Embedded Battery Safety

Embedded Battery Safety
Introduction
Custom made Lithium-polymer batteries allow the MacBook Air and MacBook Pro to be incredibly thin and light; as well as run for hours on a single
charge.
Due to the delicate nature of these rechargeable batteries, special care must be exercised when servicing these Apple portable products. This course
will cover important safety precautions and battery handling procedures.
Service Qualification Exam
Specific products may require technicians to complete this course, a product specific course and pass a service qualification exam
in order to perform repairs and order parts. Refer to GSX for additional information.
Lesson Overview
Lesson Objectives
Upon completion of this course you should be able to:
Explain the importance of exercising special care when handling lithium ion/polymer batteries.
Demonstrate the proper and safe handling of batteries and top case assemblies with battery.
Recognize and identify signs and symptoms of damaged batteries and top case assemblies with battery.
Respond to various battery and top case assembly with battery damage events.
Audience
Prerequisites
Time Required
Service Technicians
None
Approximately 45 Minutes
About Embedded Batteries
Apple portables come with batteries that are directly embedded into the computer's case. This allows for thinner and lighter designs while still
maintaining long battery life.
Cell Packs
Cell packs (containing chemical electrolyte), are the actual parts of a battery that are recharged, hold energy and provide power to the portable
computer.
Because they are soft and exposed (not shielded by a protective enclosure or cover) they can be inadvertently punctured or damaged.
Top Case Assembly with Battery
Batteries for some Apple portable products are built into the top case assembly (such as the MacBook Pro (Retina, Mid 2012) and MacBook Pro (Retina,
13-inch, Late 2012).
Replacing a defective battery will require replacement of the whole top case assembly. Batteries in these assemblies are NOT stand-alone parts. Refer
to GSX for more information.
Never attempt to separate or remove the battery from a top case assembly with battery.
Battery Safety Procedures
Use care when handling the battery or top case assembly with battery. Always exercise proper safety procedures. Damage to a
battery may result in a thermal event.
1. Handle the battery or top case assembly with battery by the edges, with two hands at all times.
2. Do not lift or hold the battery or top case assembly with battery using the cable or connector.
3. Never drop, stack, puncture, press, crush, twist, torque, strike, squeeze or apply unnecessary pressure to an actual battery, its cell packs (or top
case assembly with battery).
4. Inspect the battery for dents, scratches or other possible defects. Refer to the Visual Battery Inspection section of this training module.
5. Always replace a dropped battery or top case assembly with battery. They may have an abnormal charge current or voltage that can possibly lead
to thermal issues.
6. Never expose batteries, exposed cells or top case assemblies with battery to liquid.
7. Never apply liquid or water onto a battery experiencing a thermal event.
8. Keep batteries, top case assemblies with battery and computers away from heat and open flames. Store them in a cool dry place.
9. When the bottom case is removed, keep the protective battery service cover on the battery at all times.
10. When replacing a battery or top case assembly with battery, use the battery cover as directed by the product's service guide.
11. Always ship or transport batteries or top case assemblies with batteries in its original packaging. It should be bagged and properly packed in the
original packaging as shown in the Returning Packaging section of this training course. Be sure required IATA Caution and Packing List labels are
attached to the packaging.
If something unusual is noticed (such as an odor, discoloration, deformity, or overheating), disconnect and stop using the battery.
Follow the safety guidelines contained in this training course.
Workstation Setup
Play
Watch workstation setup video
Workstation Criteria
Designated workstations used to service portable computers should meet the following criteria:
Non-flammable and ESD safe workbench
Adequate ventilation
Unobstructed access to a portable fire extinguisher (CO2 or dry chemical rated ABC or equivalent) located within 20 feet (6.1m) travel distance of
the workstation.
Keep combustible materials away
Be sure to keep paper and other combustible materials at least 4 feet (1.2m) away from the workstation.
Additional safety procedures
The work area should be near locally available safety equipment.
Steel-toed shoes are recommended when handling a large container of batteries or top case assemblies with battery.
Check with local management on additional protocols and procedures regarding workstation setup and safety.
Equipment Checklist
Lab apron
Nitrile/latex gloves
Thermal resistant gloves
Safety glasses or goggles
Fire extinguisher (CO2 or dry chemical rated)
Fire safety box (recommended)
Materials Checklist
Baking soda (sodium bicarbonate) or sand
Liquid acid neutralizer
Chemical absorbent pads
Cleanup brush
Tongs (non-conductive)
Sealable disposable bags (large enough to fit a top case with battery)
Ordering safety equipment and supplies
Refer to Apple Support article HT5298 for information on ordering recommended safety equipment and supplies.
Service Tools
Special tools are used to remove and replace batteries (or top case assemblies containing batteries) in Apple portables. As required
tools may vary from product to product, consult the appropriate service guide in GSX for required tools and use instructions.
Always use the correct tools as instructed by the product's service guide. Incorrect tools or improper use can result in damage.
Battery Cover
The battery cover can prevent items such as loose parts, tools, and screws from unintended contact with the actual battery surface.
Apply and attach the battery cover:
Immediately after opening the computer (removing the bottom case)
Before beginning battery removal (or battery with top case removal)
Prior to installing a replacement battery (if a cover is not already attached)
When preparing to package a battery for shipment
Depending on the computer model, covers are equipped with tabs, adhesive, magnetic or plastic clips used to secure itself to the
battery.
Protect the exposed cells of embedded batteries at ALL times!
Use the Correct Battery Cover
Depending on the product, battery covers vary in size and design. Only use the correct battery cover for the product being serviced.
If the correct battery cover is not available, or it is worn, torn, or damaged in any way, STOP the repair and order a replacement
battery cover.
Refer to the product's service guide in GSX for the correct part number.
When to Remove Battery Cover
Only remove the battery cover immediately before installing the computer's bottom case.
Upon removal of the battery cover:
Inspect the battery for any damage or debris.
Pay special attention to any dents, divots, dots and scratches; these can result in thermal events with prolonged use over time.
Battery covers can be reused as long as it is free of dust, dirt, or damage.
Visual Battery Inspection
To ensure safety and performance of the batteries, inspect and verify the condition of the cells when performing service.
Cosmetic issues you may encounter include:
Dents or dot imprints
Scratches or imprinted lines
Swelling
Inspection instructions
1. Make sure there is sufficient lighting in the area.
2. View the battery from about one foot away.
3. Exercise special care to avoid accidental damage to the cell packs when measuring cosmetic issues.
Note: If you have an imminent safety concern about a scenario you have encountered (regardless if the scenario falls outside of
these guidelines) follow your normal safety escalation path.
Cosmetic Issue: Dents or Dot Imprints
If dents or dots exceed these guidelines, replace the battery/top case assembly with battery.
Diameter
Total Number of Dents/Dots
Less than or equal to 0.5mm
-
Greater than 0.5mm,
equal to or lesser than 1.0mm
10 or less
Greater than 1.0mm,
equal to or lesser than 1.5mm
6 or less
Greater than 1.5mm,
equal to or lesser than 2.0mm
3 or less
Important: The depth of any dent or dot shouldn't exceed a depth greater than half the diameter of the dent or imprint. For example, a dent 1mm
wide should not be greater than .5mm deep.
Cosmetic Issue: Scratches
If scratches exceed these guidelines, replace the battery/top case assembly with battery.
Diameter
Total Number of Scratches
Less than or equal to 15mm
5 or less
Greater than 15mm,
equal to or lesser than 30mm
Greater than 30mm,
equal to or lesser than 40mm
3 or less
2 or less
Cosmetic Issue: Swelling
If the battery is swollen, replace the battery/top case assembly with battery. First exercise the procedures outlined in the Scenario: Swollen Batteries
section of this training course.
Removal and Replacement
Important First Steps
Immediately after opening the computer (removing the bottom case):
1. Apply a battery cover to the battery
2. Disconnect the battery from the logic board
(disconnect battery cable or remove BMU interlock screw)
Next Steps: Battery/top case assembly with battery removal and replacement techniques vary from product to product. As a result,
specific procedures will not be covered in this course. Refer to the appropriate service guide in GSX for product specific
instructions.
Reminder: Top case assembly with battery
Batteries for some products are built into the top case assembly (such as the MacBook Pro (Retina, Mid 2012) and MacBook Pro
(Retina, 13-inch, Late 2012). NEVER attempt to separate or remove the battery from the top case as it is not a stand alone part.
Replacing a defective battery will require replacement of the whole top case assembly. Refer to GSX for more information.
Do not overtighten screws
When replacing a battery, tighten the battery's screws finger tight. Do not overtighten them by any amount as irreparable damage
to the battery pack can result.
Return Packaging
Embedded batteries and top case assemblies (containing batteries) ship in special packaging. Always use this original packaging when transporting or
returning these parts to Apple.
If either box has been damaged or lost, order a replacement service package. The service package includes:
Outer cardboard box
Inner cardboard box
ESD bag and yellow label (see below)
Service packages for top case assemblies (containing batteries) include:
Outer cardboard box, foam frame and padding, labels, and an ESD bag.
Always use tape to seal boxes. Do not use staples!
Always ship or transport with a battery cover
When returning a battery to Apple, reuse the battery cover that was included with the known good battery (or top case assembly
with battery). If the battery cover was lost or damaged, order a new one. Never attempt to transport or ship a battery (or top case
assembly with battery) without the battery cover.
Part numbers
Refer to GSX for the correct replacement service package or replacement battery cover part number(s).
Emergency Responders
IMPORTANT
Only properly trained and equipped emergency responders should handle the situations in the next four sections:
1. Hot Batteries
2. Swollen Batteries
3. Leakage Event
4. Thermal Event
Scenario: Hot Batteries
When a battery’s temperature rises above safe operating temperature, it can be potentially hazardous.
Response
1. Clear work bench of any materials or debris.
2. Put on thermal gloves, safety goggles or glasses, and apron.
3. In the case of an external short circuit, unplug the computer's power adapter. The battery should immediately start to cool.
4. Using tongs to hold the battery or top case with battery, place it in the fire safety box for at least 2 hours. (If the battery or top case with battery
is not easily removed, place the entire system in the fire box.
5. Dispose of batteries according to Apple disposal procedures and local regulatory requirements.
If the hot cell persists
If the battery or top case with battery doesn’t cool significantly after 2 hour there an increased likelihood of a thermal event. Refer
to the thermal event section of this module for additional guidance.
Scenario: Swollen Batteries
Damage or overheating of a soft cell battery may cause it to swell with gasses. These gasses may be flammable and can pose a health risk.
Caution
Do not puncture, crush or attempt to flatten a swollen battery.
Response
1. Put on chemical resistant gloves, lab apron, and safety goggles or glasses.
2. Prepare an absorbing pad in case it is needed.
3. Prepare a disposal bag.
4. Clear work bench of any materials or debris.
5. Unplug the computer's power adapter. If the battery or top case with battery is hot, it should immediately start to cool.
6. When the battery or top case with battery is cool, wrap it in an absorbent pad.
7. Place the wrapped battery or top case with battery into a disposal bag.
8. Put the disposal bag containing the wrapped battery into the fire safety box.
9. Dispose of batteries according to Apple disposal procedures and local regulatory requirements.
Scenario: Leakage Event
In the event of a leaking battery, keep everyone at a safe distance. Do not touch or walk through any spilled electrolyte.
Response
Caution
Immediately eliminate any ignition source or debris near or around the battery.
1. Clear work bench of any materials or debris.
2. Put on nitrile/latex gloves, lab apron, and safety goggles or glasses.
3. Apply liquid acid neutralizer to the spilled electrolyte.
4. Use tongs to pick up the battery / top case with battery.
5. Wrap the battery / top case with battery in an absorbent pad.
6. Place the wrapped battery / top case with battery in a disposal bag with any contaminated absorbent material.
7. Put the disposal bag in the fire safety box.
8. Use liquid acid neutralizer (preferred) or baking soda to clean the area of the spill.
9. Wipe down the spill area with your regular cleaning solution.
10. Dispose of batteries according to Apple disposal procedures and local regulatory requirements.
Scenario: Thermal Event
In the unlikely event that a battery is involved in a thermal event, the primary concern is personal safety.
Never use water to suppress a battery fire!
If you are trained to do so, use a portable fire extinguisher. Fire extinguisher should be CO2 or dry chemical (rated ABC or
equivalent).
Caution!
When properly trained emergency responders cannot extinguish a fire within 10 seconds, immediately call 911 or the local
emergency service. Vacate the area in accordance with normal evacuation procedures for your location.
Response (Once the thermal event is contained)
Proceed with the following steps:
1. After containment, leave room for 15 minutes before re-entering.
2. Put on chemical resistant gloves, lab apron, and safety goggles or glasses.
3. Use tongs to place the battery in a disposal bag.
4. Place the disposal bag and its contents into a fire safety box for a minimum 2 hours.
5. If employees are injured or were exposed as a result of the thermal event, notify your company's management and Environmental Health and
Safety (EHS) department.
6. Use liquid acid neutralizer (preferred) or baking soda to clean affected areas.
7. Wipe down the affected area with your regular cleaning solution.
8. Dispose of batteries according to Apple disposal procedures and local regulatory requirements.
First Aid Response
In case of exposure to smoke, fumes, or electrolyte from a leaking battery or cell, follow these general first aid procedures.
Inhalation
1. Move victim to fresh air.
If needed:
2. Call 911 or other emergency medical service.
3. Take appropriate first aid/CPR actions as necessary (only if you have been properly trained to do so).
Skin or eye contact
1. Remove and isolate contaminated clothing and shoes.
2. Call 911 or emergency medical service.
3. In case of contact with internal battery materials or fluids, immediately flush skin or eyes with running water for at least 20 minutes.
4. Ensure that medical personnel are aware of the material(s) involved and take precautions to protect themselves.
Disposal Procedures
Under normal circumstances, all batteries should be sent back to Apple for proper disposal.
When to dispose a battery or top case with battery
Do not ship batteries or top case assemblies (containing batteries) that were:
Damaged
Exhibited excessive heat
Leaked electrolyte
Currently or previously swollen
Dispose of batteries with these conditions locally in accordance with local, state and federal laws.
How to dispose a battery or top case assembly with battery
Dispose of the spent battery according to local environmental laws and guidelines.
Resources
Apple Portables: Battery terminology and key concepts
Apple Portables: Troubleshooting swollen or expanded batteries
About MacBook Pro (Retina, Mid 2012), MacBook Pro (Retina, 13-inch, Late 2012) and MacBook Air embedded battery safety
Air shipment regulations for lithium-based batteries beginning January 1, 2009
Intel-based Apple Portables: How to replace or service a built-in battery
MacBook Air (Late 2010 and later) and MacBook Pro (Retina, Mid 2012): Visual battery inspection
OS X Mountain Lion: If your battery won’t charge