Battery-Powered Tools

Interaction Between the Tool and Battery 

Users should be cognizant when operating battery powered tools and be aware of certain hazards and safety features for how a battery interacts with the tool.  

 See below for safety tips, as well as common hazardous issues seen in the field, and how to avoid them. 

Do’s and Dont’s 

• Do not use a battery that is overly cold or hot. 
• Do not disassemble the tool outside of manufacturers’ recommendations for service. 
• Do not use counterfeit batteries.  
• Do not use second source batteries. 
• Do not use battery-powered tools in the rain, including charging, unless they are rated to do so. 
• Remove battery before clearing jammed fasteners or doing user serviceable work to the tool. 
• Only use batteries that are approved for use by the manufacturer.  
• Disconnect battery from tool when not in use. 
• Send to an approved service provider for repairs. 
• Always read and follow tool manufacturers’ safety and maintenance instructions in the tool’s user manual.  

Safe Use of Battery Tools 

See the Power Tool Institute’s Website for more Battery Safety information: 

• Recharge the battery only with chargers specified by the manufacturer. 
• Storage for longer than 30 days: 
  • Store where temperature is below 80 degF and away from moisture 
  • Store in a 30%-50% charged condition 

Battery Interactions 

Use the manufacturer’s recommended batteries: Batteries and Tools are designed specifically to support the requirements of the tool. Everything from cell chemistry, voltage, ampacity, pack construction and tool / battery interface are all unique to specific brands and tool models. Environmental conditions are also an important consideration as any electric tool / battery system has its limitations when exposed to extreme temperatures, moisture, debris and even extended exposure to sunlight. 

Consult the manufacturer’s website prior to replacing the battery: All tools are designed for specific battery packs. Consult your manual and manufacturer’s websites to determine if the particular pack model number is the appropriate pack that will lead to a good customer experience and years of reliable service. 

Common Hazards and Safety Issues Associated with Battery-Operated Fastening Tools  

Do not store small fasteners in the same transportation container as a battery, tool, or charger in case they become ingested in the equipment. 

Avoid using battery adapters that can be found online which will allow a tool to be run with a different brand’s battery. Using battery adapters may disrupt battery safety features. 

Use a properly sized battery pack.  Manufactures will recommend the best battery for the specific tool. Electric tools benefit greatly from matching the tool to the recommended battery performance specifications. Substituting a lower ampacity battery pack can lead to greatly reduced performance. Be aware of a pack that has a low state of charge. When the state of charge of the pack is low, tool performance can be reduced.  

Some User Behavior to Warn Against 

Work contact elements should not be tied/wedged up in the activated position. This will create a tool that will fire only by using the trigger, defeating the 2-inputs requirement. 

Tools should not be used as hammers for standing nails on rare occasions, or used to move lumber into position frequently. 

Only use the size and length fastener appropriate for the tool.  – Example: Use 18GA brads in a tool designed for that sized fastener, Avoid installing 18GA brad nails into a 16GA straight finish nailer. 

Users should not use battery-powered tools in the rain, including charging, unless they are rated to do so. 

Different Types of Battery Fastening Tools 

• Pressure or vacuum generated 
• Flywheel 
• Pressurized Cylinder/ Gas Spring 
• Hammer Type (Palm nailer) 

Battery Storage and Transportation 

Keep battery charging and storage away from work areas to avoid accidental Battery Fastener interaction. 

For Lithium-ion battery safety, avoid extreme temperatures and refer to the manufacturer’s directions for proper storage.  Use the manufacturer’s provided charger. 

• Always refer to the latest edition of the International Air Transport Association (IATA) Dangerous Goods Regulations (DGR) for the most up-to-date and specific shipping requirements: https://www.iata.org/en/publications/newsletters/iata-knowledge-hub/what-to-know-about-how-to-ship-lithium-batteries/ 

Additional Resources 

• Transporting Lithium Batteries – USDOT 
• How to Safely Pack and Ship Batteries – UPS 
• How to Ship Batteries – FedEx 
• Shipping Lithium Batteries – IATA 
• Shipping Lithium Ion Batteries, 2020 Edition – EPTA 

Battery Standards 

North American Standards 

North American standards for battery-powered tools focus on safety, particularly regarding lithium-ion technology, with primary standards including UL 2595 (general requirements), UL 62841-1 (motor-operated tools), and CSA (Canadian Standards Association) requirements. These regulations cover thermal protection, charging systems, and battery management systems to prevent fire or explosion.  

Key North American Standards and Regulations 

• UL 2595 / CSA C22.2 No. 60745-1: The standard for safety for general requirements for battery-powered appliances, including tools and lawn and garden machinery. 
• UL 62841 Series (62841-1, 62841-2-1, etc.): Harmonized standards for electric motor-operated hand-held tools, transportable tools, and lawn and garden machinery, focusing on Li-ion cell safety. 
• IEC 62133 / UL 62133: Safety requirements for portable sealed secondary cells (lithium-ion). 
• OSHA 1910.242 / 1926.302: Occupational Safety and Health Administration standards for hand and portable powered tools. 

Global Standards 

Global standards for battery-powered tools focus on safety, performance, and transport, primarily governed by IEC (International Electrotechnical Commission) and UL (Underwriters Laboratories) standards. Key standards include IEC/UL 62841-1 for tool safety, UL 2054 and IEC 62133 for battery safety, and UN/DOT 38.3 for transportation, ensuring protection against fire, overcharging, and mechanical damage.  

Key Global Standards for Battery Tools 

• Tool Safety (Hand-held/Portable): 
  • IEC 62841-1 / UL 62841-1: The primary international and harmonized standard covering electric motor-operated hand-held tools, transportable tools, and lawn/garden machinery. 
  • UL 2595: Standard for Safety for General Requirements for Battery-Powered Appliances. 

• Battery Pack and Cell Safety: 
  • IEC 62133-1/-2: Safety requirements for portable sealed secondary cells (Nickel and Lithium systems). 
  • UL 2054: Covers safety for household and commercial lithium-ion battery packs, focusing on fire, leakage, and mechanical damage. 
  • IEC 62619: Safety requirements for secondary lithium cells and batteries for use in industrial applications. 

• Transportation Safety: 
  • UN/DOT 38.3 (T1-T8): Mandatory safety tests for transporting lithium-ion cells and batteries. 
  • IATA DGR (2025/2026 Updates): New regulations require many lithium-ion batteries transported by air to have a state-of-charge (SoC) of no more than 30%. 

• Charger Safety: 
  • IEC/UL 60335-2-29: Requirements for battery chargers for household and similar appliances.  

Key Requirements and Trends 

• System Approach: Standards now require evaluating the tool, battery pack, and charger as a single integrated system to ensure safety. 
• Battery Management Systems (BMS): Standards necessitate robust protection against overcharge, short-circuits, and cell imbalances. 
• Standardization Trend: To reduce waste and cost, there is a push toward universal battery platforms, with some systems supporting over 1,600 different tools, potentially reducing battery needs by 60-70%. 
• Thermal Protection: Stringent requirements for monitoring heat during operation. 

Recycling Resources 

• Federal regulations for used Lithium-ion Batteries: https://www.epa.gov/recycle/used-lithium-ion-batteries  
• Call 2 Recycle-https://www.call2recycle.org/ 
  • Recycling Laws by State: https://www.call2recycle.org/recycling-laws-by-state/?srsltid=AfmBOoqq1u9lCesLGw0W7W8wCCOy3yyDi_N6oehKbILQ0yY6XiwS-PX_  

• The Home Depot partners with Call2Recycle to provide a free, in-store recycling program for rechargeable batteries (up to 11 lbs and 300 watt-hours) in over 2,000 U.S. and Canadian locations. Located near store entrances or customer service, these kiosks accept batteries from power tools, laptops, and cell phones, having diverted over 14 million pounds of batteries from landfills since 2001.   

Additional Resource 

For proper recycling, disposal, refer to the Power Tool Institute’s (PTI) Website page on Battery Recycling: https://www.powertoolinstitute.com/battery-safety/battery-recycling/ and PTI’s “Take Charge of Your Battery” campaign: https://takechargeofyourbattery.com/