PD-133.pdf

NAVSUP WSS PD-133

17 March, 2014

PURCHASE DESCRIPTION/SPECIFICATION

BATTERY, STORAGE

(LEAD ACID, INDUSTRIAL PORTABLE SERVICE)

1. SCOPE AND CLASSIFICATION

1.1 Scope. This specification covers industrial batteries and cells for those batteries of the lead-acid type, both flooded and VRLA (absorbed glass mat (AGM) and Gel types), for use in electric fork trucks, electric tractors, electric platform trucks and electric pallet trucks.

1.2 Classification. Individual storage batteries, as covered by this specification, shall be of the type E

(general) for shore base FLTs, EE (spark enclosed) for shore base or shipboard FLTs or EX (explosion proof) shore base or shipboard FLTs . Batteries shall either be Flooded or VRLA.

This should be reflected in 6.2.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification.

This section does not include documents 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 documents cited in sections

3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications and standards. The following specifications and standards form a part of this document to the extent specified herein. Unless otherwise indicated, the issues of these documents are those listed by the Standardization Document Order Desk.

SPECIFICATIONS

FEDERAL

O-S-801 - Sulfuric Acid, Electrolyte; for Storage Batteries.

PPP-B-140 - Batteries, Storage, Industrial, Packaging of

NAVSUP WSS-PD-133

MILITARY

MIL-S-901 - Shock Tests, H.I. (High Impact); Shipboard Machinery, Equipment, and Systems, Requirements for, STANDARDS

MILITARY

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

Subsystems and Equipment

MIL-STD 810 -Environmental Engineering Considerations and Laboratory Tests

(Unless otherwise specified, copies of military specifications and federal standards are available from the Standardization Document Order Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, http://www.dodssp.daps.mil, Phone (215) 697-2667. Electronic copies of standards may be obtained from http://assist.daps.dla.mil)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless a specific issue is identified, the issue in effect on the date of invitation for bids or request for proposal shall apply.

BATTERY COUNCIL INTERNATIONAL (BCI)

BCIS-02 – Recommended Test Procedures for Battery Materials Specifications, Vehicular, Ignition, Lighting and Starting Types.

BCIS-10 – Recommended Practices for Warning Messages, General Labeling & Marking –

Shipping & Packaging.

BCIS-17 - Procedures for Evaluating Plastic Jars and Covers for Motive Power Industrial

Batteries.

(Copies of BCI standards may be obtained from the Battery Council International, 401 North

Michigan Avenue, 24 th

Floor, Chicago, IL 60611.)

SOCIETY OF AUTOMOTIVE ENGINEERS, INC. (SAE)

http://www.dodssp.daps.mil/ http://assist.daps.dla.mil/

SAE J 551-1 - Performance Levels and Methods of Measurement of Electromagnetic

Compatibility of Vehicles, Boats (up to 15 m), and machines (16.6 Hz to 18 GHz).

(Application for copies should be addressed to: Society of Automotive Engineers, 400

Commonwealth Drive, Warrendale, Pennsylvania 15096)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein the text of this document shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), a sample shall be subjected to first article inspection in accordance with 4.2.

3.2 Materials. The contractor shall select the materials, but the materials shall be capable of meeting all of the operational and environmental requirements specified in BCIS-02.

3.3 Warning labels. The warning labels shall be in accordance with manufacturer's standard practice and comply with BCIS-10.

3.4 Cell.

3.4.1 Element. The design of the element shall ensure that the cell meets the specified electrical requirements.

3.4.2 Grids. The grids shall be made of a suitable lead alloy.

3.4.3 Workmanship. The active material shall be free from breaks and loose parts. The grids shall be free of open sections, cold pouring, cracks, and blowholes. Breaks are permitted in those parts of the grid used to retain the active material only when the break does not impair the strength of the grid or permit the active material to become separated from the plate. The sections of the element involving lead burning shall be free from defective bonds.

3.5 Electrolyte (Flooded). The specific gravity of the electrolyte shall be within the range shown on the battery nameplate or in the manufacturer's published instructions. The electrolyte shall be in accordance with O-S-801. Except for organic matter, the values of the impurities shall be determined by any recognized analytical test method. The organic matter shall be determined in accordance with paragraph 4.5.6.1.

3.6 Terminal markings. The polarity of the positive terminal shall be permanently marked "POS", "P", or

"+". The negative terminal shall be marked "NEG", "N" or "-". In addition, colors may be used on the terminals; red for positive and black for negative.

3.7 Connectors. The battery interface cable and connector shall be of sufficient size to handle a continuous current, in amperes, equal to one fifth of the battery ampere-hour rating. Cable, cell, and terminal connectors, other than exposed lead parts, shall be protected against corrosion. The type of connector shall be type “Euro Connector” unless otherwise specified by paragraph 6.2. The connector position and lead length shall be specified in 6.2.

3.8 Jars. Jars shall be of single cell or multi-cell construction. The material shall be commercially acceptable and free of rough spots, pinholes, or cracks. When subjected to the electrical breakdown test in

4.5.5, there shall be no evidence of perforation or burn through.

3.8.1 Impact resistance. The impact resistance of sample pieces cut from single cell and multi-cell jars shall be 120 inch-pounds minimum, when tested in accordance with 4.5.3.

3.8.2 Sediment space. Jars shall have sufficient sediment space to minimize contact between the sediment and element that may cause a short.

3.8.3 Space above element. The space above the element shall be in accordance with commercial practice.

3.8.4 Acid-resistance. The jars and covers shall not absorb an excessive amount of electrolyte, when tested in accordance with 4.5.4. The material shall not comply if the increase in weight exceeds 1.5 percent, if visible blisters or cracks are found, or if the dimensions are increased 2.0 percent or more.

3.9 Cell covers. The cell cover shall be compatible with the jar. The design of the cover shall prevent distortion of the cover and leakage of electrolyte when the cell is operated in accordance with the manufacturer's instructions.

3.9.1 Vent caps. Suitable baffling shall be provided in the cell or vent to avoid spraying and minimize loss of electrolyte while permitting gas to escape during charging, discharging, or open circuit.

3.9.2 Seal. The joint between the cover and jar shall be gas-tight and effectively seal against leakage of electrolyte. An unbroken seal between the cover and jar shall be maintained throughout a temperature range of 0 degrees F (-18 degrees C) to +140 degrees F (+60 degrees C).

3.10 Trays. The tray must have the ability to be bolted into the fork lift truck, electric pallet jack, Reach & tier, etc for shipboard batteries. Trays shall be of suitable strength, construction, and material, for the intended service and equal to the manufacturer's standard product. All surfaces of metal covers and lifting means and all exposed vertical surfaces of metal trays shall be protected against exposure to sulfuric acid.

3.10.1 Battery tray covers. Covers, required for shipboard batteries and when requested, which weigh in excess of 35 pounds shall be provided with dual handles allowing personnel simultaneous lifting capability.

The cover shall be capable of being bolted shut and have a tab for locking.

3.10.2 Hinges. Hinges shall contain a nylon sleeve to prevent rust and corrosion

3.11 Assembly.

3.11.1 Cells. Cells shall be furnished as single cells or complete batteries, as specified in the invitation for bid or order.

3.11.2 Batteries. The battery shall be of standard groupings, dimensions, and connections and include a charging plug, receptacle or Euro Connector connection. Batteries shall conform to dimensional limitations specified (see 6.2). Cell connectors shall be burned (fused together) or bolted to the terminals and be adequate to carry the rated current.

3.12 Weight. The actual weight of the trayed battery shall be permanently stamped into the wall of the tray near one of the lifting points as "SERVICE WEIGHT-_____LBS" in upper case letters. This weight shall be as specified by the equipment manufacturer of the applicable forklift truck.

3.13 Charge condition . As specified in the solicitation (see 6.2), cells or batteries shall be shipped either charged-and-wet or charged-and-dry. When the purchaser does not specify, batteries shall be shipped charged-and-wet and ready for service.

3.13.1 Charged-and-wet. Batteries shall be shipped filled with electrolyte of proper specific gravity. After receipt and equalized/topped off, according to the manufacturer’s instructions, batteries shall be required to deliver 90 percent of their rated capacity on or before the third cycle. Reference 3.16.1.

3.13.2 Charged-and-dry (Flooded). Batteries intended for storage in the charged-and-dry condition within the time limit specified by the manufacturer, shall contain a dry element. When necessary to prevent deterioration of the element due to exposure to moisture, vents shall be sealed. When filled with electrolyte, according to the manufacturer's instructions, batteries shall be required to deliver 90 percent of their rated capacity on or before the third cycle when conditioned in accordance with manufacturer's instructions.

Reference 3.16.1.

3.14 Markings. Batteries shall be legibly and permanently marked with the following:

(a) Name or trademark of the manufacturer.

(b) Manufacturer's designation.

(c) Six-hour ampere capacity rating in ampere hours.

(d) Month and year of manufacture. (must state explicitly month and year not in a serial number)

(e) Service weight of battery.

(f) Specific gravity of electrolyte (Flooded) in fully charged condition.

(g) Warning labels.

(h) The words "SHOCK HARDENED" when battery is required to meet HI shock requirement (see

6.2).

(i) Battery voltage

The data plate shall be metal and mechanically affixed or epoxied to the top/lid. (e) & (h) shall be stamped in/on case in addition to being stated on the data plate.

3.15 Instructions . Each battery shall have a set of instructions for the proper installation and maintenance of the battery, including cycling characteristics. Pertinent data shall identify the battery with relation to type, size, and manufacturer. The instructions shall be hand held and for filing/reference.

3.16 Performance.

3.16.1 Rated capacity. After conditioning in accordance with manufacturer's instructions, cells or batteries shall have not less than 90 percent of their rated ampere-hour capacity (see 6.2), at the end of the third cycle, when tested in accordance with 4.5.1. The number of cycles necessary to deliver 100 percent of the manufacturer's rated capacity shall not exceed 10.

In lieu of performing the as stated requirements in Test Method 1 (see A.3) , automatic testing with printed test results can be substituted as long as the automatic tester meets the same requirements and performs the same actions as the following example tester.

Example: Battery Test inc. tester model: MCBA200-18D.

3.16.2 Life cycle capacity. Each cell of a new battery shall deliver a minimum of 80 percent of its rated 6-hour ampere-hour capacity throughout its life when tested in accordance with 4.5.1.

3.16.3 Cycle life.

A: FLOODED - The cell or battery shall complete a minimum of 1,500 cycles when tested in accordance with 4.5.7. The cells or batteries tested shall be representative of the range of capacities of the cells or batteries produced.

B: VRLA - The cell or battery shall complete a minimum of 1,100 cycles when tested in accordance with

4.5.7. The cells or batteries tested shall be representative of the range of capacities of the cells or batteries produced.

If the proposed battery/battery design maintains the same cell structure/design as those previously used/qualified the manufacture can contact

Attn:

NAVSUP WSS MHE Program Office

Code N954, Bldg 410

5450 Carlisle Pike, P. O. Box 2020

Mechanicsburg PA 17055-0788 and request historical usage data for cell performance. Please reference the purpose of the call and this specific section of the PD upon making the request.

3.16.4 Retention of charge.

3.16.4.1 FLOODED Single cells or cells of a battery shall not show a drop in specific gravity greater than 0.015 units in 14 days, when tested in accordance with 4.5.2.1

3.16.4.2 VRLA Single cells or cells of a battery shall show no more than 0.03 volts per cell voltage drop in 14 days, when tested in accordance with 4.5.2.2

3.16.5 H.I. (High Impact) Shock requirement. [SHIPBOARD Battery] When battery is specified to meet the H. I. shock requirements of MIL-S-901 (see 6.2), it shall be designed to be a Grade A item when tested in accordance with 4.5.10. Previous successful testing may be deemed to be evidence of compliance with requirements unless manufacturing specs/processes have changed. Testing can be accomplished in either of the following two ways:

a. Heavy Weight with the battery installed in an electric forklift mounted on a large floating shock platform in accordance with 4.5.10.1.

b. Medium Weight with the battery installed on a medium weight shock machine in accordance with 4.5.10.2.

3.16.6 Electromagnetic interference (EMI) characteristics. [SHIPBOARD Battery] When required (see

6.2), batteries and battery leads shall be shielded as necessary to meet EMI characteristics required of trucks on which batteries are mounted while trucks are in operation. Test for this requirement shall be in accordance with 4.5.8. Previous successful testing may be deemed to be evidence of compliance with requirements unless manufacturing specs/processes have changed. General purpose (Shorebased) trucks with battery shall be suppressed in accordance with SAE J 551-1. Shipboard trucks shall comply with MIL-

STD-461. For radiated emissions, procedure RE102 shall be used with limits shown in RE 102-1 over a frequency range of 10 KHZ to 1 GHZ. For susceptibility to electric fields, procedure RS103 shall apply with a frequency range from 10 KHZ to 1 GHZ at a limit level of 10 Volts/Meter. EMI test shall precede test of

4.5.9.

3.16.7 Resistance to saline corrosion. [SHIPBOARD Battery] When required (see 6.2), battery shall show no evidence of corrosion or inability of cover(s) to open and close when battery is tested in accordance with 4.5.9. Previous successful testing may be deemed to be evidence of compliance with the requirements of 4.5.9 unless manufacturing specs/processes have changed.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3).

4.2 First article inspection. First article inspection shall be performed on one complete battery when a first article sample is required (see 6.2). This inspection shall include the examination of 4.4 and the tests of 4.5.1 through 4.5.8. In addition, the tests of 4.5.9.and 4.5.10 are required for shipboard batteries.

4.3 Conformance inspection. Conformance inspection shall include the examination of 4.4.

4.4 Examination. Each battery shall be examined for compliance (visually or via design dwg/BOM)

[ex - 3.4.1, 3.4.2, 3.8.2 and 3.11.1via design dwg] with the requirements specified in 3.4.1, 3.4.2, 3.6, 3.7, 3.8, 3.8.2, 3.8.3, and 3.9 through 3.15.

Any redesign or modification of the contractor's standard product to comply with specified requirements, or any necessary redesign or modification following failure to meet the specified requirements shall receive particular attention to adequacy and suitability. This element of inspection shall encompass all visual examinations and dimensional measurements. Noncompliance with any specified requirements or presence of one or more defects preventing or lessening maximum efficiency shall constitute cause for rejection.

4.5 Tests.

4.5.1 Capacity test. To determine compliance with 3.16.1 and 3.16.2, cells or batteries shall be subjected to capacity tests in accordance with Test Method No. 1( see A.3).

4.5.2 Retention of charge test

4.5.2.1.1 FLOODED To determine conformance with 3.16.4.1 the cells or batteries shall be fully charged with the specific gravity of each cell corrected to 77 degrees F (25 degrees C). The cell or battery shall then be allowed to stand on open circuit in an ambient temperature of 75 to 90 degrees F (24 to 32 degrees C) for a period of 14 days. At the end of the 14-day period, the specific gravity shall be measured and corrected to 77 degrees F (25 degrees C).

4.5.2.1.2 VRLA To determine conformance with 3.16.4.2 the cells or batteries shall be fully charged.

The cell or battery shall then be allowed to stand on open circuit in an ambient temperature of

75 to 90 degrees F (24 to 32 degrees C) for a period of 14 days. At the end of the 14-day period, the battery shall show no more than 0.03 volts per cell voltage drop.

4.5.3 Impact resistance. To determine conformance with 3.8.1, samples from jars shall be tested in accordance with BCIS-17. The area of impact shall be the geometric center of the test specimen.

4.5.4 Acid-resistance test. To determine conformance to 3.8.4, jars and covers shall be tested in accordance with BCIS-17.

4.5.5 Electrical breakdown test. To determine conformance with 3.8, jars shall be tested in accordance with BCIS-17. The voltage applied shall be 100 volts per mil of wall thickness or 15,000 RMS volts, 60 HZ

AC whichever is greater.

4.5.6 Electrolyte (Flooded). The impurity values specified in O-S-801 (except organic matter) shall be determined by any recognized analytical test method (see 3.5).

4.5.6.1 Organic matter(Flooded). Heat 200 ml of electrolyte in a clean beaker until the acid begins to fume strongly. To pass the test, there shall be no perceptible charring; a slight yellow color that appears when the acid is hot but disappears on cooling should be disregarded.

4.5.7 Cycle life. To determine conformance with 3.16.3, the cycle life shall be determined in accordance with Test Method No. 2.

Or

If the proposed battery/battery design maintains the same cell structure/design as those previously used/qualified the manufacture can contact

Code N954, Bldg 410 and request historical usage data for cell performance. Please reference the purpose of the call and this specific section of the PD upon making the request.

4.5.8 Electromagnetic Interference. To determine compliance to 3.16.6, a battery shall be tested in accordance with MIL-STD-461 or SAE J 551-1 (see 6.2). Test shall precede test of 4.5.9 when applicable.

4.5.9 Resistance to saline corrosion. When required (see 3.16.7), the entire battery or, at the option of the supplier, a scale model or sample shall be tested in accordance with Salt Fog, Method 509 of MIL-STD 810.

The scale model or sample, if tested, shall include material and surface treatment of the designed battery tray, shielded leads and connector, cover and fastener or hinge to be supplied as the production item.

Electrolyte, plates, grids and jars are not required during this test. Pursuant to paragraph 4 of Method 509, the following details are designated:

(a) Upon visual inspection, test item is required to be free of corrosion; cover shall be capable of opening and closing the same as before the test.

(b) 5-Percent.

(c) Mount heavy test item on wood blocks or suspend light test item by cord or hook. In either case, hinge or fastener shall be in plane 30 degrees from vertical and exposed to the falling droplets.

(d) 72 hours.

(e) 168 hours. Test item shall be dried at room temperature while loosely covered with clear plastic to retard drying.

(f) Visual inspection only after 24 hours and 72 hours of exposure. No washing or operation prior to completion of 72 hours exposure and 168 hours drying."

4.5.10 H.I.(High Impact) Shock. When the battery is specified to be designed to meet H.I. Shock requirements (see 6.2), prior to the start of production a battery shall be tested by the contractor in accordance with MIL-S-901. The contractor shall locate a non-government shock test facility, arrange the test, and pay for the test. Testing can be accomplished in either Heavy Weight with the battery installed in an electric forklift mounted on a large floating shock platform or Medium Weight with the battery installed on a medium weight shock machine.

4.5.10.1 Heavy Weight. Pursuant to 6.2 of MIL-S-901 the following ordering data shall apply to the test battery installed as a component of the truck which shall be mounted on the floating shock platform during test and to the batteries furnished by the supplier:

(a) "Shock Tests; H.I. (High Impact); Shipboard Machinery, Equipment and Systems, Requirements for”

(b) Issue of the ASSIST Database shall be the issue in effect on date of invitation for bids or request for proposals.

(c) Grade A shock-proofness required.

(d) Each battery is required to meet Class I on a truck which is Class I, modified. The modification is that the truck rests on solid rubber or polyurethane tires which are similar in action to some resilient mountings.

(e) Type A test in which the truck is the principal unit and the battery is a subsidiary unit.

(f) The battery is mounted in truck which is deck mounted.

(g) The battery is mounted in truck which is base mounted.

(h) The battery is mounted in truck which has unrestricted orientation.

(i) The truck with battery installed shall be secured to the deck simulator of the floating shock platform with tiedowns furnished by testing laboratory. The battery shall be secured to the truck in accordance with method used at the time the truck was tested in compliance with MIL-S-901.

(j) N/A

(k) The truck shall not be operated during the shocks, but it shall be operated briefly through each performance characteristic after each shock.

(l) Following the explosion of the depth charge at 20-feet standoff, the battery shall successfully demonstrate the ability to operate the truck. Minor permanent deformation of battery components and minor loss of electrolyte from splashing are permitted. Cracked or leaking cells, fractured intercell connectors, major loss of electrolyte, or failure to power the truck in accordance with (k) shall constitute failure of the battery to meet the H.I. Shock requirement. Failure of the truck to comply with (k) from causes not attributed to the battery shall not be regarded as failure of the battery to meet the H.I. Shock requirements.

Post shock inspection shall confirm that the battery can still reach 100% of its rated capacity as defined in 3.16.1 when recharged in accordance with the manufacturer’s recommendations.

(M) Acceptance authority is

Code N954, Bldg 410

4.5.10.2 Medium Weight. Pursuant to 6.2 of MIL-S-901 the following ordering data shall apply to the test battery furnished by the supplier:

(a) "Shock Tests; H.I. (High Impact); Shipboard Machinery, Equipment and Systems, Requirements for”

(b) Issue of the ASSIST Database shall be the issue in effect on date of invitation for bids or request for proposals.

(c) Shock Grade - Grade A

(d) Class - Class I.

(e) Equipment Classification – Subsidiary Component

(f) Test Type – Type B

(g) Test Classification – Medium Weight

(h) Mounting – Deck Mounted

(i) Mode of Operation – Test Energized Mode

(j) Testing – A total of nine hammer blows, consisting of three groups of three each, will be applied.

The first group of three blows will be applied with each cell mounted in the normal horizontal orientation. The second group of three blows will be applied with each cell inclined 30 degrees. The third group of three blows will be applied with each cell inclined 30 degrees, as in the second group, rotated 90 degrees on the 30 degree incline. The height of the hammer drop will be determined by the total mass on the anvil table of the medium weight shock machine and will be in conformance with Table I of MIL-S-901 with group numbers I, II, III corresponding to the three blows of each orientation.

(k) Inspection – Each battery will be inspected for breakage and deformation after each shock blow.

Cracked or leaking intercell connectors, major loss of electrolyte, or failure of power as evidenced by the monitored circuits shall constitute failure of the battery to meet high impact shock requirements.

(l) Acceptance – Compliance with Grade A, Type B, Class I requirements and successful completion of post-shock functional testing disassembly inspection under cognizant authority will constitute successful completion of the high impact shock tests on the cells.

(m) Acceptance authority is:

Code N954, Bldg 410

5. PACKAGING

(a) If the subject solicitation contains clauses FAR 52.223-3 “Hazardous Material Identification and

Material Safety Data” and DFARS 252.223-7001 “Hazard Warning Labels” the issuer is required to list any hazardous material to be delivered under the resultant contract by the submission of Material

Safety Data Sheets (MSDSs) to the Contracting Officer prior to award. A copy must also be provided to NAVICP, Code 0772, P.O. Box 2020, 5450 Carlisle Pike, Mechanicsburg, PA 17955-

0788 or via FAX number 717-605-3480.

(b) The packaging, packing, marking, labeling and certification of hazardous materials (HAZMAT) to be shipped by any mode or combination of modes shall comply with all requirements of the applicable modal regulation(s) selected for shipment (e.g. 49 CFR).

(c) Under no circumstances shall the contractor knowingly use materials, marking or procedures that are not in accordance with the laws and regulations applicable to the mode of transportation employed.

6. NOTES

(This section contains information of general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. The flooded and valve regulated lead acid batteries covered by this specification are intended for use in electric fork trucks, electric tractors, electric platform trucks and electric pallet trucks.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. Type of battery required (see 1.2);

E (general) shore base, EE (spark enclosed) shore base/shipboard

EX (explosion proof) shore base/shipboard

c. Flooded or VRLA (see 1.2)

d. Voltage, ampere-hour capacity, number of cells, overall dimensions (L x W x H) and weight shall comply with the applicable forklift manufacturer’s battery specifications.

e. Type of charging connector, position, and length of leads

(see 3.7).

f. When Cover is required (see 3.10.1).

g. Condition of charge (Flooded)(see 3.13).

h. Battery assembly (see 3.11, 3.11.1 and 3.11.2).

i. When First article is required (see 3.1)

j. When Battery is to meet the H. I. Shock requirements of MIL-S-901 (see 3.16.5) (shipboard batteries only).

k. When Electromagnetic Interference (EMI) testing is required. (shipboard – yes; shorebased – depending upon situation) (see 3.16.6).

l. When resistance to saline corrosion is required (shipboard only) (see 3.16.7).

7. RESULTS.

(This section contains information pertaining to the required material to be provided in reply to the above as justification that all requirements have been met from the above stated sections)

7.1 Format. In addition to the BQL, a spread sheet (excel, etc.) shall be provided with each section of this document listed in column A and signed off with a signature or initials in Column B. The Description column for each section shall state either how and or why conformance is met and provide technical or vernacular justification. If referencing a document or dwg as proof this section shall state the document or dwg pg number and location on dwg that is being referenced. There shall also be a statement of conformance. If there is no stated conformance in a section, state “reviewed” in the Description column after the Sign off.

7.2 Example

Statement of Conformance: Battery Model ### meets all sections and descriptions stated here-in. Please see the below and the attached for justification of requirements.

John Q Public.

Section Sign off Conformance Description (And how and or why conformance is met, etc)

1 JQP -- SCOPE AND CLASSIFICATION; REVIEWED

1.1 JQP -- SCOPE; REVIEWED

1.2 JQP -- CLASSIFICATION; REVIEWED

2 JQP -- APPLICABLE DOCUMENTS; REVIEWED

2.1 JQP -- Specifications and standards; REVIEWED

2.2 JQP -- Government documents; REVIEWED

2.3 JQP -- Non-Government publications; REVIEWED

2.4 JQP -- Order of precedence REVIEWED;

3 JQP -- REQUIREMENTS; REVIEWED

3.1 JQP -- First Article: REVIEWED

3.2 JQP YES Materials: IAW BCIS-02

3.3 JQP YES Warning Labels: xxxxx

3.4.1 JQP YES Element: dwg # xyx, pg 2, item c

3.4.2 JQP YES Grids: dwg # xyx, pg 2, item d

ETC…

8.0 Change History– Applicable sections are to be highlighted in yellow.

20110412 – Vernacular additions/changes; connector changed to “Euro”; Workmanship description moved to 3.4.3; 3.10, 3.10.1 revised; 3.10.2 added; 3.14 Markings updated; 3.16.1 & 3.16.3 revised; 3.16.5, 6, 7 updated; 4.4 Examination revised; 4.5.7 revised; 6.2 part b updated; Section 7 added; Section 8.0 added.

APPENDIX A

TEST METHODS

A.1 SCOPE

A.1.1 Scope. The appendix contains the test methods to determine whether batteries procured under this specification conform to the requirements set forth. This appendix is a mandatory part of this specification.

A.2 APPLICABLE DOCUMENTS

(This section is not applicable to this appendix.)

A.3 TEST METHODS

TEST METHOD NO. 1

CAPACITY

1. Test Conditions:

(a) Charged and Dry Batteries (Flooded) - A charged and dry battery shall be filled with electrolyte and charged in accordance with the manufacturer's published instructions.

(b) State of Charge - Batteries shall be fully charged in accordance with the manufacturer's published instructions within 24 hours prior to the start of the test discharge.

(c) Voltage - The final voltage of the battery after charging shall read 2.12 volts minimum times the number of cells. The battery voltage shall be measured on the post of the terminal cells, excluding the battery cables.

(d) Electrolyte Level (Flooded) - The electrolyte level shall be adjusted in accordance with the manufacturer's published instructions.

(e) Temperature - The electrolyte temperature during charging shall be within the range of 65 F (18.3

C) through 115

F (46.1

C). The ambient temperature during the test discharge shall be within the range of 63 F (17.2

C) through 91

F (32.8

C). The electrolyte temperature of all cells at the start of a test discharge shall be within the range of 63 F (17.2

C) through 91

F (32.8

C). This temperature on a VRLA cell shall be measured on the negative terminal surface.

(f) Specific Gravity (Flooded) - The specific gravity of the electrolyte of a fully charged battery, when corrected to 77 F (25

C) and with the electrolyte at the maximum level, shall be within the range shown on the battery nameplate or in the manufacturer's published instructions. If the specific gravity of the electrolyte of any cell is not within the specified range, the electrolyte shall be adjusted in accordance with the manufacturer's published instructions.

(g) Readings - All voltage, specific gravity (flooded cell batteries) and temperature readings shall be taken from the positive terminal cell to the negative terminal cell, recorded and numbered in this order.

(h) Test Equipment - All equipment shall be clean, in good working order and calibrated.

ANALOG METERS

1. Thermometer - Thermometers shall be graduated so that each scale division will not represent more than 2 F (1.1

C) and shall have an accuracy of at least +/- 1 F (0.56

C).

2. Hydrometers (Flooded Cells/Batteries) – Hydrometer floats shall be graduated so that each scale division will not represent more than 0.005 units of specific gravity (5 points) and shall have an accuracy of at least +/- 0.0025 units of specific gravity

3. Voltmeters - Meter accuracy shall be in minimum of 0.5 percent of the full-scale value with a minimum resistance of 1000 ohms per volt. Galvanometer-type voltmeter graduations shall be as follows and readings shall fall in the upper half of the meter scale.

Voltage Range

(Volts)

Maximum Voltage Per Scale Division (Volts)

0 to 3 0.02

3 to 15 0.10

15 to 75 0.20

75 to 150 1.00

4. Ammeters - Galvanometer-type ammeters shall be graduated to have a minimum of one hundred scale divisions. Ammeters shall be used with an appropriate shunt so that current readings will fall in the upper third of the meter scale. The meter and shunt, including shunt leads, shall have an accuracy of at least

0.5 percent of the full-scale value.

DIGITAL METERS

5. Digital voltmeters and millivoltmeters shall have a minimum display of

3.5 digits with a resolution of at least 3200 counts and a minimum accuracy of +/-

0.1 percent of reading plus one least significant digit.

6. Shunts - The size of the shunt used on a discharge shall have a current rating between the discharge rate and 1.5 times the discharge rate in amperes. The accuracy of shunts shall be within 0.5 percent of the current rating of the shunt.

7. Timers – Timers shall be graduated so that each division will represent not more than 1 minute and, during a 360-minute period, shall have an accuracy of at least +/- 2 minutes.

(i) Pilot Cell - A pilot cell shall be selected for every six cells in the battery in locations which represent average conditions.

2. Test Procedure:

(a) Individual cell voltage, temperature and specific gravity (flooded cells only), as well as total battery voltage and charging rate, shall be recorded during the last 30 minutes of the charge.

(b) Individual pilot cell temperature and electrolyte specific gravity readings (flooded cells only) shall be recorded during the 60 minutes prior to the start of the test discharge.

The test discharge shall be started no sooner than 1 hour after charging and no later than

24 hours after charging.

(c) When all Test Conditions have been met, the test discharge shall be initiated.

(d) The discharge current shall be maintained within +/- 1 percent of a rate in amperes equal to one-sixth of the battery's rated 6-hour ampere-hour capacity until the battery voltage at the terminal cells equals the final voltage.

(e) The battery voltage shall be recorded at 30 minute intervals until it reaches an average of 1.80 volts times the number of cells, at which time the individual cell voltages shall be recorded. The battery voltage shall then be recorded at 5-minute intervals until it reaches the final voltage.

(f) The elapsed time to final voltage and the voltage of each cell shall be recorded at which time the discharge test shall be terminated.

(g) The temperature of all cells and the specific gravity (flooded cells) shall be recorded within 10 minutes of the termination of the test discharge.

(h) The actual capacity in ampere-hours obtained during the test discharge shall be the product of the discharge rate in amperes and the time in decimal hours required to reach final voltage.

(i) If the average electrolyte temperature at the start of the discharge differs from 77

F

(25 C), the measured capacity in ampere-hours obtained shall be corrected by using the following formula:

Corrected Ampere-hour Capacity at 77

F = (measured Ampere-hour Capacity) /

(1 + 0.0025(t-77))

Where:

t = the average pilot cell temperature ( F) taken before the start of the discharge (see paragraph b).

0.0025 = capacity temperature coefficient.

(j) The battery shall be recharged in accordance with manufacturer's published instructions. Failing to meet the requirements of paragraph 3.16.1 shall be cause for rejection.

TEST METHOD NO. 2

CYCLE LIFE TESTING

1. Test Conditions:

(a) Cells for Determining Life Performance - Cell or cells to be used for determining life performance of a battery shall be representative samples of the product being tested.

Cells shall be selected at random from productions and shall not be specifically built.

(b) Test for Determining Initial Capacity Requirements - A test for determining initial capacity requirements in accordance with TEST METHOD NO. 1 shall be started within 90 days after the cell or cells have been filled with electrolyte and fully charged.

(c) Life Testing - Life testing shall be started within 30 days after meeting the initial capacity requirements.

(d) Temperature - The ambient temperature during storage of the cells, before testing is started, shall not exceed 100 F (37

C). The cell temperature throughout the test shall be within a range of 70 F (21.1

C) through 115

F (46.1

C).

(e) Equalizing Charge - Cells shall be given an equalizing charge, in accordance with the manufacturer's published instructions, prior to the initiation of the test.

(f) Electrolyte Level (Flooded) - The electrolyte level and specific gravity in all cells should be maintained in accordance with the manufacturer's published instructions.

2. Test Procedure:

(a) Method - The test shall consist of a series of cycles as follows:

1. A discharge of 4 hours at an average rate of 0.2C6 (C6=rated capacity in ampere-hours at the 6-hour rate) to remove a total of 0.8C6 +/- 2 percent ampere-hours.

2. A charge in accordance with the manufacturer's published instructions, but not to exceed 115 percent of the ampere hours removed. The charge, including any open circuit period, shall not exceed 8 hours.

3. The total time for one complete cycle shall equal 12 hours. Not less than 10 cycles per week shall be run.

(b) Additional Charging - Additional charging, not exceeding the rated 6-hour ampere hour capacity, may be given monthly to assure the cells are in a fully charged state.

(c) Voltage at End of Discharge at Intervals of Not More Than 100 Cycles - At intervals of not more than 100 cycles, the voltage at the end of discharge shall be not less than 1.70 volts per cell.

(d) Alternate Test for Intervals Not More than 100 Cycles - In lieu of paragraph (c) above, the test unit shall be tested at intervals of not more than 100 cycles in accordance with TEST METHOD NO. 1.

(e) Test When Terminal Voltage of Unit is Less than 1.70 Times the Number of

Cells - If the terminal voltage of the unit is less than 1.70 times the number of cells, the unit may be retested in accordance with TEST METHOD NO. 1. Failing to meet the requirements on the second capacity test, the life test shall be considered complete and the cycle number of this discharge shall be considered the number of life cycles obtained.

If the test unit meets the capacity requirements on the second discharge, the test unit may be returned to cycle life testing.

(f) Evaluation - If cells are damaged as a result of malfunction of test equipment, the life test shall be considered void.