनक इ छ प आग क क यष ह क ललए व षय सलमनत क भज ज न क ब द रलख क अ नतम प द ददय ज एग क पय न ट क कक मस द क तकन क व षय स त क स ल ननत नह ककय गय ह क य कक य मस द आई. ई. स. म नक क सम प ह व स तत ब य क ललए क पय स ब चधत ष र य र क कथन म उ ललखखत आई. ई. स. रक शन पढ अथ अध हस त षर त क स पकष क धन य द, भ द य, ( ड ग स म ) ञ ननक एफ ए रमख (व यत तकन क ) स लग न : उपर ललखखत

3 BUREAU OF INDIAN STANDARDS Manak Bhavan, 9 Bahadur Shah Zafar Marg New Delhi TeleFax Website : Phones Extn eetd@bis.org.in DRAFTS IN WIDE CIRCULATION DOCUMENT DESPATCH ADVICE Reference Date -5-6 ETD / T-, 5,6,8,9,3 TECHNICAL COMMITTEE ETD ADDRESSED TO:. All Members of Primary Cells and Batteries Sectional Committee, ETD. All Members of Electrotechnical Division Council; and 3. All other Interested. Dear Sir(s), Please find enclosed a copy of the following draft Indian Standard: Doc No. Title ETD (39) Watch Batteries Specification ETD (4) Alkaline manganese dioxide cells specification ETD (4) ETD (44) Primary Batteries- Safety of Lithium Batteries Primary Batteries - Safety of batteries with aqueous electrolyte ETD (45) Flashlight- Specification ETD (37) Primary Batteries Part : Physical and electrical specifications Kindly examine the draft standards and forward your views stating any difficulties which you are likely to experience in your business or profession, if these are finally adopted as Indian Standards. Comments, if any, may please be made in the format given overleaf and mailed to the undersigned. Last date for comments: In case no comments are received or comments received are of editorial nature, you will kindly permit us to presume your approval for the above documents as finalized. However,

4 in case of comments of technical in nature are received then it may be finalized either in consultation with the Chairman, Sectional Committee or referred to the Sectional Committee for further necessary action, if so desired by the Chairman, Sectional Committee. Thanking you, Yours faithfully (D.Goswami) Sc F & Head (Electrotechnical) eetd@bis.org.in Encl : See attachment.

5 Date -5-6 Sl. No. Name of the Organization Clause/ Subclause Paragraph/ Figure/Table Document No. Doc: ETD ( 39, 4, 4, 44, 45, 37 ) Type of Comment (General/ Technical/ Editorial Comments Proposed Change

6 Doc: ETD (39) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard WATCH BATTERIES SPECIFICATION (First Revision of IS 675) Last date for receipt of comments is: -7-6 Foreword (Formal clauses will be added later) SCOPE This standard specifies dimensions, designation, methods of tests and requirements for primary batteries for watches. In several cases, a menu of test methods is given. When presenting battery electrical characteristics and/or performance data, the manufacturer specifies which test method was used. NORMATIVE REFERENCES The following referenced documents are in dispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IS No. Title Doc ETD (69) Primary batteries General Doc ETD (4) Primary batteries Safety of lithium batteries Doc ETD (44) Primary batteries Safety of batteries with aqueous electrolyte. 3 TERMS AND DEFINITIONS For the purposes of this document, the terms and definitions given in IS 633as well as the following terms and definitions apply. 3. Capacitive reactance Part of the internal resistance that leads to a voltage drop during the first seconds under load. 3. Capacity Electric charge (quantity of electricity) which a cell or battery can deliver under specified discharge conditions. NOTE The SI unit for electric charge is the coulomb ( C = As) but, in practice, capacity is usually

7 expressed in ampere hours (Ah). 3.3 Fresh Battery undischarged battery 6 days maximum after date of manufacture 3.4 Ohmic Drop part of the internal resistance that leads to a voltage drop immediately after switching the load on. 4 PHYSICAL REQUIREMENTS 4. Battery dimensions, symbols and size codes Dimensions and tolerances of batteries for watches shall be in accordance with Figure, Table and Table. The dimensions of the batteries shall be tested in accordance with 7..The symbols used to denote the various dimensions in Figure are in accord ance with Doc ETD (37), Clause 4. Dimensions in millimetres II,5, h5 d4 h/h ( ) (+) d d <,5, d Key h maximum over all height of the battery h minimum distance between the flats of the positive and negative contacts h5 d maximum and minimum diameter of the battery d minimum diameter of the flat positive contact d4 minimum diameter of the flat negative contact minimum projection of the flat negative contact NOTE this numbering follows the harmonization in the IEC686 series. Figure Dimensional drawing

8 Table Dimensions and size codes Height h//h Diameter Codea d Toleranc e d4 -, 4,8 -, 5 5 5,8 -, 5 6 6,8 4 -, 5 -, 5 7 7,9 9 9,5,6 -, 5 -,,5 -, , 5 -, 5 -,8 -, 5 Code a 6 7,65, 5,5,5,45,65, 5 3,,5,5,45,65, 5,6,5,5,45, 65,,6,5,5,45,65, 5,5,5,45,65, 5,,6, 4,5 6, 4, 3 3 Tolerance -, -, -, -, -, 5 -, 5 -,5,6 3, ,5 -,5 -, 5,7 3,,7,6 3,6 3,6 3, 5 3,6,5 NOTE Open boxes in the above matrix are not necessarily available for standardization due to the concept of overlapping tolerances. a See Annex A. 4 4, 5,4

9 Table Dimensions and size codes Dimensions in millimetres Height h /h Diameter Codea Codea d d4 Tolerance ,3b,3b Tolerances,b,b,5b,3b 6 6,5 5,,,6,,5 3,,5 8,,,6,,5 3, 3 3,3 8,,,6,,5 4 4,5,3 8,,,6 3, NOTE Open boxes in the above matrix are not necessarily available for standardization due to the concept of over-lapping tolerances. a See Annex A. b To be reduced in the future. 4. Terminals Negative contact ( ): the negative contact (dimension d 4 ) shall be in accordance with Tables and.this is not applied to those batteries with a twostep negative contact. Positive contact (+): the cylindrical surface is connected to the positive terminal. Positive contact should be made to the side of the battery but may be made to the base. 4.3 Projection of the negative terminal (h 5) The dimension h 5 shall be as follows: h5, for h /h,65 h 5,6 for,65 < h /h <,5 h5,8 for h /h,5 NOTE the negative contact should be the highest point of the battery. 4.4 Shape of negative terminal The space requirements shall be contained within an angle of 45 (seefigure).the minimum values of l,for different heights of h /h,aregivenintable3.

10 h/h l d 45º IEC 56/ Figure Shape of negative terminal Table 3 Minimum values of l Dimensions in millimetres 4.5 h /h l min <h /h,9,,9<h /h 3,,35 3,6 h /h 4,,7 5,4 h /h,9 Mechanical resistance to pressure A force F(N),as specified in Table 4, applied for s through a steel ball of mm diameter, at the centre of each contact area, shall not cause any deformation prejudicial to the proper functioning of the battery, i.e. after this test, the battery shall pass the tests specified inclause7. Table4 Applied force F by battery dimensions Battery dimensions d mm <7,9 7,9 4.6 h /h mm Forc e F N <3, 5 3, <3, 3, Deformation The dimensions of batteries shall conform with the relevant specified dimensions at all times including discharge to the defined end-point voltage. NOTE A battery height increase up to.5mm can occur in B, C, L and S systems, if discharged below this voltage. NOTE A battery height decrease can occur in B and C systems as discharge continues.

11 Leakage 4.7 Undischarged batteries and, if required, batteries tested according to 7..6 shall be examined as stated in 7.3.The acceptable number of defects shall be agreed between the manufacturer and the purchaser. Marking General The designation and the polarity shall be marked on the battery. All other markings may be given on the packing instead of on the battery: a) Designation according to normative Annex A, or common; b) Expiration of are commended us age period or year and month or week of manufacture; The year and month or week of manufacture may be in code. The code is composed by the last digit of the year and by a number indicating the month. October, November and December should be represented by the letters O, Y and Z respectively. EXAMPLE 4: January 4; 4Y: November 4. c) polarity of the positive(+) terminal; d) nominal voltage; e) name or trade mark of the supplier; f) cautionary advice; g) caution for ingestion of swallowable batteries shall be given. Refer to Doc ETD (44) NOTE Battery marking should not impede electrical contact. NOTE Examples of the common designations can be found in Annex D of Doc ETD (37) Disposal Marking o f batteries with respect to the method of disposal shall be in accordance with local legal requirements ELECTRICAL REQUIREMENTS Electro chemical system, nominal voltage, end-point voltage and opencircuit voltage The requirements concerning the electro chemical system, the nominal voltage, the endpoint voltage and the open-circuit voltage are given in Table 5.

12 Table 5 Standardised electro chemical systems Letter Negative electrode Electrolyte B Lithium(Li) Organic electrolyte C Lithium(Li) Organic electrolyte L Zinc(Zn) S Zinc(Zn) 5. Positive electrode Carbon mono fluoride (CF) x Nominal End-point Open-circuit voltage voltage voltage (EV) (U OC orocv) (V n ) V V V Max. Min. 3,, 3,7 3, Manganese di oxide (MnO ) 3,, 3,7 3, Alkali metal hydroxide Manganese di oxide (MnO ),5,,68,5 Alkali metal hydroxide Silver oxide(ag O),55,,63,57 Closed circuit voltage Ucc (CCV), internal resistance and impedance Closed circuit voltage and internal resistance shall be measured according to 7..AC impedance should be measured with an LCR meter. Limit values shall be agreed between the manufacturer and the purchaser. 5.3 Capacity The capacity shall be agreed between the manufacturer and the purchaser on the basis of a continuous discharge test lasting approximately 3 days, according to Capacity retention The capacity retention is the ratio between the capacities under the given discharge conditions measured on fresh batteries and a sample of the same lot stored during 365 days at (7±) C and a relative humidity between 45% and 75%. The ratio of capacity retention shall be agreed between the manufacturer and the purchaser. The minimum value should be at least 8% for a period of months. The capacity measurement is carried out according to Sampling and quality assurance General The use of sampling plans or product quality indices may be agreed between manufacturer and purchaser. Where no agreement is specified, the options in 6. and/or 6.3 are recommended.

13 6. Sampling 6.. Testing by attributes When testing by attributes is required, the sampling plan chosen shall be in accordance with relevant Indian standard. The individual parameters to be tested and the acceptance quality level (AQL) values shall be defined (a minimum of three batteries of the same type shall be tested). 6.. Testing by variables When testing by variables is required, the sampling plan chosen shall be in accordance with the relevant Indian Standard. The individual parameters to be tested, the sample and the acceptance quality level (AQL) shall be defined. 7 Test methods Shape and dimensions Shape requirement The shape of the negative contact is checked preferably by optical projection or by an open gauge according to Figure 3. The measurement method shall be agreed between the manufacturer and the purchaser. h/h l d 45 IEC 57/ Figure 3 Shape requirement Electrical characteristics Environmental conditions Unless otherwise specified, the sample batteries shall be tested at a temperature of (7±) C and a relative humidity between 45% and 75%. During use, batteries maybe exposed to low temperatures; it is therefore recommended to carry out complementary tests at (±) C and at( ±) C. 7.. Equivalent circuit effective internal resistance DC method Resistance of any electrical component determined by calculating the ratio between the voltage drop ΔU across this component and the range of current Δi passing through this component and causing the voltage drop R = ΔU / Δi.

14 NOTE As an analogy, the internal d.c. resistance R i of any electro chemical cell is defined by the following relation: U(V) Ri( ) Δ Δi(A) ()

15 U The internal d.c. resistance is illustrated by the schematic voltage transient as given below in Figure 4. U(t) U=f(i,t) U' U U U(i) t t U(i) t' t t t3 Figure 4 Schematic voltage transient As can be seen from this diagram, the voltage drop U of the two components differs in nature, as shown in the following relation: U= UΩ+ U(t) () The first component UΩ for (t=t ) is independent of time (ohmic drop), and results from the increase in current i according to the relation: UΩ= i R Ω (3) In this relation, RΩ is a pure ohmic resistance. The second component U (t) is time dependent and is of electro chemical origin (capacitive reactance) Equipment The equipment used for the voltage measurements shall have the following specifications: accuracy:,5 %; precision: 5 % of last digit; internal resistance: MΩ measurement time: in the tests proposed in the following sub clauses, it is important to make sure that the measurement is taken during the flat period of the voltage transient (see Figure5 ). Otherwise, a measurement error due to the capacitive reactance may occur (lower internal resistance). The time t' necessary for the measurement shall be brief in comparison to t, and the measurement equipment compatible with these criteria.

16 U 3 4 t t Key open-circuit voltage U oc (OCV) effect of capacitive reactance 3 closed circuit voltage U cc(ccv) 4 Δt'(measurement U cc ) Figure 5 Curve:U=f(t) 7..4 Measurement of open-circuit voltage Uoc(OCV) and closed circuit voltage Ucc(CCV)(seeFigure6) V Key Reading U cc/u oc R m resistance of measurement Figure 6 Circuitry principle First measurement Uoc: The switch is left open while this measurement is being carried out. Next measurement Ucc: The battery being tested shall be connected to the load R m.the switch shall be left closed during the duration t according to Table 6.

17 Table 6 Test method for U cc(ccv) measurement Test method Ab Bc Battery with KOH electrolytea Rm t Ω s All other batteries t ms Rm Ω 5±,5% ±5% 5±,5% ±5% 5±,5%,5 47±,5% 5 ±,5% 5±5% ±,5% 7,8±5% Cd NOTE R m should take into consideration the resistance of the connection lines of the battery being tested and the contact resistance of the switch. a Application with high peak current. b Method A (recommended test): requires specialized test equipment. c Method B: to be used in the absence of method A test equipment. d Method C: to be used only by agreement between the manufacturer and the purchaser Calculation of the internal resistance R i The internal resistance may be determined by the following calculation: U -U cc Ri= oc Ucc/ Rm NOTE The relation U cc/r m corresponds to the current delivered through the discharge resistance R m(see7..4) Measurement of the capacity General There are two methods for measuring capacity: The recommended method is method A, which is more indicative of watch requirements; method B is a more general method and is already specified in Doc ETD (69) and Doc ETD (44). When presenting capacity data, the manufacturer shall specify which test method was used a) Method A Circuitry principle(seefigure7)

18 V 3 Key Reading U cc/u oc R m resistance of measurement 3 R d resistance of continuous discharge Figure 7 Circuitry principle for method A b) Procedure The duration of the discharge test at the resistor R d approximates to 3days. Value of the resistance R d: the value of the resistive load (specified in Table 8 )shall include all parts of the external circuit and shall be accurate to within ±,5%. c) Determination of the capacity The measurements of the open-circuit voltage U' oc and that of the closed circuit voltage Ucc are carried out at least once a day on the battery permanently connected to R d, until the first passage of the U ccunder the end-point voltage defined in Table 5 is obtained. ) First measurement U' oc : the resistance R d being much higher than R m, U' oc approximates to Uoc. The switch is left open while the measurement is being carried out. ) Next measurement U cc : the battery being tested is connected to R m.the switch is left closed during the duration t according to Table7. Table 7 Test method A for U cc(ccv)measurement Batteries with KOH electrolyte R m Ω 5±,5% All other batteries t Rm Ω 5±,5% s ±5% t ms ±5% NOTE The value of resistive loads (which includes all parts of the external circuit) should be as specified in Table 7 and Table 8. 3) Calculation of the capacity C : the capacity of the battery is obtained by adding the partial capacity amounts C p, calculated after each measurement with the following formula: U' t i C p= oc Rd Where t i is the time between two measurements C=ƩC p NOTE At the end of the discharge, it is recommended to carry out several measurements a day in order to obtain sufficient accuracy.

19 a) Method B Circuitry principle (see Figure 8 ) V Key Reading U cc R d resistance of continuous discharge Figure 8 Circuitry principle for method B See procedure in (7..6. b). b) c) Determination of the capacity: when the on-load voltage of the battery under test drops for the first time below the specified end point as specified in Table 5, the time t is calculated and defined as service life. The capacity is calculated by the following formula: C= U cc(average)t Rd where C is the capacity; Ucc(average)is the average voltage value of Ucc during discharge duration time (-t); t 7..7 is the service life. Calculation of the internal resistance R i during discharge in case of method A (optional) After each measurement of U' oc and Uccis carried out according to the procedure described in 7..6,it is possible to calculate the internal resistance R iof the battery using the following formula: Ri = oc cc cc/ m

20 Table 8 Discharge resistance (values) Code number according to the dimensions Letter for electro chemical systems L S Discharge resistance Code number according to the dimensions Letter for electro chemical systems C B Discharge resistance kω kω ,8 NOTE Blank values under consideration Test methods for determining the resistance to leakage Preconditioning and previous examination Before carrying out the tests specified in 7.3. and 7.3.3, the batteries shall be submitted to a visual examination according to the requirements stated in Clause 8.

21 For tests in and 7.3.., batteries shall be pre conditioned at the specified temperature (4 C and 45 C respectively) for h to avoid condensation at elevated humidity High temperature and humidity test Recommended test The battery shall be stored under the conditions specified in Table 9. Table 9 Storage conditions for the recommended test Temperatu re Relative humidity Test time C % day 9to95 3or9 4 of 3 days may be used for an accelerated routine quality control test, whereas the NOTE The test time test time of 9 days applies to qualification testing of new batteries Optional test After agreement between the manufacturer and purchaser, the following testing conditions may be chosen (see Table). Table Storage conditions for optional test Temperature Relative humidity Test time C % day 45 9 to 95 or 6 NOTE The test time of days may be used for an accelerated routine quality control test, whereas the test time of 6 day applies to qualification testing of new batteries Test by temperature cycles The battery shall be submitted to 5 temperature cycles according to the schedule infigure 9: cycle (6 ±) C Room temperature (- ± ) C,5 h h h h h Figure 9 Test by temperature cycles The relative humidity shall be 5% to 6% at room temperature; it will subsequently vary with the temperature variation.

22

23 8 8. Visual examination and acceptance conditions Pre conditioning Before carrying out the previous visual examination or after the tests specified in Clause7, the batteries shall be stored for at least 4h at room temperature and at a relative humidity between 45% and 7%. NOTE The leakage should, as a rule, be observed after crystallization of the electrolyte. The time of the storage of 4h can be prolonged if necessary. NOTE This examination may be applied to new or used batteries, or to batteries which have been submitted to different tests. 8. Magnification The visual examination shall be carried out at a magnification of x to x5.the magnification of x5 is necessary in order to detect small leaks. 8.3 Lighting The visual examination shall be carried out under a diffuse white light of 9 lx to lx at the surface of the battery to be inspected. 8.4 Leakage levels and classification The leakage levels and classification are given in Table.

24 Table Leakage levels and classification Leakage levels Diagram Classification S Salting Definition Grade Little salting found near the gasket, affecting less than % of the perimeter of the gasket, detected while observing at a magnification of x5. The leak Is not detectable with the naked eye S Traces of salting near gasket can be detected with the naked eye. At a magnification of x5, it may be noted that these salts affect more than % of the perimeter of the gasket S3 Salt spreads on both sides of the gasket can be detected with the naked eye, but do not reach the flat of the negative contact

25 Table Leakage levels and classification (continued) Leakage levels Diagram Classification Definition Grade C Leaks spread in clouds on both sides of the gasket, do reach the flat of the negative contact but do not reach the central part of the flat negative contact C Leaks spread in clouds, which reach the central part of the flat negative contact L The accumulation of crystallised liquid coming from the electrolyte swells up on part of the cloud spread, which covers the entire surface of the flat negative contact L The accumulation of crystallised liquid coming from the electrolyte swells up on the entire cloud spread, which covers the entire surface of the flat negative contact Clouds Leaks 8.5 Acceptance conditions The acceptable level, as well as the proportion of defective pieces, shall be agreed between the manufacturer and the purchaser. Fresh batteries, with a level of leakage exceeding S, shall not be submitted for qualification. The acceptance criteria may be less restrictive for batteries which have been tested according to If necessary, photographic references may be established..

26 Annex A (normative) Designation Watch batteries manufactured with the express purpose of complying with this standard should be designated by a system of coded letters and numbers as shown below. However, the letter W is used to indicate compliance with IS 675. EXAMPLE: S R 7 Electro chemical system letter according to Table 4 Round cell: (Doc ETD (69) Dimension: diameter in millimetres Dimension: height in tenths of millimetres Electrolyte: - S:SodiumhydroxideNaOH(optional) - P:PotassiumhydroxideKOH(optional) - Organic electrolyte: null Letter P may be left out in the case of electro chemical system letter S Letter W : compliance with Doc ETD (4) S W

27 Doc: ETD (4) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard ALKALINE MANGANESEDIOXIDE CELLS SPECIFICATION (First Revision of IS 563) Last date for receipt of comments is: -7-6 Foreword (Formal clauses will be added later) SCOPE This standard covers the dimensions, tests and the performance requirements of primary alkaline Manganese dioxide cells of designation LR, LR8D45, LR3, LR6, LR9, LR4, LR, LR4, LR55, LR54, LR43, LR44, 3LR, 4LR44, 4LR6, 4LR5X, 6LR6. REFERENCES The following Indian Standards are necessary adjuncts to this standard: IS No. 48 ( Part ) : ( Par t 5) : :6 (Under Preparation Doc ETD (69)) Title Direct acting indicating analogue electrical measuring instruments and their accessories: Part Ammeters and voltmeters Electrotechnical vocabulary: Part 5 Primary cells and batteries Primary Batteries General (Second Revision) 3 TERMINOLOGY For the purpose of this standard, the definitions given in IS 885 (Part 5) shall apply. The words battery and cell are used interchangeably in this standard as this covers both of them. 4 DESIGNATION The cells/batteries are designated in accordance with 4..5 of IS 633:6 (Under Preparation Doc ETD (69)) 5 DIMENSIONS The overall dimensions and nominal voltages are shown in Tables A to L. Note all dimensions are in mm.

28 Table A Dimensions h h h3 h4 d d3 d6 LR 3, 9,,5,,,9 4, 5, LR8D45 4,5 4,5,7, 8,3 7,7 3,8,3a,5, P a This battery does not fulfill the requirement d6 > d3 due to constructional constraints. nominal voltages Vn (V),5,5 OCV (V),68,68 Table B Dimensions h h h3 h4 LR3 d3 d6 44,5 43,5,8,5,5 9,8 3,8 4,3 P,5 d nominal voltages Vn (V),5 OCV (V),68

29 Table C Dimensions h h h3 h4 LR6 d3 d6 5,5 49,5,,5 4,5 3,7 5,5 7, P,5 d nominal voltages Vn (V),5 OCV (V),68 Table D LR9 Dimensions h 6, h 5,6 h3, h5, 6, d 5, d, d3 3,5 d4, d5,5 nominal voltages Vn (V),5 OCV (V),68

30 Table E Dimensions h h h3 h4 d d3 d6 P LR4 5, 48,6,5,9 6, 4,9 7,5 3,, nominal voltages Vn (V),5 OCV (V),68 Table F Dimensions h h h3 h4 d d3 d6 P LR 6,5 59,5,5, 34, 3,3 9,5 8,, nominal voltages Vn (V),5 OCV (V),68

31 Table G Dimensions h / h d d d4 Vn (V) OCV (V) LR4 LR55 LR54 3,6, 3,5 3,3,85,75 7,9,6,6 7,55,5,5 3,8 3,8 3,8 3, 3,8 3,8 nominal voltages,5,5,5,68,68,68 LR43 4, 3,8,6,5 3,8 3,8 LR44 5,4 5,,6,5 3,8 3,8,5,68,5,68 Table H 3LR Dimensions 67, h 63, 6, l 6,, l, l3 3, l4 6, l5, l6 3, 7, l7 6, nominal voltages Vn (V) 4,5 OCV (V) 5,4

32 Table I 4LR44 Dimensions 5, h 3,9 h3,7,4 h5,5 d 3 d d 5, d3 6,5 d4 5, nominal voltages Vn (V),5 OCV (V),68

33 Table J Dimensio ns ma h h h3 h4 l l l3 l4 l l6 x. 48,5 ma 47, ma, ma,8 ma,3 x. x. x. x.,7,3,8 35,6 ma 35, ma 8,7 ma 6, ma 6,5 ma, x. x. x. x. x. 4LR6 9, 6,5 8,,5,5, α -45 nominal voltages Vn (V) 6, OCV 6,7 (V)

34 Table K 4LR5X Dimensions ma 5 x. h min 8. ma x. h6 min 97. ma 67 x. l min 65. ma 67 x. l min 65. ma 7 x. l3 min nominal voltages Vn (V) 6, OCV (V) 6,7 Table L 6LR6 Dimensions 48,5 h 46,5 46,4 h6 6,5 l 4,5 7,5 l 5,5,95 l3,45 nominal voltages Vn (V) 9, OCV (V),

35 6 MATERIALS AND CONSTRUCTION 6. The Chemical System of the Cell / Battery Shall Be: a) Manganese dioxide (cathode); b) Zinc (anode); and c) Potassium hydroxide solution in water (electrolyte). 6. The Internal Design of the Cell / Battery and the Choice Of Material Shall Be Such That the Product meets the Following Criteria: a) The terminals shall be free from corrosion; b)terminals should maintain positive contact with external circuits; c) There shall not be any distortion / dents; d) There shall not be any leakage of electrolyte during normal storage and use under normal discharge conditions; and e) There shall be a system of venting to prevent the explosion due to generation of hydrogen gas inside the cell during storage/discharge/usage. 7 BATTERY CONNECTIONS 7. In All Assembled Batteries, Electrical Connections between Cells and Terminals Shall Be Permanent And Preferably of A Welded Construction. 7. All Soldered or Welded Connections Shall Be Made in Such A Manner As Not to Interfere with Subsequent Battery Performance. 8 TERMINALS Terminals shall be in accordance with respective tables provided in the standard and 4..3 of IS 633:6 (Under Preparation). 9 MARKING 9. Marking of Terminals Each terminal shall be clearly marked with the relevant nominal Voltage and polarity, where applicable. 9. Marking of Batteries The marking shall be done in accordance with of IS 633:6 (Under Preparation.) 9.3 BIS Certification Marking The product may also be marked with the Standard Mark The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 986 and the rules and regulations made thereunder. The details of conditions under which a licence for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards.

36 TESTS. General General provision of 5.3 to 5.7 and 6. of IS 633:6 (Under Preparation) shall apply.. Type Tests.. The Following Shall Constitute Type Tests. a) Checking of dimensions and terminals. b) Materials and construction. c) Checking of markings. d) Initial life. e) Delayed life. f) Leakage test for batteries... Samples Checking of dimensions,terminal and markings all samples. Initial life test: 9 pcs Delayed life test: 9 pcs.3 Lot Acceptance Test. The following shall constitute type tests. a. Initial life test of specified lot acceptance test given in Table b. Sampling inspection, testing and acceptance quality level shall be in accordance with 7. of IS 633:6 (Under Preparation) Table SI No i) ii) iii) iv) v) No. of Type Load cells No Ohm to be tested 3 4 LR LR LR4 9 LR 9 6LR6 6 9 Test Condition 5 Continuous Continuous Continuous Continuous Continuous End Minimum Voltage requirement Initial Life Test..4. Test shall be carried out in accordance with 5.3 and 6. of IS 633:6 (under preparation) and respective tables 3A to 3L..4. The Following Reading Shall Be Taken a. Initial closed circuit Voltage b. Closed circuit voltage at the end of each discharge period.

37 .4.3 The test shall continue until the closed circuit voltage of the battery falls below the appropriate end voltage specified in tables 3A to 3L. The life of the battery shall include a full discharge period of the day during which the voltage drops for the first time below the specified end point of the battery..4.4 The battery shall not show any leakage during or at the end of the test..5 Delayed Life Test a. Test shall be carried out in accordance with 5.3 and 6. of IS 633:6 (Under Preparation.) b. After storage test shall be done as specified in.4. Batteries shall meet the requirements given in tables 3A..3B..6 Leakage Test Nine cells are stored at 45 ± C (humidity < 7 percent) for a period of 3 days and are observed for leakage of electrolyte or sealing compound. No electrolyte, sealing compound or other internal component shall appear on any of the external surface of the battery. No deformation of cells shall take place..7 CODE OF PRACTICE FOR TRANSPORTATION, STORAGE, USE AND DISPOSAL BATTERIES See Annex G of IS 633:5. Table 3A : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR & LR8D45 Representative application Resistance/ power /current drain Discharge schedule End Voltage 3 4 Portable lighting 5, Ω 5 min /,9 94 min 9 min 75 min 7 min Pager Pulse: Ω Background: 3 Ω 5 s on, 59 min 55 s off for 4 h per dayb,9 888 min -- 7 min -- Laser pointer 75 Ω h, h -- h Service output test 75 Ω h, h -- h Hearing aid 3 Ω h,9 3 h -- 4 h -- Life initial LR 5 LR8D4 5 life after months LR 6 LR8D4 5

38 Table 3B : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR 3 Representative application Resistance 3 Portable lighting Toy Digital audio Remote control 4 Discharge schedule End Voltage Life initial life after months 4 4 min/h 8 h/day h/day h/day 5sec/min 8 h/day min 4 min.8.9 min. h 96 min 9.6 h. 4.5 h.6 h Table 3C : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR6 Resistance/ power Representative Discharge End life after Life initial /current application schedule Voltage months drain Digital still camera 4 5 mw 65 mw ##.5 4 Pulses 3 Pulses.9 3 min 84 min h 5. h 4. h 4. h Portable lighting (LED) 3.9 Ω Motor/toy Toy, non-motorized CD, digital audio, wireless gaming and accessories 3.9 Ω 5mA 4 min on, 56 min off for 8h per day h/day h/day ma h/day.9 5. h. h 5mA h on, 7 h off for 4 h per day 3. h 4. h Radio / Clock / Remote Control ## Repeat times per hour: 5 mw for s, then 65 mw for 8 s, then mw for 55

39 Table 3D : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR9 Resistance/ power Representative Discharge End Life life after /current application schedule Voltage initial months drain Service output test 3,39 kω 4 4 h h 7 38 h Table 3E : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR4 Resistance/ power Representative Discharge End life after Life initial /current application schedule Voltage months drain Toy 3,9 Ω h/day.8 4. h. h Portable Lighting 3,9 Ω 4 min on, min off for 8 h per day.9 79 min 63 min Portable stereo Current drain 4 ma h/day.9 8. h 6.4 h Table 3F : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR Resistance/ power Representative Discharge End life after Life initial /current application schedule Voltage months drain min on, Portable, Ω min off for min 6 min Lighting h per day Toy, Ω h/day.8 6. h.8 h Current Portable stereo h/day.9. h 8.8 h drain 6 ma

40 Table 3G : Initial Discharge Application Test Regime and Minimum Performance Requirements for LR4, LR55, LR54, LR43, LR44. Discha Representati Resista LR LR LR LR LR LR LR LR LR LR rge End ve nce schedul Voltage 4 application e 3 4 Life initial life after months Service output test kω Service output test kω 4 h, Service output test 5 kω 4 h, Service output test Service output test kω 6,8 kω 4 h, 75 h No Test 4 h 4 h,, 4 h 3 h No Test No Tes t 35 h No Tes t No Tes t No Tes t 359 h No Test No Tes t h 34 h No Tes t No Tes t 8 h No Tes t No Tes t No Tes t 87 h No Tes t 7 h Table 3H : Initial Discharge Application Test Regime and Minimum Performance Requirements for 3LR. Resistance/ Representative Discharge life after power /current End Voltage Life initial application schedule months drain Portable lighting Ω h/day.7 h 9.6 h Radio Ω 4 h/day.7 3 h 4 h Table 3I : Initial Discharge Application Test Regime and Minimum Performance Requirements for 4LR44 Resistance/ Representative Discharge life after power /current End Voltage Life initial application schedule months drain Accelerated Pulse:,6 kω application test a h 48 h Background: 7 for automatic kω camera Service output 7 kω 4 h/day h 336 h test Pulse test, kω 4 h/day pulses 76 pulses a Pulse load for s every 6 s for 5 min per day. Background load alternately and continuously for 4 h per day

41 Table 3J : Initial Discharge Application Test Regime and Minimum Performance Requirements for 4LR6 Resistance/ Representative Discharge life after power /current End Voltage Life initial application schedule months drain Electric.33 kω 4 h h 9. h equipment Service 6.8 kω 4 h h 56 pulses output test Table 3K : Initial Discharge Application Test Regime and Minimum Performance Requirements for 4LR5X Resistance/ Representative Discharge life after power /current End Voltage Life initial application schedule months drain Portable 8. Ω 3 min min 7 min Lighting 3 min on, 3 Portable 9. Ω min off for 8 h 3.6 min 86 min Lighting per day Road Ω h h 48 h warning lamp Table 3L : Initial Discharge Application Test Regime and Minimum Performance Requirements for 6LR6 Representative application Toy Clock radio Smoke detector* Resistance/ power /current drain 3 7 Ω 6 Ω Background: kω Pulse:,6 kω Discharge schedule 4 h/day h/day s on, 3599 s off for 4 h per day# End Voltage Life initial life after months h 33 h h 6.4 h days.8 days

42 Doc: ETD (4) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard PRIMARY BATTERIES SAFETY OF LITHIUM BATTERIES (First revision of IS 633(Part 4)) Last date for receipt of comments is: -7-6 Foreword (Formal clauses will be added later) SCOPE This standard specifies tests and requirements for primary lithium batteries to ensure their safe operation under intended use and reasonably foreseeable misuse. NOTE Primary lithium batteries that are standardized and are expected to meet all applicable requirements herein. It is understood that consideration of this standard might also be given to measuring and/or ensuring the safety of non-standardized primary lithium batteries. In either case, no claim or warranty is made that compliance or noncompliance with this standard will fulfill or not fulfill any of the user s particular purposes or needs. NORMATIVE REFERENCES The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IS No. 633: 6 (Under Preparation Doc ETD PRIMARY General (69)) 3 Title BATTERIES TERMS AND DEFINITIONS For the purposes of this document, the following terms and definitions apply. 3. Battery One or more cells electrically connected and fitted in a case, with terminals, markings and protective devices etc., as necessary for use 3. Coin Cell Coin Battery Small round cell or battery where the overall height is less than the diameter NOTE to entry: In English, the term coin (cell or battery) is used for lithium batteries only while the term button (cell or battery) is only used for non-lithium batteries. In languages other than English, the terms coin and button are often used interchangeably, regardless of the electrochemical system. NOTE In practice terms, the term coin is used exclusively for non-aqueous lithium cells. replaced with a different note)] Cell basic functional unit, consisting of an assembly of electrodes, electrolyte, container, terminals and usually separators, that is a source of electric energy obtained by direct

43 conversion of chemical energy 3.4 Component Cell Cell contained in a battery 3.5 Cylindrical (cell or battery) Round cell or battery in which the overall height is equal to or greater than the diameter 3.6 Depth of Discharge DOD Percentage of rated capacity discharged from a battery 3.7 Fully Discharged State of charge of a cell or battery corresponding to % depth of discharge 3.8 Harm Physical injury or damage to health of people, or damage to property or the environment 3.9 Hazard Potential source of harm 3. Intended Use Use of a product, process or service in accordance with information provided by the supplier, 3. Large Battery Battery with a gross mass of more than kg 3. Large Cell Cell with a gross mass of more than 5 g 3.3 Lithium Cell Cell containing a non-aqueous electrolyte and a negative electrode of lithium or containing lithium 3.4 Nominal Voltage Suitable approximate value of the voltage used to designate or identify a cell, a battery or an electrochemical system 3.5 Open Circuit Voltage OCV, UOC, Off-Load Voltage Voltage across the terminals of a cell or battery when no external current is flowing 3.6 Prismatic Cell Prismatic Battery Qualifies a cell or a battery having the shape of a parallelepiped whose faces are rectangular 3.7 Protective Devices Devices such as fuses, diodes or other electric or electronic current limiters designed to interrupt the current flow, block the current flow in one direction or limit the current flow in an electrical circuit 3.8 Rated Capacity Capacity value of a cell or battery determined under specified conditions and declared

44 by the manufacturer 3.9 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. Risk Combination of the probability of occurrence of harm and the severity of that harm Safety freedom from unacceptable risk 3. Undischarged State of charge of a primary cell or battery corresponding to % depth of discharge 4 REQUIREMENTS FOR SAFETY 4. Design Lithium batteries are categorized by their chemical composition (anode, cathode, electrolyte), internal construction (bobbin, spiral) and are available in cylindrical, coin and prismatic configurations. It is necessary to consider all relevant safety aspects at the battery design stage, recognizing the fact that they can differ considerably, depending on the specific lithium system, power capability and battery configuration. The following design concepts for safety are common to all lithium batteries: Abnormal temperature rise above the critical value defined by the manufacturer shall be prevented by design. b) Temperature increases in the battery shall be controlled by a design which limits current flow. a) c) Lithium cells and batteries shall be designed to relieve excessive internal pressure or to preclude a violent rupture under conditions of transport, intended use and reasonably foreseeable misuse. See Annex A for guidelines for the achievement of safety of lithium batteries. 4. 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 SAMPLING General Samples should be drawn from production lots in accordance with accepted statistical methods. 5. Test Samples The number of test samples is given in Table. The same test cells and batteries are used for tests A to E in sequence. New test cells and batteries are required for each of

45 tests F to M. 3

46 Table Number of test samples Tests Tests A to E Discharge state Cells and single cell batteries a Undischarged 4 Fully discharged 4 Undischarged 5 5 component cells Fully discharged 5 5 component cells Fully discharged component cells Undischarged 5 5 Test F or G Test H Tests I to K Test L Test M Multi-cell batteries Undischarged (see Note ) n/a 5 % pre discharged (see Note ) n/a 75 % pre discharged (see Note 3) n/a a single cell batteries containing one tested component cell do not require retesting unless the change could result in a failure of any of the tests. Key: n/a: not applicable NOTE Four batteries connected in series with one of the four batteries reversed (5 sets). NOTE Four batteries connected in series, one of which is 5 % pre discharged (5 sets). NOTE 3 Four batteries connected in series, one of which is 75 % pre discharged (5 sets). 6 TESTING AND REQUIREMENTS 6. General 6.. Test Application Matrix Applicability of test methods to test cells and batteries is shown in Table. 4

47 Table Test application matrix Applicable tests Form A B C D E F G H s x x x x x xa xa x m x x x x x x a, x a, x d Test description: d d Intended use tests Reasonably foreseeable Form misuse tests I x x J x x K x x Key: L xb n/a M xc n/a A: Altitude B: Thermal cycling C: Vibration D: Shock a b c d E: External short-circuit s: cell or single cell F: Impact battery Applicability G: Crush H: Forced discharge x: applicable I: Abnormal charging J: Free fall n/a: not applicable K: Thermal abuse Only one test shall be test Finstallation or test G. L: applied, Incorrect Only applicable to CR7345, CR5H7 and similar type batteries of a spiral construction that could be installed incorrectly and charged. Only applicable to CR7345, CR5H7 and similar type batteries of a spiral construction that could be over discharged. Test applies to the component cells. 6.. Safety Notice WARNING: These tests call for the use of procedures which can result in injury if adequate precautions are not taken. It has been assumed in the drafting of these tests that their execution is undertaken by appropriately qualified and experienced technicians using adequate protection Ambient Temperature Unless otherwise specified, the tests shall be carried out at an ambient temperature of 7 C ± C Parameter Measurement Tolerances The overall accuracy of controlled or measured values, relative to the specified or actual parameters, shall be within the following tolerances: a) ± % for voltage; b) c) d) e) for current; for temperature; for time; for dimensions; ± % ± C ±, % ± %

48 f) ± % for capacity. These tolerances comprise the combined accuracy of the measuring instruments, the measurement techniques used, and all other sources of error in the test procedure Pre Discharge Where a test requires pre discharge, the test cells or batteries shall be discharged to the respective depth of discharge on a resistive load with which the rated capacity is obtained or at a current specified by the manufacturer Additional Cells Where additional cells are required to perform a test, they shall be of the same type and, preferably, from the same production lot as the test cell Evaluation of Test Criteria Short-Circuit A short-circuit is considered to have occurred during a test if the open-circuit voltage of the cell or battery immediately after the test is less than 9 % of its voltage prior to the test. This requirement is not applicable to test cells and batteries in fully discharged states. 6.. Excessive Temperature Rise An excessive temperature rise is considered to have occurred during a test if the external case temperature of the test cell or battery rises above 7 C Leakage Leakage is considered to have occurred during a test if there is visible escape of electrolyte or other material from the test cell or battery, or the loss of material (except battery casing, handling devices or labels) from the test cell or battery such that the mass loss exceeds the limits in Table 3. 6

49 In order to quantify mass loss m / m, the following equation is provided: = -m Δm / m m % m Where m is the mass before a test; m is the mass after that test. Table 3 Mass loss limits Mass of cell or battery m m< g g m m75> g75 g Mass loss limit m / m,5 %, %, %

50 6..4 Venting Venting is considered to have occurred if, during a test, an excessive build up of internal gas pressure escapes from a cell or battery through a safety feature designed for this purpose. This gas may include entrapped materials Fire A fire is considered to have occurred if, during a test, flames are emitted from the test cell or battery Rupture A rupture is considered to have occurred if, during a test, a cell container or battery case has mechanically failed, resulting in expulsion of gas, spillage of liquids, or ejection of solid materials but no explosion Explosion An explosion is considered to have occurred if, during a test, solid matter from any part of a cell or battery has penetrated a wire mesh screen as shown in Figure, centred over the cell or battery on the steel plate. The screen shall be made from annealed aluminium wire with a diameter of,5 mm and a grid density of 6 to 7 wires per cm.,3 m,6 m IEC NOTE The figure shows an aluminium wire mesh screen () of octagonal shape resting on a steel plate (). Figure Mesh screen 7

51 Tests and Requirements Overview 6.3 This standard provides safety tests for intended use (tests A to D) and reasonably foreseeable misuse (tests E to M). Table 4 contains an overview of the tests and requirements for intended use and reasonably foreseeable misuse. Table 4 Tests and requirements Test number Intended use tests Reasonably misuse tests foreseeable A B C D E F G H I J K L M Tests A through E shall be Designation Altitude Thermal cycling Vibration Shock External short-circuit Requirements N N N N N NF L, V,NV, C, N R, N E, NF NL, NC, NV, N R, N E, NF NL, NC, NV, N R, N E, NF NL, NC,N N R, N NF E, T, R, E, Impact N N NF T, E, Crush N N NF T, Forced discharge N E, NF E, Abnormal charging N NF E, Free fall N N NF V, Thermal abuse N E, NF E, Incorrect installation N NF E, Over discharge N NF E, cell or battery. conducted in sequence on the same Tests Key F and G are provided as alternatives. Only one of them shall be conducted. NC: No shortcircuit NE: No explosion NF: No fire NL: No leakage NR: No rupture NT: No excessive 6.4 Tests for Intended Use 6.4. Test A: Altitude a) Purpose This test simulates air transport under low pressure conditions. b) Test procedure Test cells and batteries shall be stored at a pressure of,6 kpa or less for at least 6 h at ambient temperature. 8

52 c) Requirements There shall be no leakage, no venting, no short-circuit, no rupture, no explosion and no fire during this test Test B: Thermal Cycling a) Purpose This test assesses cell and battery seal integrity and that of their internal electrical connections. The test is conducted using temperature cycling. b) Test procedure Test cells and batteries shall be stored for at least 6 h at a test temperature of 7 C, followed by storage for at least 6 h at a test temperature of 4 C. The maximum time for transfer to each temperature shall be 3 Each test cell and battery shall undergo this procedure times. This is then followed by storage for at least 4 h at ambient temperature. NOTE Figure shows one of ten cycles. For large cells and batteries the duration of exposure to the test temperatures shall be at least h instead of 6 h. The test shall be conducted using the test cells and batteries previously subjected to the altitude test. +7 C 4 C t t t t IEC Key t 3 min t 6 h ( h for large cells and batteries) Figure Thermal cycling procedure c) Requirements There shall be no leakage, no venting, no short-circuit, no rupture, no explosion and no fire during this test. 9

53 6.4.3 Test C: Vibration a) Purpose This test simulates vibration during transport. The test condition is based on the range of vibrations as given by ICAO []. b) Test procedure Test cells and batteries shall be firmly secured to the platform of the vibration machine without distorting them and in such a manner as to faithfully transmit the vibration. Test cells and batteries shall be subjected to sinusoidal vibration according to Table 5 which shows a different upper acceleration amplitude for large batteries. This cycle shall be repeated times for a total of 3 h for each of three mutually perpendicular mounting positions. One of the directions shall be perpendicular to the terminal face. The test shall be conducted using the test cells and batteries previously subjected to the thermal cycling test. Table 5 Vibration profile (sinusoidal) Frequency range From To Amplitudes f = 7 Hz f a = gn f f3 s =,8 mm f f 4 = a 3 and Hz back to f = 7 Hz Duration of logarithmic sweep cycle (7 Hz Hz 7 Hz) 5 min Axis Numb er of cycles X Y Z Total 36 NOTE Vibration amplitude is the maximum absolute value of displacement or acceleration. For example, a displacement amplitude of,8 mm corresponds to a Key f, f4 lower and upper frequency f, f3 cross-over frequencies; f 7,6 Hz; and f3 49,84 Hz, except for large batteries, where f 3 4,9 Hz a, a acceleration amplitude a = 8 gn except for large batteries, where a = gn NOTE g n = 9,8665 m / s c) Requirements There shall be no leakage, no venting, no short-circuit, no rupture, no explosion and no fire during this test a) Test D: Shock Purpose This test simulates rough handling during transport.

54 b) Test procedure Test cells and batteries shall be secured to the testing machine by means of a rigid mount which will support all mounting surfaces of each test cell or battery. Each test cell or battery shall be subjected to 3 shocks in each direction of three mutually perpendicular mounting positions of the cell or battery for a total of 8 shocks. For each shock, the parameters given in Table 6 shall be applied. Table 6 Shock parameters Waveform Cells or batteries except large ones Large cells or batteries Peak acceleration 5 g n 5 gn Half sine Half sine Pulse duration 6 ms ms Number of shocks per half axis 3 3 NOTE g n = 9,8665 m / s² The test shall be conducted using the test cells and batteries previously subjected to the vibration test. c) Requirements There shall be no leakage, no venting, no short-circuit, no rupture, no explosion and no fire during this test. 6.5 Tests for Reasonably Foreseeable Misuse 6.5. Test E: External Short-Circuit a) Purpose This test simulates conditions resulting in an external shortcircuit. b) Test procedure The test cell or battery shall be stabilized at an external case temperature of 55 C and then subjected to a short-circuit condition with a total external resistance of less than, Ω at 55 C. This short-circuit condition is continued for at least h after the cell or battery external case temperature has returned to 55 C. The test sample shall be observed for a further 6 h. The test shall be conducted using the test samples previously subjected to the shock test. c) Requirements There shall be no excessive temperature rise, no rupture, no explosion and no fire during this test and within the 6 h of observation.

55 6.5. Test F: Impact a) Purpose This test simulates mechanical abuse from an impact that can result in an internal short circuit. b) Test procedure The impact test is applicable to cylindrical cells greater than mm in diameter. The test cell or component cell is placed on a flat smooth surface. A stainless steel bar (type 36 or equivalent) with a diameter of 5,8 mm ±, mm and a length of at least 6 mm or of the longest dimension of the cell, whichever is greater, is placed across the centre of the test sample. A mass of 9, kg ±, kg is dropped from a height of 6 cm ±,5 cm at the intersection of the bar and the test sample in a controlled manner using a near frictionless, vertical sliding track or channel with minimal drag on the falling mass. The vertical track or channel used to guide the falling mass shall be oriented 9 degrees from the horizontal supporting surface. The test sample is to be impacted with its longitudinal axis parallel to the flat surface and perpendicular to the longitudinal axis of the stainless steel bar lying across the centre of the test sample (see Figure 3) IEC NOTE The figure shows a flat smooth surface () and a stainless steel bar () which is placed across the centre of the test sample (3). A mass (4) is dropped at the intersection in a controlled manner using a vertical sliding channel (5). Figure 3 Example of a test set-up for the impact test Each test cell or component cell shall be subjected to one impact only. The test sample shall be observed for a further 6 h. The test shall be conducted using test cells or component cells that have not been previously subjected to other tests. c) Requirements

56 There shall be no excessive temperature rise, no explosion and no fire during this test and within the 6 h of observation. Test G: Crush a) Purpose This test simulates mechanical abuse from a crush that can result in an internal short circuit. b) Test procedure The crush test is applicable to prismatic, flexible, coin cells and cylindrical cells not more than mm in diameter. A cell or component cell is to be crushed between two flat surfaces. The crushing is to be gradual with a speed of approximately,5 cm / s at the first point of contact. The crushing is to be continued until one of the three conditions below is reached: ) The applied force reaches 3 kn ±,78 kn; Example: The force can be applied by a hydraulic ram with a 3 mm diameter piston until a pressure of 7 MPa is reached on the hydraulic ram. ) The voltage of the cell drops by at least mv; or 3) The cell is deformed by 5 % or more of its original thickness. As soon as one of the above conditions has been obtained, the pressure shall be released. A prismatic or flexible cell shall be crushed by applying the force to the side with the largest surface area. A coin cell shall be crushed by applying the force on its flat surfaces. For cylindrical cells, the crush force shall be applied perpendicular to the longitudinal axis. See Figure IEC IEC IEC

57 a) Prismatic or flexible cell b) Coin cell c) Cylindrical cell NOTE Figures 4a) to 4c) show two flat surfaces ( and ) with batteries (3) of different shapes placed between them for crushing, using a piston (4). Figure 4 Examples of a test set-up for the crush test Each test cell or component cell is to be subjected to one crush only. The test sample shall be observed for a further 6 h. The term flexible cell is used in this document in place of the term pouch cell which is used in [9]. It is also used in place of the terms cell with a laminate film case and laminate film cell. The test shall be conducted using test cells or component cells that have not previously been subjected to other tests. c) Requirements There shall be no excessive temperature rise, no explosion and no fire during this test and within the 6 h of observation Test H: Forced Discharge a) Purpose This test evaluates the ability of a cell to withstand a forced discharge condition. b) Test procedure Each cell shall be force discharged at ambient temperature by connecting it in series with a V direct current power supply at an initial current equal to the maximum continuous discharge current specified by the manufacturer. The specified discharge current is obtained by connecting a resistive load of appropriate size and rating in series with the test cell and the direct current power supply. Each cell shall be force discharged for a time interval equal to its rated capacity divided by the initial test current. This test shall be conducted with fully discharged test cells or component cells that have not previously been subjected to other tests. c) Requirements There shall be no explosion and no fire during this test and within 7 days after the test Test I: Abnormal Charging a) Purpose This test simulates the condition when a battery is fitted within a device and is exposed to a reverse voltage from an external power supply, for example memory back-up equipment with a defective diode (see 7..). The test condition is based upon UL 64 [7]. b) Test procedure Each test battery shall be subjected to a charging current of three times the 3 by the battery manufacturer by connecting it abnormal charging current Ic specified

58 in opposition to a d.c. power supply. Unless the power supply allows for setting the current, the specified charging current shall be obtained by connecting a resistor of the appropriate size and rating in series with the battery. The test duration shall be calculated using the formula: td =,5 Cn / (3 Ic) where t d is the test duration. In order to expedite the test, it is permitted to adjust the test parameters such that t d does not exceed 7 days; C n is the nominal capacity; Ic is the abnormal charging current declared by the manufacturer for this test. c) Requirements There shall be no explosion and no fire during this test Test J: Free Fall a) Purpose This test simulates the situation when a battery is accidentally dropped. The test condition is based upon IEC [7]. b) Test procedure The test batteries shall be dropped from a height of m onto a concrete surface. Each test battery shall be dropped six times, a prismatic battery once from each of its six faces, a round battery twice in each of the three axes shown in Figure 5. The test batteries shall be stored for h afterwards. The test shall be conducted with undischarged test cells and batteries. z x y IEC Figure 5 Axes for free fall c) Requirements There shall be no venting, no explosion and no fire during this test and within the h of observation.

59 Test K: Thermal Abuse a) Purpose This test simulates the condition when a battery is exposed to an extremely high temperature. b) Test procedure A test battery shall be placed in an oven and the temperature raised at a rate of 5 C/min to a temperature of 3 C at which the battery shall remain for c) Requirements There shall be no explosion and no fire during this test. Test L: Incorrect Installation a) Purpose This test simulates the condition when one single cell battery in a set is reversed. b) Test procedure A test battery is connected in series with three undischarged additional single cell batteries of the same brand and type in such a way that the terminals of the test battery are connected in reverse. The resistance of the interconnecting circuit shall be no greater than, Ω. The circuit shall be completed for 4 h or until the battery case temperature has returned to ambient (see Figure 6) B B...B 4 IEC Key B Test cell B B4 Additional cells, undischarged Figure 6 Circuit diagram for incorrect installation c) Requirements There shall be no explosion and no fire during this test a) Test M: Over Discharge Purpose This test simulates the condition when one discharged single cell battery is connected in series with other undischarged single cell batteries. The test further simulates the use of batteries in motor powered appliances where, in general, currents over A are required. NOTE CR7345 and CR5H7 batteries are widely used in motor powered appliances where currents over A are required. The current for non-standardized batteries may be different.

60 b) Test procedure Each test battery shall be pre discharged to 5 % depth of discharge. It shall then be connected in series with three undischarged additional single cell batteries of the same type. A resistive load R is connected in series with the assembly of batteries in Figure 7 where R is taken from Table 7. The test shall be continued for 4 h or until the battery case temperature has returned to ambient. The test shall be repeated with 75 % pre discharged test batteries. Table 7 Resistive load for over discharge Resistive load R Battery type Ω CR7345 8, CR5H7 8, NOTE Table to be modified or expanded when additional batteries of a spiral construction are standardized. EXAMPLE When CR7345 and CR5H7 batteries were standardized, R was determined from the end voltage of the assembly in Figure 7, using the formula R = 4, V / A where, V is the end voltage taken from the specification tables in + + B + + B...B 4 R IEC Key B Test battery, 5 % pre discharged and, in separate tests, 75 % pre discharged. B... B4 Additional batteries, undischarged R Resistive load Figure 7 Circuit diagram for over discharge

61 c) Requirements There shall be no explosion and no fire during this test. 6.6 Information to Be Given In the Relevant Specification When this standard is referred to in a relevant specification, the parameters given in Table 8 shall be given in so far as they are applicable: Table 8 Parameters to be specified Item Parameters Clause and/or subclaus e 6..5 a) Pre discharge current or resistive load and end-point voltage specified by the manufacturer b) Shape: prismatic, flexible, coin or cylindrical; Diameter: not more than mm or greater than mm and c) Maximum continuous discharge current specified by the manufacturer for test H NOTE Forced discharge of a cell can occur when it is connected in series with other cells and when it is not protected with a bypass diode. d) Rated capacity specified by the manufacturer for test H e) Abnormal charging current declared by the manufacturer for test I NOTE Abnormal charging of a cell can occur when it is connected in series with other cells and one cell is reversed or when it is connected in parallel with a power supply and the protective devices do not operate correctly. f) Normal reverse current declared by the manufacturer which can be applied to the battery during its operating life NOTE Normal reverse current flow through a cell can occur when it is connected in parallel with a power supply and the protective devices are operating properly. 6.7 Evaluation and Report 7..

62 When a report is issued, the following list of items should be considered: a) name and address of the test facility; b) name and address of applicant (where appropriate); c) a unique test report identification; d) the date of the test report; e) design characteristics of the test cells or batteries according to 4.; f) test descriptions and results, including the parameters according to 6.6; g) type of the test sample(s): cell, component cell, battery or battery assembly; h) weight of the test sample(s); i) lithium content of the sample(s); j) A signature with name and status of the signatory. 7 INFORMATION FOR SAFETY 7. Safety Precautions during Design of Equipment 7.. General See also Annex B for guidelines for designers of equipment using lithium batteries. 7.. Charge protection When incorporating a primary lithium battery into a circuit powered by an independent main power source, protective devices shall be used in order to prevent charging the primary battery from the main power source, for example a) b) c) a blocking diode and a current limiting resistor (see Figure 8a); two series blocking diodes (see Figure 8b); circuits with a similar blocking function based on two or more independent protective devices; provided that the first protective device is capable of limiting the charging current through the lithium battery to the normal reverse current specified by the manufacturer which can be applied to the battery during its operating life, while the second protective device is capable of limiting the charging current to the abnormal charging current specified by the battery manufacturer and used for conduction of test I, Abnormal charging. The circuit shall be so designed that at least one of these protective devices remains operational when any one component of the circuit fails. RAM RAM

63 + + IEC a) Diode and resistor IEC b) Two diodes Figure 8 Examples of safety wiring for charge protection 7..3 Parallel connection Parallel connection should be avoided when designing battery compartments. However, if required, the battery manufacturer shall be contacted for advice. 7. Safety Precautions during Handling of Batteries When used correctly, lithium batteries provide a safe and dependable source of power. However, if they are misused or abused, leakage, venting or in extreme cases, explosion and/or fire can result. a) Keep batteries out of the reach of children In particular, keep batteries which are considered swallowable out of the reach of children, particularly those batteries fitting within the limits of the ingestion gauge as defined in Figure 9. In case of ingestion of a cell or battery, seek medical assistance promptly. Swallowing lithium coin cells or batteries can cause chemical burns, perforation of soft tissue, and in severe cases can cause death. They must be removed immediately if swallowed. See Figure for an example of appropriate warning text. NOTE Refer to [4] for general information on hazards from batteries.

64 +, 57, +, 5,4 +, 3,7 IEC Dimensions in millimetres NOTE This gauge defines a swallowable component and is defined in ISO 84- [6]. Figure 9 Ingestion gauge WARNING KEEP OUT OF REACH OF CHILDREN. Swallowing can lead to chemical burns, perforation of soft tissue, and death. Severe burns can occur within hours of ingestion. Seek medical attention immediately.

65 IEC Figure Example for warning against swallowing, particularly lithium coin cell batteries b) c) Do not allow children to replace batteries without adult supervision Always insert batteries correctly with regard to polarity (+ and ) marked on the battery and the equipment When batteries are inserted in reverse they might be short-circuited or charged. This can cause overheating, leakage, venting, rupture, explosion, fire and personal injury. d) Do not short-circuit batteries When the positive (+) and negative ( ) terminals of a battery are in electrical contact with each other, the battery becomes short-circuited. For example loose batteries in a pocket with keys or coins, can be short-circuited. This can result in venting, leakage, explosion, fire and personal injury. e) Do not charge batteries Attempting to charge a non-rechargeable (primary) battery can cause internal gas and/or heat generation resulting in leakage, venting, explosion, fire and personal injury. f) Do not force discharge batteries When batteries are force discharged by means of an external power source, the voltage of the battery will be forced below its design capability and gases will be generated inside the battery. This can result in leakage, venting, explosion, fire and personal injury. g) Do not mix new and used batteries or batteries of different types or brands When replacing batteries, replace all of them at the same time with new batteries of the same brand and type. When batteries of different brand or type are used together or new and used batteries are used together, some batteries might be over-discharged / force discharged due to a difference of voltage or capacity. This can result in leakage, venting, explosion or fire, and can cause personal injury. h) Exhausted batteries should be immediately removed from equipment and properly disposed of When discharged batteries are kept in the equipment for a long time, electrolyte leakage can occur causing damage to the equipment and/or personal injury. i) Do not heat batteries When a battery is exposed to heat, leakage, venting, explosion or fire can occur and cause personal injury. j) Do not weld or solder directly to batteries The heat from welding or soldering directly to a battery can cause leakage, venting, explosion or fire, and can cause personal injury.

66 k) Do not dismantle batteries When a battery is dismantled or taken apart, contact with the components can be harmful and can cause personal injury or fire. l) Do not deform batteries Batteries should not be crushed, punctured, or otherwise mutilated. Such abuse can cause leakage, venting, explosion or fire, and can cause personal injury. m) Do not dispose of batteries in fire When batteries are disposed of in fire, the heat build-up can cause explosion and/or fire and personal injury. Do not incinerate batteries except for approved disposal in a controlled incinerator. n) A lithium battery with a damaged container should not be exposed to water Lithium metal in contact with water can produce hydrogen gas, fire, explosion and/or cause personal injury. o) Do not encapsulate and/or modify batteries Encapsulation or any other modification to a battery can result in blockage of the safety vent mechanism(s) and subsequent explosion and personal injury. Advice from the battery manufacturer should be sought if it is considered necessary to make any modification. p) Store unused batteries in their original packaging away from metal objects. If already unpacked, do not mix or jumble batteries Unpacked batteries could get jumbled or get mixed with metal objects. This can cause battery short-circuiting which can result in leakage, venting, explosion or fire, and personal injury. One of the best ways to prevent this from happening is to store unused batteries in their original packaging. q) Remove batteries from equipment if it is not to be used for an extended period of time unless it is for emergency purposes It is advantageous to remove batteries immediately from equipment which has ceased to function satisfactorily, or when a long period of disuse is anticipated (e.g. camcorders, digital cameras, photoflash, etc.). Although most lithium batteries on the market today are highly leak resistant, a battery that has been partially or completely exhausted might be more prone to leak than one that is unused. 7.3 Packaging The packaging shall be adequate to avoid mechanical damage during transport, handling and stacking. The materials and packaging design shall be chosen so as to prevent the development of unintentional electrical contact, short-circuit, shifting and corrosion of the terminals, and afford some protection from the environment. 7.4 Handling of Battery Cartons Battery cartons should be handled with care. Rough handling might result in batteries being short-circuited or damaged. This can cause leakage, explosion, or fire.

67 7.5 Transport 7.5. General Tests and requirements for the transport of lithium cells or batteries are given in IEC 68 []. Regulations concerning international transport of lithium batteries are based on the UN Recommendations on the Transport of Dangerous Goods [8]. Regulations for transport are subject to change. For the transport of lithium batteries, the latest editions of the following regulations should be consulted Air Transport Regulations concerning air transport of lithium batteries are specified in the Technical Instructions for the Safe Transport of Dangerous Goods by Air published by the International Civil Aviation Organization (ICAO) [] and in the Dangerous Goods Regulations published by the International Air Transport Association (IATA) [] Sea Transport Regulations concerning sea transport of lithium batteries are specified in the International Maritime Dangerous Goods (IMDG) Code published by the International Maritime Organization (IMO) [3] Land Transport Regulations concerning road and railroad transport are specified on a national or multilateral basis. W hile an increasing number of regulators adopt the UN Model Regulations [8], it is recommended that country-specific transport regulations be consulted before shipping. 7.6 Display and Storage a) Store batteries in well ventilated, dry and cool conditions High temperature or high humidity can cause deterioration of the battery performance and/or surface corrosion. b) Do not stack battery cartons on top of each other exceeding a specified height If too many battery cartons are stacked, batteries in the lowest cartons might be deformed and electrolyte leakage can occur. c) Avoid storing or displaying batteries in direct sun or in places where they get exposed to rain When batteries get wet, their insulation resistance might be impaired and selfdischarge and corrosion can occur. Heat can cause deterioration. d) Store and display batteries in their original packing When batteries are unpacked and mixed they can be short-circuited or damaged. See Annex C for additional details.

68 7.7 Disposal Batteries may be disposed of via communal refuse arrangements provided no local rules to the contrary exist. During transport, storage and handling for disposal, the following safety precautions should be considered: a) Do not dismantle batteries Some ingredients of lithium batteries might be flammable or harmful. They can cause injuries, fire, rupture or explosion. b) Do not dispose of batteries in fire except under conditions of approved and controlled incineration Lithium burns violently. Lithium batteries can explode in a fire. Combustion products from lithium batteries can be toxic and corrosive. c) Store collected batteries in a clean and dry environment out of direct sunlight and away from extreme heat Dirt and wetness might cause short-circuits and heat. Heat might cause leakage of flammable gas. This can result in fire, rupture or explosion. d) Store collected batteries in a well-ventilated area Used batteries might contain a residual charge. If they are short-circuited, abnormally charged or force discharged, leakage of flammable gas might be caused. This can result in fire, rupture or explosion. e) Do not mix collected batteries with other materials Used batteries might contain residual charge. If they are short-circuited, abnormally charged or force discharged, the generated heat can ignite flammable wastes such as oily rags, paper or wood and cause a fire. f) Protect battery terminals Protection of terminals should be considered by providing insulation, particularly for those batteries with a high voltage. Unprotected terminals might cause shortcircuits, abnormal charging and forced discharge. This can result in leakage, fire, rupture or explosion. 8 INSTRUCTIONS FOR USE a) Always select the correct size and type of battery most suitable for the intended use. Information provided with the equipment to assist correct battery selection should be retained for reference. b) c) Replace all batteries of a set at the same time. Clean the battery contacts and also those of the equipment prior to battery installation. e) Ensure that the batteries are installed correctly with regard to polarity (+ and ). d) f) Remove exhausted batteries promptly.

69 9 9. MARKING General With the exception of small batteries (see 9.), each battery shall be marked with the following information: a) designation, IEC or common; b) Expiration of a recommended usage period or year and month or week of manufacture. The year and month or week of manufacture may be in code; c) polarity of the positive (+) terminal; d) nominal voltage; e) name or trade mark of the manufacturer or supplier; f) cautionary advice; g) Caution for ingestion of swallowable batteries, see also 7. a). 9. Small Batteries For batteries that fit entirely within the Ingestion Gauge (Figure 9) the designation 9. a) and the polarity 9.c) shall be marked on the battery, while all other markings shown in 9. may be given on the immediate package. However, when batteries are intended for direct sale in consumer-replaceable applications, caution for ingestion 9.g) shall also be marked on the immediate package. 9.3 Safety Pictograms Safety pictograms that could be considered for use as an alternative to written cautionary advice are provided in Annex D.

70 Annex A (informative) Guidelines for the achievement of safety of lithium batteries The guidelines given in Figure A. were followed during the development of high power batteries for consumer use. They are given here for information. EXAMPLE Design Prevent abnormal temperature rise of the battery by incorporating a current limitation Provide intrinsic current limitation High current drain can result in a rapid temperature increase in the lithium battery. The designer should make sure that the current drain is controlled by design. One method that has been used successfully is the incorporation of a resettable PTC which activates rapidly when the battery is exposed to a current drain exceeding its design criteria. In the design of the battery, the designer should make sure that the current flow is limited if the battery temperature rises above its design criteria. One method that has been used successfully is to incorporate a separator system whose ability to pass current is significantly reduced with excess temperature. Prevent explosion of the battery by a means to release internal pressure when temperature rises excessively Lithium batteries are tightly sealed to prevent leakage. Therefore, the design of the battery should provide a method to release excessive internal pressure. This should occur at a temperature range consistent with the battery s design criteria Pilot production Confirm that actual batteries can be produced according to design quality Establish necessary safety precautions Mass production Mass production of batteries according to design quality Request equipment manufacturers to carefully observe the safety precautions Reject defects in the production process Make this information available to end users Inspection Confirm that batteries meet design quality Reject defects by the inspection IEC Figure A. Battery design guidelines

71

72 ANNEX B (informative) GUIDELINES FOR DESIGNERS OF EQUIPMENT USING LITHIUM BATTERIES Table B. sets out the guidelines to be used by designers of equipment which employs lithium batteries (see also Doc ETD (44),Annex B, for guidelines for the design of battery compartments). Table B. Equipment design guidelines ( of 3) Item () When a lithium battery is used as main power source Sub-item Recommendations (.) Selection of a suitable battery Select most suitable battery for the equipment, taking note of its electrical characteristics (.) Number of batteries (series connection or parallel connection) to be used and method of use a) Multi-cell batteries (CR5, CRP, CR35 and others); one piece only b) Cylindrical batteries (CR7345 and others); less than three pieces c) Coin type batteri es (CR6, CR5, CR8 and others); less than three pieces d) When more than one battery is used, different types should not be used in the same battery compartment Possible consequences if the Battery might overheat If the capacity of batteries in series connection is different, the battery with the lower capacity will be over discharged. This can result in electrolyte leakage, overheating, rupture, explosion or fire

73 (.3) Design of battery circuit e) When batteries are used in parallel a protection against charging should be provided If the voltages of batteries in parallel connection are different, the battery with the lower voltage will become charged. This can result in electrolyte leakage, overheating, rupture, explosion or fire a) Battery circuit shall be isolated from any other power source Battery might be charged. This can result in electrolyte leakage, overheating, rupture, explosion or fire Short-circuiting a battery can result in electrolyte leakage, overheating, rupture, explosion or fire b) Protective devices such as fuses shall be incorporated in the circuit a See 7..3.

74 Table B. ( of 3) Ite m SubItem () When a lithium (.) Design of battery is used as battery circuit back-up power source (.) Design of battery circuit for memory back-up application (3) Battery holder and battery compartment Recommendatio ns Possible consequences if the The battery should Battery might be be over- discharged used in separate to reverse circuit so that it is polarity or charged. not force This can result in discharged or electrolyte leakage, charged by the main overheating, power source rupture, explosion or fire When a battery is connected to the circuit of a main power source with the possibility of being charged, a protective circuit must be provided with a combination of diode and resistor. The accumulated amount of the leakage current of the diode should be below % of the battery capacity during expected life time Battery might be charged. This can result in electrolyte leakage, overheating, rupture, explosion or fire a) Battery compartments should be designed so that if a battery is reversed, open circuit is achieved. Battery compartments should be clearly and permanently marked to show the correct orientation of batteries Unless protection is provided against battery reversal, damage to equipment can occur from resultant electrolyte leakage, overheating, rupture, explosion or fire

75 b) Battery compartments should be designed so that batteries other than the specified size cannot be inserted and make contact Equipment might be damaged or might not operate c) Battery compartments should be designed to allow generated gases to escape Battery compartments might be damaged when internal pressure of the battery becomes too high due to gas generation d) Battery compartments should be designed to be water proof e) Battery compartments should be designed to be explosion proof when tightly sealed f) Battery compartments should be isolated from heat generated by the equipment Battery might be deformed and leak electrolyte due to excessive heat g) Battery compartments should be designed so that they cannot easily be opened by children Children might remove batteries from the compartment and swallow them

76 Table B. (3 of 3) Ite m SubItem (4) Contacts and terminals (5) Indication of necessary precautions Recommendatio ns Possible consequences if the a) Material and Heat might generate shape of contacts at the contact due to and terminals insufficient should be selected connection so that effective electric contact is maintained b) Auxiliary circuit should be designed to prevent reverse installation of batteries Equipment might be damaged or might not operate c) Contact and terminal should be designed to prevent reverse installation of batteries Equipment might be damaged. Battery might cause electrolyte leakage, overheating, rupture, explosion or fire d) Direct soldering or welding to a battery should be avoided Battery might leak, overheat, rupture, explode or catch fire (5.) On the equipment Orientation of batteries (polarity) should be clearly indicated at the battery compartment When a battery is inserted reverse and charged, it can result in electrolyte leakage, overheating, rupture, explosion or fire (5.) In the instruction manual Precautions for the proper handling of batteries should be indicated Batteries might be mishandled and cause accidents

77 ANNEX C (informative) ADDITIONAL INFORMATION ON DISPLAY AND STORAGE This annex provides additional details concerning display and storage of lithium batteries to those already given in 7.6. The storage area should be clean, cool, dry, ventilated and weatherproof. For normal storage, the temperature should be between + C and +5 C and should never exceed +3 C. Extremes of humidity (over 95 % and below 4 % relative humidity) for sustained periods should be avoided since they are detrimental to both batteries and packings. Batteries should therefore not be stored next to radiators or boilers nor in direct sunlight. Although the storage life of batteries at room temperature is excellent, storage is improved at lower temperatures provided that special precautions are taken. The batteries should be enclosed in special protective packing (such as sealed plastic bags or variants) which should be retained to protect the batteries from condensation during the time they are warming to ambient temperature. Accelerated warming is harmful. Batteries which have been cold-stored may be put into use after return to ambient temperature. Batteries may be stored fitted in equipment or packages, if determined suitable by the battery manufacturer. The height to which batteries may be stacked is clearly dependent on the strength of the packaging. As a general rule, this height should not exceed,5 m for cardboard packages or 3 m for wooden cases. The above recommendations are equally valid for storage conditions during prolonged transit. Thus, batteries should be stored away from ship engines and not left for long periods in unventilated metal box cars (containers) during summer. Batteries shall be dispatched promptly after manufacture and in rotation to distribution centres and on to the users. In order that stock rotation (first in, first out) can be practised, storage areas and displays should be properly designed and packs adequately marked.

78 ANNEX D (informative) SAFETY PICTOGRAMS General D. Cautionary advice to fulfill the marking requirements in this standard has, on a historical basis, been in the form of written text. In recent years, there has been a growing trend toward the use of pictograms as a complementary or alternative means of product safety communication. The objectives of this annex are: () to establish uniform pictogram recommendations that are tied to long-used and specific written text, () to minimize the proliferation of safety pictogram designs, and (3) to lay the foundation for the use of safety pictograms instead of written text to communicate product safety and cautionary statements. Pictograms D. The pictogram recommendations and cautionary advice are given in Table D.. Table D. Safety pictograms ( of ) Referen ce A Pictogram Cautionary advice DO NOT CHARGE B DO NOT DEFORM OR DAMAGE C DO NOT DISPOSE OF IN FIRE D DO NOT INSERT INCORRECTLY NOTE The grey shading highlights a white margin appearing when the pictogram is printed on coloured or black background.

79 Table D. ( of ) Referen ce E Pictogram Cautionary advice KEEP OUT OF REACH OF CHILDREN F DO NOT MIX DIFFERENT TYPES OR BRANDS G DO NOT MIX NEW AND USED H DO NOT OPEN OR DISMANTLE I DO NOT SHORT CIRCUIT J INSERT CORRECTLY NOTE The grey shading highlights a white margin appearing when the pictogram is printed on coloured or black background. D.3 Instruction for Use The following instructions are provided for use of the pictograms. a) Pictograms shall be clearly legible. b) Whilst colours are permitted, they shall not detract from the information displayed. If colours are used, the background of pictogram J should be blue and the circle and diagonal bar of the other pictograms should be red.

80 c) Not all of the pictograms need to be used together for a particular type or brand of battery. In particular, pictogram D and J are meant as alternatives for a similar purpose.

81 Doc: ETD (44) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard PRIMARY BATTERIES SAFETY OF BATTERIES WITH AQUEOUS ELECTROLYTE Last date for receipt of comments is: -7-6 Foreword (Formal clauses will be added later) SCOPE This standard specifies tests and requirements for primary batteries with aqueous electrolyte to ensure their safe operation under intended use and reasonably foreseeable misuse. NORMATIVE REFERENCES The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IS No. Title Doc ETD (69) Doc ETD (69) Doc ETD (4) Doc ETD (39) Doc ETD (37): Primary batteries - General Multipurpose dry batteries Alkaline battery Watch batteries Primary Batteries: Physical and Electrical Specifications IEC Environmental testing Part -6: Tests Test Fc : Vibrations (sinusoidal) Environmental testing Part -7: Tests Test Ea and guidance: Shock Environmental testing Part -3: Tests Test Ec: Rough handling shocks, primarily for equipment-type specimens IEC IEC TERMS AND DEFINITIONS For the purpose of this document, the terms and definitions given in IS 633 as well as the following terms and definitions apply.

82 3. Battery One or more cells electrically connected by permanent means, fitted in a case, with terminals, markings and protective devices etc, as necessary for use 3. Button Battery Small round battery, where the overall height is less than the diameter. 3.3 Cell Basic functional unit, consisting of an assembly of electrodes, electrolyte, container, terminals and usually separators that is a source of electric energy obtained by direct conversion of chemical energy 3.4 Cylindrical (Cell or Battery) Cell or battery with a cylindrical shape in which the overall height is equal to or greater than the diameter 3.5 Explosion (Battery Explosion) An instantaneous release wherein solid matter from any part of the battery is propelled to a distance greater than 5 cm away from the battery 3.6 Harm Physical injury or damage to the health of people. 3.7 Hazard Potential source of harm 3.8 Intended Use Use of a product, process or service in accordance with information provided by the supplier 3.9 Leakage Unplanned escape of electrolyte, gas or other material from a cell or battery 3. Nominal Voltage (Of A Primary Battery) Vn (symbol) Suitable approximate value of the voltage used to designate or identify a cell, a battery or an electrochemical system 3. Primary (Cell or Battery) Cell or battery that is not designed to be electrically recharged 3. Prismatic (Cell or Battery) Cell or battery having the shape of a parallelepiped whose faces are rectangular 3.3 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. Reasonably Foreseeable Misuse Use of a product, process or service in a way not intended by the supplier, but which may result from readily predictable human behavior.

83 3.5 Risk Combination of the probability of occurrence of harm and the severity of that harm 3.6 Round (Cell or Battery) Cell or battery with circular cross section 3.7 Safety Freedom from unacceptable risk 3.8 Undischarged State of charge of a primary cell or battery corresponding to % depth of discharge 3.9 Venting release of excessive internal pressure from a battery in a manner intended by design to preclude explosion 4 REQUIREMENTS FOR SAFETY 4. Design 4.. General Batteries shall be so designed that they do not present a safety hazard under conditions of normal (intended) use. 4.. 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 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 5 +V 4. 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.

84 5 SAMPLING 5. General Samples should be drawn from production lots in accordance with accepted statistical methods. Sampling for Type Approval 5. The number of samples drawn for type approval is given in Figure. Open circuit voltage (n = 7) Dimensions (n = 7) Intended use A Partial use (n = 5) B- Transportationshock (n = 5) B- Transportationvibration (n = 5) Reasonably foreseeable misuse C Climatic (n = 5) D Incorrect installati on see NOTE (n = ) E Exter nal short circui t (n = 5) F Overdischarg e see NOTE (n = ) G Fre e fall (n = 5) NOTE Four batteries connected in series with one of the four batteries reversed (5 sets). NOTE Four batteries connected in series, one of which is discharged (5 sets). Figure Sampling for type approval tests and number of batteries required 6 TESTING AND REQUIREMENTS General Applicable safety tests Applicable safety tests are shown in Table.

85 The tests described in Tables and 6 are intended to simulate conditions which the battery is likely to encounter during intended use and reasonably foreseeable misuse. Syste m letter No letter A Nega tive elect Zinc (Zn) Zinc (Zn) No Positive mi Electrolyte electrode nal vol Ammonium Manganese,5 chloride, dioxide Zinc (MnO ) chloride Ammonium chloride, Zinc chloride Oxygen (O ) R B Pr M,4 L Zinc (Zn) Alkali metal hydroxide Manganese,5 dioxide (MnO ) P Zinc (Zn) Alkali metal hydroxide Oxygen air,4 (O ) Zinc (Zn) Alkali metal Silver hydroxide oxide (Ag O) S Form Table Test matrix,55 A B Applicable tests C D E F G x x x x x x R B Pr M x x x x x x x x x R B Pr M R B Pr M R B Pr M x x x x x x x x x x x x N Rx x x x x x x x x x x x x x Test description: A: storage after partial use Key B-: transportation-shock R: cylindrical (3.4) B-: transportation-vibration B: button (3.) C: climatic-temperature cycling Pr: prismatic single cell (3.) NR N xr x N x R N x RN xr x N x R x x N x Rx x N x R NR N x Rx x N NR x R N x Rx x N R x: x x x x x x x x x x x N Rx N R N Rx x x x x N R N Rx x x x x x required NR: Not required D: incorrect installation Systems L and S button cells or batteries under 5 mah capacity and system P button cells or M: batteries under 7 mah capacity are exempt from any testing.

86 6.. 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 Ambient temperature Unless otherwise specified, these tests shall be carried out at (7 ±5) C. 6. Intended Use 6.. Intended Use Tests and Requirements Table Intended use tests and requirements Test Intended use simulation Electrical test A Environmental tests Climatictemperature 6.. Requirements Storage after partial use No leakage (NL) No fire (NF) No explosion (NE) B- Transportation-shock No leakage (NL) No fire (NF) No explosion (NE) B- Transportation-vibration No leakage (NL) No fire (NF) No explosion (NE) C Climatic-temperature cycling No fire (NF) No explosion (NE) Intended Use Test Procedures 6... 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

87 condition, with the lowest resistive load test as defined in D o c E T D ( 4 ), D o c E T D ( 3 9 ) a n d D o c E T D ( 3 7 ) until the service life falls by 5 % of the minimum average duration (MAD) value, followed by storage at (45 ±5) C for 3 days. c) Requirements There shall be no leakage, no fire and no explosion during this test Test B- 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 b) Test procedure An undischarged battery shall be tested as follows. The shock test shall be carried out under the conditions defined in Table 3 and the sequence in Table 4. Shock pulse The shock pulse applied to the battery shall be as follows: Table 3 Shock pulse Minimum average acceleration first three milliseconds Accelerat ion 75 g n Peak acceleration Waveform 5 g n to 75 gn Half sine NOTE g n = 9,8665 m/s². Table 4 Test sequence Step Storage time h Battery orientation a a a Number of shocks each each a The shock shall be applied in each of three mutually perpendicular directions. Visual examination periods Pre-test Post-test

88 Step Record open circuit voltage in accordance with 5.. Steps to 4 Apply shock test specified in Table 3 and the sequence in Table 4. Step 5 Rest battery for h. Step 6 Record examination results. c) Requirements There shall be no leakage, no fire and no explosion during this test a) Test B- Transportation-vibration Purpose This test simulates vibration during transportation. This test condition is generally specified in IEC 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,8 mm, with a total maximum excursion of,6 mm. The frequency shall be varied at the rate of Hz/min between the limits of Hz and 55 Hz. The entire range of frequencies ( Hz to 55 Hz) and return (55 Hz to Hz) shall be traversed in (9 ±5) min for each mounting position (direction of vibration). Table 5 Test sequence Step Storage time h Battery orientation a a a Vibration time Visual examination periods (9 ±5) min each (9 ±5) min each (9 5) min Pre-test Post-test a The vibration shall be applied in each of three mutually perpendicular directions. Step Record open circuit voltage in accordance with 5.. Steps to 4 Apply the vibration specified in in the sequence in Table 5. Step 5 Rest battery for h. Step 6 Record examination results. c) Requirements There shall be no leakage, no fire and no explosion during this test.

89 Test C Climatic-temperature cycling 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 ) to 7) below and/or Figure ) ) Place the batteries in a test chamber and raise the temperature of the chamber to (7 ±5) C within t = 3 ) Maintain the chamber at this temperature for t = 4 h. 3) Reduce the temperature of the chamber to ( ±5) C within t = 3 min and maintain at this temperature for t3 = h. 4) Reduce the temperature of the chamber to ( ±5) C within t = 3 min and maintain at this temperature for t = 4 h. 5) Raise the temperature of the chamber to ( ±5) C within t = 3 6) Repeat the sequence for a further nine cycles. 7) After the th cycle, store the batteries for seven days prior to examination. a) 7 C C C t t t3 t t t t t IEC 47/ t = 3 min t = 4 h t3 = h

90 Figure Temperature cycling procedure c) Requirements There shall be no fire and no explosion during this test. 6.3 Reasonably Foreseeable Misuse 6.3. Reasonably Foreseeable Misuse Tests and Requirements Table 6 Reasonably foreseeable misuse tests and requirements Test Electrical tests Misuse simulation D Incorrect installation E External short circuit F Environmental test G Overdischarge Free fall * See NOTE of 6.3..b) 6.3. Reasonably Foreseeable Misuse Test Procedures Test D Incorrect installation (four batteries in series) Requirements No fire (NF) No explosion (NE)* No fire (NF) No explosion (NE) No fire (NF) No explosion (NE) No fire (NF) No explosion (NE)

91 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 (B) as shown in Figure 3. The circuit shall be completed for 4 h or until the battery case temperature has returned to ambient. The resistance of the inter-connecting circuitry shall not exceed. Ω. B IEC 48/ Figure 3 Circuit diagram for incorrect installation (four batteries in series) NOTE The circuit in Figure 3 simulates a typical misuse condition. NOTE 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.f)). c) Requirements There shall be no fire and no explosion during this test (see NOTE of 6.3..b) 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 4 h or until the battery case temperature has returned to ambient. The resistance of the inter-connecting circuitry shall not exceed. Ω. + IEC 49/ Figure 4 Circuit diagram for external short circuit c) Requirements There shall be no fire and no explosion during this test a) Test F Over discharge Purpose

92 This test simulates the condition when one () discharged battery is seriesconnected with three (3) other undischarged batteries. b) Test procedure One undischarged battery (C) is discharged under the application or service output test condition, with the highest MAD value (expressed in time units), as defined in IS 563, IS 675 and IS XXXX until the on-load voltage falls to (n x,6 V) where n is the number of cells in the battery. Then, three undischarged batteries and one discharged battery (C) 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,6 V). The value of the resistor (R) shall be approximately four times the lowest value from the resistive load tests specified for that battery in IS 563, IS 675 and IS XXXX. The final value of the resistor (R) shall be the nearest value to that prescribed in 6.4 of IS 633.

93 C + + R + + IEC 43/ Figure 5 Circuit diagram for over discharge c) Requirements There shall be no fire and no explosion during this test 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 b) Test procedure Undischarged test batteries shall be dropped from a height of 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 h afterwards. z x y IEC 43/ Figure 6 XYZ axes for free fall c) Requirements There shall be no fire and no explosion during this test.

94 7 7. Information for Safety Safety Precautions during Handling Of Batteries When used correctly, primary batteries with aqueous electrolyte provide a safe and dependable source of power. However, battery misuse or abuse may result in leakage, or in extreme cases, fire and/or explosion. a) Always insert batteries correctly with regard to the polarities (+ and ) marked on the battery and the equipment Batteries which are incorrectly placed into equipment may be short-circuited, or charged. This can result in a rapid temperature rise causing venting, leakage, explosion and personal injury. b) Do not short-circuit batteries When the positive (+) and negative ( ) terminals of a battery are in electrical contact with each other, the battery becomes short-circuited. For example loose batteries in a pocket and/or handbag with keys or coins can be short-circuited. This may result in venting, leakage, explosion and personal injury. c) Do not charge batteries Attempting to charge a non-rechargeable (primary) battery may cause internal gas and/or heat generation resulting in venting, leakage, explosion and personal injury. d) Do not force discharge batteries When batteries are force discharged with an external power source, the voltage of the battery will be forced below its design capability and gases will be generated inside the battery. This may result in venting, leakage, explosion and personal injury. e) Do not mix old and new batteries or batteries of different types or brands When replacing batteries, replace all of them at the same time with new batteries of the same brand and type. When batteries of different brand or type are used together, or new and old batteries are used together, some batteries may be over-discharged due to a difference of voltage or capacity. This can result in venting, leakage and explosion and may cause personal injury. f) Exhausted batteries should be immediately removed from equipment and properly disposed of When discharged batteries are kept in the equipment for a long time, electrolyte leakage may occur causing damage to the appliance and/or personal injury. g) Do not heat batteries When a battery is exposed to heat, venting, leakage and explosion may occur and cause personal injury. h) Do not weld or solder directly to batteries The heat from welding or soldering directly to a battery may cause internal shortcircuiting 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.

95 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. 5,4 +, 57, +, Dimensions in millimetres 3,7 +, IEC 65/ 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

96 that has been partially or completely exhausted may be more prone to leak than one that is unused. 7. Packaging The packaging shall be adequate to avoid mechanical damage during transport, handling and stacking. The materials and packaging design shall be chosen so as to prevent the development of unintentional electrical contact, corrosion of the terminals and some protection from the environment. 7.3 Handling of Battery Cartons Rough handling of battery cartons may result in battery damage and impaired electrical performance and may result in leakage, explosion, or possibly fire. 7.4 Display and Storage a) Batteries shall be stored in well-ventilated, dry and cool conditions High temperature or high humidity may cause deterioration of the battery performance or surface corrosion. b) Battery cartons should not be piled up in several layers (or should not exceed a specified height) If too many battery cartons are piled up, batteries in the lowest cartons may be deformed and electrolyte leakage may occur. c) When batteries are stored in warehouses or displayed in retail stores, they should not be exposed to direct sun rays for a long time or placed in areas where they get wet by rain When batteries get wet, their insulation resistance decreases, self-discharge may occur and rust may be generated. d) Do not mix unpacked batteries so as to avoid mechanical damage and/or shortcircuit among each other When mixed together, batteries may be subjected to physical damage or overheating resulting from external short circuit. Leakage and/or explosion may then occur. To avoid these possible hazards, batteries should be kept in their packaging until required for use. e) 7.5 See Annex A for additional details 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.

97 7.6 Disposal Do not dismantle batteries. Do not dispose of batteries in fire except under conditions of controlled incineration. Primary batteries may be disposed of via the communal refuse arrangements, provided that no local rules to the contrary exist. d) Where there is provision for the collection of used batteries, the following should be considered: a) b) c) i. Store collected batteries in a non-conductive container. ii. Store collected batteries in a well-ventilated area. Since some used batteries may still contain a residual charge, they could be short circuited, charged or force discharged and thereby evolve hydrogen gas. If collection containers and storage areas are not properly ventilated, hydrogen gas can build up and explode in the presence of an ignition source. iii. Do not mix collected batteries with other materials. Since some used batteries may still contain a residual charge, they could be short circuited, charged or force discharged. The subsequent possible heat generation can ignite flammable wastes such as oily rags, paper or wood and can cause a fire. iv. Consider protecting used battery terminals, particularly those batteries with high voltage, to preclude short circuits, charging and force discharging, for instance, by means of covering battery terminals with insulating tape. v. Failure to observe these recommendations may result in leakage, fire, and/or explosion. 8 Instructions for use a) f) Always select the correct size and grade of battery most suitable for the intended use. Information provided with the equipment to assist correct battery selection should be retained for reference. Replace all batteries of a set at the same time. Clean the battery contacts and also those of the equipment prior to battery installation. Ensure that the batteries are installed correctly with regard to polarity (+ and ). Remove batteries from equipment which is not to be used for an extended period of time. Remove exhausted batteries promptly. 9 MARKING b) c) d) e) 9. General (see Table 7) With the exception of small batteries (see 9.), each battery shall be marked with the following information: a) designation, IEC or common; b) expiration of a recommended usage period or year and month or week of

98 manufacture. The year and month or week of manufacture may be in code; c) polarity of the positive (+) terminal; d) nominal voltage; e) name or trade mark of the manufacturer or supplier; f) cautionary advice. NOTE The common designation can be found in Annex D of Doc ETD (37). 9. Marking Of Small Batteries (See Table 7) a) Batteries designated in IEC as small, mainly category 3 and category 4 batteries have a surface too small to accommodate all markings shown in 9.. For these batteries the designation 9.a) and the polarity 9.c) shall be marked on the battery. All other markings shown in 9. may be given on the immediate packing instead of on the battery. b) For P-system batteries, 9.a) may be on the battery, the sealing tab or the immediate packing. 9.c) may be marked on the sealing tab and/or on the battery. 9.b), 9.d) and 9.e) may be given on the immediate packing instead of on the battery. c) Caution for ingestion of swallowable batteries shall be given. Refer to 7.l) for details. Table 7 Marking requirements Marking a) Designation, IEC or common b) Expiration of a recommended usage period or year and month or week of manufacture. The and month week of c) year Polarity of the or positive (+) terminal d) Nominal voltage e) Name or trade mark of the manufacturer or supplier f) Cautionary advice A: shall be marked on the battery. Batteries with the A of exception Small batteries Psystem A C A A A B A B B D B A B B A Ba Ba B: may be marked on the immediate packing instead on the battery. C: may be marked on the battery, the sealing tab or the immediate packing. D: may be marked on the sealing tab and/or on the battery. a Caution for ingestion of swallowable batteries shall be given. Refer to 7. l).

99

100 ANNEX A (informative) Additional Information To 7.4 The purpose of this annex is to describe these good practices in general terms and, more specifically, to warn against procedures known from experience to be harmful. It takes the form of advice to battery manufacturers, distributors, users, and equipment designers. Storage and stock rotation a) For normal storage, the temperature should be between + C and +35 C and should never exceed +4 C. Extremes of humidity (over 95 % RH and below 4 % RH) for sustained periods should be avoided since they are detrimental to both batteries and packing. Batteries should therefore not be stored next to radiators or boilers nor in direct sunlight. b) Although the storage life of batteries at room temperature is good, storage is improved at lower temperatures provided special precautions are taken. The batteries should be enclosed in special protective packing (such as sealed plastic bags or variants) which should be retained to protect them from condensation during the time they are warming to ambient temperature. Accelerated warming is harmful. c) Batteries which have been cold-stored should be put into use as soon as possible after return to ambient temperature. d) Batteries may be stored fitted in equipment or packages if determined suitable by the battery manufacturer. e) The height to which batteries may be stacked is clearly dependent on the strength of the pack. As a general guide, this height should not exceed,5 m for cardboard packs or 3 m for wooden cases. f) The above recommendations are equally valid for storage conditions during prolonged transit. Thus, batteries should be stored away from ship engines and not left for long periods in unventilated metal box cars (containers) during summer. g) Batteries should be dispatched promptly after manufacture and in rotation to distribution centres and on to the users. In order that stock rotation (first-in, firstout) can be practised, storage areas and displays should be properly designed and packs should be adequately marked.

101 ANNEX B (informative) Battery Compartment Design Guidelines Background B. B.. General In order to meet the ever-growing advances in battery-powered equipment technology, primary batteries have become more sophisticated in both chemistry and construction with resultant improvements to both capacity and rate capability. Resulting from these continuing developments and recognising the need for both safety and optimum battery performance it was established that the majority of reported battery failures resulted from electrical abuse generally arising from consumer accidental misuse. The following text and figures are intended to aid the battery-powered equipment designer to significantly reduce or eliminate such battery failures. B.. Battery failures resulting from poor battery compartment design Poor battery compartment design may lead to reversed battery installation or to short- circuiting of the batteries. B..3 Potential hazards resulting from battery reversal If a battery is reversed in a circuit with three or more batteries in series as shown in Figure B., the following potential hazards exist: a) charging of the reversed battery; NOTE The charging current limited by the external circuit/load. b) gas generation within the reversed battery; c) vent activation of the reversed battery; d) leakage of electrolyte from the reversed battery. NOTE Battery electrolytes are harmful to body tissues. Reversed battery IEC 43/ Figure B. Example of series connection with one battery reversed

102 B..4 a) b) c) d) e) Potential Hazards Resulting From A Short Circuit Heat generation resulting from high current flow. Gas generation. Vent activation. Electrolyte leakage. Heat damage to insulating jackets (e.g. shrinkage). NOTE Battery electrolytes are harmful to body tissues and generated heat can cause burns. B. B.. General Guidance for Appliance Design Key Battery Factors to Be First Considered These guidelines are essentially directed toward cylindrical batteries with sizes ranging from R to R. The battery systems involved are commonly referred to as alkaline manganese and zinc carbon. Whilst the two systems are interchangeable they should never be used in combination. The following physical differences between the two systems and permitted design features should be noted during the early phases of battery compartment design. a) The positive terminal of the alkaline manganese battery is connected to the battery case. b) The positive terminal of the zinc carbon battery is insulated from the battery case. c) Both battery types have an outer insulated jacket. This may be of paper, plastic or other non-conductive material. On occasion, the outer jacket may be metallic (conductive); in such instances this is insulated from the basic unit. d) When forming the negative contact it should be noted that the corresponding battery terminal may be recessed. (For clarification refer to IS 633). To ensure good electrical contact, completely flat negative equipment contacts should be avoided. e) Under no circumstances should battery connectors or any part of the equipment circuitry come into contact with the battery jacket. Any design of battery compartment permitting this, risks the possibility of a short circuit. NOTE For example, helical (not parallel) springs used for negative connection should compress uniformly when the battery is inserted and not bridge across to the battery jacket. (Spring connection to the positive terminal of a battery is not recommended.) B.. a) Other Important Factors to Consider It is recommended that companies producing battery-powered equipment should maintain close liaison with the battery industry. The capabilities of existing batteries should be taken into account at design inception. W henever possible, the battery type selected should be one included in IS 844 Doc ETD (69), IS

103 563 Doc ETD (4), Doc ETD (4). b) c) Design compartments so that batteries are easily inserted and do not fall out. Design compartments to prevent easy access to the batteries by young children. d) Dimensions should not be tied to a particular battery manufacturer as this can create problems when replacements of different origin are installed. Only consider the battery dimensions and tolerances defined within Doc ETD (69), Doc ETD (4), Doc ETD (4)when designing the battery compartment. e) Clearly indicate the type of battery to use, the correct polarity alignment (+ and ) and directions for insertion. f) Although batteries are very much improved regarding their resistance to leakage, it can still occasionally occur. When the battery compartment cannot be completely isolated from the equipment, it should be positioned so as to minimise possible equipment damage from battery leakage. g) Design equipment circuitry such that equipment will not operate below,7 V per battery (,7 V x ns where ns is the number of batteries connected in series). To continue discharging below this level may result in unfavourable chemical reactions within the battery/batteries resulting in leakage. B.3 B.3. Specific Measures Against Reversed Installation General To overcome the problems associated with the reversed placement of a battery, consideration should be given at the design stage to ensure that batteries cannot be installed incorrectly or, if so installed, will not make electrical contact. B.3. Design Of The Positive Contact Some suggestions for the R3, R, R6, R4 and R size battery compartments are illustrated in Figures B. and B.3 below. Provision should also be made to prevent unnecessary movement of batteries within the battery compartment. NOTE Battery contacts should be shielded to prevent contact during reverse installation.

104 Insulated ribs hold the negative terminal away from contact IEC 433/ IEC 434/ Figure B.a Correct insertion of the battery insertion of the battery Figure B.b Incorrect Figure B. Positive contact recessed between ribs Negative terminal contacts only the insulated surround IEC 436/ IEC 435/ Figure B.3a Correct insertion of the battery insertion of the battery Figure B.3b Incorrect Figure B.3 Positive contact recessed within surrounding insulation

105 B.3.3 Design of the Negative Contact The following suggestion is given for R3, R, R6, R4 and R size battery compartments (see Figure B.4). Positive terminal does not contact U-shaped negative contact but only insulated centre IEC 437/ IEC 438/ Figure B.4a Correct insertion of the battery Figure B.4b Incorrect insertion of the battery Figure B.4 Negative contact U-shaped to ensure no positive (+) battery contact B.3.4 Design With Respect To Battery Orientation In order to avoid reverse insertion of batteries, it is recommended that all batteries have the same orientation. Examples are shown in Figures B.5a and B.5b. Figure B.5a shows the preferred battery arrangement inside a device while Figure B.5b shows an alternative recommendation. IEC 439/ NOTE Protection of the positive contact should be as shown in Figures B. and B.3. Figure B.5a Preferred battery orientation

106 IEC 44/ NOTE Protection of the contacts should be as shown in Figures B. or B.3 for the positive and Figure B.4 for the negative contact. NOTE This arrangement (Figure B.5b) is only considered practical for R4 and R size batteries due to the small negative terminal area (dimension C of the relevant specification) of the other sizes. Figure B.5b Alternative recommendation for battery orientation Figure B.5 Design with respect to battery orientation B.3.5 Dimensional Considerations Table B. provides critical dimensional details relating to the battery terminals and the recommended dimensions for the devices positive contact. By making reference to Figure B.6, and designing in accordance with the dimensions shown in Table B., subsequent reversal of a battery, such that its negative terminal is presented to the devices positive contact, will result in a fail safe situation, i.e. there will be no electrical contact. Table B. Dimensions of battery terminals and recommended dimensions of the positive contact of an appliance in Figure B.6 Dimensions in millimetres Relevant dry batteries R, LR Dimension of the negative battery terminal d6 a (minim 8, um) Dimension of the positive battery terminal d3a (maxim um) 9,5 h3 a (minim um), 5 Recommended dimensions of the positive contact of an appliance in Figure B.6 X 9,6, Y,5,4

107 R4, LR4 R6, LR6 R3, LR3 R, LR 3, 7,5,5 7,6 9,,5,4 7, 5,5, 5,6 6,8,4,9 4,3 3,8,8 3,9 4,,4,7 5, 4,,5 4, 4,9,,4 a ReferDoc ETD (37).

108 X d3 Y h3 d6 Insulator Insulator Positive contact of an appliance Negative contact of an appliance IEC 44/ Figure B.6a Correct insertion NOTE insulation. IEC 44/ Figure B.6b Incorrect insertion Positive contact of an appliance is recessed within surrounding Figure B.6 Example of the design of a positive contact of an appliance The diameter of the recessed hole is larger than the diameter (d 3 ) of the positive battery terminal but is smaller than the diameter (d 6) of the negative battery terminal. The insertion of the battery in Figure B.6a is correct. In Figure B.6b the reverse insertion of the battery is shown; in this instance the negative terminal of the battery only contacts the surrounding insulation thereby preventing electrical contact. The letter codes in Figure B.6 are as follows: d6 minimum outer diameter of the negative flat contact surface; d3 maximum diameter of the positive contact within the specified projection height; h3 minimum projection of the flat positive contact;

109 686-5 IEC: X Diameter of 3 the recessed hole as a positive contact with the positive battery Y terminal. X should be bigger than d 3 but smaller than d6 ; Depth of the recessed hole as a positive contact with the positive battery terminal. Y should be smaller than h 3. B.4 Specific Measures To Prevent Short-Circuiting Of Batteries B.4. Measures To Prevent Short-Circuiting Due To Battery Jacket Damage In alkaline manganese batteries, the steel case, which is covered by an insulating jacket (see B.. c), has the same voltage as the positive terminal. Should the insulating jacket be cut or pierced by any conductive circuitry within an appliance, a short circuit may occur as shown in Figure B.7. (It should be noted that the damage described above can be aggravated if the appliance is subjected to physical abuse, e.g. abnormal vibration, dropping, etc.). NOTE The potential hazards resulting from a short circuit are defined in B..3. Short Circuit IEC 443/ Figure B.7 Example of a short circuit, a switch is piercing the battery insulating jacket NOTE Whilst the example shown in Figure B.7 commonly relates to alkaline manganese battery systems, the batteries addressed in this annex are interchangeable (see B..). Prevention: insulating material positioned as shown in Figure B.8 prevents the switch from damaging the battery jacket. Insulator IEC 444/ Figure B.8 Typical example of insulation to prevent short circuit It is also essential that no part of the equipment or equipment circuitry, including rivets or screws, used to secure the battery contacts etc. is allowed to contact the battery case/jacket.

110 B.4. Measures to prevent external short-circuit of a battery caused when coiled spring contacts are employed for battery connection Placement of a battery (positive (+) end foremost) as shown in Figure B.9 may result in distortion of the negative ( ) spring contact and subsequent cutting and piercing of the battery insulating jacket when a battery is inserted against the spring as shown in Figure B.. IEC 445/ Figure B.9 Insertion against spring (to be avoided) IEC 446/ IEC 447/

111 Figure B.a Spring slides underneath the jacket and contacts the metal can Figure B.b Jacket is punctured Figure B. Examples showing distorted springs Prevention: in order to eliminate the possible incidents shown in Figure B., it is recommended that the design of the battery compartment allows the battery, when correctly inserted (negative terminal first), to evenly compress the coil spring as shown in Figure B.. The insulated guide above the negative ( ) connections in Figure B. ensures this. Insulated guide IEC 448/ Figure B. One example of protected insertion The end of the spring coil i.e. that part in final contact with the battery should be bent toward the centre of the coil so that no sharp edges are presented to the battery jacket. The spring wire should be of sufficient diameter as specified in Table B.. The spring contact pressure should be sufficient to ensure that the batteries make and maintain good electrical contact at all times. However, the spring contact pressure should not be so great as to preclude easy battery insertion and removal. Excessive spring contact pressure can cause cutting or piercing of the insulating jacket or contact deformation. This can lead to a short circuit and/or leakage. Table B. contains details on the recommended diameters of the spring wire. Spring coil contacts should only contact the negative terminals of cylindrical batteries.

112 Table B. Minimum wire diameters Batter y type R R 4 R 6 R 3 R B.5 Minimum wire diameter LR LR4 LR 6 LR3 LR mm, 8, 8, 4, 4, 4 Special Considerations Regarding Recessed Negative Contacts Doc ETD (69) specifies the maximum recess of the negative battery terminal from the external jacket. Many R, LR, R4 and LR4 batteries have a recessed negative terminal. Some batteries are provided with projections of insulating resin on the negative terminal in order to prevent electrical contact if the battery is reversed. NOTE It is imperative that the above shapes and dimensions of negative battery terminals are taken into account during the early stage of the design of the negative contact of an appliance. Specific precautions of three (3) kinds of contacts which are generally used are described in the following. a) When a spring coil is used as the negative contact of an appliance: the diameter of the coil which interfaces with the battery should be smaller than d 6, where d 6 is the external diameter of the contact surface of the negative battery terminal. b) Where sheet metal is cut and formed to make a negative contact (see Figure B.), it is essential that the dimensions h4 and d 6, as defined in Table B.3, are noted and acted upon. As shown in Figure B. a projection/pip should be provided. This projection/pip should be of sufficient depth to overcome any recess in the battery terminal (dimension h4). Failure to follow this advice may result in loss of battery contact. c) Where it is proposed to employ a flat metal plate as the negative contact of an appliance, it is essential that one or more pips /projection(s) are provided to ensure battery contact. The projection(s) should be of sufficient depth to overcome any recess in the negative terminal of the battery (dimension h 4 ) and be placed within the confines of the battery terminal contact area (dimension d 6). h4 d6 d6 h4

113 IEC 449/ 45/ Figure B.a Spring coil contact IEC Figure B.b Plate spring Figure B. Example of negative contacts Table B.3 Dimensions of the negative battery terminal Dimensions in millimetres Battery type R, LR R4, LR4 R6, LR6 R3, LR3 R, LR Maximum recessed dimension External diameter of the of negative battery contact surface of negative, 8,, 3, 9, 7, 5, 4,3 5, 5, a Reference Doc ETD (4) and Doc ETD (69). It should be stressed that battery compartment dimensions should not be tied to dimensions and tolerances of a particular manufacturer as this can create problems if replacements of different origin are installed. For dimensional details, particularly those related to the positive and negative terminals, reference should be made to Figure a and Figure b of Doc ETD (37) and the relevant battery specifications contained in Doc ETD (69). B.6 Waterproof And Non-Vented Devices It is important that hydrogen gas generated in the batteries is either removed by recombination reaction or allowed to escape; otherwise a spark could ignite the entrapped hydrogen/air mixture resulting in an explosion of the device. The advice of the battery manufacturer should be sought at the design stage of such applications. B.7 Other Design Considerations Only the battery terminals should physically contact the electric circuit. Battery compartments should be electrically insulated from the electric circuit and positioned so as to minimise possible damage and/or risk of injury resulting from battery leakage. b) Much equipment is designed to operate with alternative power supplies (e.g. mains, additional batteries, etc.) and this is particularly relevant to primary battery memory back- up applications. In these situations, the circuitry of the equipment should be so designed to either ) prevent charging of the primary battery, or a)

114 ) include primary battery protective devices, for example a diode, such that the reverse charging current from the protective device(s) to which the primary battery would be subjected does not exceed that recommended by the battery manufacturer. Any intended protective device circuit should be selected so as to be appropriate to the type and electrochemical system of the primary battery concerned and preferably not subject to single component failure. It is recommended that equipment designers obtain advice from the battery manufacturer concerning the primary battery memory back-up protection device circuit. Failure to observe these precautions may lead to short service life, leakage or explosion. c) Positive (+) and negative ( ) battery contacts should be visibly different in form to avoid confusion when inserting batteries. d) Select terminal contact materials with the lowest electrical resistance and compatible with battery contacts. Battery compartments should be non-conductive, heat resistant, non-flammable and have good heat radiation. They should not deform when a battery is inserted. f) Equipment designed to be powered by air-depolarised batteries of either the A or P system should provide for adequate air access. For the A system, the battery should preferably be in an upright position during normal operation. g) Parallel connections are not recommended since an incorrectly placed battery causes continuous discharge of the batteries even if the device is not switched on. To overcome the problem of reversed placement described above and with the end user in mind, consideration should be given to the arrangement in Figure B.5a and Figure B.5b. e) WARNING In some parallel battery circuits the discharge current can be similar to that of a battery under short circuit conditions. Potential hazards arising from the reversal of a battery in a parallel circuit are described in B..3. NOTE In extreme cases, battery explosion may occur. h) Series connection of batteries with multiple voltage outputs as shown in Figure B.3 is not recommended since a discharged section may be driven into reverse voltage. Example In Figure B.3, two batteries are discharging through resistor R; if, following their discharge, the switch is positioned toward the R3 circuit, forced discharging of the former two batteries may occur. IEC 45/ Figure B.3 Example of series connection of batteries with voltage tapping

115 Potential hazards arising from forced discharging (driving into reverse voltage). ) ) Gas generation within the forced discharged battery/batteries. Vent activation 3) Electrolyte leakage NOTE Battery electrolytes are harmful to body tissues

116 Annex C (informative) Safety Pictograms C. Overview Cautionary advice to fulfil the marking requirements in this standard has, on a historical basis, been in the form of written text. In recent years, there has been a growing trend toward the use of pictograms as a complementary or alternative means of product safety communication. The objectives of this annex are: () to establish uniform pictogram recommendations that are tied to long-used and specific written text, () to minimize the proliferation of safety pictogram designs, and (3) to lay the foundation for the use of safety pictograms instead of written text to communicate product safety and cautionary statements. C. Pictograms The pictogram recommendations and cautionary advices are given in Table C.. Table C. Safety pictograms Referen ce A Pictogram Cautionary advice DO NOT CHARGE B DO NOT DEFORM / DAMAGE C DO NOT DISPOSE OF IN FIRE D DO NOT INSERT INCORRECTLY NOTE The grey shading highlights a white margin appearing when the pictogram is printed on coloured or black background.

117 Table C. Safety pictograms (continued) Referen ce E Pictogram Cautionary advice KEEP OUT OF REACH OF CHILDREN F DO NOT MIX DIFFERENT TYPES OR BRANDS G DO NOT MIX NEW AND USED H DO NOT OPEN / DISMANTLE I DO NOT SHORT CIRCUIT J INSERT CORRECTLY NOTE The grey shading highlights a white margin appearing when the pictogram is printed on coloured or black background. C.3 Instructions for Use The following instructions are provided for use of the pictograms. a) Pictograms shall be clearly legible. Whilst colours are permitted, they shall not detract from the information displayed. If colours are used, the background of pictogram J should be blue and the circle and diagonal bar of the other pictograms should be red. c) Not all of the pictograms need to be used together for a particular type or brand of battery. In particular, pictogram D and J are meant as alternatives for a similar purpose. b)

118 Doc: ETD (45) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard FLASHLIGHT SPECIFICATION (Third Revision) Last date for receipt of comments is: -7-6 Foreword (Formal clauses will be added later) SCOPE 4. Materials. This standard lays down the requirements and test for replaceable dry and rechargeable battery operated portable flashlights... This Standard is also applicable to built-in rechargeable battery operated portable flashlight as per Annex A.. This Standard is applicable to pre- focused as well as focusing type of incandescent bulb and LED (Light Emitting Diode) as light source of flashlights. 4.. The body of the flashlight shall be made of aluminum, brass, plastic or any other suitable material (See 5, 8.4 and 8.6.) 4.. The front protecting sheet shall be made of glass or any other suitable material of adequate transparency The total circuit resistance excluding cells and lamps with switch in ON position shall not exceed 5 milliohms The Light source (incandescent bulb) shall conform to IS 6: 975.and LED shall conform to Annex D REFERENCES The Indian Standards listed in Annex B are necessary adjuncts to this standard. 4. Construction 3 TERMINOLOGY 3. For the purpose of this standard, the following definitions shall apply: 3. Type Tests Tests carried out to prove conformity with the requirements of the specification. These tests are intended to assess the general quality and design of a given type of flashlight. 3. Acceptance Tests Tests carried out on sample drawn from a lot or batch for the purposes of acceptance of the lot or batch. 3.3 Routine Tests Tests carried out on each flashlight to check requirements which are likely to vary during production. 4 MATERIAL, CONSTRUCTION AND WORKMANSHIP 4.. The reflecting surface of the reflector shall be free (when seen with the naked eye) from defects, such as scratches and deformations. 4.. Contact parts of the switch shall be so constructed as to offer ease of operation and shall be capable of maintaining good electrical contact while in the ON position. The design of the switch shall be such as to prevent accidental short circuits Joints, if any, in the body of the flashlight shall be firm The fit between threaded parts shall be smooth and even Springs, if used, in the construction of the flashlight shall be of necessary strength and durability and shall be corrosion- resistant. 4.3 Workmanship Workmanship of the flashlight and its component parts shall conform to good engineering practice. 5 FINISH The finish of the flashlight shall be pleasing and durable, In case of flashlight with metallic bodies this

119 8.. Samples for Type Tests A minimum number of eight samples of the same type of flashlight shall be required for conducting the type tests. The distribution of the tests among these eight samples shall be as following: a ) Checking of dimensions, All sample materials and construction b ) Test for finish c ) Drop test d ) Climatic test e ) Life test for switch 7 MARKING f)light depreciation test 3 7. Each Flashlight packaging shall be marked with of LED flashlight (8.) the following information: may be achieved by anodizing, lacquering, chromium plating, painting or any other suitable process. 6 DIMENSIONS The internal dimensions of the body of the flashlight shall be such as to properly accommodate the required number of dry batteries conforming to IS 633:5 ( under revision Doc ETD (69)) and IS 844 : 5 ( under revision- Doc ETD (69)). a) Designation; b) Expiration of a recommended usage period or year and month or week of manufacture. Notes The other tests, such as insulation resistance, light distribution and contact resistance of the switch may be done on any of these samples. An additional sample may be required in case the dry cold test is also to be conducted. NOTE The year and month or week of manufacture may be in code. 8. Acceptance Tests c) Polarity of terminals (when applicable); The following shall comprise acceptance tests: d) Nominal voltage; and a) Checking of dimensions, materials and e) Name or trade mark of the manufacturer or supplier. construction ( 4 and 6 ), f) Legal Metrology or applicable guidelines. b) Functional test for switch ( 8.7. ), 7.. Any special marking may be added if required c) Light distribution test ( 8.9 ), and d) Insulation resistance test ( 8.8 ) by the purchaser. 7.. Each flashlight may also be marked with the e) Test for contact resistance of switch ( 8:) 8.. Sample for Acceptance Tests standard mark. In case of large consignments, a sampling procedure may be agreed to between the purchaser and the 8 TESTS manufacturer. A recommended sampling procedure for flashlights is given in Annex C. 8. Type Tests The type tests shall comprise the following: a) Checking of dimensions, materials and construction ( 4 and 6 ) : b) Test for finish ( 8.4 ) : c) Drop test ( 8.5 ) : d) Climatic test (8.6 ): e) Life test for switch ( 8.7 ) ; f) Insulation resistance test ( 8.8 ) g) Light distribution test ( 8.9) h) Test for contact resistance of Switch ( 8. ) i) Light depreciation test for LED flashlight (8.) j) Tests of light source (Annex D) k) Colour chromaticity and colour rendering index (CRI) (Annex E) Note The test for lumen output of lamp as light source is proposed to be included when sufficient information is available. 8.3 ROUTINE TESTS The following shall comprise routine tests: a) Checking of material and construction ( 4 ) and b) Functional tests, for switch ( 8.7. ) c) Circuit current of LED flashlight (8.) 8.4 Tests for Finish 8.4. The plating shall be a minimum of 3 microns of bright nickel followed by a minimum of.5 micron of regular chromium a) Thickness of chromium plating to be determined by stripping method as per 6 of IS 33: 98 b) Thickness of nickel plating to be determined by BNF jet test method as per 5 of IS 33:98 For method of measurement of lumen output of LED as light source refer to IS 66.

120 a) Plating on steel parts should withstand operation in accordance with There shall also be acetic acid salt spray test as per IS 69: 985 for 8 no deterioration to the finish of the flashlight Damp Heat (Accelerated) Test hours. b) Plating on copper and copper alloy should The flashlight shall be placed in a humidity chamber withstand 6 hours of plain salt in which the temperature is 55 ±⁰C. The relative spray test as prescribed in IS 68 : 985 humidity at all times shall be not less than 95 percent. The flashlight shall be exposed to these c) Plating on zinc and zinc alloy parts should conditions for 6 hours at the end of which the withstand acetic acid salt spray test as per IS 69 : sources of heat and humidity shall be cut off and the 985 for 8 hour. chamber allowed to cool to room temperature, the air being circulated meanwhile. The flashlight shall 8.4. In the case of painted flashlight, the specimen shall be immersed in 5 percent salt solution at about 5C for one hour. At the end of the period, the surface be subjected to two such cycles of damp heat and the switch shall be tested for functioning as of the painted specimen shall not soften, specified in The insulation resistance shall 3 Peel off or produce blobs Unless otherwise agreed, anodized aluminum also be checked and there shall be no deterioration parts should be tested for continuity of anodized to the finish. The paint film shall show no sign of coating as per IS 8375: 977 and for sealing by breakdown and the metal surface shall show no sign of corrosion, and no sign of deformation or colour marking test as per 5. of IS 553: 983. change shall observe in body of any other material Dry Cold Test (Optional) 8.5 Drop Test 8.5. The flashlight, complete with battery (batteries), If required for special purposes, the flashlight shall be shall be held in a normal position of use. (In the case placed for one hour in a cold chamber at 4±3⁰C of tubular type of flashlights, the axis of the body shall At the end of this period the specimen shall be checked for functioning of the switch and for insulation be kept horizontal). It shall be dropped in this position from a height of resistance. meter on to a board made of seasoned deodar wood of 8.7 Life Test for Switch The flashlight shall be loaded with the appropriate following dimensions placed on a concrete floor: 3 battery (or batteries) and the switch operated through 5 cycles successively. Each cycle shall comprise a Thickness Width Length full operation of the switch including locking, if 3mm 5 mm ( At least twice the length of provided. The number of cycles per minute shall be 5 Min ) the flashlight under test to 35. The battery (or batteries) and bulb shall be changed after every cycles (or earlier, if There shall be no severe deformation, split or necessary).in case of LED flashlight, LED need not to crack in any part of the body or cover of the flashlight be changed during switch test. At the end of the test, after a single drop. There shall also be no defect in the the switch shall continue to function. functioning of the flashlight Functional Test for Switch (for Acceptance only) NOTES The height of the drop shall be measured as the distance from the For the purposes of acceptance of samples, the test as lowest part of the flashlight to the upper surface of the wooden given in 8.7 shall be carried out through cycles board. Any damage to the incandescent bulb or front protecting sheet shall only. The contact resistance then measured shall not not be considered for rejection under this test. exceed milliohms Functional Test for Switch (for Routine Test 8.6 CLIMATIC TESTS only) The test as given in 8.7 shall be carried out through only one cycle as a routine test Dry Heat Tests The flashlight shall be placed in a chamber maintained 8.8 Insulation Resistance Test at 5⁰C ± ⁰C for a period of 6 hours. At the end of At a temperature of 7±⁰C and relative humidity of this period, it shall be taken out and cooled to room 65±4 percent, with the dry cells removed and the temperature and the switch shall then be tested for switch in open circuit condition, the insulation resistance between the anode and cathode for the cells shall be measured with an insulation resistance tester

121 of rated voltage 5 V ( see also IS 99:987).The insulation resistance value shall be not less than MΩ. 8.9 Light Distribution Test Light from the loaded flashlight shall be projected on to a plane at a distance of m from the source and held perpendicular to the central line of the optical axis. In the case of focusing type of flashlight, this shall be done after focusing. The bright spot produced on the plane shall not exceed 3 cm in diameter and shall not less than cm. Note The use of an open box of not less than 6cm x 6cm x 6cm with a circle having a black border and diameter 3cm placed at the center of one side with a white background is recommended to carry out this test. 8. Test for contact Resistance of the Switch The contact resistance of the switch shall be measured with a current of 3mA flowing through switch contacts and source voltage being not greater than 3 v. The resistance shall not exceed milliohms when the flashlight is new and 3 milliohms after operations of the switch. 8.Light depreciation test for LED flashlight: LED flashlight shall have minimum 9% of initial lux (LT) after hour usage. This shall be verified as per following test method: a) Light from flashlight shall be projected on to a plane at a distance of m from the source and held perpendicular to the central line of the DC power supply Ammeter to measure circuit current Fig: b) c) d) e) optical axis. Measure the initial lux (LT) using photocell at the brightest spot produced on the plane. For dry cell operated flashlight battery shall be fresh and for rechargeable flashlight battery shall be fully charged. Flashlight shall continue to be ON till the lux value at the brightest spot become % of its initial lux. Note the time elapsed between initial lux to % of initial lux in Hrs. Repeat the process a) to c) after changing( dry Cell operated flashlight ) or Charging ( Rechargeable flashlight) the battery until the ON time become hours. After hours ON time, Light from flashlight shall be projected on to a plane at a distance of m from the source and held perpendicular to the central line of the optical axis and measure the lux(lt) using photocell at the brightest spot produced on the plane using fresh battery for dry cell operated flashlight and fully charged battery for rechargeable flashlight. 8. Circuit current of LED flashlight The quantitative value with tolerance for the circuit current of LED flashlight under specific operating conditions shall be specified by the manufacturer and test method will be as shown infig: Control unit LED

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123 ANNEX A GUIDELINES FOR THE CHARACTERSTICS OF PORTABLE RECHARGABLE FLASHLIGHTS A- The flashlight shall be a composite unit with a separate or inbuilt charger included. Charging shall be hands free operation. A- BATTERY A-. Suitable rechargeable battery depending upon its application shall be weather resistant provided with a charging socket on top of it. A-3 LIGHT SOURCES A-3. The incandescent bulb shall conform to IS 6 : 975. A-3. LED shall confirm to Annex D A-4 CHARGER A-4. A suitable charger with input 3V AC with preferably solid state circuitry and automatic monitoring of the current may be provided. The DC leads of the charger are plugged into the socket of the flashlight with separate charger for recharging. Manufacturer guideline shall be available for charging batteries.

124 ANNEX B (Clause No: ) LIST OF REFERRED INDIAN STANDARDS IS No. 633 : :5 68 : : 99 6 : : 987 Title Primary Batteries General ( under revision Doc ETD (69) ) Zinc Carbon Batteries ( under revision Doc ETD (69)) Electroplated coating of nickel plus chromium and copper plus Nickel plus chromium on iron and steel ( second revision ) Flashlights ( second revised ) Lamps for flashlight(first revision ) Insulation resistance testers ( magneto generator type ) ( second revision) IS No. 33 : 98 Title Methods of testing local thickness of electroplated coating ( first revision ) 495 : : 983 Methods for random sampling Methods of testing anodic coatings on aluminium and its alloys ( first revision ) Method of testing corrosion resistance of electroplated and anodized aluminium Coatings by acetic acid salt spray test ( first revision ) Method for checking continuity of anodized coatings. 69 : : : Method of Electrical and Photometric Measurements of Solid-State Lighting (LED) Products

125 ANNEX C ( Clause No: 8.. ) SAMPLING PLAN AND CRITERIA FOR CONFORMITY FOR FLASHLIGHTS C- LOT C-. All the flashlights of the same type and size manufactured by the same factory during the same period, using the same materials and process shall constitute a lot. C-. Sample shall be tested from each lot. C - SCALE OF SAMPLING NOTES: Whenever the lot size is below 4 all the flashlights shall be tested and no defective flashlight shall be permissible. The sampling plan is such that the lots with 4 percent or less defectives would be accepted most of the time C-. Flashlights shall be selected at random. In order to ensure the randomness of selection, suitable Procedures as given in IS 495 : 968 shall be adopted. C-. The number of flashlights to be selected from each lot shall depend upon the lot size and shall be in C-3 NUMBER OF TESTS AND CRITERIA FOR accordance with col and of Table. CONFORMITY Table Sample Size and Permissible Number of Defectives ( Clause C-. ) Lot Size ( N) () Up to to 3 3 to 5 5 to and above Sample Size (n) () C-3. All the flashlights selected in the sample shall be subjected to the acceptance tests given in 8.. A flashlight shall be called a defective if it fails in any one of the acceptance tests. The lot shall be considered Permissible No. as conforming to the requirements of the acceptance of Defectives tests, if the num9ber of flashlight failing to satisfy in (a) any one or more of the acceptance tests does not (3) exceed the corresponding number of permissible defective (see col 3 Table )

126 ANNEX D ( Annex A 3. ) SPECIFICATION OF LED AS LIGHT SOURCE OF FLASHLIGHT D- LUMEN: Unit of flux. It is equal to the flux emitted in a solid angle of one steradian by uniform point source of one candela. D- Rated Value The quantitative value for the characteristic of a LED under specific operating conditions. The value and the conditions are assigned by the manufacturer. D-3 Test Voltage, Current or Power Input voltage, current or power at which tests are carried out. D-4 Efficacy: Quotient of the luminous flux emitted by the power consumed by the LED. LED efficacy shall be calculated from the measured initial luminous flux of the LED divided by the measured initial input6 power of the same LED. Up to one watt the efficacy shall be minimum lumen/ watt at rated voltage and rated current declared by the manufacturer D-5: Lumen maintenance: Value of the luminous flux at a given time in the life of a LED divided by the initial value of the luminous flux of the LED and expressed as a percentage of the initial luminous flux value. Lumen maintenance of LED shall have a minimum value of initial luminous flux when subjected to hour test at rated current and rated voltage specified by manufacturer as mentioned in the table DA. D-6:TESTS : Type Tests The following shall constitute the type tests to be carried out on selected sample of LED being drawn from regular production lot. For method of measurement refer to IS 66. Dimension of integrating sphere shall be cm to 5 cm as per CIE 7. TABLE : DA LED wattage <=.4W >.4W & <=3W Initial lumen % % Minimum Lumen after Hr 5% 8% Table D Sampling Sizes (Annex D) Sl No Ref of Clause Test Annex D ( D-4 ) Annex D ( D-5 ) Efficacy Lumen maintenance Minimum Number of Samples 5 5

127 ANNEX E COLOUR NOMENCLATURE, VARIATION AND RENDERING OF LED AS A LIGHT SOURCE voltage and current. To comply with this standard, the measured initial and maintained chromaticity values of each LED in the sample shall be within the range as mentioned in table E and colour tolerances shall fall within the area on the chromaticity chart bounded by straight lines joining the points indicated for the colours as specified in Table E. E. COLOUR NOMENCLATURE, VARIATION AND RENDERING E..: CCT and Chromaticity Co-Ordinate: The chromaticity of a LED is measured both initially and maintained after an operation time of Hrs at rated TABLE : E LED wattage <.4W >.4W & <=3W Intermediate White (CCT) 4K-5K 4K-5K Cool white(cct) 56K-3K 56K-K Warm White(CCT) 5K-35K 5K-35K TABLE: E Cool white (55K-3K) LED wattage <.4W X Y Cool white (55K-K) LED wattage >.4W & <=3W X Y Intermediate white(4-5k) LED wattage <.4W & <=3W X Y Warm white(5-35k) LED wattage <.4W & <=3W X Y E.. (colour rendering index ) CRI: Minimum CRI value shall be greater than equal to (Ra) 4. Initial colour rendering index of an LED shall be measured as is the value after total operation of hrs.to comply this standard all measured Initial CRI values shall be greater than or equal to the rated CRI Value(declared by manufacturer) less than 3 points and all measured maintained CRI values (at hrs) shall be greater than or equal to rated CRI value(declared by manufacturer) less 5 points For method of measurement refer to IS 66. Dimension of integrating sphere will be cm to 5 cm.

128 (Annex E) Table E Sampling Sizes Sl No Ref of Clause Test Annex E ( E. ) Annex E ( E.. ) CCT and Chromaticity Co-Ordinate colour rendering index(cri) Minimum Number of Samples 5 5

129 Page No: Doc: ETD (37) BUREAU OF INDIAN STANDARDS DRAFT FOR COMMENTS ONLY (Not to be reproduced without the permission of BIS or used as a STANDARD) Draft Indian Standard PRIMARY BATTERIES Part : Physical and electrical specifications Last date for receipt of comments is: Foreword (Formal clauses will be added later) SCOPE This part of IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} is applicable to primary batteries based on standardized electro- chemical systems. It specifies The physical dimensions, The discharge test conditions and discharge performance requirements. Normative References The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} Primary batteries General 3 TERMS, DEFINITIONS, SYMBOLS AND ABBREVIATIONS For the purposes of this document, the terms, definitions, symbols and abbreviations given in IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} and the following apply. 3. Terms and Definitions 3.. Application Test Simulation of the actual use of a battery in a specific application 3.. CLOSED-CIRCUIT VOLTAGE CCV Voltage across the terminals of a battery when it is on discharge

130 Page No: 3..3 End-Point Voltage Ev Specified voltage of a battery at which the battery discharge is terminated 3..4 Minimum Average Duration MAD Minimum average time on discharge which is met by a sample of batteries Note to entry: The discharge test is carried out according to the specified methods or standards and designed to show conformity with the standard applicable to the battery types Nominal Voltage (Of A Primary Battery) Vn Suitable approximate value of the voltage used to designate or identify a cell, a battery or an electrochemical system 3..6 Open-Circuit Voltage OCV Voltage across the terminals of a cell or battery when it is off discharge 3..7 Primary (Cell or Battery) Cell or battery that is not designed to be electrically recharged 3..8 Round (Cell or Battery) Cell or battery with circular cross section 3..9 Service Output (Of A Primary Battery) Service life, or capacity, or energy output of a battery under specified conditions of discharge 3.. Service Output Test Test designed to measure the service output of a battery Note to entry: A service output test may be prescribed, for example, when a. an application test is too complex to replicate. b. The duration of an application test would make it impractical for routine testing purposes. 3.. Storage Life Duration under specified conditions at the end of which a battery retains its ability to perform a specified service output 3.. Terminals (Of A Primary Battery) Conductive parts of a battery that provide connection to an external circuit 3. EV MAD OCV SYMBOLS AND ABBREVIATIONS end-point voltage minimum average duration open-circuit voltage (off-load voltage)

131 Page No: 3 R Vn load resistance nominal voltage of a primary battery

132 Page No: 4 4 BATTERY DIMENSIONS, SYMBOLS The symbols used to denote the various dimensions are as follows: h h h3 h4 h5 d3 d4 d5 d6 d7 maximum overall height of the battery; minimum distance between the flats of the positive and negative contacts; minimum projection of the flat positive contact; maximum recess of the negative flat contact surface; minimum projection of the flat negative contact; d maximum and minimum diameters of the battery; d minimum diameter of the flat positive contact; maximum diameter of the positive contact within the specified projection height; minimum diameter of the flat negative contact; maximum diameter of the negative contact within the specified projection height; minimum outer diameter of the negative flat contact surface; maximum inner diameter of the negative flat contact surface; P concentricity of the positive contact. Recesses are permitted in the negative flat contact surface defined by dimensions d6 and d7 for batteries having the shape shown in Figure a, provided that batteries placed end to end in series make electrical contact with each other and that the contact separation is an integral multiple of the contact separation for one battery. The following conditions shall be satisfied: d6 > d3 d > d7 h3 > h CONSTITUTION OF THE BATTERY SPECIFICATION TABLES Batteries Are Categorized Into Several Groups According To Their Shapes. 5. In each category, batteries having the same shape but belonging to a different electrochemical system are grouped together and shown in succession. 5.3 Batteries are always listed in ascending order of nominal voltage and, within each nominal voltage, in ascending order of volume. 5.4 One common shape drawing of these batteries which fall in the same group is exhibited. 5.5 Designation, nominal voltage, dimensions, discharge conditions, minimum average duration and application for these batteries which fall into the same group are summarized in one table. 5.6 When a drawing represents only one type of battery, the dimensions of the relevant battery may be directly shown on the drawing. 5.7 a) Batteries are categorized into the following groups: Category batteries

133 Page No: 5 FRG445, FR455 b) Category batteries CR45, CR5H7, CR7345, CR745, BR7335 c) Category 3 batteries CR8 d) Category 4 batteries PR7, PR4, PR48, PR44 SR6, SR63, SR65, SR64, SR6, SR67, SR66, SR58, SR68, SR59, SR69, SR4, SR57, SR55, SR48, SR54, SR4, SR43, SR44 CR5, CR6, CR, CR66, CR, CR6, CR6, CR5, CR3, CR3, CR33, CR43, CR354, CR33, CR45 BR5, BR6, BR3, BR35, BR33 e) Category 5: Other round batteries Miscellaneous CR35 4SR44 5AR4 f) Category 6: Non-round batteries Miscellaneous 3RP, 3RS, CR-P CR5 4R5X, 4R5Y 4R5-, 6F, 6LP346 6AS4 6AS6 5.8 The specification drawings show the shape of the relevant batteries. Dimensions for each battery are shown in the tables of Clause 6. NOTE See Annexes A, B and C for ease of locating battery sizes.

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135 PHYSICAL AND ELECTRICAL SPECIFICATIONS General d3 h3 For the definition of the dimensions, see Clause 4. The cylindrical surface is insulated from the contacts. Terminals: flat/cap and base. For general information, see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} Figure a: negative contact surface may not be flat over the whole area. h6 h3 d 3 d Figure b: negative contact surface shall be essentially flat over the whole surface area. 3 For batteries complying with Figures a and b, flat negative contact is not necessarily recessed. d7 d 6 d h h4 h4 6.. Category Batteries h 6. P 6 When the flat negative contact surface forms the lower part of the battery, dimensions "h" and "h" are both measured from the surface and dimension "h4" is zero. Dimensions " P" to be measured in accordance with ISO. The profile over the dotted lines is not specified. : Positive contact : Optional pip (Dimension "h6" for batteries having the pip is,4 mm ) 3: Negative contact area

136 Page No: 6 Figure a h3 d3 h3 d3 h6 h h4 h4 h P 3 d6 d Figure b Figure Dimensional drawing: Category

137 6.. Category Specifications: FR455 Dimensions in millimetres h3 Dimensions h4 h h P d3 FR455 h 5,5 h 49,5 h3, h4,5 4,5 3,7 d3 5,5 d6 7, P,5 d d6 d Figure 4 Dimensional drawing: FR455 Electrochemical system letter IEC designation Common designation Vn (V) OCV (V) Delayed discharge performance after months Application Load Daily EV (V) s Period 5 Digital still mw b,5 camera 65 mw F FR45 5AA, FR6,5,83 95 MADa (Initial) 37 pulses

138 Page No: 8 High Intensity lighting a b mw 4 min on, min off for 8 h per day, min Standard conditions (see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)}Table 4, Initial discharge test). Repeat times per hour: 5 mw for s, then 65 mw for 8 s, then mw for

139 6..3 Category Specifications: FRG445 Dimensions in millimetres h3 Dimensions 44,5 h 43,5 h3,8 h4,5,5 9,8 d3 3,8 d6 P d h4 FRG445 h h h P d3 4,3,5 d 6 d Figure 5 Dimensional drawing: FRG445 Electrochemical system letter IEC designation Common designation Vn OCV (V) (V) Delayed discharge performance after months (% of MAD) Applications Load Daily Period EV (V) Digital still mw b,5 camera 65 mw Digital audio High Intensity lighting a b 5 ma 4 mw h on, hr off for 4 h,9 4 min on, min off for 8 h per day, F FRG4 45 AAA, FR3, 5, MADa (Initial) pulses 6 h 4 min Standard conditions (see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)}Table 4, Initial discharge test). Repeat times per hour: mw for s, then 65 mw for 8 s, then mw for

140 Page No: 6. Category Batteries Specifications: CR45, CR5H7, CR7345, CR745, BR7335 Dimensions in millimetres h / h h4 h3 Dimension CR4 CR5H CR734 CR745 BR73 45, 3533,5 s 55, 77, b 5 34,5 h / (+) 3,5 33,5 43,5 3, 6, b hh,,,,, ,, h 4 9,5, 4 5 4,5 5,6 7, 7, 7, d 3,5 5, 6, 6, 6, d 8, 7, 9, 8, 8, d6 3 6 d 5, 8,, 5, 5, 5 d For6 the definition of the dimensions, see Clause 4. The cylindrical surface is insulated from the contacts. Terminals: flat/cap and base. Figure 7 Dimensional For general information, see IS 633 : 6 {UNDER drawing: CR45, PREPARATION DOC ETD (69)} CR5H7, CR7345, CR745, BR7335 d3 C B CR45 CR5H CR73 CR74 BR , 5 35 CRCR CR3 CR-A BRCommon designation /AA A3, 3, 3, 3, /3A 3, Vn 3, 3, 3,7 3,7 3, OCV (V) (V) Delayed discharge performance after months E Application Load Daily V MADa (Initial) (V s Period Current 3 s on, 7 s ) 4 Phot drain off for 4 h,5 No Test 84 pulses No No 5, No Test pulses Test Serviceo output 9, kω per day 4 No 4 h Test No No test h Test Test Test Service output, kω 4, No Test 48 h No No No test h Test Test Test Service output kω 4, No Test No No No 38 h test h 8 Test Test Test Service output kω 4, No Test No No 7 h No test h Test Test Test Service output 3 kω 4, 75 h No No No No a test h : 6 {UNDER PREPARATION Test Test DOC Test ETDTest Standard conditions (see IS 633 (69)}Table 4,Initial discharge test). b The h /h dimensions shall be measured on the label overlap. Electrochemical system letter IEC designation

141 6.3 Category 3 Batteries Specifications: CR8 Dimensions in millimetres Dimensions d 5,4 h3 - h5,,6,4 d 9, d3 - d4 3, d5 9, ( ) d (+) h For the definition of the dimensions, see Clause 4. h d d 3 d h5,8 h h h h5 h3 d 4 h CR8 The cylindrical surface is connected to the positive terminal. Terminals: flat/cap and case. For general information, see IS 633:5. d 5 d 4 No part of the battery shall project beyond the positive contact area. Marking: of IS 633:5 is applicable. : Optional pip ( ) (+) d d Figure 8 Dimensional Drawing: CR8 C Electrochemical system letter CR8 IEC designation /3N Common designation Vn (V) 3, 3, OCV (V) 7 98 Delayed discharge performance after months (% of MAD) EV (V) Applications Load Daily MADa Period Service output 5 kω 4, 6 h test h a Standard conditions (see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)}Table 4,Initial discharge test).

142 Page No: 6.4 Category 4 Batteries 6.4. General For the definition of the dimensions, see Clause 4. d4 h / h ( ) (+) d d Figure 9 Dimensional drawing: Category 4 The cylindrical surface is connected to the positive terminal. Positive contact should be made to the side of the battery but may be made to the base. Terminals: flat/cap and case. The flat negative contact shall project. Contact pressure resistance, see of IS 633 : 6 {UNDER PREPARATION DOC ETD (69)}. For general information see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} Any difference between the height of the battery and the distance between the contacts shall not exceed, mm. No part of the battery shall project beyond the positive contact. Marking: 4..6 of IS 633 : 6 {UNDER PREPARATION DOC ETD (69)} is applicable.

143 Category 4 Specifications: PR7, PR4, PR48, PR44 Dimensions in millimetres Dimensions d4 ( ) (+) PR7 PR4 PR48 PR44 3,6 3,6 5,4 5,4 3,3 3,3 5,5 5,5 5,8 7,9 7,9,6 5,65 7,7 7,7,3 d - 3,8 3,8 3,8 d4-3, 3, 3,8 h / h h / h 6.4. d d Figure Dimensional drawing: PR7, PR4, PR48, PR44 d

144 Page No: 4 P PR7 b PR4 b PR48 b PR44 b, PR Common,,,, Vn ,59,59,59,59 OCV (V) (V) Delayed discharge performance after months 95 (% of MAD) Application Current Daily EV MADa (Initial) (V) shearing aid Drain Period Pulse: 5 ma standard Background: d,,5 5 h No No No Hearing aid Pulse: 5 ma high Background: d,, 35 h No No No Hearing aid Pulse: ma standard Background: d,,5 No 55 h No No Wireless Pulse: 5 ma (5 streaming min) d,, No 3 h No No Hearing aid Pulse: ma standard Background: 3 d,,5 No No 55 h No Wireless Pulse: 5 ma (5 streaming min) d,, No No 45 h No Hearing aid Pulse: 5 ma standard Background: 5 d,,5 No No No 7 h Hearing aid Pulse: 4 ma high Background: 8 d,,5 No No No 45 h a Standard conditions (see IS 633 : 6 {UNDER PREPARATION DOC ETD (69)}Table 4, Initial discharge test). b A period of at least min shall elapse between activation and commencement of electrical measurement. Electrochemical system letter IEC designation c d Equipment designers' attention is drawn to the importance of making positive electrical contact on the side of the battery so that air access is not impeded for "P" system batteries. The pulse load alone shall be applied across the battery. It is the effective load. It is not added in series or parallel to the background load. See diagram in footnote f. e f Six repeated cycles of the pulse load for ms, followed by the background load for 9 min, 59 s, 9 ms, then off for h. g Twelve repeated cycles of the pulse load for 5 min, followed by the background load for 45 min, then off for h.

145

146 6.4.3 Fit Acceptance Gauge For PR Batteries d H h D Figure Gauge opening for P system batteries Table Gauge opening dimension (mm) Electro- Designation chemical system letter D d H h Nominal Tolerance Nominal Tolerance Nominal Tolerance Nominal Tolerance PR7 5,8 ±,5 4, ±,5 3,6 ±,5,8 ±,5 PR4 7,9 ±,5 5,5 ±,5 3,6 ±,5,4 ±,5 PR48 7,9 ±,5 5,5 ±,5 5,4 ±,5 4, ±,5 PR44,6 ±,5 9, ±,5 5,4 ±,5 4, ±,5 P PR7 PR4 PR48 PR44 Gauge should maintain physical integrity for

147 form, fit and function. (All dimensions in mm) Figure Suggested gauge layout

148 d l l l3 Electr ochemi cal P d Designati on PR7 PR4 PR48 PR44 5,8 7,9 7,9,6 5,65 7,7 7,7,3 l () 3,7 3,7 5,8 l (),3,3 3,8 l 3 (),,,,