SpecP-313-0504.LithiumBatt.doc

Specification 505 3/28/2008

UNITED STATES COAST GUARD

OCEAN ENGINEERING DIVISION

WASHINGTON, DC

MARCH 2007

SPECIFICATION 505

FOR

LITHIUM BATTERY PACK

FOR ICE BUOYS

1.

SCOPE.

1.1 Scope. This specification details the requirements of a sealed lithium battery pack for use in lighted maritime aids to navigation ice buoys on U.S. waterways of the Great Lakes and from New England down to the Chesapeake Bay. This battery pack is deployed during the extreme environmental conditions of the designated ice season. The item covered by this specification is:

Lithium Battery Pack (NSN: 6135-01-556-7138)

2.0

APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are referenced in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification which are recommended for additional information or used 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 cited in sections 3 and 4 of this specification, whether or not the referenced documents are listed here.

2.2 Government Documents. The following documents form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification.

MIL-STD-129P (3)

Standard Practice for Military Marking

10/29/2004

SPECIFICATIONS

2.3 Industry Publications. The following documents of the issues specified form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document will be omitted from future references to the document in this specification.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 3951 (2004)

Standard Practice for Commercial Packaging

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

ANSI/ASQC

Quality Systems - Model for Quality Assurance in

Q9002-1994 Production, Inspection, and Servicing

2.4 Source of Documents. The documents may be obtained from the following sources:

Government Documents.

Standardization Documents Order Desk

Building 4, Section D

700 Robbins Avenue

Philadelphia, PA 19111-5094

Industry Publications.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

1916 Race Street

Philadelphia, PA 19103-1187

2.5 Precedence. Any ambiguity or conflict between the specification and applicable documents shall be resolved by utilizing the following documents in the precedence shown:

a. This Specification

b. Applicable Documents

3.

REQUIREMENTS.

3.1 General. The lithium battery pack, defined by these requirements, shall be 12-VDC (nominal) with a capacity of 96 ampere-hours at an average discharge current of 80 milliamps. (Figure 1) The battery will be expected to flash (at night) a signal load that consumes 300-400 ma (depending on color) with a 0.3 to 2.0 second pulse length and a 10% to 30% duty cycle. Coast Guard personnel will suspended the battery pack from a steel bulkhead (battery pocket cover plate) and compress it between the bulkhead and a bottom plate using a CG provided mounting kit. (Figure 2) When installed in an ice buoy, the battery will be housed in an airtight compartment subject to extreme shock, vibration, orientation and cold temperatures.

3.2 Design and Construction.

3.2.1 Design, Dimensions, and Dimensional Tolerances. All items shall conform to the design, dimensions, and tolerances described in this section and as shown in figures 1 and 2 of this specification.

3.3 Material Safety Data Sheet (MSDS). A MSDS or chemical analysis certificate shall be submitted with each delivery order (destination) where the batteries are shipped. The chemical analysis certificate shall contain a list of materials used in the battery by weight, including the overall case and any precautions necessary should the materials come into contact with personnel.

3.4 Environmental. The batteries shall be designed and constructed to withstand and operation in the following environment:

Ambient Temperature

-30o C to 25o C (storage –25o F to 140o F)

Air Pressure

3 psig (in air tight container)

Humidity

0-100% relative

Atmosphere

Salt air

Shock & Vibration Incidental to transportation to and operation on a buoy subjected to severe ice flow motion

Off Axis Operation

72o from normal vertical operating position

3.5 Cells. Cells shall be Lithium Thionyl-Chloride primary cell technology. Other cell technologies may be proposed, if they meet the physical and performance requirements of this specification.

3.6 Battery Pack. Lithium Thionyl-Chloride cells, mounting tubes, capacitors (if used) and associated reverse polarity and overload protection devices shall be packaged so that they fit and can be secured within the battery pocket, as described in paragraph 3.1. The cells and associated components shall be double wrapped in a heavy-duty heat shrink wrapper with rigid insulating material at the top and bottom to prevent shorting with the steel upper bulkhead in the buoy and the lower plate, or with the lower battery pack of an end-user installed two-pack configuration. Banding may be used around the pack to prevent movement of internal components during periods of severe vibration, heaving and rotation. The center access tube shall have an inside diameter of 1 inch, +0.0625/ - 0.0 inches. The four mounting tubes shall have an inside diameter of 0.5 inch +0.0625/ - 0.0 inches, equally spaced on an 8.1875 inch diameter B.C. The center access tube and associated mounting tubes shall be longer than the cells to prevent any exertion on the cell bodies when the cell pack is compressed. The cell pack shall be 9.5-inches in diameter and 2.75-inches in height +0.0/ - 0.0625 inches.

Figure 1

Figure 2

3.7 Internal Wiring. The battery pack shall be protected with self-resetting circuit breakers/fuses in the event that the pack is shorted externally. Individual cell strings and the battery pack shall be protected with diodes to prevent charging of failed cells. Capacitors may be used to reduce the surge current required during flashing of the LED signal. Note: Coast Guard personnel will stack together two battery packs that will be wired in parallel in order to increase the overall battery capacity for buoys with higher power consumption requirements.

3.8 Power Leads. The battery pack shall have two leads exiting from the side or through the center tube of the battery pack. They shall be protected with heat shrink tubing (to prevent chaffing inside the battery pocket) and color-coded black (+) and white (-). The ends shall be sufficiently insulated to prevent inadvertent shorting during transport and installation. The leads shall be long enough to project beneath the lowest battery pack, when two packs are stacked together, to facilitate connection to each other and the power cable.

3.9 Electrical Characteristics.

3.9.1 Nominal Voltage. The battery pack shall be nominal 12 VDC with an operating voltage range of 10-18 volts. 10 volts is the minimum operating voltage and capacity shall be rated at this cutoff voltage at the temperatures detailed in paragraph 3.4.

3.9.2 Max Open Circuit Voltage. The maximum open circuit voltage shall be 18.0 volts.

3.9.3 Capacity. The battery pack shall be capable of supplying a minimum of 96 ampere-hours (AH) at -10 degrees C and 64 AH at -30 degrees C, at an average discharge current of 80 milliamps to a cutoff voltage of 10.0 volts.

3.9.4 Loads. The battery will power a LED lantern, operating only at night that consumes 300-400 ma (depending on color) with a 0.3 to 2.0 second pulse length and 10% to 30% duty cycle. The period of performance is up to 150 days after installation. The battery shall not limit the current to the lantern and may use high-density capacitors contained within the pack to meet these current demands, if necessary.

3.10 Labels. The battery pack shall be labeled with the manufacturer’s name, battery type (Lithium Thionyl-Chloride) and orientation of installed pack (arrows, “TOP” or “UP”). The label shall contain, as a minimum, the following information:

12 VDC, 96 AH Ice Buoy Battery Manufacture Date: MM/YY NSN 6135-01-xxx-xxxx Contract No. DTCG##-##-#-###### Serial No. ###### Manufacturer’s Name & Address

Property of U.S. Coast Guard

To aid disposal, an additional label on the side of the case shall list the contents of the battery:

Contains Lithium Thionyl-Chloride Used battery pack must be recycled for proper disposal 3.11 Documentation.

3.11.1 Quality Assurance Inspection Form. The Contractor shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the inspections and tests performed on every item throughout its fabrication process. The form shall be typewritten on standard (i.e., 8½x11 inch) white paper. Inspection results may be handwritten on the form. The form shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction. The form shall be made available to the Contracting Officer’s Technical Representative (COTR) for review.

3.11.2 QAIF Content. At a minimum the QAIF shall include:

a) Item serial number.

b) Date of test or inspection.

c) Test or inspection to be performed (list every test and inspection required by section 4.0).

d) Result of test or inspection.

e) Accept/Reject criteria for each test or inspection.

f) Corrective action taken (if any).

g) Notes.

h) Initials or signatures of Contractor’s test personnel.

3.11.4 Material Inspection and Receiving Report (DHS Form 700). A form DHS-700 shall be used as a certification of product quality assurance, as a packing list, and as a certification of acceptance. The Contractor shall prepare a separate DHS-700 for each shipping lot.

Prior to shipment, the DHS-700 must be signed by the COTR.

4.0 QUALITY ASSURANCE PROVISIONS.

4.1 General. The Contractor's quality assurance program shall meet the requirements of

ANSI/ASQC Q9002. However, the Contractor does not have to be Q9002 certified.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First Article Inspection (paragraph 4.3)

b. Contractor Production Inspection (paragraph 4.4)

c. Coast Guard Production Inspection (paragraph 4.5)

4.3 First Article Inspection. When first article samples are required, the Contractor shall perform a first article inspection in accordance with paragraph 4.6.

4.3.1 First Article Tests and Inspections Notification. The Contractor shall notify the Contracting Officer in writing at least 7 calendar days prior to the scheduled commencement of any inspections and tests required by this specification.

4.3.2 Waiver of First Article Requirements. The Contracting Officer reserves the right to waive all or part of the first article requirements specified herein.

4.3.3 Rejection Criteria. The first article inspection results will be reviewed by the Contracting Officer, to determine compliance with the requirements of this specification. Failure of any of the tests or inspections described herein will be cause for rejection of the first article. If the first article is rejected, the Contractor will be notified in writing by the Contracting Officer and allowed 14 calendar days to fix or resubmit a new first article. Repair or replacement of the first article shall be by the Contractor at the Contractor's expense.

4.3.4 Authorization to Proceed. Upon successful completion of the first article inspection, the Contracting Officer will provide the Contractor with written authorization to begin fabricating production quantities.

4.3.5 Standardization. Materials, parts, design, and fabrication methods used in the production quantities shall be identical to those used in the first articles, unless otherwise authorized in writing by the Contracting Officer.

4.4 Contractor Production Inspection. The tests and inspections required by this specification are not intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to assure product quality. The Contractor shall perform the tests and inspections specified in paragraph 4.6 to ensure conformance to this specification. The Contractor shall provide space, personnel, and test equipment to conduct all inspection and test requirements.

4.5 Coast Guard Production Inspection. The Coast Guard reserves the right to observe, verify, or perform the tests and inspections outlined in paragraph 4.6. A random sample of lithium batteries (the number and type to be specified by ANSI/ASQC Z1.4, Table IIA, based on General Inspection Level II from Table I) shall be selected from each production lot. A production lot shall be all of the lithium batteries from an identifiable production period from one manufacturer and one plant and submitted for acceptance at one time. Production inspection shall consist of the examinations of paragraph 4.5.1 and the inspection and tests of paragraph 4.6.

4.5.1 Examination: Each battery pack in the sample lot shall be examined to verify conformance to design, dimensions and workmanship, as stated in section 3 above. A battery pack that fails to comply with any of the mechanical requirements (material selection, dimensions, etc.) of this specification or has any defects that will interfere with its use or decrease its life expectancy is deemed a failure. Lots shall be rejected when the percent of nonconformance is in excess of ANSI/ASQC Z1.4, AQL = 0.65.

4.5.2 Rejection for Defects. The Coast Guard will reject all items which do not conform to the requirements of this specification. Repair or replacement of the rejected items shall be by the Contractor at the Contractor's expense. All rejected items shall be resubmitted for inspection only when they conform to the requirements of this specification. Resubmitted items shall be identified as such, and shall be kept separate from new items. If defective items are found, no further items will be accepted by the Coast Guard until the Contractor has demonstrated that the defects have been corrected and that the cause of the defects has been eliminated from the production process.

4.6 Tests and Inspections. The following tests and inspections shall be conducted for each first article unit and subsequent production units:

a. Visual inspection

c. Vibration, Shock, Impact Test

d. External Short Test

e. Forced Discharge Test

f. Documentation Review Sample Submission. The manufacturer shall prepare three 12VDC, 96 ampere-hour battery packs for First Article Inspection and notify the government of their desire to conduct First Article Testing. The battery packs shall be representative of the manufacturer’s proposed normal production.

4.6.1 Visual Inspection. Each sample battery pack shall be visually inspected for quality of workmanship and conformance to this specification and the drawings. Measure and check samples for the following features:

a. Labels are properly placed and legible

b. Conformance to specified physical dimensions

c. Conformance to required materials

d. Battery terminals protected against shorting during shipment

4.6.2 Vibration, Shock, Impact Test. All sample battery packs shall be selected for vibration, shock and impact testing.

4.6.2.1 Vibration Test. Battery packs are firmly secured to the platform of the vibration machine without distorting the cells in such a manner as to faithfully transmit the vibration. The vibration shall be a sinusoidal waveform with a logarithmic sweep between 7 Hz and 200 Hz and back to 7 Hz traversed in 15 minutes. This cycle shall be repeated 12 times for a total of 3 hours for each of three mutually perpendicular mounting positions of the sample pack. One of the directions of vibration must be perpendicular to the terminal face. The logarithmic frequency sweep is as follows: from 7 Hz a peak acceleration of 1 Gn (Gn is the Newtonian constant of acceleration) is maintained until 18 Hz is reached. The amplitude is then maintained at 0.8 mm (1.6 mm total excursion) and the frequency increased until a peak acceleration of 8 Gn occurs (approximately 50 Hz). A peak acceleration of 8 Gn is then maintained until the frequency is increased to 200 Hz.

4.6.2.1.1 Requirement. Battery packs meet this requirement if there is no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test battery pack, after testing, is not less than 90% of its voltage immediately prior to this procedure.

4.6.2.2 Shock Test. Test battery packs shall be secured to the testing machine by means of a rigid mount which will support all mounting surfaces of each test battery. Each battery pack shall be subjected to a half-sine shock of peak acceleration of 50 Gn and pulse duration of 11 milliseconds. Each battery pack shall be subjected to three shocks in the positive direction followed by three shocks in the negative direction of three mutually perpendicular mounting positions of the battery pack for a total of 18 shocks.

4.6.2.2.1 Requirement. Battery packs meet this requirement if there is no mass loss, no leakage, no venting, no disassembly, no rupture and no fire and if the open circuit voltage of each test cell or battery, after testing, is not less than 90% of its voltage immediately prior to this procedure.

4.6.2.3 Impact Test. Test battery packs shall be raised to a height of 12 + ¼ inches above a level unyielding surface. Drop the battery packs five times, once flat on its bottom and four times on different locations of the flat radial side.

4.6.2.3.1 Requirement. Battery packs meet this requirement if there is no mass loss, no leakage, no venting, no disassembly, no rupture and no fire from any individual cells. The shrink-wrap and banding must remain intact with no loosening of any individual cells. The original shape of each battery pack must be unchanged. The open circuit voltage of each battery pack, after testing, is not less than 90% of its voltage immediately prior to this procedure.

4.6.3 External Short Circuit Test. One battery pack shall be temperature stabilized so that its external case temperature reaches 55 ± 2 °C and then the battery pack shall be subjected to a short circuit condition with a total external resistance of less than 0.1 ohm at 55 ± 2 °C. This short circuit condition is continued for at least one hour after the battery pack external case temperature has returned to 55 ± 2 °C. The battery pack must be observed for a further six hours for the test to be concluded.

4.6.3.1 Requirement. The battery pack meets this requirement if its external temperature does not exceed 170 °C and there is no disassembly, no rupture and no fire within six hours of this test.

4.6.4 Forced Discharge Test. One battery pack shall be forced discharged at ambient temperature by connecting it in series with a 12 V D.C. power supply at an initial current equal to the maximum discharge current specified by the manufacturer. The specified discharge current is to be obtained by connecting a resistive load of the appropriate size and rating in series with the test cell. The battery pack shall be forced discharged for a time interval (in hours) equal to its rated capacity divided by the initial test current (in amperes).

4.6.4.1 Requirement. The battery pack meets this requirement if there is no resultant disassembly and fire from the test.

4.7 Documentation Review. The documentation required in paragraph 3.11 shall be reviewed for conformance with this specification and provided to the COTR upon request.

5.0

PREPARATION FOR DELIVERY.

5.1 Packaging. Each battery shall be individually packaged in a cardboard carton. The preservation and packing shall conform to ASTM D 3951.

5.2 MSDS. One copy of the MSDS shall be included with the battery pack (s) for each destination.

5.3 Marking. Marking shall be in accordance with MIL-STD-129. Each box shall be marked with the following:

12 VDC, 96 AH Ice Buoy Battery Manufacture Date: MM/YY Box/Pallet Weight: XXX lbs NSN: 6135-01-xxx-xxxx Contract No.: DTCG##-##-#-###### Manufacturer’s Name & Address

Primary Battery Contents:

Lithium Thionyl-Chloride Cells

6.0 Notes

Specification 505 Lithium Battery Pack for Ice Buoys

March 2007 Prepared by:

Reviewed by:

D. W. WHITE

J. T. GRASSON

ELC AtoN Hardware Technical Signal & Power Team Leader

Support Team Leader Approved by:

STANLEY D. WALKER

Date

Chief, Ocean Engineering Division

� EMBED Word.Document.8 \s ���

_1210590211.ppt

Typical Battery Pack

Cells

Capacitors

Center Tube

Mounting Tubes

_1265200569.doc

REVISION:

DATE: FEB08

SPECIFICATION OR

STATEMENT OF WORK

COVER SHEET

TITLE:

SPECIFICATION

FOR

LITHIUM BATTERY PACK

FOR ICE BUOYS

SPECIFICATION NUMBER

P-313-0504

(Formerly HQ Specification No.505)

ORIGINATED BY: David W. White DATE: Feb2008

ORIGINATOR’S COMMAND: ENGINEERING LOGISTICS CENTER (ELC)

DEPARTMENT/DIVISION: 022

INTERNAL REVIEWER: DATE:

SOWRB APPROVAL: DATE: ____

_1210589405.ppt

Battery

Pack

3/8” All-Thread (4)

Lock Nuts (4)

Crimp Connectors

Pocket

Cover Plate

Cable

Gland

8.185” Dia Bolt Circle

10”

(Buoy Battery Pocket)

4 Holes, 3/8” UNC

12-1/4”

Dia

¾” NPT