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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 Requirements

Some products may require service qualification to perform repairs and order
parts. Obtaining service qualification for portable Mac products will require:
Completion of this course (Embedded Battery Safety)
Completion of the product's self-paced training (SPT) course
Passing the qualification exam for the particular product
Please refer to GSX for additional information.

Lesson Overview
Lesson Objectives
Upon completion of this course you should be able to:

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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

You will need...

Service Technicians

None

Approximately 45

No additional

Minutes

materials or
equipment.

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.

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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.

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Example: MacBook Pro (Retina, Mid 2012)

Replacing a defective battery in these instances 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.

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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

Important: Review the entire video. Concepts presented are covered in product qualification exams.

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Workstation 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
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)

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Ordering safety equipment and supplies

Refer to Apple Support article OP685 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!

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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.

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Visual Battery Inspection

To ensure safety and performance of the batteries, inspect and verify the condition of the cells when
performing service.

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

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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

3 or less

Greater than 30mm,

equal to or lesser than 40mm

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.

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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:

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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

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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 batterys 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 doesnt 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.

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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.

Immediately eliminate any ignition source or debris near or around a leaking battery.

Response
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.

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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).

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

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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
Air shipment regulations for lithium-based batteries beginning January 1, 2009

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Enclosure separation due to expanded battery

Mac notebooks with built-in batteries: How to service or replace the battery
Mac notebooks: Battery terminology and key concepts
MacBook (13-inch, Late 2009, Mid 2010) and MacBook Pro (13-inch, Mid 2009, Mid 2010, Early /
Late 2011, Mid 2012): Safety - Battery Precautions
MacBook Air (11-inch, Late 2010, Mid 2011, Mid 2012, Mid 2013): Battery Safety Precautions
MacBook Air (13-inch, Late 2010, Mid 2011, Mid 2012, Mid 2013): Battery Safety Precautions
MacBook Air: Battery Leaking or Swollen
MacBook Pro (Retina, 13-inch, Late 2012 and Early 2013): Battery Handling and Storage
MacBook Pro (Retina, 13-inch, Late 2012 and Early 2013): Battery Leaking or Swollen
MacBook Pro (Retina, Mid 2012) and MacBook Pro (Retina, 15-inch, Early 2013): Battery Handling and
Storage
MacBook Pro (Retina, Mid 2012) and MacBook Pro (Retina, 15-inch, Early 2013): Battery Leaking or
Swollen
SERVICE: MacBook Air (Late 2010 and later), MacBook Pro with Retina display computers: Visual
battery inspection
SERVICE: MacBook Pro with Retina display, MacBook Air (Late 2010 and later): About embedded
battery safety

Copyright 2013, AppleCare

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