Primary Lithium Battery Safety and Handling Guidelines

Introduction
Electrochemical Solutions Inc., a subsidiary of Greatbatch Ltd., manufactures a wide variety of lithium batteries in various
sizes, temperature ranges, and rate capabilities. As a tested expert in design, manufacturing, assembly, and integration,
we are synonymous with reliability and safety. For decades, the world’s top research institutions, industry leading
companies, and government agencies have chosen Electrochemical Solutions Inc. for the best in non-rechargeable and
rechargeable power assurance. We are standard in critical applications such as oil and gas services, military
communications, medical devices, oceanographic monitoring and more, ensuring power in places where others fall
short.

The success of these systems is partially since they contain more energy per unit weight than conventional batteries.
However, the same properties which result in a high energy density also contribute to potential hazards if the energy is
released at a fast, uncontrolled rate. With proper use and handling, Electrochemical cells and batteries have
demonstrated an excellent safety record. The cells and batteries manufactured by Electrochemical are used safely and
successfully in many applications where safety and reliability are of the utmost importance.

Due to the recognition of hazards associated with high energy density systems, safety has been incorporated into the
design and manufacture of all Electrochemical primary lithium cells and batteries. While we have designed our cells and
batteries to be tolerant of adverse conditions, these very active chemical systems have limitations. Certain hazards are
associated with exposure to heat and its subsequent effects on sealed cells. These hazards include the potential for cell
venting, explosion, and/or fires. The initial source of heat can be external (welding, soldering, etc.) or internal such as
heating caused by short circuiting, excessive running currents for prolonged periods of time, forced over-discharge,
charging, or excessive mechanical abuse.

Specifically, mechanical abuse in the form of excessive shock or vibration can result in case deformation, crushing, and
damage to the electrode materials.

Most primary lithium cells have a warning printed on the label that cautions against the following conditions:

- Short-circuit

- Charging

- Forced over-discharge

- Excessive heat or incineration

- Crush, puncture, or disassembly

Not guarding against these conditions may result in a hot cell or a battery pack that could vent or explode. With
Electrochemical cells, the ensuing hazards associated with a hot cell typically will not occur the instant the cell is abused.
Rather, the cell will heat up over a period. This can take place in a matter of seconds or hours. Subsequently, the end
result has the potential to result in a cell vent or explosion once the critical temperature is reached. All electrochemical
primary cells and batteries are labelled with their maximum operating temperature, indicated in degrees Celsius. This
temperature should not be exceeded.
Safe Handling Guidelines
The guidelines identified in this document should be incorporated into all areas of the facility as Best Management
Practices and/or Safe Work Practices.

The intent of this section is to provide primary lithium cell and battery users with guidelines necessary for safe handling
of cells and batteries under normal assembly and use conditions. This document will address three principal areas:
1. Receiving, inspection, and storage of cells and batteries
2. Handling during product assembly
3. Packaging for shipment
Receiving, Inspection, and Storage

In general, the conditions that cause damage to cells and batteries and jeopardize the safety of personnel are
summarized on the label of each cell. These conditions include:
- Short circuit
- Charging
- Forced over-discharge
- Excessive heating or incineration
- Crush, puncture, or disassembly
- Rough handling or excessive shock and vibration
The most frequent form of handling abuse during Receiving Inspection and Storage is inadvertent short circuiting.
Control measures to protect against this form of abuse should be implemented throughout the workplace. It is
Electrochemists experience that inadvertent short circuits during handling are the largest single cause of field failures.
More specifically, accidental short circuiting is a common occurrence in a receiving inspection environment due to
frequent handling.

All electrochemical high-rate cells are internally protected against the hazards associated with short circuits. This is
accomplished by incorporating a fast-acting use under the terminal cap. While the fused cells are less likely to heat, vent,
or explode under a direct short circuit condition, they will be rendered non-functional. Steps should be taken throughout
the receiving and inspection processes to avoid short circuiting cells and batteries.

Issues associated with short circuiting, as well as other hazardous conditions, can be significantly reduced by observing
the following guidelines:
- Cover all conductive work surfaces with an insulating material
- Work areas should be free of sharp objects that could puncture the insulating material
- Never disassemble a cell or battery pack or attempt to replace a blown fuse
- Conductive materials (jewellery, etc.) should not be worn by personnel handling cells and batteries
- Cells should be stored in their original packaging or by similar means
- Cells should be moved in trays using pushcarts to reduce the probability of dropping. Dropped cells or batteries
should be treated as a potential Hot Cell.
- All inspection tools should be non-conductive, or covered with a non-conductive material
- Cells should be inspected for physical damage
- Open-circuit-voltage (OCV) should be checked. The nominal OCV for each cell is printed on the label.
- After a cell has been inspected, it should be returned to its storage container
- If leads or tabs need to be trimmed, cut only one at a time
Cell Storage
Storage of hazardous materials is generally regulated by Federal, State, and local regulations. These regulations will vary
by region and it is up to each user to determine the appropriate regulations to comply with. Along with regulatory
guidance, the following guidelines should be followed:
- Cells should be stored in their original containers or equivalent
- Cells should be stored in a dry, well ventilated area. Ideally, cells will be stored in a temperature-controlled
environment at 23°C or below.
- Cells should be segregated from other combustible or flammable materials
- Fresh cells should be isolated from depleted or used cells
- Appropriate fire extinguishing means should be available
- Storage areas should be equipped with sprinklers
- Appropriate personal protective equipment should be available
- Exercise caution when stacking boxes to prevent crushing of cells in lower boxes

Handling During Assembly

The guidelines identified in this document should be incorporated into all areas of the facility as Best Management
Practices or Safe Work Practices. Additional precautionary measures should be observed in production areas to avoid
more serious problems associated with heat, particularly around soldering and welding equipment or during routine
performance testing at elevated temperatures. These guidelines include, but are not limited to:
- Written work and training instructions for each manufacturing procedure
- Transport cells in trays on pushcarts to reduce the probability of dropping
- Heat sensitive sheets can be placed on top of cells. These will change colour when heated. Some heat sensitive
sheets have life expectancy limitations.
- Never solder or use improper assembly techniques when attaching leads or conducting tabs to the cell case
- Heat sinks should be used when soldering to tabs. Contact should be limited to a few seconds.
- Use caution when handling cells around solder pots. When tinning leads, only tin one at a time to prevent short
circuiting. A cell dropped into a solder pot can short circuit and become a Hot Cell.
- Cells should not be forced into housings as this can lead to deformation
- Excessive force should not be used to free a battery or cell from a housing
- Ovens or environmental chambers should be equipped with over temperature protection
- When loading cells and/or packs during short duration electrical tests, use caution not to exceed the current
rating of the fusing
- When loading cells and/or packs during long duration performance tests, use caution not to exceed the
maximum continuous current rating of the cells
- Cells subjected to continuous high current discharge may overheat, resulting in an unsafe condition. The risk of
overheating is elevated when the cells are in an insulated environment.
Packaging for Shipment
The regulations that govern the transportation of primary lithium batteries and cells include the International Civil
Aviation Organization (ICAO), the International Air Transport Association (IATA) and the International Maritime
Dangerous Goods Code (IMDG). In addition to international requirements, domestic regulations must be adhered to. The
United States Department of Transportation (DOT) regulates the shipment of lithium cells and batteries domestically
under part 49 of the Code of Federal Regulations (49 CFR).

All shipments of hazardous materials in must comply with current packaging regulations based on the United Nations
Manual of Tests and Criteria. The packaging requirements require performance-oriented packaging, meaning that a
package must pass the following:
- Drop test
- Vibration test
- Leak proof test (where applicable)
- Internal pressure test (where applicable)
- Stacking test
These tests are performed by authorized independent testing organizations or by an authorized packaging supplier. Once
a packaging system has been certified, the packaging is stamped with a UN marking. UN marked packaging may only be
used to transport hazardous materials that have been used in the packaging tests. electrochemical packaging may only
be re-used when packaged in its original configuration.
Lithium cells and batteries are classified as a hazardous material in the United States unless the specific cell or battery
meets an exemption in the 49 CFR. Consult current regulations to determine whether or not an exemption applies.
When transporting lithium cells and batteries by air, IATA Dangerous Goods Regulations must be adhered to. The
provisions of the IATA DGR require cells and batteries to meet the requirements of the UN Manual of Tests and Criteria,
Part III Subsection 38.3. electrochemical Solutions can provide a Transport Certificate acknowledging that a specific
lithium cell or battery meets the testing requirements. This certificate is maintained as long as no changes are made to
the cell or pack as manufactured and transported from electrochemical.
The United States DOT prohibits the transportation of primary lithium metal cells and batteries aboard passenger-
carrying aircraft into, out of, or within the United States. Consult current regulations for details on exemptions and
package weight restrictions associated with this prohibition.
Battery Pack Assembly
While electrochemical cells possess a high power and energy density, many applications require even greater voltage,
current, or capacity than a single cell can provide. The solution can be a battery pack of series and/or parallel configured
cells. electrochemical Solutions can provide this system, or it may be designed and built by the users of electrochemical
cells. The following guidelines should be followed:
- Series fuses should be fitted external to the battery to allow for replacement
- Blocking diodes should be implemented wherever multiple cells are tied in parallel
- Thermal cut-off (TCO) or resettable polymeric positive temperature coefficient (PTC) devices can be used to
prevent a battery pack from exceeding a safe operating temperature
- Both the surrounding environment and the heat output of a pack during operation should be evaluated to
ensure a safe operating temperature is maintained
- Additional thermal management should be considered for large batteries or batteries intended to run at high
rates
- Cells connected in series should not have a centre voltage tap
- Batteries should not be encapsulated without first consulting with electrochemical Solutions
- Battery compartments should be designed to allow for expansion of the battery pack
- All cells and batteries should be protected against excessive shock and vibration

Battery Fabrication
It is essential that engineering drawings and work instructions are reviewed and completed prior to the initial pack
construction. The general handling procedures outlined in this document should also be observed. Safety procedures
should be in place to prevent any hazards that may arise while assembling and handling battery packs.
Personnel assembling battery packs should adhere to the following recommendations:
- All jewellery should be removed to prevent short circuiting the battery
- Appropriate personal protective equipment should be worn
- Cells received from electrochemical should remain in their original packaging until they are placed into the battery pack
- Work surfaces should be non-conductive
- Do not solder directly to the cell case
- Solder tabs extending from the cell should be insulated
- Avoid cutting or piercing the insulating shrink wrap on the cells
- Loose wires should not be stripped until they are ready for termination
- Wires should be trimmed one at a time
- All packs should be labelled with the appropriate warnings as they appear in the cell label
- Certain potting materials may be exothermic. Utilize thermal management techniques to remain within the safe
temperature range of the cells - Never disassemble the cell
Handling Under Adverse Conditions
Abusive conditions discussed in this document must be avoided to ensure the safe operation of electrochemical cells and
batteries. Errors in pack design and assembly can result in emergency conditions that the user must be equipped to
mitigate. The intent of this section is to provide a general knowledge of how to handle cells and batteries that have been
subject to these adverse conditions. This document will focus on the following:
- Hot cells
- Leaking or venting cells
- Cells that have exploded
- Fires involving lithium batteries
The guidelines in this document are minimum recommendations. Each user shall determine the personal protective
equipment needs, training, and emergency response procedures for cells and batteries that are involved in emergency
conditions.
Only trained and equipped emergency responders shall be allowed to respond to a vented cell incident. Consult federal,
state, and local regulations for emergency response regulations and training requirements.

Hot Cells
A hot cell is a condition that arises due to a short circuit of the cell or battery, either internal or external. The cell/battery
temperature rises as the event continues which can lead to the cell reaching critical temperature and the potential to
vent or explode.
The following are guidelines for a hot cell emergency response. A hot cell is a potentially dangerous situation and
extreme caution needs to be exercised. Only properly trained and equipped emergency responders shall be allowed to
respond to a hot cell incident. Consult federal, state, and local regulations for emergency response regulations and
emergency responder training requirements.
As soon as a hot cell is detected, all personnel should be evacuated from the affected area. The area should then be
secured to ensure no unauthorized personnel enter.
If the situation allows, prior to evacuating, the person that identified the hot cell should quickly determine if an external
short circuit is present. After the short is removed, the cell temperature should start to fall. The area should remain
evacuated until the cell has cooled to room temperature and has been removed from the area. If the hot cell situation
persists, an emergency response may need to be implemented.
Equipment for responding to a hot cell emergency should include a non-contact means of temperature monitoring
(thermal imager, thermometer, etc.); safety glasses and an impact resistant face shield; body, arm, and hand protection;
and a means by which to move or pick up the battery or cell.
Response Procedure
- Evacuate and secure area as soon as hot cell is detected
- Monitor the temperature from a safe distance using a non-contact thermometer or thermal imager
- If temperature monitoring equipment is not available, keep the area evacuated and secure and do not handle
the cell/battery for at least 24-hours
- If the cell cools, continue to monitor until it reaches ambient temperature
- Remove the cell from the area once it is cool
- Dispose of the cell in accordance with waste or recycling protocols
Vented Cells
Electrochemical cells have a very high energy density. It is the combination of high voltage and capacity coupled with
high reliability and lightweight construction that make electrochemical cells attractive for many specialty applications.
When a large amount of energy is contained in a small package, the results can be disastrous if the system is abused.
All Electrochemical lithium cells are hermetically sealed in a stainless-steel case. A glass-to-metal seal is used as an
insulator for the positive terminal. Under normal conditions, a cell will not leak or vent, however; cell leakage or venting
can occur if the cell is overheated, or the glass seal is compromised by excessive physical abuse.
The severity of a vent can range from a slight leak of electrolyte around the glass-to-metal seal to a violent expulsion of
material through the seal or an explosion. In instances where the cell is unrestrained, this can lead to the cell becoming a
projectile.
It is unlikely that any lithium battery would explode. These events are rare and are usually the result of an abusive
condition or misuse that raises the cell temperature above its critical point. In the event of a lithium battery explosion, a
room can quickly fill with a dense white smoke that can cause severe irritation to the respiratory tract, eyes, and skin.
Precaution must be taken to limit exposure to these fumes.
The electrolyte contained in electrochemical cells can cause severe irritation to the respiratory tract, mucous
membranes, eyes, and skin. Electrolyte reacts with moisture to form Hydrogen Chloride (HCl) and sulfuric Dioxide (SO2)
gases. Some electrolytes can release Bromine (Br2) and Chlorine (Cl2) gases as well as HCl and SO2.
Equipment for responding to a vented cell should include a non-contact means of temperature monitoring (thermal
imager, thermometer, etc.); safety glasses and an impact resistant face shield; respiratory, head, body, arm, and hand
protection; neutralizing agent (baking soda); individual, sealable plastic bags; and a means by which to move or pick up
the battery or cell.
A leaking cell can be handled quickly by trained and equipped assemblers or an emergency response team. After
ensuring that the cell is not hot, capture the cell, place it into a sealable plastic bag, fill the bag with baking soda and seal
it. Place that bag into a second bag and seal it as well. This will neutralize any leaking electrolyte and stop the formation
of fumes. Once the cell is captured, and in a safe place, ventilate the affected area. Ventilation should last as long as it
takes for the odori to dissipate. The cell can then be disposed of in accordance with your hazardous waste disposal
procedures.
Should a cell explode, ensure that all personnel are evacuated and accounted for from the affected area. Ventilation
should be initiated and remain in place until the smoke is cleared and the odori is gone. Clean up of the affected area
involves sweeping up any debris and containing it in a sealable plastic bag. The debris may consist of metallic pieces of
the cell. Ensure that this debris is not in contact with any other cells, as this may lead to a hot cell. The affected area
should be cleaned with a baking soda/water solution or a commercially available liquid acid neutralizer. After cleaning is
complete, a second wipe down with a typical cleaning solution may be necessary.
The bag of debris can be disposed of in accordance with applicable hazardous waste disposal regulations. Contact your
waste disposal coordinator for proper markings and packaging requirements.
Fires Involving Lithium Batteries
WARNING
The following statements are intended for guidance purposes only. Attempting to fight a lithium battery fire should
only be attempted by trained and equipped responders. Consult federal, state, and local regulations for emergency
response regulations, emergency responder training requirements, and fire brigade training and protective equipment
requirements. Cells or batteries exposed to excessive heat beyond their recommended temperature range can
explode. During thermal decomposition chlorine (Cl2), hydrogen chloride (HCl), and sulfuric dioxide (SO2) can be
formed.
In the unlikely event that primary lithium batteries are involved in or near a fire, the principal concern is personal safety.
The area should immediately be evacuated, and all personnel accounted for. Emergency response organizations, either
internal or external, should be immediately notified. The secondary concern in the unlikely event of a fire involving
lithium batteries is to prevent the spread of the fire and minimize cell venting. The most effective way of achieving these
goals is through the use of large amounts of water. Lithium metal is a water reactive material; however, in the unlikely
event of a lithium fire, the lithium would be rapidly consumed thus minimizing the risk of a lithium-water reaction.
Flooding the area with water accomplishes two tasks. The water will cool surrounding cells and batteries and reduce the
likelihood of additional cells venting. Flooding waters will also help to extinguish any secondary fires present in the area.
In the event of a cell venting, a water fog pattern will help to reduce airborne concentrations of sulfuric dioxide gas. The
water will become a very weak sulfuric acid and is typically diluted by the large amounts of water used.
When attempting to fight a lithium battery fire, appropriate personal protective equipment should be worn. Respiratory
protection should include self-contained breathing apparatus and protective clothing should include firefighter turnout
or bunker gear per local regulations.
Portable fire extinguishers should be considered a last resort for fighting a lithium battery fire as they require emergency
responders to be in very close proximity to the fire. There are several types of portable extinguishers available
commercially.
Class D fire extinguishers (copper based) have been developed for and proven successful for extinguishing lithium and
lithium alloy fires. The compound acts as a smothering agent and also acts as a heat sink. Copper-based extinguishing
media is able to cling to vertical surfaces. Care should be taken to ensure that Class D fire extinguishers are of the
copper-type, and not sodium chloride. The sodium chloride extinguishing agent is not intended for the high heat of a
lithium fire, nor will it cling to vertical surfaces.
Graphite-based extinguishing media are effective on smaller lithium metal fires. These work by smothering the fire. This
material will not cling to vertical surfaces but has been developed for high-heat metal fires such as magnesium and
lithium.
First Aid Procedures for Electrolyte Exposure
Electrolyte composition will vary depending on the type of cell used, but the first aid procedures remain constant.
Electrolyte will react with moisture to yield sulfuric dioxide, hydrogen chloride, and chlorine depending on the
electrolyte. Immediately refer to the Material Safety Data Sheets for additional information.
Eyes – flush with cool water for at least 15-minutes. Hold eyelids open and rinse thoroughly. Seek immediate
medical attention.
Skin – flush with cool water for at least 15-minutes. Remove contaminated clothing. Seek medical attention if
necessary.
Inhalation – move to fresh air. If difficulty breathing, administer oxygen according to local protocols. If not
breathing, begin artificial respirations and seek immediate medical attention.
Ingestion – DO NOT INDUCE VOMITTING. Drink copious amounts of water. Notify Poison Control or seek
immediate medical attention. Never give anything to drink to a person that cannot swallow.
Cell/Battery Disposal
Electrochemical primary cells and batteries require special handling for disposal. Disposal requirements are region
specific, and many waste handlers have further requirements that need to be followed when disposing of cells or
batteries. Primary cells and batteries can be recycled or disposed of as a hazardous waste.
General practices that should be followed when packaging a cell or battery for disposal or recycling include:
- Secure terminals to prevent short circuiting
- Package each cell or battery in a manner that prevents shorting with the container or another cell/battery
- Package leaking cells/batteries in a manner that contains the leak (refer to Vented Cells)
- Use packaging material that is in compliance with local regulations
Regulatory Considerations
Each region of the world has differing regulations that the end user of electrochemical cells and batteries is responsible
for complying with. Throughout this document, recommendations have been made on the safe and proper handling of
lithium cells and batteries. These recommendations do not take into consideration local requirements or regulations. It is
the responsibility of each end user to establish their own internal policies and procedures while adhering to all applicable
local regulations.
This document is not intended to provide all the information that you will need to be able to work safely. The guidelines
are established to help facilitate site specific guidance in accordance with local regulations.
Electrochemical Solutions is a resource to our customers. If there are concerns around the safe handling of
Electrochemical cells or batteries, we will help to address those concerns. Our goal is to provide all of our customers with
safe and reliable portable power. Safety starts with those handling the cells or batteries.
 Li-Ion Battery Safety and Handling Guideline

PURPOSE
The intent of this guideline is to provide the users of lithium-ion batteries with guidance to facilitate the safe handling of
battery packs and cells under normal and emergency conditions.
DEFINITIONS
Secondary or rechargeable lithium-ion cells
- Rechargeable secondary cells utilize lithium ions that are intercalated into graphite, lithium metal oxides,
and/or lithium salts. There is no metallic lithium in a lithium-ion battery.
Cell
- A single battery without external modification.
Battery Pack
- An assembly of cells that are connected in series and/or parallel. Each battery pack contains only one cell model
regardless of the number of cells used, and is protected from external conditions by a Battery Management
System. Voltage and Capacity of a battery pack is directly proportional to the number and configuration of cells.
RESPONSIBILITIES
Engineers/Designers/Manufacturing Operations
* Implementation of all applicable provisions of this guideline.
* Obtain and review the battery manufacturers Material Safety Data Sheet (MSDS), Technical Specification sheet(s)
and/or other available documentation prior to the design and use of battery packs. Perform hazard analysis (a.k.a. risk
assessment) to understand the various failure modes and hazards associated with the proposed configuration and
type(s) and number of batteries used.
* Based on a hazard analysis, incorporate appropriate safety-related design and testing criteria into battery pack and
device design, with the design objective of increasing the safety margin during the battery pack life cycle. Ensure safety-
related requirements are incorporated into design.
* Ensure that written standard operating procedures (SOPs) for Lithium-Ion battery pack production and installation are
developed that include mechanisms to mitigate possible battery failures that can occur during: assembly, deployment,
data acquisition, transportation, storage, and disassembly/disposal.
* Ensure that acceptance and quality-control procedures include verification of safety design features.
CELL HANDLING PROCEDURES
Inadvertent short circuits are the major cause of failures for Lithium Ion (Secondary) cells. Problems associated with
shorting as well as other hazardous conditions can be reduced by observing the following guidelines (Please note that
these are general recommendations):
* Written work instructions or checklists should be generated for assembly and testing procedures.
* Wear safety glasses whenever handling batteries.
* Remove all exposed jewellery and metal items such as rings, wristwatches, pendants, etc., that could come in contact
with the battery terminals.
* All dented cells or batteries with dented cells should be disposed, regardless of electrolyte leakage. Denting of sides or
ends increases the likelihood of developing an internal short circuit at a later time.
* Cover all metal work surfaces with an insulating material. Work areas should be clean and free of sharp objects that
could puncture the insulating sleeve on each cell.
* If cells are removed from their original packages for inspection, they should be arranged to preclude shorting. Do not
stack or scatter the cells. They should be placed in non-conductive carrying trays with individual compartments for each
cell.
* Cells should be transported in non-conductive carrying trays. This will reduce the chances of cells being dropped,
causing shorting or other physical damage.
* All inspection tools (including callipers, rulers, etc.) should be made from, or covered with, a non-conductive material.
* Cells should not be forced into battery holders or other types of housings. This could deform the cell casing causing an
internal short circuit. Furthermore, the terminal cap could be crushed putting internal component and structure at risk.
This could result in a cell venting. Check for proper fit before inserting the cells into any type of housing.
* Excessive force should not be used to free a cell or battery lodged inside the housing.
Cells and/or packs should not be exposed to any voltage sources other than those that meet the exact criteria identified
by the pack/cell specification. Secondary cells should be charged only according to the cell or battery manufacturer’s
directions, particularly with respect to maximum applied voltage.
CELL STORAGE
* Cells should be stored in their original containers.
* Lithium-Ion batteries should be stored at ~40% rated capacity. Shipments direct from the cell manufacturer will be
received at this relative state of charge.
* Store the cells in a well ventilated, dry area. Optimal storage temperature should be maintained at or below room
temperature of 60-75° F. Observe the manufacturers’ minimum and maximum storage temperatures.
* Store the cells in an isolated area, away from combustible materials. Store depleted cells in an area separate from fresh
cells.
* Never stack heavy objects on top of boxes containing lithium batteries to preclude crushing or puncturing the cell case.
Severe damage can lead to internal short circuits resulting in a cell venting or explosion.
* Do not allow excessive quantities of cells to accumulate in any storage area.

BATTERY PACKS
Cell Matching and Combination
Obtain and review the battery manufacturer’s design information for the cells to be used. It is important to know the
working limits of the cells selected, so that the battery packs will meet performance requirements without undesirable
reactions.
The following basic rules must be observed in pack construction:
* Always use the same model cells in series or parallel connections.
* Cells fabricated into a battery pack shall be of the same age (lot code) and history.
- Li-ion cell lot codes that exceed one (1) year from date of manufacture shall be measured with a DMM (Digital
Multi Meter) and screened to be within .010V of each other.
* Primary and secondary cells shall not be mixed together in a battery pack.
* Partially discharged cells shall not be mixed with fresh cells in a battery pack.
Battery Pack Design
The design of a battery pack can either enhance or reduce the safety characteristics of individual cells and the pack.
Combinations of series and parallel configurations may cause voltage and current potentials unsafe for the individual
cells in the strings. A proper BMS 6 (Battery Management System) shall be designed and integrated according to the cell
manufacturer’s safety requirements while also considering the safety of the host device powered by the battery and
related charging system.
Battery packs should be designed to avoid conditions leading to short circuiting, forced over-discharging, over-charging,
overheating or other known electrical and mechanical failure conditions. Packs must also be designed to avoid conditions
leading to low level current leakage paths which could lead to internal cell short circuiting. This can be accomplished by
choosing proper insulating materials for use in the pack construction. It should be noted that the insulation resistance of
materials decreases rapidly with increased temperature. Also, absorbed moisture reduces the insulation resistance, and
moisture and humidity could have a large effect on the surface leakage of a battery and the BMS.
Pack construction materials must have good abrasion or puncture resistance in addition to having good electrical
properties. For example, if circuit boards are mounted directly on top of the battery, cell terminations must be isolated
from traces on the underside of the board. Solder points can have sharp protrusions that can puncture thin materials.
Thick, puncture resistant insulation must be used in these areas.

Additional hazard control measures that should be considered include:

* In-line fuses should be incorporated in any li-ion pack design.
* Thermal cut-off (TCO) or resettable polymeric, positive temperature coefficient (PTC) resistors can be used to limit cell
temperature rise when that rise is caused by external current flow through the protective device. Charging schemes
should carefully monitor pack temperature and not violate cell capability.
* Batteries should not be encapsulated without first consulting the manufacturer.
* Battery pack construction should take into account the need for cell vents to function. There should be an minimally
restricted escape path for the fumes such that pressure does not build up in the battery pack or housing. A vent
mechanism should also be incorporated in rigid housings to avoid rupture or an explosion in the event of overpressure.
* Shock and vibration requirements must be considered in the design of any battery pack. All cells must be protected
from excessive shock and vibration.
* In general, regulations specific to the mode of transportation intended to be used (air, land, water) may influence the
battery pack design. In larger format batteries, it may be imperative to follow a modular approach.
Hazard Analysis
To increase the safety margin and decrease the failure rate, the hazard analysis process should be considered during the
design phase. This can be the case for battery pack designs, where there is a possibility that a component failure could
give rise to an increased 7 hazard. A number of different methods can be used, varying from simple analytical
approaches to complex mathematical modelling. The hazard analysis method should be appropriate to the system
design.
Examples of hazard analysis methods are listed below.
Checklists: Checklists can be used as a basic method for itemizing potential hazards or undesirable outcomes that need
to be considered. Conditions of internal battery pack safety as well as likely environmental or usage case concerns should
be addressed.
Fault modes and effects analysis (FMEA): Identification and frequency analysis of all possible fault modes within a
battery pack design to determine their effects. This is typically followed by a PFMEA where Production elements are
assessed for risk in constructing the battery pack design.
Hazard and operability studies (HAZOP): HAZOP studies examine each part of an entire system to determine how
deviations from the intended function or performance can lead to undesirable outcomes.
Battery Pack Fabrication
Personnel assembling battery packs should comply with the following recommendations:
* Safety glasses must be worn at all times. All jewellery should be removed so that cells are not inadvertently shorted.
* Cells received from the factory should remain in their original containers until they are to be assembled into battery
packs.
* Cells should not be placed on electrically conductive surfaces. All work surfaces should be constructed with non-
conductive materials.
* Do not solder directly to the cell case or cell terminals. Only solder to the solder tabs welded to the case or weld
terminals.
* Solder tabs that extend from the case and terminal cap should be insulated.
* Avoid cutting or piercing the insulating shrink wrap on the cells.
* Loose wires should not be stripped until it is time to install a connector. If no connector is used, wire ends should be
insulated.
* Should wire trimming be necessary, only cut one wire at a time.
* All battery packs should be labelled with the appropriate warnings as required by international, federal, and local
regulation.
* Operators should be aware of potential abuse to cells within a battery construction either from thermal rise, physical
damage, or short circuit.

SHIPMENT
All batteries must be made safe for handling prior to packing for shipment. A written SOP should specify steps to take in
preparation for shipment or transportation of each unique cell or battery pack design.
U. S. domestic transportation is regulated by the Department of Transportation (DOT). Internationally, air transportation
is regulated by the International Air Transport Association (IATA) and International Civil Aviation Organization (ICAO).
Maritime transport is controlled by International Maritime Organization (IMO) whose regulations are contained in the
International Maritime Dangerous Goods (IMDG) Code.
Various weight limits apply to batteries, batteries with equipment, and batteries installed in equipment for all
transportation methods. Pursuant to 49 CFR 173.185, all shipments of hazardous materials must comply with packaging
regulations based on recommendations made by the United Nations. Fines and penalties for non-compliance can be
substantial.
EMERGENCY PROCEDURES
Releases from Cells (Vented, Leaked or Exploded)
The electrolyte contained within the lithium cells can cause severe irritation to the respiratory tract, eyes and skin. In
addition, violent cell venting could result in a room full of hazardous air contaminants, including corrosive or flammable
vapours. All precautions should be taken to limit exposure to the electrolyte vapor. Review the MSDS or product
information sheet PRIOR to working with cells, so that you are familiar with the steps to take in the event of a release.
Handling a Hot Cell or Battery Pack
* As soon as it has been determined that a hot cell situation exists, completely evacuate all personnel from the area. The
area should be secured such that no unnecessary persons enter.
* If it is safe to do so before evacuating the area, quickly determine if an external short-circuit is present and remove it as
quickly as possible. Note that some cell chemistries may enter a thermal runaway reaction above a certain temperature;
thus, a cell may continue to gain heat and there may be a cascade to other cells.
* If it is safe to do so before evacuating the area, the cell or battery pack should be carefully put into the emergency sand
container nearest the incident. Proper gloves and eye-ware 9 must be worn while containing/isolating the thermal event.
The area should remain evacuated until the cell has cooled to room temperature.
* Because there is no metallic lithium in a lithium-ion battery, ordinary extinguishing agents can be used effectively on a
fire involving lithium-ion batteries.
* In addition to the battery itself, packaging materials, plastics, electronic components, and flammable solvents may be
involved in a fire.
FIRST AID PROCEDURES
In case of contact with electrolyte, gases, or combustion by-products from a lithium-ion battery release, the following
first aid measures should be considered:
* EYES: Immediately flush eyes with a direct stream of water for at least 15 minutes with eyelids held open, to ensure
complete irrigation of all eye and lid tissue. Get immediate medical attention.
* SKIN: Flush with cool water or get under a shower, remove contaminated garments. Continue to flush for at least 15
minutes. Get medical attention, if necessary.
* INHALATION: Move to fresh air. Monitor airway breathing and circulation. If troubled breathing, dizziness, or
discomfort persists, get immediate medical attention.
WASTE MANAGEMENT
All waste management steps (collection, temporary storage, recycling, disposal, etc) for spent or waste lithium-ion
batteries must conform with federal, state, and local regulations.
There are several facilities that will recycle Lithium-Ion Batteries. The Rechargeable Battery Recycling Corporation (RBRC)
is an excellent source for determining a facility for cell and pack reclamation. This is the preferred disposal method of
cells and battery packs.
Li-ion batteries can be incinerated if there is a large quantity and proper notification to the waste company must include
clear marking of “li-ion batteries contained.” Incineration must be performed by an approved and permitted waste
treatment facility that handles lithium-ion batteries.
Before any type of disposal, the batteries should be discharged completely. Tape the contacts with electrical tape and
package so as to prevent contacts accidentally coming together at any time.

Safety Precautions for the Lithium-Ion Batteries use and Designing Equipment.
In general, lithium-ion batteries are used in battery-packs that contain both lithium-ion batteries and battery safety
circuits. Both items are sealed in a container made of a material such as resin so that the battery_pack cannot be easily
disassembled.
Charging the Batteries
The “constant voltage/constant current „ method is used to charge lithium-ion batteries. (See Figure below)

Charge Voltage
The maximum voltage is 4.2 V x the number of cells connected in series.
Charge Current
We recommend the following current.
NNP Series Cylindrical type: 0.3 It, Prismatic type :0.7 It
PSS and Cobalt acid series Cylindrical type :0.7It , Prismatic type :1.0 It (or 0.7 It for certain models)
When the voltage per cell is 2.9V or less, charge using a charge current of 0.1 It or less.
(contact Panasonic for information regarding pulse charging.)

Charge Temperature
The batteries should be charged at temperatures between 0°C and 45°C.
Reverse-polarity Charging
Verify the polarity of the batteries before charging to ensure that they are never charged with the polarity reversed.

Discharging the Batteries

Discharge Current
The current should be maintained at 1.0 It or less (contact Panasonic if you plan to discharge the batteries with a current
more than 1.0 It).

Discharge Temperature
The batteries should be discharged at a temperature between -10°C and +60°C. (contact Panasonic if you plan to
discharge the batteries at temperatures less than -10°C.)

Discharge Termination Voltage

NNP series 2.5V per cell
PSS and Cobalt acid series 3.0V per cell
Avoid discharging at voltages less than these.
Over discharge can damage the performance of the battery. Equip the unit with a mechanism to prevent over discharge,
especially in situations where the user may forget to turn the equipment off.

Equipment Design
Installing Battery-Packs in the Equipment
To avoid damage to the battery-pack, make sure that the battery-pack is positioned away from heat sources in the
equipment or in the battery charger.

Mechanisms to Prevent Dropping

Be sure to use a battery-pack lock mechanism to prevent the battery-pack from being ejected when the equipment is
dropped or receives a sudden impact.

Preventing Short Circuits and Reversed Connections

Use a terminal structure that makes it unlikely that the terminals will be shorted by metallic necklaces, clips, hairpins,
etc. Structure the battery and the terminals to the battery in such a way that the battery-pack cannot be put in
backwards when installed in the charger or the equipment.

Inclusion in Other Equipment

If the battery is built into other equipment, use caution to strictly avoid designing airtight battery compartments.

Terminal Materials in the External Equipment

Use materials that are highly resistant to corrosion (such as nickel or nickel-coated copper). If contact resistance is an
issue, we recommend that you use contact plating (such as gold plating) on the terminals.
Storing the Batteries,
The batteries should be stored at room temperature, charged to about 30 to 50% of capacity. We recommend that
batteries be charged about once per year to prevent over discharge.

Use of the Batteries,

See the section on “Safety Precautions”.

Other
The Chemical Reaction
Because batteries utilize a chemical reaction, they are considered a chemical product. As such, battery performance will
deteriorate over time even if stored for a long period of time without being used. In addition, if the various usage
conditions such as charge, discharge, ambient temperature, etc. are not maintained within the specified ranges the life
expectancy of the battery may be shortened or the device in which the battery is used may be damaged by electrolyte
leakage. If the batteries cannot maintain a charge for long periods of time, even when they are charged correctly, this
may indicate it is time to change the battery.

When exporting the batteries, they are likely to undergo the judgment on classification of strategic products according to
the Export Trade Control Ordinance Please contact Panasonic.

Please Note
The performance and life expectancy of batteries depends heavily on how the batteries are used. In order to
ensure safety, be sure to consult with Panasonic in advance regarding battery charging and discharging
specifications and equipment structures when designing equipment that includes these batteries.

Safety Precautions
When Using the Battery

DANGER
1. Misusing the battery may cause the battery to get hot, explode, or ignite and cause serious injury. Be
sure to follow the safety rules listed below:
 Do not place the battery in fire or heat the battery.
 Do not install the battery backwards so that the polarity is reversed.
 Do not connect the positive terminal and the negative terminal of the battery to each other with any
 metal object (such as wire).
 Do not carry or store the batteries together with necklaces, hairpins or other metal objects.
 Do not penetrate the battery with nails, strike the battery with a hammer, step on the battery, or
otherwise subject it to strong impacts or shocks.
 Do not solder directly onto the battery.
 Do not expose the battery to water or salt water or allow the battery to get wet.
2. Do not disassemble or modify the battery. The battery contains safety and protection devices which, If
damaged, may cause the battery to generate heat, explode or ignite.
3. Do not place the battery on or near fires, stoves, or other high-temperature locations. Do not place
the battery in direct sunshine or use or store the battery inside cars in hot weather. Doing so may
cause the battery to generate heat, explode, or ignite. Using the battery in this manner may also result
in a loss of performance and a shortened life expectancy.
4. Do not insert the battery into equipment designed to be hermetically sealed. In some cases, hydrogen
or oxygen may be discharged from the cell which may result in rupture, fire or explosion.

WARNING
1. Immediately Discontinue use of the battery if, while using, charging, or storing the battery, the battery
emits an unusual smell, feels hot, changes colour, changes shape, or appears abnormal in any other
way. Contact your sales location if any of these problems are observed.
2. Do not place the batteries in microwave ovens, high-pressure containers, or on induction cookware.
3. In the event that the battery leaks and the fluid gets into one’s eye, do not rub the eye. Rinse well with
water and immediately seek medical care. If left untreated the battery fluid could cause damage to the
eye.

CAUTION
1. If the device is to be used by small children, the caregiver should explain the contents of the user’s
manual to the children. The caregiver should provide adequate supervision to ensure that the device is
being used as explained in the user’s manual.
2. When the battery is worn out, insulate the terminals with adhesive tape or similar materials before
disposal

DANGER
Be sure to follow the rules listed below while charging the battery. Failure to do so may cause the battery to
become hot, explode, or ignite and cause serious injury.
 When charging the battery, either use a specified battery charge or otherwise insure that the battery
charging conditions specified by battery manufactures
 Do not attach the batteries to a power supply plug or directly to a car’s cigarette lighter.
 Do not place the batteries in or near fire, or into direct sunlight. When the battery becomes hot, the
built-in safety equipment is activated, preventing the battery from charging further, and heating the
battery can destroy the safety equipment and can cause additional heating, breaking, or ignition of the
 battery.

WARNING
Do not continue charging the battery if it does not recharge within the specified charging time. Doing so may
cause the battery to become hot, explode, or ignite.

While Charging

CAUTION
The temperature range over which the battery can be charged is 00 C to 450C. Charging the battery at
temperatures outside of this range may cause the battery to become hot or to break. Charging the battery
outside of this temperature range may also harm the performance of the battery or reduce the battery’s life
expectancy.

When Discharging the Battery

DANGER
Do not discharge the battery using any device except for the specified device. When the battery is used in
devices aside from the specified device it may damage the performance of the battery or reduce its life
expectancy, and if the device causes an abnormal current to flow, if may cause the battery to become hot,
explode, or ignite and cause serious injury.

CAUTION
The temperature range over which the battery can be discharged is -10 0C to 600C. Use of the battery outside of
this temperature range may damage the performance of the battery or may reduce its life expectancy.