MIL-PRF-32383A 20210505 Draft Release.pdf

AMSC N/A FSC 6140

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited

INCH-POUND

MIL-PRF-32383A

Draft

PERFORMANCE SPECIFICATION

BATTERIES, RECHARGEABLE, SEALED

GENERAL SPECIFICATION FOR

This specification is approved for use by all Departments and Agencies of the Department of Defense.

1 SCOPE

This specification covers sealed rechargeable batteries designed to power portable communications electronics devices used by the US military. Detailed electrical and physical requirements for individual batteries are specified on specification sheets.

Batteries described by this specification have the following types:

Type I – Batteries with a nickel cadmium (Ni-Cd) electrochemical system

Type II – Batteries with a nickel metal hydride (Ni-MH) electrochemical system

Type III – Batteries with a lithium ion (Li-ion) electrochemical system

Part or identifying number (PIN). PINs to be used for batteries described by this specification are created as described in TABLE I below. Additional differentiation may be required (see 3.1).

TABLE I. PIN description

M 32383 /1 -31 M prefix Specification number Specification sheet number Type

NOTES

1 Roman numeral type numbers are converted to Arabic digits in the PINs to provide a consistent number of characters in the PINs assigned by this specification.

1.1 Scope.

1.2 Classification.

NOTE: This draft, dated 5 May 2021 prepared by US Army CECOM LCMC, has not been approved and is subject to modification. DO NOT USE PRIOR TO APPROVAL. (Project 6140-2020-005)

Comments, suggestions, or questions on this document should be emailed to usarmy.apg.ccdc-c5isr.mbx.standardization-crx@mail.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST online database at https://quicksearch.dla.mil/.

2 APPLICABLE DOCUMENTS

The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8 + 100

(See ASSIST database for list of specification sheets.)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Department of Defense Standard Practice: Identification Marking Of

U.S. Military Property

MIL-STD-882 Department of Defense Standard Practice System Safety

MIL-STD-1472 Department of Defense Design Criteria Standard Human Engineering

MIL-STD-810 Department of Defense Test Method Standard: Environmental

Engineering Considerations and Laboratory Tests

(Copies of these documents are available online at https://quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.1 General.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks.

mailto:usarmy.apg.ccdc-c5isr.mbx.standardization-crx@mail.mil mailto:usarmy.apg.ccdc-c5isr.mbx.standardization-crx@mail.mil https://quicksearch.dla.mil/ http://quicksearch.dla.mil/

The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NAVSEA S9310-AQ-SAF-010 Technical Manual for Batteries, Navy Lithium Safety

Program Responsibilities and Procedures

(Copies of this document may be obtained from the Naval Ordnance Safety and Security Activity (NOSSA), Farragut Hall Building D-323, 23 Strauss Avenue, Indian Head, MD 20640- 5555.)

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

IEC 61000-4-5 Electromagnetic compatibility (EMC) – Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test

IEC 61000-4-9 Electromagnetic compatibility (EMC) – Part 4-9: Testing and measurement techniques Pulse magnetic field immunity test

(Copies of this specification are available online from International Electrotechnical Commission https://webstore.iec.ch )

ASTM G115-10 Standard Guide for Measuring and Reporting Friction Coefficients (Copies of this specification are available online from ASTM International https://astm.org)

ASTM-D-1141 Standard Practice for the Preparation of Substitute Ocean Water

(Copies of these documents may be obtained from the American Society for Testing and Materials, 100 Bar Harbor Drive West, Conshohocken, PA, USA, 19428-2959, or at https://astm.org)

System Management Bus Specification

Smart Battery Data Specification

System Management Bus, SMBus, Smart Battery, Smart Battery System, SBS, SMBus and SBS logos are trademarks of the System Management Interface Forum (SMIF), Inc.

(Copies of these documents may be obtained from the System Management Interface Forum (SMIF), Inc, on-line at http://powersig.org)

2.2.2 Other Government documents, drawings, and publications.

2.3 Non-Government publications.

https://webstore.iec.ch/ https://astm.org/ https://astm.org/ http://powersig.org/

Universal Serial Bus Power Delivery Specification 3.0

The USB Type-C Connectors and Cable Assemblies Compliance Document v 2.0

USB Power Delivery Compliance Test Specification Version 1.0 Revision 1.2, September 2020, https://www.usb.org/document-library/usb-power-delivery-compliance-test-specification

(Copies of these documents may be obtained from https://usb.org)

SAE-AMS-STD-595 Colors Used in Government Procurement

(Copies may be obtained from https://sae.org/, or SAE International Customer Service, 400 Commonwealth Drive, Warrendale PA 15096.

UL 94 Standard for Safety, Test for Flammability of Plastic Materials for Parts in Devices and Appliances

UL 1642 Standard for Safety, Lithium Batteries

(Applications for copies should be addressed to the Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062-2096, or at https://www.ul.com/).

UN Manual of Tests and Criteria

(Copies of this document may be obtained from the United Nations Publications Centre, 2 United Nations Plaza, Room DC2-853, New York, NY 10017, or at https://un.org)

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3 REQUIREMENTS

The individual item requirements shall be as specified herein and in accordance with the applicable specification sheet. In the event of any conflict between the requirements of this specification and the specification sheet, the latter shall govern.

When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.4.

2.4 Order of precedence.

3.1 Specification sheets.

3.2 First Article requirements.

https://www.usb.org/document-library/usb-power-delivery-compliance-test-specification https://www.usb.org/document-library/usb-power-delivery-compliance-test-specification https://usb.org/ https://sae.org/ https://www.ul.com/ https://un.org/

Certification of conformity shall be provided for the following requirements. The Government reserves the right to verify any or all certifications.

TABLE II. Certifications of conformity

REQUIREMENT PARAGRAPH

Metals 3.3.1 Dissimilar metals 3.3.2 Resistance of elastomeric materials 3.3.5 Electrical connection wires and tabs 3.3.6 Electrical contacts 3.4.4.1 Connector 3.4.4.1.1 Battery case1 3.4.5 Display window2 3.4.5.1 Dust cap or cover 3.4.7.1 Display, smart3 3.5.8.2 SMBus4 3.5.9.1 Battery Safety 3.7.2 High temperature temporary cutoff devices5

3.7.2.4

Inter-cell protective devices 3.7.2.6 Redundant safety protection 3.7.2.7 Transportation requirements 3.9 Connector pull force 3.4.4.1.1.1

NOTES

1 UL Standard 94 – flammability 2 Transparency during battery life 3 Requirements f and a 4 Charge enable 5 Number of devices

All metals which do not enter into the basic electrochemical reaction of the cell shall resist, or be treated to resist, corrosion. Certification is required.

When dissimilar metals which would adversely affect battery performance are used in intimate contact with each other, protection against electrolysis and corrosion shall be provided. Certification is required.

External parts of the battery shall show no evidence of cracking, pitting, chipping, scaling, corrosion or other deleterious effects after being tested as specified herein.

3.2.1 Certifications.

3.3 Materials.

3.3.1 Metals.

3.3.2 Dissimilar metals.

3.3.3 Corrosion resistance.

Insulating, impregnating, potting and sealing compounds used in manufacturing shall be capable of performing their intended purpose under the use conditions described by this specification. Compounds shall not inhibit the operation of any safety features. When tested as specified in 4.7.1.5, the insulating, impregnating, potting and sealing compounds shall not flow at high temperature, and shall not crack or draw away from the sides of a container at low temperature. Any compound used shall be non-flammable and non-toxic (see 6.4.8).

All elastomeric materials used in the battery shall show no cracks, blisters or other deterioration, nor cause degradation of battery performance after being tested as specified herein. Any elastomeric material used shall be non-flammable and non-toxic (see 6.4.8). Certification is required.

All points inside a battery that have positive and negative polarity in close proximity shall have not less than one layer of insulation between the positive and negative. Insulating material, or layers of multiple insulating materials between positive and negative points, shall have the following characteristics as a minimum:

a. Softening temperature (see 6.4.9): Not less than 302°F (150°C).

b. Lengthwise shrinkage: Not greater than 3% after application

c. Thickness: Not less than 0.005 inch

d. Material shall not shrink, soften, or crack during any of the tests of this specification.

e. The material shall be non-flammable, non-toxic (see 6.4.8), and impervious to the electrolyte of the battery.

f. Certification is required.

When specified (see 3.1), batteries shall be subjected to additional materials requirements.

Each battery shall be free of the visual mechanical defects listed in TABLE XIV.

The battery shall be made up of the necessary number of individual series and/or parallel connected cells, which have demonstrated their capability to meet the specified electrical and safety requirements.

Cells used to build batteries shall have an individual protective sleeving or coating. Material selected shall meet the requirements of 3.3.4; and 3.3.5 if applicable.

The dimensions and weights of each battery shall be as shown on the applicable specification sheets.

3.3.4 Insulating compounds, flow, and shrinking.

3.3.5 Resistance of elastomeric materials.

3.3.6 Electrical connection wires and tabs.

3.3.7 Additional materials requirements.

3.4 Physical characteristics.

3.4.1 Visual and mechanical.

3.4.2 Cells.

3.4.2.1 Protective coverings.

3.4.3 Dimensions and weight.

All electrical contacts of each battery shall be resistant to corrosion and shall be capable of withstanding the required number of insertions or connections specified herein (see 3.4.4.1.1.2 and 3.4.4.1.2). Each contact shall consist of the base metal and finish specified in the applicable specification sheet. Compliance to base metal and finish requirements shall be certified.

Unless otherwise specified (see 3.1), the battery shall contain a connector as shown on the applicable specification sheet.

When specified (see 3.1), the battery connector shall have the specified disconnect pull force. Certification is required.

When specified (see 3.1), the battery connector shall maintain a fully functional interface after 500 insertions and extractions. The final insertion and extraction forces shall be within 15% of the initial insertion and extraction forces. When tested as specified in 4.7.1.3, battery connector shall not tear, rip, be displaced, or separate from the battery case.

The battery shall contain flat terminals as specified in the applicable specification sheet. Battery terminals, including data and charge terminals, shall be of sufficient strength to withstand 250 connections without damage that would interfere with connections and shall maintain a fully functional interface. When tested as specified in 4.7.1.4, battery terminals shall not tear, rip, be displaced, or separate from the battery case.

When specified (see 3.1), electrical interfaces shall be finished according to the following:

a. Electrolytic copper flash, not less than 99.5% pure, thickness 10-20 micro inches.

b. Electroless nickel plate; not less than 800 Knoop hardness; not less than 200 micro-inches thickness.

c. Gold plate, not less than 99% pure; 130-200 Knoop hardness; not less than 30 micro-inches thickness.

When specified (see 3.1), electrical interfaces shall be finished according to the following: Gold plate, not less than 99% pure, 91-129 Knoop hardness, 25 micro-inches thick or better.

When specified (see 3.1), the battery shall include the specified number and type(s) of USB connector(s). Location(s) shall be as specified.

The USB connector shall have the following characteristics (see 4.7.2.17):

a. One USB Dedicated Charging Port (DCP) capable of supplying 1.5 A of current.

3.4.4 Battery connector and other electrical interfaces.

3.4.4.1 Electrical contacts.

3.4.4.1.1 Connector.

3.4.4.1.1.1 Connector pull force.

3.4.4.1.1.2 Connector insertions.

3.4.4.1.2 Flat terminal.

3.4.4.1.3 Multilayer finish.

3.4.4.1.4 Gold plating.

3.4.4.1.5 USB power port connector(s).

3.4.4.1.5.1 USB type A connector.

b. A tethered protective cover.

c. A charger adapter emulator circuit to accommodate proprietary fast charging protocols and be interoperable with Apple devices, Samsung devices, or devices containing Qualcomm Quick Charge.

d. The USB power port connector(s) shall be located as specified (see 3.1).

The USB connector shall have the following characteristics (see 4.7.2.17):

a. A minimum of 3 Amps at specified (see 3.1) VDC female port (receptacle) shall be available.

b. A tethered protective cover.

c. The USB power port connector(s) shall be located as specified (see 3.1).

d. The USB power port shall support dual-role power capabilities as specified in the

USB PD specification (See 3.5.9.2).

e. The USB power port shall use a certified USB Type-C connector.

The battery case shall be capable of maintaining the specified dimensions during the life of the battery. The surface of the case shall have a smooth finish free from pitting, blow-holes, rough spots, or other deformations. The battery case edges, seams, and corners shall be smooth. The case shall be fabricated of material having sufficient strength to withstand the environmental and electrical tests specified herein. Material shall be nonflammable. When plastics are used for the battery case, the material shall be classified in accordance with UL Standard 94, Test for Flammability of Plastic Materials for Parts in Devices and Appliances, except as otherwise noted herein. Acceptable ratings include: HB; V-0; V-1; V- 2; 5VA; 5VB; VTM-0; VTM-1; and VTM-2. If the manufacturer elects to use material classified in accordance with UL 94, certification is required. If the manufacturer elects to use a plastic material that doesn’t have UL-94 classification, then the test of 4.7.1.7 shall be performed.

When tested as specified in 4.7.1.7, test specimens shall self-extinguish within 5 seconds after removal from flame.

The window shall remain intact, in place, and transparent during the life of the battery. The window shall have a smooth finish free from pitting, blow-holes, rough spots, or other deformations and shall be fabricated of material having sufficient strength to withstand the environmental and electrical tests specified herein. Certification for transparency during the life of the battery is required.

The battery shall be designed to prevent dimensional expansion that will prevent its removal from equipment.

A pressure release device shall be incorporated into the battery case as specified (see 3.1). This device shall be designed to release below the bursting pressure of the container and above the normal operating pressure of the battery. The design of the battery shall be such that the paths from the individual cell units to the battery vent are sufficient to permit the removal of gases. The device shall not permit the entry of liquids into the

3.4.4.1.5.2 USB type C connector.

3.4.5 Battery case.

3.4.5.1 Display window.

3.4.5.2 Battery case expansion.

3.4.5.3 Battery case vent.

battery case. When tested as specified in 4.7.1.6, each battery case shall not exhibit any signs of visible damage other than the case vent opening, and each battery shall pass through the test fixture with a force not greater than 12 pounds.

The color of the battery case shall be as specified below, in accordance with

SAE-AMS-STD-595:

a. Type I (Ni-Cd) and Type II (Ni-MH) batteries shall be lusterless green, chip number 34088.

b. Type III (Li-ion) batteries shall be lusterless “Tan 686A”, chip number 33446.

A writable/erasable label shall be attached to each battery. This rectangular label shall state "User Info" and contain an area that allows writing and erasing multiple times. The label shall be a minimum of 1 inch X 13/16 inch.

Batteries shall not interfere with the operation of the system. When specified (see 3.1), batteries shall have the specified surface friction when tested in accordance with 4.7.1.8.

Each battery shall be provided with a permanent, legible hot-stamped or printed marking as specified herein. Direct printing on the battery is the preferred method. For rectangular batteries, the marking may be placed on more than one surface. Lettering shall be without serif (sans-serif) fonts. Unless otherwise specified (see 3.1), all markings shall be in accordance with MIL-STD-1472 for low lighting conditions and a 28-inch viewing distance.

The identification marking shall contain the following information. The information in parentheses shall be filled in by the manufacturer.

a. BATTERY, RECHARGEABLE, (Type Designation, PIN)

b. (Chemistry)

c. (Battery Voltage) V, (Full Capacity Rating) Ah / (Full Energy Rating) Wh

d. (NSN)

e. (Contract Number)

f. (MFG DATE) (Serial Number)

g. (MFG Warranty Details)

h. (Manufacturer)

i. (Manufacturer’s location)

When specified (see 3.1), batteries shall contain

IUID marking in accordance with MIL-STD-130.

Unless otherwise specified (see 3.1), the following warning marking shall appear on each battery in capital letters:

3.4.5.4 Color.

3.4.5.5 Writable label.

3.4.5.6 Surface friction.

3.4.6 Marking.

3.4.6.1 Identification marking.

3.4.6.1.1 Item unique identification (IUID).

3.4.6.2 Warning marking.

WARNING/STORAGE

DO NOT STORE ABOVE 122°F (50°C),

CRUSH, MUTILATE, REVERSE POLARITY,

DISASSEMBLE, OR DISPOSE OF IN FIRE.

The code shown shall indicate the month and year of manufacture of the battery by means of a four-digit number in which the first two digits shall indicate the number of the month and the last two digits shall indicate the year. Months earlier than the tenth month shall be a single digit preceded by "0". A forward slash (“/”) shall separate the first two digits from the last two (e.g. 01/13 indicates January 2013). When a battery is completed during the last three working days of a month or the first three working days of the subsequent month, the manufacturer is permitted to use either month as the coded month of manufacture.

Positive terminals shall be legibly indicated by "+", and negative terminals shall be identified by "-". The polarity markings shall be placed as close as possible to the applicable side of the receptacle where required. A schematic drawing shall be placed as close as possible to the receptacle or terminals as shown on the applicable specification sheet (see 3.1).

Each battery shall be marked with complete instructions for operation and charging of the battery, which shall include the following:

a. (Preferred charging method)

b. Specific instructions can be found in the applicable specification sheet (see 3.1).

c. (Alternate charging method)

d. Specific instructions can be found in the applicable specification sheet (see 3.1).

e. SOCI matrix (see 3.5.8)

f. Self discharge rate

g. Maintenance (e.g. discharging and charging periodically) where applicable

h. Other notes when specified (see 3.1)

The simplified battery label is designed to provide the end user with an easily understandable label containing the most pertinent information. The label size and location shall be as specified (see 3.1). Numeric values shall be for a complete battery, in new condition, at room temperature. The entire label shall be framed by 2 concentric arrows, indicating a rechargeable battery. The statement “For more information see https://battery.army.mil” shall be printed below the label. See FIGURE 1 for a sample representation of the simplified battery label.

The simplified battery label shall contain the following:

a. Type designation

b. Total energy in watt hours (rounded to nearest whole number), presented inside a battery icon

3.4.6.3 Manufacture date.

3.4.6.4 Terminal marking.

3.4.6.5 Instructions/notes.

3.4.6.6 Simplified battery label.

https://battery.army.mil/

c. The total weight in pounds (rounded to the nearest 0.1 pounds), presented inside a barbell icon

d. Energy density shall be calculated in watt hours per kilogram. The value shall be rounded to the nearest 50 Wh/kg, and one star icon shall be presented for every 50 Wh/kg. The actual numeric value (rounded to nearest whole number) shall be placed below the stars.

e. Battery chemistry (see 3.1)

For more information see https://battery.army.mil.

FIGURE 1. Sample simplified battery label Note: Battery nomenclature and values are fictitious

The color of the marking shall be as specified below:

a. Type I (Ni-Cd) batteries – black

b. Type II (Ni-MH) batteries – white

c. Types III (Li-ion) batteries – black

BB-1234/U

Wh100

WEIGHT

lb

TOTAL ENERGY

ENERGY DENSITY

220 Wh/kg

1.0

LITHIUM ION

3.4.6.7 Color.

https://battery.army.mil/

Marking shall be capable of withstanding all tests of 4.7, except projectile (see 4.7.4.11), without evidence of any of the following:

Blistering Delamination Separation Discoloration Chipping Dissolving Softening Illegibility Corrosion Loosening Splitting Flaking Cracking Peeling Warping Fading

When specified (see 3.1), batteries shall be subjected to additional markings.

All batteries shall be supplied with instructions cards (see 3.1) and a dust cap or cover over the connector.

Types I and II Batteries: Each battery shall be furnished fully charged as indicated by five state of charge segments where applicable.

Type III Batteries: Each battery shall be 30% SOC +0/-10% and indicate two state of charge segments (see TABLE III).

Each battery shall be furnished with a dust cap for shipping/transportation. The dust cap or cover shall not fall off during normal handling and shall be removable by hand at temperatures from -4 to 131°F (-20 to 55°C). The material used for the dust cap shall be non-toxic and non-flammable and shall withstand temperatures from -40 to 195°F (-40 to 90°C) without shrinkage or cracking. The dust cap or cover shall not leave any residue on the battery contacts nor have any adverse effect on the connection interface. Dust cap or cover compliance to these requirements shall be certified (3.2.1).

When specified (see 3.1), batteries shall be subjected to additional physical characteristics requirements.

Cells used to build each battery shall be matched to the limits specified below in order to avoid shortened cycle life. When tested as specified in 4.7.2.1, the capacity of each cell tested shall not vary from the average capacity obtained by more than the following specified limits:

a. Type I (Ni-Cd) and Type II (Ni-MH) cells: ± 5%

b. Type III (Li-ion) cell: ± 2.5%

The open circuit voltage (OCV) shall be within the voltage range specified (see 3.1).

The discharge in amperes hours or watt hours as required (see 3.1) for each discharge shall be not less than the value listed in the applicable specification sheet. The minimum cutoff voltage shall be the value listed in the applicable specification sheet. The

3.4.6.8 Permanency and durability.

3.4.6.9 Additional markings.

3.4.7 Battery condition for shipping.

3.4.7.1 Dust cap or cover.

3.4.8 Additional physical characteristics requirements.

3.5 Electrical requirements.

3.5.1 Cell balance.

3.5.2 Battery voltage.

3.5.3 Capacity.

batteries shall meet the specified minimum requirements. The surface temperature of the battery shall not exceed 185°F (85°C).

When tested as specified in 4.7.2.4 batteries shall be capable of retaining the specified capacity during and after the specified number of cycles (see 3.1).

When specified (see 3.1), batteries shall be capable of providing inrush currents required by the system. When tested as specified in 4.7.2.12, battery voltages shall not fall below the specified value. After completion of the test, batteries shall meet the capacity requirements of 3.5.3 and the criteria of TABLE XIV.

The battery shall have the specified charging interface (see 3.1).

When specified (see 3.1), batteries shall be equipped with a charge enable circuit that allows charging (see 3.1) on approved chargers (see 6.5) and disallows charging when connected to a charger that doesn’t recognize the charge enable circuit protocol.

Whenever a charger doesn’t recognize the charge enable protocol, the battery shall terminate any charge with current that exceeds the maximum specified (see 3.1). Unless otherwise specified, the charge enable pin shall have an equivalent input circuit of a resistor of specified value in series with a diode of specified VF (see 3.1). The circuit shall require activation current not less than the value specified (see 3.1). When tested as specified in 4.7.2.6, (1) the charge current shall not exceed the value specified without a charge enable circuit protocol being applied, and (2) battery current shall meet the preferred charging method while the charge enable is connected to a charge circuit equipped to allow the preferred charging method if the charge enable terminal or socket meets specified requirements (see 3.1).

The power consumption for all electronics within the battery shall be less than 350 micro-ampere average, per battery or independent section where applicable, at 68 ± 5°F (20 ± 2.8°C) (See 4.7.2.13).

Batteries shall display their status to the user. The value displayed shall compensate for use temperature and discharge rate of the battery.

When specified (see 3.1), the battery shall have a non-smart display. The display location shall be as specified (see 3.1). The display shall have five distinct segments showing the ranges of state of charge of the battery. Dual section batteries require a separate display for each section. As the battery ages and experiences capacity fade from use, the display shall compensate by showing the fully charged state as a percentage of the original fresh capacity (commonly referred to as “state of health” or “true capacity”). The state of charge ranges displayed shall be as follows (see 4.7.2.14):

3.5.4 Cycle life.

3.5.5 Inrush current.

3.5.6 Battery charging.

3.5.6.1 Charging interface.

3.5.6.2 Charge enable.

3.5.7 Power consumption.

3.5.8 Display.

3.5.8.1 Display, non-smart.

TABLE III. State of charge ranges

SEGMENTS STATE OF CHARGE

0 0% (Fully Discharged) 1 1 to 20% 2 21 to 40% 3 41 to 60% 4 61 to 80% 5 81 to 100%

When specified (see 3.1), the battery shall have an always-on state of charge indicator (SOCI). The segments shall be black in color on a white or pale gray background. The display shall be on continuously with no user action required except that it may go blank temporarily as it refreshes the display.

When specified (see 3.1), the battery shall have a user activated state of charge indicator (SOCI). The display shall be activated as specified. The display shall remain active for 3 seconds ± 1 second. The segments shall be illuminated white and shall be compatible with Night Vision Imaging Systems. The output of the display, measured in a direction normal to the display shall be 1.0 to 10.0 millicandelas.

Certification of light intensity is required.

When specified (see 3.1), the battery shall have a user activated

SOCI. The display height and location shall be as specified (see 3.1). See 4.7.2.14.2.

The display shall have the following characteristics:

a. The display shall be a 6 character display which shall indicate the following fields:

TABLE IV. Display content

Fields Character

Character

Character

Character

Character

Character

State of Charge (SOC) Number Number Number % State of Health (SOH) Number Number Number H Run-Time-To-Empty

(RTTE)

Number (Hour)

Number (Hour)

: Number (Minute)

Number (Minute)

E

Charge-Time-To-Full

(CTTF)

Number (Hour)

Number (Hour)

: Number (Minute)

Number (Minute)

F

Battery Cycle Count

(BCC)

Number Number Number Number C Y

Unusable condition 0 0 0

b. The output of the display shall be legible from a viewing angle of not less than 45 degrees in any direction. The viewing angle shall be certified.

3.5.8.1.1 Display, non-smart, always on.

3.5.8.1.2 Display, non-smart, user activated.

3.5.8.2 Display, smart.

c. There shall be an actuator button to the right side of the display that is recessed to protect from inadvertent operation. The operations of the actuator button shall have four possible inputs as follows:

i. Single quick depression. (≤ 6 seconds)

ii. Multiple quick depressions. (≤ 6 seconds each)

iii. Long depression. (> 6 seconds)

The display shall remain illuminated from 3 to 5 seconds following a depression. The actuator shall reset after 5 seconds of inactivity.

The operation of the display shall be as follows:

TABLE V. Display functions Input Function Action

Single quick depression

Wake-up The display shall illuminate the previously displayed field within 2 seconds.

Multiple quick depression

Cycle display

The display shall cycle to the next field with each depression in not less than 0.25 seconds following the order of FIGURE 2.

Long depression Orientation The orientation of the display shall rotate 180 degrees. If the display is at rest, the display shall illuminate the previously displayed field within 2 seconds.

FIGURE 2. Display circular display function transition

d. If the battery is not in a usable condition, the digital display shall flash 000. The display shall continue indefinitely with 000 flashing until the fault is gone or the battery is fully depleted.

e. When illuminated, the output of the display shall be 1.0 to 10.0 millicandelas when measured in a direction normal to the display. The output intensity shall be certified.

f. The push-button shall be capable of operation by Soldiers wearing Mission Oriented Protective Posture (MOPP) IV and cold weather gloves. The push-button actuator shall comply with the following displacement and resistance requirements in TABLE

VI.

TABLE VI. Push button requirements displacement Push button requirements displacement Resistance

Not less than 0.008 in. 0.25 lbs.

Not greater than 0.050 in. 5.50 lbs.

The values of the display shall be accurate within +0/-5% of the actual values for the battery. See 4.7.2.14.3.

When specified (see 3.1), batteries shall be compliant with System Management Bus (SMBus) Specification Revision 1.1 and Smart Battery Data (SBData) Specification, version 1.1, with the exception that SBData safety signal hardware requirements therein shall be replaced with a charge enable when a charge enable is specified (see 3.1 and 3.5.6). Certification is required. Batteries shall be compatible with appropriate Level 2 and Level 3 chargers (see 6.4.7). When tested as specified in 4.7.2.15.1, SMBus data output shall be accurate within +0/-5% of the actual state of charge for the battery under test throughout the discharge. Manufacturer and battery data shall be correctly programmed (see 4.7.2.15.1).

SMBus shall use 5V logic circuitry. Pull-up resistors will be provided by the charger. SMBus circuitry shall respond to a SMBus query within 2 seconds. Smart batteries may act as master or slave on the bus, but must perform bus master timing arbitration according to the SMBus specification when acting as master.

When specified (see 3.1), batteries shall be compliant with Universal Serial Bus Power Delivery (USB PD) Specification. When tested as specified in 4.7.2.15.2, batteries shall pass all USB PD 3.0 compliance tests.

When specified (see 3.1), batteries shall be able to utilize the USB as both a source and a sink, acting as a dual-role power device as specified in the USB PD 3.0 specification. When tested as specified in 4.7.2.15.2, batteries shall advertise both source and sink power data objects in its Source_Capabilities message.

Batteries shall be capable of operating over a temperature range of -4°F to 122°F (-20°C to 50°C). When tested as specified in 4.7.2.7 and

4.7.2.8 batteries shall meet the capacity requirements of 3.5.3 and the visual mechanical requirements of TABLE XIV.

3.5.8.3 Accuracy.

3.5.9 Communication protocols.

3.5.9.1 SMBus.

3.5.9.2 USB power delivery.

3.5.9.2.1 Dual-role power device.

3.5.10 Normal operating temperatures.

When tested as specified in 4.7.2.9, batteries shall meet the capacity requirements 3.5.3 and the visual mechanical requirements of TABLE XIV. The surface temperature of the battery shall not exceed 185°F (85°C).

Batteries shall be capable of maintaining the required minimum capacity after storage at 122°F (50°C) for 7 days. When tested as specified in 4.7.2.10, batteries shall meet the capacity requirements 3.5.3 and the visual mechanical requirements of TABLE

XIV.

When tested as specified in 4.7.2.16, the battery shall be capable of being charged and simultaneously discharged as specified (see 3.1).

subjected to additional electrical requirements.

Each battery when subjected to specified environmental tests of TABLE VII below shall show no:

a. Defects listed in TABLE XIV

b. Dimensional distortion beyond specified limits (see 3.1).

c. Sharp current or over voltage fluctuations during any charge or discharge period.

d. Mechanical failure of any part.

e. Failure to mate with a corresponding part.

f. Diminution of the rated capacity below the minimum specified in the applicable specification sheet following the performance of each test.

g. Electrical leakage.

h. Evidence of rupturing, burning or exploding.

i. Loss of functionality.

3.5.10.1 Charge acceptance.

3.5.10.2 Retention of charge.

3.5.11 Concurrent charge/discharge.

3.5.12 Additional electrical requirements.

3.6 Environmental requirements.

TABLE VII. Environmental requirements Tests Requirement Paragraph Test Paragraph Extreme low temperature discharge 3.6.1 4.7.3.2 Extreme high temperature discharge 3.6.1 4.7.3.3 Altitude 3.6.2 4.7.3.4 Temperature shock 3.6.3 4.7.3.5 Mechanical shock 3.6.4 4.7.3.6 Vibration 3.6.5 4.7.3.7 Immersion 3.6.6 4.7.3.8 Transit drop 3.6.7 4.7.3.9 Battery storage life 3.6.8 4.7.3.10 Impact 3.6.9 4.7.3.11 Solar radiation 3.6.10 4.7.3.12 Salt fog 3.6.11 4.7.3.13 Electrostatic discharge 3.6.12 4.7.3.14 Chemical resistance 3.6.13 4.7.3.15 Rapid decompression 3.6.14 4.7.3.16 Explosive atmosphere 3.6.15 4.7.3.17 Combined temperature, altitude, and humidity 3.6.16 4.7.3.18 Additional environmental requirements 3.6.17 4.7.3.19

Type III (Li-ion) batteries shall be capable of discharging over a temperature range of -22°F to 131°F (-30°C to 55°C). When tested as specified in 4.7.3.2 and 4.7.3.3 the batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

Batteries shall experience no deleterious effects from high altitude. When tested as specified in 4.7.3.4, batteries: (1) shall meet the requirements of 3.6; (2) batteries in the fully charge state shall meet the battery voltage requirements of 3.5.2.

Batteries shall not bulge, crack, break, leak electrolyte, rupture, burn, or explode as a result of varying rates of thermal expansion or contraction of cell and battery components when subjected to temperature shock temperature cycling in the range of 167°F to -75°F (75°C to -59°C). When tested as specified in 4.7.3.5, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

Batteries shall be capable of withstanding mechanical shock environments without sustaining physical or electrical damage. When tested as specified in 4.7.3.6, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

3.6.1 Extreme discharging temperatures.

3.6.2 Altitude.

3.6.3 Temperature shock.

3.6.4 Mechanical shock.

Batteries shall be capable of withstanding vibration environments without sustaining physical or electrical damage. When tested as specified in 4.7.3.7 and 4.7.3.7.1: (1) batteries shall exhibit no voltage fluctuations during vibration; (2) shall meet the requirements of 3.6; (3) shall meet the capacity requirements of 3.5.3.

Batteries shall be capable of withstanding water immersion without sustaining physical or electrical damage. When tested as specified in 4.7.3.8.1 or 4.7.3.8.2, batteries shall: (1) show no evidence of leakage of water into cases; (2) exhibit weight gain of not greater than 0.01 oz (0.3 g); (3) shall meet the requirements of 3.6.

Batteries shall be capable of withstanding drops at severe temperature conditions without sustaining physical or electrical damage. When tested as specified in

4.7.3.9.1 or 4.7.3.9.2, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6 (with the exception of defects in 106 of TABLE XIV, and minor reworkable deformations beyond specification limits).

Each battery shall be capable of not less than 3 years of warehouse storage, without any maintenance during storage, during which storage temperatures may vary between the limits of -4°F to 122°F (-20°C to 50°C). When tested as specified in 4.7.3.10, batteries shall, after 3 full cycles of charge and discharge, meet the capacity requirements of 3.5.3 and the requirements of 3.6.

Batteries may enter sleep mode during storage. See

4.7.3.10.1.

If sleep mode is utilized (see 3.6.8.1), batteries shall become fully operational when subjected to the specified wake up protocol (see 3.1). See 4.7.3.10.2.

When specified (see 3.1), batteries shall be capable of being impacted without sustaining physical or electrical damage. When tested as specified in 4.7.3.11 batteries shall meet the impact test capacity requirements of 3.5.3 and the requirements of 3.6 (with the exception of defects in 106 of TABLE XIV).

When specified (see 3.1), batteries shall be capable of withstanding prolonged exposure to sunlight without sustaining physical or electrical damage. When tested as specified in 4.7.3.12 batteries shall meet the requirements of 3.5.3 and the requirements of 3.6.

When specified (see 3.1), batteries shall withstand a salt fog atmosphere.

When tested as specified in 4.7.3.13 batteries for unconnected, unplugged/unprotected power connector shall meet the salt fog test capacity requirements of 3.5.3 and the requirements of 3.6.

3.6.5 Vibration.

3.6.6 Immersion.

3.6.7 Transit drop.

3.6.8 Battery storage life.

3.6.8.1 Battery sleep mode.

3.6.8.2 Battery wake up.

3.6.9 Impact.

3.6.10 Solar radiation.

3.6.11 Salt fog.

When specified (see 3.1), batteries shall withstand ESD to ±8 kV, contact discharge and ±15 kV air discharge on any surface, panel component (including vent), charge contacts, or power / data connectors, including exposed pins, in both operating and non-operating mode. When tested as specified in 4.7.3.14 batteries shall meet the ESD capacity requirements of 3.5.3 and the requirements of 3.6.

When specified (see 3.1), batteries shall not be affected by common chemicals in the operational environment such as military decontamination or fuel.

When testing in accordance of 4.7.3.15 batteries shall meet the requirements of 3.6.

When specified (see 3.1), batteries shall not bulge, crack, break, leak electrolyte, rupture, burn, or explode as a result of rapid decompression. When tested as specified in 4.7.3.16 and 4.7.3.5, batteries shall meet the capacity requirements of

3.5.3 and the requirements of 3.6.

When specified (see 3.1), batteries shall operate in fuel/air explosive atmospheres without causing ignition. When tested as specified in 4.7.3.17 and 4.7.3.5, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

When specified (see 3.1), batteries shall not bulge, crack, break, leak electrolyte, rupture, burn, or explode as a result of the combined temperature, altitude, and humidity. When tested as specified in 4.7.3.5 and 4.7.3.18, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

subjected to additional environmental requirements.

All protective devices employed shall not adversely affect battery performance or life. Batteries shall be evaluated for any unsafe conditions. An unsafe condition includes but is not limited to, (a) temperature above 338°F (170°C) on the surface of the battery case, (b) sustained flame and/or smoke generation, (c) violent reaction or (d) ejection of materials that present an unsafe condition to the user.

Each cell when subject to the specified electrical tests of

TABLE VIII shall not:

a. Explode

b. Catch Fire

c. Rupture

d. Spark

e. Leak any material

f. Have a loss of mass greater than 0.1%

3.6.12 Electrostatic discharge (ESD).

3.6.13 Chemical resistance.

3.6.14 Rapid decompression.

3.6.15 Explosive atmosphere.

3.6.16 Combined temperature, altitude, and humidity.

3.6.17 Additional environmental requirements.

3.7 Safety.

3.7.1 Cell safety.

3.7.1.1 Cell electrical safety.

g. Have a surface temperature that exceeds 200°F (93°C)

TABLE VIII. Cell electrical safety tests Tests Req’t Paragraph Test Paragraph Cell overcharge 3.7.1.1.1 4.7.4.1 Cell short circuit 3.7.1.1.2 4.7.4.2 Cell forced discharge 3.7.1.1.3 4.7.4.3

Cells used to build batteries shall be capable of withstanding overcharge.

Cells used to build batteries shall be capable of withstanding short circuiting (see 4.7.4.2).

Cells used to build batteries shall be capable of withstanding forced discharge (see 4.7.4.3).

When specified (see 3.1), cells shall not react violently when cell containers are penetrated by sharp objects. Cells tested in accordance with 4.7.4.4 shall not burn or explode, and the external temperature of each test sample shall be not greater than 338°F (170ºC). The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

When specified (see 3.1), cells shall not react violently when crushed.

When subjected to the test of 4.7.4.5, no cell shall burn or explode.

All internal insulation used shall have an insulation resistance of not less than 25 megaohms when tested as specified in 4.7.4.6.

Batteries shall be capable of withstanding overcharge conditions without failure. When tested as specified in 4.7.4.7: batteries shall not exceed the voltage limit specified during overcharge (see 3.1); no potential in excess of 0.5 V shall be obtained from the case or non-connected terminal to any terminal; and batteries shall meet the visual mechanical requirements of TABLE XIV and 3.6, and shall meet the capacity requirements of 3.5.3. The surface temperature of the battery shall not exceed 185°F (85°C).

Each battery shall be protected against short circuits. When tested as specified in 4.7.4.8, there shall not be any damage to the battery, and the battery shall be able to meet the full discharge capacity requirement of 3.5.3 after full charge.

3.7.1.1.1 Cell overcharge.

3.7.1.1.2 Cell short circuit.

3.7.1.1.3 Cell forced discharge.

3.7.1.2 Nail penetration, cell.

3.7.1.3 Crush, cell.

3.7.2 Battery safety

3.7.2.1 Insulation resistance.

3.7.2.2 Overcharge/electrical leakage.

3.7.2.3 Short circuit protection.

Each battery shall contain a minimum quantity of normally closed thermoswitches that shall open at 158 ± 9°F (70 ± 5°C) and close at 122 ± 9°F (50 ± 5°C). Each thermoswitch shall make physical contact with not less than one cell. The minimum quantity shall be as specified (see 3.1). The quantity of thermoswitches shall be certified. When tested as specified in 4.7.4.9, battery voltage shall be zero volts after each high temperature storage and batteries shall meet the voltage requirement of 3.5.2 after cooling.

After completion of the test the battery shall be able to meet the full discharge capacity requirement of 3.5.3 after full charge.

Each battery shall be permanently shut off when the temperature of the battery reaches 199 ± 9°F (93 ± 5°C). The device shall prevent charging and discharging of the battery. The minimum quantity shall be as specified in the applicable specification sheet. When tested as specified in 4.7.4.10, battery voltage shall be zero volts after high temperature storage and shall remain at zero after 104°F (40°C) storage.

When specified (see 3.1), batteries shall include protective devices/circuitry/material to prevent thermal event propagation between cells.

Certification is required.

When specified (see 3.1), batteries shall include the specified redundant protective devices.

When specified (see 3.1), batteries shall not present a risk to the user when subjected to a flame. When tested as specified in 4.7.4.11, the production of smoke and flames and the passing of small particles through the wire mesh are permitted; heat damage to the wire mesh is also permitted. Test must be set up in accordance to UL1642 Projectile Test.

During test, batteries must be secured to the screen with a single wire tied around the sample.

Video of the test is required from start of testing to end of testing for each battery. Pictures are to be taken and to include but are not limited to; pre-test apparatus (including all equipment), pre-test battery, post-test battery, post- test apparatus (including all equipment), post-test room, and any post-test shrapnel found with reference object. The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

When specified (see 3.1), batteries shall not react violently when battery containers are penetrated by sharp objects. Batteries tested in accordance with

4.7.4.12 shall not burn or explode, and the external temperature of each test sample shall be not greater than 338ºF (170°C). The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

When specified (see 3.1), Types III batteries shall be designed and built in a manner that provides protection from bulging, leaking, venting, rupturing, burning and exploding under conditions of extreme electrical abuse.

Additionally, batteries shall be designed in a manner that prevents the production of shrapnel in the event of failure of internal protection devices under extreme conditions.

3.7.2.4 High temperature temporary cut off devices.

3.7.2.5 High temperature permanent cut off devices.

3.7.2.6 Inter-cell protective devices.

3.7.2.7 Redundant safety protection.

3.7.2.8 Projectile.

3.7.2.9 Nail penetration, battery.

3.7.2.10 Lithium battery safety program (US Navy).

When tested in accordance with

4.7.5.1 through 4.7.5.3, the battery case shall not fragment. Case distortion, cracking, or bulging, and venting of gases or liquids through purposely designed cell vents, are permitted.

When tested in accordance with

4.7.5.4, no battery shall bulge, leak, vent, rupture, burn, or explode.

When specified (see 3.1), batteries shall be capable of safely withstanding penetration by bullets/projectiles. When tested as specified in 4.7.4.13, batteries shall not have thermal propagation to adjacent cells. Batteries shall not exhibit unsafe conditions of 3.7 for greater than two minutes. The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

When specified (see 3.1), batteries shall be subjected to additional safety requirements.

When specified (see 3.1), the battery shall be electromagnetically compatible with the system specified in the applicable specification sheet.

When tested as specified in 4.7.7, batteries shall meet the specified requirements.

Batteries and cells shall be tested per applicable US DOT and UN Manual of Tests and Criteria shipping regulations and meet requirements therein.

Certification is required.

subjected to additional transportation requirements.

Batteries shall be interoperable with currently fielded chargers and adapters as specified (see 3.1). When tested as specified in 4.7.6.1, batteries shall reach not less than 90% SOC and show no anomalies.

Batteries shall be interoperable with end items as specified

(see 3.1). When tested as specified in 4.7.6.2, batteries shall operate the end item as intended and show no anomalies.

When specified (see 3.1), batteries shall meet the specified reliability requirements (see 4.7.2.4.1).

3.7.2.10.1 Destructive lithium battery safety program.

3.7.2.10.2 Non-destructive lithium battery safety program.

3.7.2.11 Weapons characterization.

3.7.3 Additional safety requirements.

3.8 Electromagnetic interference.

3.9 Transportation requirements.

3.9.1 Additional transportation requirements.

3.10 Interoperability.

3.10.1 Charger interoperability.

3.10.2 End item interoperability.

3.11 Reliability.

4 VERIFICATION

The inspection requirements specified herein are classified as follows:

a. First article inspection…