Technical Service Bulletin 521100-001

Battery Handling Guidelines

Section Topic

Personal Protective
Equipment (PPE)
and Safety

Other Topics: (hyperlinked)

+ Introduction: Lithium Ion Battery Basics
+ Personal Protective Equipment (PPE) and Safety
+ Storage Considerations
+ Maintenance & Service Guidelines
+ In Case of Damage
+ First Responder Information
+ Shipping Considerations
+ Battery Recycling
+ MSDS for Lithium Ion Cell
+ Legal Notice and Disclaimer

Rev. 6/17/2013

2013 A123 Systems, LLC. All rights reserved. Proprietary and confidential.

10

Technical Service Bulletin 521100-001

Battery Handling Guidelines

Personal Protective Equipment (PPE) and Safety
The following PPE should be available and used when working around high-voltage systems:
+

High-voltage insulated glasses, or face shields

High-voltage (rubber) gloves with protective (leather) outer gloves

Insulating equipment covers (to prevent unintended contact with covered surfaces)

Insulating bags (to capture hazardous material if necessary)

Insulated tools for use on high-voltage equipment

PPE Inspection
+

Users of PPE must check all protective wear for deterioration and damage before beginning
work. Do not use any damaged PPE items.

Insulated rubber gloves should be inspected for scratches, holes and tears.

Consider a procedure to have insulated gloves independently certified for their voltage rating at
periodic intervals. At A123, gloves are inspected and recertified every 6 months.

Insulated safety boots should be inspected for holes, damage, nails, metal pieces, wear or other
problems on the soles.

Insulated rubber sheet or cover should be inspected for holes and tears.

Rev. 6/17/2013

2013 A123 Systems, LLC. All rights reserved. Proprietary and confidential.

11

Technical Service Bulletin 521100-001

Battery Handling Guidelines

PPE and Safety, continued
Working Safely Around Batteries
Working safely on batteries involves wearing the appropriate personal protective equipment, having
the right tools for the task and preparing the work area to protect both the worker and nearby
personnel.

Low Voltage (LV) Cell/Small Module Handling

Short circuits and physical damage are the most common causes of failure when handling lithium
ion batteries. These may be mitigated by following the cell handling guidelines listed below:
+

Appropriate PPE (nitrile gloves and eye protection) should be worn whenever handling LV
lithium ion cells or batteries;

Metallic jewelry (rings, bracelets, watches, necklaces, etc.) that may come into contact with
battery contact points should be removed or covered with a non-conductive material; remove
or have a heightened awareness of all metal objects (tools, etc.) in the vicinity of cells.

Metal work surfaces should be avoided; but if used must be covered with a non-conductive
material in order to avoid contact with battery terminals;

Ensure that work areas are clear of sharp objects or other materials that could potentially
damage or puncture cells.

High Voltage (HV) Large Module/Pack Handling

WARNING!
Exposure to high voltages from a large module or pack can cause shock, burns or even death.
The high voltage components in a large module or pack can only be serviced by technicians
with special high voltage training. Follow all necessary precautions before working on them.
Safely working on a high voltage pack or large module requires proper training, as well as wearing
proper PPE and clothing.
+

Remove all jewelry that may potentially contact a live electrical source.

Always wear the high voltage PPE (Class 0 gloves, face shield) when working with HV packs.

Heavy cotton clothing is preferred because it will only burn, not melt and adhere to skin.

Wearing rubber sole shoes will increase electrical resistance to earth ground, reducing the
possibility of current passing through a body to ground.

Refer to external sources for detailed information on safely working

around high voltage batteries, which can be helpful for developing your
internal procedures.
An example is attached on the right.
Rev. 6/17/2013

2013 A123 Systems, LLC. All rights reserved. Proprietary and confidential.

12

Technical Service Bulletin 521100-001

Battery Handling Guidelines

PPE and Safety, continued
Work Area Precautions
+

Work Area Must Remain Dry and Should be Indoors if Possible

The work area must be protected from rain, snow, sand, and other substances.
The work area floor must be dry, do not allow rain soaked or snow covered vehicles to enter
the work area.
Ideal conditions would be an air conditioned area to prevent condensation from forming as a
result of high temperature and humidity.

Work Area Must Be Free Of Foreign Material

The work area should be isolated from other shop areas that might introduce airborne
contaminates, such as metal powders, oil or other foreign substances.
If necessary, use a plastic curtain or other means to block off the work area.

Work Area Size

The work area space should be approximately the size of one vehicle, maintaining a secured
area for disassembly.
Use cones or other means to maintain a secured area to prevent unauthorized persons from
entering.
Display an appropriate warning sign in the work area indicating that disassembly is in
progress.

HV Safety Training Resources

Training is available from the National Fire Protection Association (NFPA) on Electrical Safety in the
Workplace. The NFPA website lists resources available for on-site seminars, regional and on-line
training and DVD training dedicated to this subject. Visit the following site for more information:
http://www.nfpa.org/categoryList.asp?categoryID=1263&URL=Training

Rev. 6/17/2013

2013 A123 Systems, LLC. All rights reserved. Proprietary and confidential.

13