MIL-PRF-32383-X 30 January 2020.docx

MIL-PRF-32383/X DRAFT

NOTE: This draft, dated 23 January 2020 has been prepared by US Army PM CCS and C5ISR, and it has not been approved and is subject to modification. DO NOT USE PRIOR TO APPROVAL. (Project 6140-2015-001)

INCH-POUND

MIL-PRF-32383/X(CR)

30 January 2020 DRAFT SUBJECT TO CHANGE WITHOUT NOTICE

SUPERSEDING

MIL-PRF-32383/4

6 March 2013

PERFORMANCE SPECIFICATION SHEET

BATTERY, RECHARGEABLE, SEALED, LITHIUM-ION, BB-2525 and BB-3525

The requirements for acquiring the product herein shall consist of this specification sheet and MIL-PRF-32383

FIGURE 1. M32383/4-3 (BB-2525) Lithium Ion and M32383/4-4 (BB-3525) Lithium Polymer Conformal Batteries (See Figure 7 for dimensions) Note: Depicted battery is representative of a potential solution but is not a requirement within this document.

Unless otherwise specified, paragraph numbers are in reference to MIL-PRF-32383. Note that the requirement and verification paragraphs included in this document that are in addition to or modified from MIL-PRF-32383 are highlighted in BOLD.

2. APPLICABLE DOCUMENTS.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks.

Add:

DEPARTMENT OF DEFENSE SPECIFICATIONS

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

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Department Of Defense Standard Practice: Identification Marking Of U.S. Military Property

MIL-STD-461 Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

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

MIL-STD-1916 Department of Defense Test Method Standard

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

2.2.2 Other Government documents, drawings, and publications.

Add:

ADS-37A-PRF Electromagnetic Environmental Effects (E3) Performance and Verification Requirements (Relevant pages of this document can be found in APPENDIX A herein)

NWPAN-WP-01112013 Nett Warrior Interconnect Architecture White Paper (Available from: Product Manager Ground Soldier Systems (PdM GSS) Attn: SFAE-SDR-CCS, 5966 12th Street, Building 1024, Ft. Belvoir, VA. 22060) – Approved Nett Warrior compatible connectors.

2.3 Non-Government publications.

Add:

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 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 http://astm.org )

Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 (Copies of this specification are available online from SBS Implementers Forum (SBS-IF) at: www.sbs-forum.org)

3. REQUIREMENTS.

Add: Specification requirements and test methods: The following requirements and test methods of MIL-PRF-32383, identified therein as “when specified”, are applicable as indicated below:

“When Specified” Requirements

Paragraph Test Method Paragraph Applicability

4.7.2.15 Yes

1/ As modified herein, both mated and unmated configurations.

3.2.1 Certifications.

Delete 3.2.1 from MIL-PRF-32383 and replace with the following:

3.2.1 Certifications

3.

3.4.3 Dimensions and weight.

Add: Width shall be 7.60 +/- 0.06 inches.

Height shall be 8.65 +/- 0.05 inches.

Depth shall be no less than 0.50 inches and not greater than 0.70 inches.

Weight shall be no greater than 2.6 pounds.

All other dimensions shall be accordance with FIGURE 7 Conformal Battery Dimension.

3.4.4.1.1 Connector.

Delete 3.4.4.1.1. from MIL-PRF-32383 and replace with the following

3.4.4.1.1. Nett Warrior Connector.

Glenair connector Part Number 8070-1939-07ZNU6.7SY (printed circuit board tails or solder cup) or TE Connectivity Part Number: 2828420-2 (7 position). The primary (master) keyway shall be oriented downward, facing the charge terminal contacts.

The battery connector shall maintain a fully functional interface after 500 insertions and extractions. When tested as specified in 4.7.1.3, battery connector shall not tear, rip, be displaced, or separate from the battery case.

The connector shall provide a shell to shell shield impedance of not greater than 4 milliohms when mated with any of the mating connectors listed in NWPAN-WP-01112013.

Sockets 1, 2, and 3 shall be capable of carrying not less than 5 amps continuous each.

Connector shall be capable of mating with plugs having the 6-6 or 6-7 pin configuration. The connector shall be sealed to meet the requirements of section 3.6.6 (Immersion). The connector shall be sealed in a way such that insertion of a plug with a 6-7 pin configuration does not compromise the ability to meet Immersion and other requirements herein.

The pinout for the connector shall be as follows in “Nett Warrior Connector Pinout Description” with socket numbering depicted in FIGURE 2. Cerification is required

Nett Warrior Connector Pinout Description

1/ Charge + shall be input only 2/ Safety Signal IAW Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 3/ Require internal termination of Ground to Shield Ground.

4/ Shall not be used for any electrical connectivity or for grounding

FIGURE 2. Nett Warrior Connector Pinout Assignment

3.4.4.1.1.1 Nett Warrior Connector disconnect pull force.

The connector shall have a 12.0 +/- 4.0 pounds of force disconnect. Test per 4.7.1.3.1

3.4.4.1.2 Flat terminal.

Add: The charge terminals shall be as shown in FIGURE 3, Charge Terminal Pinout Assignment. Charge terminals shall be electrically protected against short circuit and shall not source battery current. All four contacts shall be recessed 0.020 +/- 0.005 inches. The contacts shall support charging at a minimum of 7.5 Amps. They shall be designed minimally to sustain a 20 Lbs. force each for 10 minutes without degradation to the battery contacts from a charge contact pin. Test per 4.6.1 and 4.7.1.4.

The battery shall be capable of being charged via both the Nett Warrior connector and the charge terminal contacts. The battery shall be capable of “wake up” charging via both the Nett Warrior connector and the charge terminal contacts. Wake up charge charging via the Nett Warrior connector shall be IAW the Smart Battery Specified behavior for the Safety Signal. Wake up charging via the charge terminal contacts shall be performed by accepting +5V between terminal 1 and 2 and responding to SMBus commands before charging voltage is provided.

Charge Terminal Descriptions

FIGURE 3. Charge Terminal Pinout Assignment

3.

3.4.4.1.3.

3.4.4.1.4.

3.4.4.1.5 USB power port connector(s).

The CWB shall provide at least one USB 3.0 Type-A connector located just above or just below the Nett Warrior connector for device output power with the following characteristics:

a. A minimum of 1.5 Amps at 5 VDC female port (receptacle) shall be available.

b. A tethered protective cover

c. Connection of the Nett Warrior connector and USB Type-A connector shall be accomplished by the user wearing cold weather gloves when tested IAW MIL-STD-1472.

d. One (1) USB BC1.2 Dedicated Charging Port (DCP) capable of supplying 1.5 A of current.

e. A charger adapter emulator circuit to accommodate proprietary charging protocols such as Apple, Samsung, or Qualcomm Quick Charge.

f. Verify in accordance of section 4.7.2.17

3.4.5 Battery case.

Delete from MIL-PRF-32383 and replace with the following:

3.4.5 Battery case.

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 case shall be fabricated of material having sufficient strength to withstand the environmental and electrical tests specified herein. Material shall be nonflammable. The case 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 V-0, 5VA, or 5VB. If the manufacturer elects to use material classified in accordance with UL 94, certification is required. If it is not UL-94 certified, test as specified in 4.7.1.7 and as approved by the government for validation; test specimens shall self-extinguish within 5 seconds after removal from flame.

3.4.5.6 Surface friction.

Batteries shall slide easily in and out of their pouch. When tested as specified in 4.7.1.8 batteries shall have a coefficient of static friction of not greater than 0.40 against a Cordura® fabric containing meta-aramid, nylon and cotton in a blend ratio of 43/30/27 percent by weight.

Add:

3.4.5.7 Battery case edges.

The battery case edges, seams, and corners shall be smooth.

3.4.6 Marking.

Add:

All marking and labels shall be in accodance with MIL-STD-130

3.4.6.2 Warning marking.

Add:

Warning labels shall be not less than a 12 point font; other labels shall not be less than a 10 point font..

3.4.6.5 Instructions / notes.

Add:

The following charging instructions shall be marked on each battery:

CHARGE CONSTANT VOLTAGE AT 16.8V AT 5 AMPS MAX THROUGH NETT WARRIOR CONNECTOR.

BATTERY TEMPERATURE SHOULD BE BETWEEN 32°F (0°C) AND 113°F (45°C) DURING CHARGE.

LOWER TEMPERATURE CHARGING IS PERMITTED BUT RUNTIMES WILL BE LOWER.

WARNING/STORAGE

DO NOT STORE ABOVE 160°F (71°C), CRUSH, MUTILATE, REVERSE POLARITY, DISASSEMBLE, OR DISPOSE OF IN FIRE.

(Note: if charge voltage is different than 16.8 VDC, appropriate voltage should be stated on battery charging instructions.)

3.4.6.6 Simplified battery label.

Add:

The simplified battery label location shall be located on the same surface as the charging instructions.

Add:

3.4.6.9 Nett Warrior connector marking.

The Nett Warrior Connector marking shall be as shown in FIGURE 4 and orientated as in FIGURE 7.

FIGURE 4. Nett Warrior Connector marking details

3.4.8 Battery condition for shipping.

Delete MIL-PRF-32383 3.4.8 in its entirety and replace with the following:

3.4.8. Battery condition for shipping.

Each battery shall be shipped with an instruction card that shall contain instructions for operation, charging, and maintenance of the battery to include long term storage/shipping requirements per (Safety Data Sheet, class of shipping, and shipping markings).

3.4.8.1 Dust cap or cover.

Replace “Each battery shall be furnished with a dust cap” to “Each battery shall be furnished with a dust cap for shipping/transportation only”

Battery voltage.

Add:

Battery shall operate within the range of 10.0 volts to 20.0 volts.

3.5.3 Capacity.

Add:

Minimum final voltage: 10 volts.

When subjected to the specific test listed below and discharged at the specified rate to minimal final voltage, the battery shall have the following minimum capacity:

Test Capacity Requirements

3.5.5 Motor inrush current.

The discharge profile shall be as follows. Verify values in accordance with 4.7.4.12.

(second:millisecond:microsecond)

3.5.8 State-of-charge Indicator (SOCI).

Delete 3.5.8 from MIL-PRF-32383 and replace with the following:

3.5.

3.5.8. Digital display characteristics.

When tested as specified in 4.7.2.14, the display shall have the following characteristics:

a. There shall be a single digital display located on the top central edge of the battery (see Figure 7) that will have the capability of displaying State of Charge (SOC) State of Health (SOH), Run-Time-To-Empty (RTTE) and Run-Time-To-Full (RTTF). The digital display actuator shall be recessed and shall be protected from inadvertent operation.

b. The load applied by the digital display circuitry on the battery shall be not greater than 50 micro-amperes in the non-operating mode.

c. The device shall be designed to compensate for usage temperature and discharge rate and shall monitor and adjust for changes in both during battery use.

d. The accuracy of the information displayed shall be +0%/-5% based upon actual initial battery capacity.

e. The digital display shall provide readings for SOC and SOH of 0 to 100% in 1% increments and RTTE and RTTF in hh:mm. The display shall not be less than ¼ inch in height. The display shall visually distinguish between SOC, SOH, RTTE and RTTF. The output of the display shall be discernable from any direction (i.e. distinguish between readings of 001 and 100 or 85 and 58)

f. The digital display shall flash 000 indicating the battery has an internal fault preventing it from providing output power through any connector.

g. RTTE shall be a display of the SMBus AverageTimeToEmpty(), calculated based on power, and represented in hh:mm format.

h. RTTF shall be a display of the SMBus AverageTimeToFull(), calculated based on power, and represented in hh:mm format.

i. The display shall be compatible with Night Vision Imaging Systems. The output of the display at full intensity, measured in a direction normal to the display shall be 1.0 to 10.0 millicandelas. The display shall be capable of providing the correct information in a temperature range of −30 to 55ºC and be capable of surviving temperature extremes of −40ºC to 93ºC. Certification to the full intensity output and storage temperature range requirements is required.

j. The digital display shall normally be in the ‘off’ mode and shall require a push-button actuator to activate the display. 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:

Push Button Requirements

k. At full intensity, the display shall only illuminate the state of charge level appropriate to its usage level when viewed from a direction normal to the indicator (i.e., no light bleed-through to levels/spaces meant for higher states of charge). Time to full light intensity shall be not greater than two seconds. The display shall remain at full intensity for not less than 3 seconds and shall self-extinguish in not greater than 7 seconds of actuation when the actuator is held down. The display shall extinguish any time the actuator is released in not greater than 7 seconds.

3.5.9 SMBus.

Delete 3.5.9 from MIL-PRF-32383 and replace with the following:

3.5.9 SMBus.

Each battery shall be compliant with System Management Bus (SMBus) Specification Revision 1.1 and Smart Battery Data (SBData) Specification, version 1.1. Batteries shall be compatible with appropriate Level 2 and Level 3 chargers (see 6.3.9). When tested as specified in 4.7.2.14, Relative State of Charge value 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).

SMBus shall use 5V logic circuitry. Pull-up resistors will be provided by the charger. SMBus output from the connector should be sufficient to maintain signal integrity through two (2) C1 Nett Warrior or equivalent cables connecting to a charger or power and data manager. SMBus circuitry shall respond to a SMBus query within 45 seconds.

Add:

3.5.11 Concurrent charge / discharge.

When tested as specified in 4.7.2.16, the battery shall be capable of being charged via pin 3 and simultaneously discharged via pin 1 of the Nett Warrior connector (3.4.4.1.1).

When tested as specified in 4.7.2.16, the battery shall be capable of being charged via the flat terminal contacts (see 3.4.4.1.2) and simultaneously discharged via pin 1 of the Nett Warrior connector (3.4.4.1.1).

3.6 Environmental Requirements.

Delete Table I and replace it with the following:

TABLE I. Environmental Requirements

3.6.5 Vibration.

Replace “When tested as specified in 4.7.3.7” with “When tested as specified in 4.7.3.7 and4.7.3.7.1”

Add:

3.6.9 Impact.

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 VIII).

Add:

3.6.10 Flexibility.

Batteries shall be capable of flexing with a 1 inch displacement in both directions on each axis without sustaining physical or electrical damage. When tested as specified in 4.7.3.12 batteries shall meet the flexibility test capacity requirements of 3.5.3 and the requirements of 3.6

Add:

3.6.11 Solar radiation.

Batteries shall be capable of withstanding prolonged exposure to sunlight without sustaining physical or electrical damage. When tested as specified in 4.7.3.13 batteries shall meet the requirements of 3.5.3.

Add:

3.6.12 Salt fog.

Batteries shall withstand a salt fog atmosphere. When tested as specified in 4.7.3.14 batteries shall meet the salt fog test capacity requirements of 3.5.3 and the requirements of 3.5.

Add:

3.6.13 Electrostatic discharge (ESD).

Batteries shall withstand ESD to ±8kV, contact discharge and ±15kV air discharge on any surface, panel component (including vent) or connector, including exposed pins, in both operating and non-operating mode. When tested as specified in 4.7.3.15 batteries shall meet the ESD capacity requirements of 3.5.3 and the requirements of 3.5.

Add:

3.6.14 Conformability.

Batteries shall be capable of bending under not greater than 35 pounds of force around curved surfaces of a 7 inch radius. Batteries shall conform to the curvature of the above cited curved surface and maintain no greater than 3/16 inch distance between the curved surface and entire battery surface while conformed. When tested in accordance of 4.7.3.16 batteries shall meet the conformability capacity requirements of 3.5.3 and the requirements of 3.5.

Add:

3.6.15 Chemical resistance.

Batteries shall not be affected by common chemicals in the operational environment such as military decontamination or fuel. When testing in accordance of 4.7.3.17 batteries shall meet the requirements of TABLE VIII.

3.7 Safety.

Add: Batteries shall be evaluated for any unsafe conditions when penetrated by a sharp object(s). An unsafe condition includes but not limited to, (a) temperature above 170 oC (338 oF) on the surface of the battery case, (b) sustained flame and/or smoke generation, (b) violent reaction or (d) ejection of materials that present an unsafe condition to the user when tested as specified in 4.7.4.8. The battery shall not exhibit any of the aforementioned unsafe conditions for not less than two minutes after the penetration of the last object as required by the specific test. The results of this test shall support a hazard no higher than a MEDIUM risk IAW MIL-STD-882.

Add:

3.7.2.2.1 Overvoltage protection.

The battery shall withstand not less than 50V continuous both on the Nett Warrior connector and charge terminal contacts.

3.7.2.4 High temperature temporary cutoff devices.

Add: The quantity of thermoswitches shall be not less than 2. Certification is required

Add:

3.7.2.8 Safety, battery.

Add:

3.7.2.8.1 Nail penetration, battery.

When tested IAW 4.7.4.12, batteries shall be capable of safely withstanding penetration by sharp objects. Battery should continue to provide degraded operational capability after being punctured. However, if a cell in the battery is determined to have failed, charging shall be disabled and SOH should be reported as flashing “000.”

Add:

3.7.2.8.2 Protective devices.

The battery shall include protective devices/circuitry/material to prevent thermal event propagation between cells. Certification is required.

Add:

3.7.2.8.3 Weapons characterization.

Batteries shall be capable of safely withstanding penetration by bullets/projectiles and not have propagation to adjacent cells. Safety characterization tests shall be conducted in accordance with 4.7.4.13 and 4.7.4.13.1.

Add:

3.7.2.8.4 Battery safety protection circuits.

The battery shall include three (3) distinct and separate protective devices/circuitry/material to prevent improper charging, system overload, or system malfunction, disabling energy entry or exit as needed to prevent catastrophic outcomes. Batteries shall have a battery management system, no less than two FETS, a resettable and permanent fuse protecting all of the terminals. Certification required.

3.8 Electromagnetic compatibility.

Add: The battery shall be appropriately filtered and shielded to comply with the applicable emissions and susceptibility requirements of MIL-STD-461 Table V, Aircraft, Army, including Flight Line and as tailored herein. When tested as specified in 4.7.7 the batteries and system shall function properly.

3.9 Transportation requirements.

Delete and replace with “Batteries shall be prepared for shipping IAW UN ST/SG/AC.10/11 current revision of 49 CFR Parts 171, 172, 173, 175 Hazardous Materials: Transportation of Lithium Batteries.”

3.10 Interchangeability.

Add: Applicable “currently fielded” chargers are listed under 4.6.3

Add:

3.11 Systems level Integration

The battery shall be capable of supplying voltage (volts) as defined in Section 3.5.2 to a connected Nett Warrior system IAW with current (amps) requirements in Section 3.5.5. The batteries shall not prevent Air Worthiness Certification for Nett Warrior.

4. VERIFICATION

4.4 First article inspection.

Modify MIL-PRF-32383 sample sizes as defined below:

a. Group 1 (GR1) – Functional tests: increase sample size from 12 samples to 16 samples.

b. Group 2 (GR2) – Electromagnetic interference tests: decrease sample size from five samples to two samples.

Add:

e. Group 5 (GR5) – Nail penetration tests (battery level) and Weapons Characterization tests - sample size of 17 Replace Table IV with the following:

TABLE IV. First article tests, test each group in the order listed in the table.

Test Method

Samples or Group (GR)

(2 ea)

GR3

(8 ea)

GR4

(15 ea)

C

C

G

C

C

C

C

C

C,G

C

C

C

C

C,G

C,G

G

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C,G

C

C

C

C

C

C

C,G

C,G

C

C,G

C

C

C

C

C

C

C

C

G

G

C

(1) – Contractor(C) and/or Government (G) conducted test

4.4 Conformance inspection.

Sampling shall be conducted IAW MIL-STD- 1916.

4.5.1 Group A inspection.

Add: to TABLE V of MIL-PRF-32383 the following rows:

4.5.2 Group B inspection.

Remove: from TABLE VI of MIL-PRF-32383 the following rows:

Add: to TABLE VI of MIL-PRF-32383 the following rows (these additional tests shall be performed in the order listed below):

4.5.3.1 Group C frequency.

Add: to TABLE VII of MIL-PRF-32383 the following rows:

4.6.1 Constant potential, current limited.

Add: A constant potential of 16.8 volts or appropriate voltage requested via the SMBus interface shall be applied with current to up 7.5 amperes, to a charge cut off of 750 milli-amperes.

4.6.3 Alternate charging.

Add: The following chargers may be used whenever the requirement allows use of alternate charging:

4.7.1.3 Connector insertion test.

Add:

Mate and un-mate the connector with a plug having the 6-7 pin configuration. Perform a visual inspection on the plug and socket and verify no pins or sockets are crushed, recessed, or otherwise damaged. Batteries shall meet requirements in 3.4.4.1.1.

Add:

4.7.1.3.1 Nett Warrior connector disconnect pull force test.

a. Secure battery in a stationary holding device and grip the cable 6 to 12 inches away.

b. The grip should not slip or damage the cable during the test.

c. Apply a static force of between 20 and 25 pounds.

d. Verify that the quick disconnect breaks.

e. Perform a visual and mechanical examination in accordance with 4.7.1.1.

f. Repeat steps a-e with force between 8 and 10 pounds and verify item does not disconnect.

Batteries shall meet requirements in 3.4.4.1.1.1.

4.7.1.4 Flat terminal strength.

Add:

a. Secure battery in a stationary holding device and apply a point force with a 20 Lbs. force for 10 minutes to the center of the right most flat terminal.

b. Repeat step a for the 2nd contact.

c. Repeat step a for the 3rd contact.

d. Repeat step a for the 4th contact.

e. Visually inspect contacts to see that there is no deformation or separation of housing.

f. Conduct an 1 meter immersion of the battery for two hours. Verify that there was no ingress of water into battery.

Batteries shall meet requirements in 3.4.4.1.2.

Add:

4.7.1.8 Surface friction.

Verify battery surface is dry and free of any lubricants prior to test. Measure and report the coefficient of static friction per test method D2394 of ASTM G115-10, Standard Guide for Measuring and Reporting Friction Coefficients. Verify that the value is not greater than 0.4. Batteries shall meet requirements in 3.4.5.6.

4.7.2.3 Capacity discharge.

Replace: a. with: “Charge batteries IAW 4.6. Use of 4.6.3 is acceptable.”

Add: to c. Use a constant rate of 18 W.

Add: Press and release digital display actuator. Observe display and verify operability.

4.7.2.4 Cycle life test.

Delete 4.7.2.4 from MIL-PRF-32383 in its entirety and replace with the following:

4.7.2.4 Cycle life test.

a. Cycles 1 through 27 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Allow batteries to rest for not greater than one hour. Discharge at 18 W to cutoff voltage. Allow batteries to rest for not greater than one hour prior to the start of the next cycle. Every seventh cycle a rest of not greater than five hours is permitted before and after charge.

b. Cycle 28 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Perform the electric leakage test of 4.7.4.7d. Allow batteries to rest for not less than 4 hours. Discharge at 2A to cutoff voltage. Record battery capacity.

c. Repeat steps a through c above until the 224 cycles are obtained.

d. After completion of the cycle life test, visually examine batteries for the criteria of TABLE VIII. Batteries shall meet the cycle life and visual mechanical requirements (see 3.1 and 3.5.3)

4.7.2.9 Charge acceptance.

Modify MIL-PRF-32383 as defined below:

- Change Step C to “Charge batteries with a Smart Battery Specification compliant charger.”

- Change the temperature in Step F from 50°C to 55°C.

4.7.2.11 Pulse discharge.

Add: Discharge at 5 A for 5 seconds, rest for 25 seconds. Continue discharge to final voltage

4.7.2.14 State-of-charge indicator.

Delete 4.7.2.14 from MIL-PRF-32383 in its entirety and replace with the following:

4.7.2.14 Digital display characteristics.

The following test shall be performed.

a. Charge each battery in accordance with 4.6; use of 4.6.3 is permitted.

b. Verify location and marking of the digital display indicator is in accordance with 3.5.8.

c. Press and release the digital display actuator.

d. Measure and record the following to the nearest tenth of a second: (1) time from actuation to full intensity of the lights or digital display; (2) time from reaching full intensity until the lights extinguish; and (3) the total time from actuation until the lights extinguish.

e. Measure displacement and resistance values for the actuator and record the results.

f. Press each sample against a flat, transparent surface with not less than 5 lbs. of force, with the face including the actuator against the surface.

g. Observe whether or not the display illuminate in accordance with 3.5.8; record and verify the response(s) as applicable.

h. Discharge batteries at the C/10 rate as follows: one battery at −10 ± 2ºC (+14ºF) and one at 55 ± 2ºC (130ºF).

i. Continuously discharge batteries to the following approximate states of charge, stopping the discharge at each state: 90%; 70%; 50%; 30%; 10%.

j. Obtain the digital display readings while the test battery is not subject to discharge. For each of the states of charge states in (i), observe the indication of the state of charge indicator, read the SMBus data output, and record both indications after each partial discharge. Environmental chambers may be paused or shut off while accessing batteries to obtain the digital display readings. For samples tested at −10°C, care is needed to limit the freezing of condensation at the battery to test circuit interface.

k. Once the digital display readings have been obtained, restart the environmental chamber and restart the discharge in not less than 15 minutes after return to the required test temperature (for samples tested at −10°C, allow sufficient time to clear the frost if condensation has frozen on batteries).

l. Discharge the batteries to final voltage.

m. Observe the indication of the state of charge indicator, read the SMBus data output, and record the indications. Batteries shall meet the requirements of 3.5.8.

n. Begin charging each battery in accordance with 4.6; use of 4.6.3 is permitted. Charge one battery at −10 ± 2ºC (+14ºF) and one at 55 ± 2ºC (130ºF).

o. Within 5 minutes from the start of charging, record the digital display Run Time to Full indication for each battery.

p. Allow charging to complete and record the total time for charging to complete for each battery.

q. Compare the values in steps o and p and verify they are within 20% of one another.

r. Discharge batteries at the 18W rate as follows: one battery at −10 ± 2ºC (+14ºF) and one at 55 ± 2ºC (130ºF).

s. Within 5 minutes from the start of discharge, record the digital display Run Time to Empty indication on each battery.

t. Allow discharge to complete and record the total time for the discharge for each battery.

u. Compare the values in steps s and t and verify they are within 20% of one another.

4.7.2.15 SMBus.

Add: Connect two 20-inch Nett Warrior C1 or two equivalent cables in series for a total length of 40 inches to the Nett Warrior connector. Connect the other end of the cable to the current Nett Warrior End User Device (EUD) with Hub and verify that the SMBus data is accuratly displayed on the EUD.

The following test shall be performed.

Battery shall meet requirements in 3.5.9.

Add:

4.7.2.16 Concurrent charge / discharge.

Perform the following charge & discharge tests. Verify that no charge condition or battery failure occurs:

a. Test A. Connect a 100% SOC battery to a 2 Amp load at pin 1 of the battery Nett Warrior connector. Apply a 16.8 VDC 1 Amp current limited supply at pin 3 of the battery Nett Warrior connector. Allow charge to continue for 2 hours at room temperature. Verify that for 2 hours that the battery does not take in a charge current less than 0.95 Amps at pin 3 and that the battery SOC is not less than 80% (+0/-5%).

b. Test B. Connect battery from Test A to a 1 Amp load at pin 1 of the battery Nett Warrior connector. Apply a 16.8 VDC 2 Amp current limited supply at pin 3 of the battery Nett Warrior connector. Allow charge to continue for 2 hours at room temperature. Verify that after 2 hours the battery does not take in a charge current greater than 1.0 Amps at pin 3 and that the battery SOC is greater than 90%. Continue charge/discharge conditions for another 4 hours and verify that the battery SOC is at 100% and verify that SMBus current never exceeds 0 Amps.

c. Test C. Connect a 90% SOC battery to a 0.9 Amp load at pin 1 of the battery Nett Warrior connector. Apply a 16.8 VDC 1 Amp current limited supply at pin 3 of the battery Nett Warrior connector. Allow charge to continue for 2 hours at room temperature. Verify that after 2 hours the battery SOC is equal to or greater than 90%.

d. Test D. Connect a 100% SOC battery to a 2 Amp load at pin 1 of the battery Nett Warrior connector. Apply a 16.8 VDC 1 Amp current limited supply at the Charge + flat terminal contact of the battery. Allow charge to continue for 2 hours at room temperature. Verify that for 2 hours that the battery does not take in a charge current less than 0.95 Amps at the Charge + flat terminal contact and that the battery SOC is not less than 80% (+0/-5%).

Batteries shall meet requirements in 3.5.11.

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4.7.2.17 USB power port connector(s).

Verify that the USB Socket output is compliant to the USB BC1.2 specification by performing the steps of USB Battery Charging 1.2 Compliance Plan, Section 8 (Dedicated Charging Port Compliance). Verify that the USB port can provide a minimum of 1.5 Amps at 5 VDC and that this is provided concurrently with an 18W load on the Nett Warrior connector. Batteries shall meet the requirements in 3.4.4.1.5.

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4.7.3.7.1 Vibration, loose cargo transportation.

Charge batteries in accordance with 4.6; use of 4.6.3 is permitted. Batteries shall be subjected to loose cargo testing in accordance with MIL-STD-810 Method 514 Procedure II for not less than 20 minutes duration. Batteries shall initially be placed stacked one on top of another in the battery tester with no other equipment present. After Step 4 of Procedure II, proceed to Step 9. Batteries shall meet the requirements of para 3.5.3.

4.7.3.8.1 Immersion, shallow.

Delete MIL-PRF-32383 4.7.3.8.1 in its entirety and replace with the following:

4.7.3.8.1 Immersion, shallow.

Test batteries in accordance with MIL-STD-810, Method 512, Procedure I. The test samples shall be fully charged and configured as follows: half of the batteries in operating configuration (with sealed mating Nett Warrior connector attached to 18 W load) and the other half of the batteries in transport configuration (i.e. connector unmated). Note, cleaning procedures allowed in accordance with Appendix B for systems under test without connector attached are allowed post immersion. Duration shall be for a minimum of 2 hours immersion at 1 meter each test.

The USB shall be unmated during the conduct of the test.

The USB shall be uncovered during the conduct of the test.

For Step 6, use a duration of 2 hours in saltwater per ASTM D-1141.

During the immersion period verify that the batteries provide a constant 18 W to the load for the connected (mated) CWBs.

For Step 9, conduct Capacity Discharge Test in 4.7.2.3. Note, immersion testing shall be conducted post other battery stress testing such as drop or flexibility as required here for test sequences. Batteries shall meet the requirements in 3.6.6.

For Group A testing ONLY; duration shall be for a minimum of 30 minutes at 1 meter each test, with the battery temperature 20°C above the water temperature. For step 9 of MIL-STD-810, Method 512, Procedure I, perform the battery open circuit voltage check according to 4.7.2.2, as well as demonstrating the USB port(s) voltage is 5.0V±0.25V. Batteries shall meet the requirements in 3.6.6.

4.7.3.8.2 Immersion, deep.

Delete 4.7.3.8.2 from MIL-PRF-32383 in its entirety.

4.7.3.9.2 Transit drop, severe.

Modify MIL-PRF-32383 delete steps a-e and replace with the following:

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted and verify that the State of Charge Indicators are properly functioning.

b. Replace “height not less than 30 inches onto cured concrete” with “height not less than 48 inches onto surface specified in MIL-STD 810 Method 516 Procedure IV”

c. Perform drops 1 – 10 in Table IX on unmated batteries.

d. Verify that here are no indications of potential start of structural or mechanical damage that could further lead to system failures. At a minimum verify each battery with visual inspection of battery skin, contact terminals, Connectors, and digital display indicators for any physical damage, also verify that capacity meets that of section 3.5.3.

Batteries shall meet requirements in 3.6.7.

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4.7.3.11 Impact.

The following test shall be performed:

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted and verify that the State of Charge Indicators are properly functioning.

b. Place the battery on an ESAPI side plate backed by a sandbag.

c. Drop a 16 lb. Professional Bowlers Association (PBA) certified bowling ball or equivalent from not less than 36 inches onto the center-point of the battery +/-one inch.

d. Repeat step c for the left and right sides of the horizontal centerlines of the battery not less than one half inch and not greater than two inches from the edge.

e. Perform the capacity discharge of 4.3.7.2 and verify that capacity is not below that of 3.5.3 for Capacity Discharge minimum.

f. Verify each battery with visual inspection of battery skin, contact terminals, Connectors, and digital display indicators for any physical damage, Batteries shall meet the requirements of 3.5.3, 3.6, and 3.6.9.

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4.7.3.12 Flexibility test.

The following test shall be performed. Refer to Figure 5.

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

b. Soak the battery for not less than four hours at not less than -20oC.

c. Place the battery in a fixture which allows the center of the battery to bend while holding the edges. The edges can pivot in the direction of the bend.

d. At a distance equidistant between the centerline edges of the battery provide sufficient force to move the battery up and down 1 inch in each direction 200 times. One flex consists of an upward and a downward motion.

e. Rotate the centerline of the battery 90 degrees in the fixture.

f. Repeat step d.

g. Soak the battery for not less than four hours at not less than 60oC.

h. Repeat steps c through f.

i. Verify proper digital display functionality with 4.7.2.14. Charge battery IAW 4.7.2.6

j. Verify each battery with visual inspection of battery skin, contact terminals, Connectors, and digital display indicators for any physical damage.

Batteries shall meet the requirements of 3.5.3, and 3.10

FIGURE 5 Battery Flexibility Note: Figure not to scale

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4.7.3.13 Solar radiation.

Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted and verify that the State of Charge Indicators are properly functioning. The following test shall be performed. Test batteries per MIL-STD-810, Method 505, Procedure II using the spectral power distribution below for seven days. Position one battery with the front face up and one battery with the front face down Wind speed shall be sufficient to maintain the battery surface temperature below 75⁰C. Below 65°C surface temperature wind speed shall be 0 mph. Batteries shall meet the requirements of 3.6.11 and 3.5.

Spectral power distribution

Spectral Region

Bandwidth (nm)

Natural Radiation (% of total)

Tolerance (% of total)

Irradiance (W/m2)

Spectral Region Irradiance (W/m2)

Ultraviolet - A

62.7

Visible

580.2

4.7.3.14 Salt fog.

The following test shall be performed. Test batteries per MIL-STD-810, Method 509 for four 24 hour cycles alternating 24-hour periods of salt fog exposure and drying conditions for a minimum of four 24-hour periods (two wet and two dry). The water used for the saltwater solution shall have a resistivity of not greater than 5 mega-ohms per cm. The battery shall meet the requirements of 3.6, 3.6.12, and 3.5.3. Note, posttest battery cleaning is allowed as described in accordance with Section 6 notes - Appendix B for cleaning of an unconnected, un plugged - unprotected power connector, prior to the verification of the requirements of 3.5, 3.6.12, and 3.5.3

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4.7.3.15 Electrostatic discharge (ESD).

Charge batteries in accordance with 4.6; use of 4.6.3 is permitted. Subject the batteries to both the contact and air discharge test of IEC 61000-4-2, Level 4, to include each contact (both charge and main connector), connector shield, battery case, seams, and the digital display. The battery shall be tested with no load and under an 18 W load. Verify that a load of 18 W can be sustained for 1 minute following the test. Fully charge the battery via the SMBus and perform the discharge test of 4.7.2.3 once with the primary connector and once with the bottom charge contacts. The battery shall meet the requirements of 3.5, 3.6.13, and 3.5.3.

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4.7.3.16 Conformability.

An Electrical Mechanical (EM) load frame equipped with a reversible load cell (capacity not to exceed 200 lb-f) shall be used to measure the compressive force required to conform the battery to the 7 inch radius curved surface. Refer to Figure 6.

FIGURE 6 Conformability test fixture Note: Figure not to scale.

Battery primary side will be with the power connector positioned in the upper left corner coming out the left side and charge contacts coming out the bottom (refer to FIGURE 7). Top to bottom will be considered the vertical axis and left to right the horizontal axis. The other side of the battery will be the secondary side.

The following test shall be performed: The rollers shall roll freely on the battery while the upper fixture moves vertically downward. The rollers shall be spread at a fixed distance when the battery is centered over the lower fixture to minimize friction as it curves the battery.

a. Ensure that the batteries are not tested in a prior conformed, pre-stressed condition, each battery shall be placed on a flat surface between each compressive trial to allow it to return to a flat condition.

b. Center the upper fixture above the lower fixture.

c. Place the battery on the center of the lower fixture, oriented primary side (power connector to left and contacts out of front of the fixture) along the vertical axis.

d. Move the upper fixture to just above or to touch the battery.

e. Ensure that the rollers are within ½ inch of the edges of the battery (+/- ¼ inch).

f. Once the battery is in position for test, allow no than 1 minute time to start test. Note: Battery relaxation may start and roller contact may be lost when the battery is placed on curved surface for an excessive amount of time.

g. Perform test by lowering the upper fixture with a compressive cross head rate of 2 inches per minute.

h. Record load, displacement, and time measurements at a data acquisition rate of 100 ms.

i. Stop the test when the compressive load threatens to crush the battery.

j. Remove the tension of the upper fixture and lay the battery down flat on a table for 2 minutes between each measurement.

k. Repeat steps b. through i. in each of the other three orientations (secondary side horizontal axis, primary side horizontal axis, and secondary side vertical axis) and record data for each orientation. Each test set shall be performed by alternating the battery orientation after each measurement.

l. Repeat the same procedure for each orientation a total of five (5) times for a total number of 20 runs for the battery.

Verify batteries meet requirements of 3.6.14.

Verify discharge capacity as part of 4.7.2.3.

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4.7.3.17 Chemical resistance.

Batteries shall be sprayed separately with each of the following substances below. The substance shall cover not less than 50% of the surface area of the battery and include portions of all seams, digital display, vent, label, charge terminal contacts, and connector.