MIL-PRF-32383.pdf

AMSC N/A FSC 6140

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

INCH-POUND

MIL-PRF-32383

16 June 2011

PERFORMANCE SPECIFICATION

BATTERIES, RECHARGEABLE, SEALED

GENERAL SPECIFICATION FOR

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

1 SCOPE

1.1 Scope

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

1.2 Classification

. Batteries described by this specification have the following types:

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

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

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

Type IV – Batteries with a lithium polymer (Li-Po) electrochemical system

Part or identifying number (PIN)

. PINs to be used for batteries described by this specification are created as follows:

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

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

Comments, suggestions, or questions on this document should be addressed to Commander, US Army Communications-Electronics RDEC, ATTN: RDER-PRQ-QE, Aberdeen Proving Ground, MD 21005, or emailed to michael.g.williams31.civ@us.army.mil. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at https://assist.daps.dla.mil.

mailto:Robert.Francis@us.army.mil� http://assist.daps.dla.mil/�

2 APPLICABLE DOCUMENTS

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

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks

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

FEDERAL STANDARDS

FED-STD-595/34088 - Green, Flat or Lusterless FED-STD-595/33446 - Yellow, Flat or Lusterless FED-STD-595/33440 - Brown, Flat or Lusterless

DEPARTMENT OF DEFENSE SPECIFICATIONS

(See ASSIST database for list of specification sheets.)

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD 202 - Test Methods for Electronic and Electrical Component Parts

MIL-STD-810 - Environmental Test Methods and Engineering Guidelines

(Copies of these documents are available online at https://assist.daps.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

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

NAVSEA S9310-AQ-SAF-010 - Technical Manual for Batteries, Navy Lithium Safety Program Responsibilities and Procedures

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

https://assist.daps.dla.mil/�

2.3 Non-Government publications

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

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

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

System Management Bus Specification Smart Battery Data Specification

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

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

UL 94 - Standard for Safety, Test for Flammability of

Plastic Materials for Parts in Devices and Appliances

UL 1642 - Standard for Safety, Lithium Batteries

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

UN Manual of Tests and Criteria

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

2.4 Order of precedence

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

3 REQUIREMENTS

3.1 Specification sheets

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

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

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3.2.1 Certifications

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

REQUIREMENT

a. Metals

PARAGRAPH

3.3.1

b. Dissimilar metals 3.3.2

c. Resistance of elastomeric materials 3.3.5

d. Electrical connection wires and tabs 3.3.6

e. Electrical contacts 3.4.4.1

f. Battery case 3.4.5

g. State of charge indicator window 3.4.5.1

h. Dust cap or cover 3.4.8.1

i. Transportation requirements 3.9

3.3 Materials

3.3.1 Metals

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

3.3.2 Dissimilar metals

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

3.3.3 Corrosion resistance

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

3.3.4 Insulating compounds, flow and shrinking

4.7.1.5

. Insulating, impregnating, potting and sealing compounds used in manufacturing shall be capable of performing their intended purpose under the use conditions described by this specification. Compounds shall not inhibit the operation of any safety features. When tested as specified in , the insulating, impregnating, potting and sealing compounds shall not flow at high temperature, and shall not crack or draw away from the sides of a container at low temperature. Any compound used shall be non-flammable and non-toxic (see 6.3.8).

3.3.5 Resistance of elastomeric materials

6.3.8

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

3.3.6 Electrical connection wires and tabs

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

a. Softening temperature (see 6.3.7): Not less than 150°C (302°F).

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

c. Thickness: Not less than 0.005 inch

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

e. The material shall be non-flammable, non-toxic (see 6.3.8), and impervious to the electrolyte of the battery.

f. Certification is required.

3.4 Physical characteristics

3.4.1 Visual and mechanical

TABLE VIII

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

3.4.2 Cells

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

3.4.2.1 Protective coverings

3.3.4

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

3.4.3 Dimensions and weight

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

3.4.4 Battery connector and other electrical interfaces

3.4.4.1 Electrical contacts

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

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

3.4.4.1.2 Flat terminal

4.7.1.4

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

3.4.4.1.3 Multilayer finish 3.1. When specified (See ), electrical interfaces shall be finished according to the following (or better).

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

Electroless nickel plate; not less than 800 knoop hardness; not less than 200 micro inches thickness.

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

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

3.4.5 Battery case

4.7.1.7

. 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. When plastics are used for the battery case, the material shall be classified in accordance with UL Standard 94, Test for Flammability of Plastic Materials for Parts in Devices and Appliances, except as otherwise noted herein. Acceptable ratings include: HB; V-0; V-1; V-2; 5VA; 5VB; VTM-0; VTM-1; and VTM-2. If the manufacturer elects to use material classified in accordance with UL 94, certification is required. The government reserves the right to require verification tests to ensure nonflammable battery cases. If the manufacturer elects to use a plastic material that doesn’t have UL-94 classification, then the test of shall be performed. When tested as specified in 4.7.1.7, test specimens shall self-extinguish within 5 seconds after removal from flame.

3.4.5.1 State of charge indicator window

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

3.4.5.2 Battery case expansion 3.1. Unless otherwise specified (see ), the battery shall be designed to prevent dimensional expansion that will prevent its removal from equipment.

3.4.5.3 Battery case vent

4.7.1.6

. A pressure release device shall be incorporated into the battery case. This device shall be designed to release below the bursting pressure of the container and above the normal operating pressure of the battery. The design of the battery shall be such that the paths from the individual cell units to the battery vent are sufficient to permit the removal of gases. The device shall not permit the entry of liquids into the battery case. When tested as specified in , each battery case shall not exhibit any signs of visible damage other than the case vent opening, and each battery shall pass through the test fixture with a force not greater than 12 pounds.

3.4.5.4 Color

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

. The color of the battery case shall be as specified below, in accordance with FED-STD-595.

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

c) Type IV (Li-Po) batteries shall be “Earth Yellow”, chip number 33245.

3.4.5.5 Writable label

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

3.4.6 Marking

. Each battery shall be provided with a permanent, legible hot-stamped or printed marking as specified herein. Direct printing on the battery is the preferred method.

For rectangular batteries, the marking may be placed on more than one surface. Lettering shall be without serifs (sans-serif). Additional markings may be required as specified in applicable specification sheets.

3.4.6.1 Identification marking

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

BATTERY, RECHARGEABLE, (Type Designation, PIN) (Chemistry) (Battery Voltage)V, (Full Capacity Rating)Ah / (Full Energy Rating)Wh

(NSN)

(Contract Number) (MFG DATE) (Serial Number) (MFG Warranty Details) (Manufacturer) (Manufacturer’s location)

3.4.6.2 Warning marking

. The following warning marking shall appear on each battery in capital letters.

DO NOT STORE ABOVE 122oF (50oC), WARNING/STORAGE

CRUSH, MUTILATE, REVERSE POLARITY,

DISASSEMBLE, OR DISPOSE OF IN FIRE.

3.4.6.3 Date of manufacture code

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

3.4.6.4 Terminal marking

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

3.4.6.5 Instructions / notes

(Preferred charging method)

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

Specific instructions can be found in the applicable specification sheet.

(Alternate charging method) Specific instructions can be found in the applicable specification sheet.

SOCI matrix (see 3.5.8) Self discharge rate Maintenance (e.g. discharging and charging periodically) where applicable Other notes when specified (see 3.1)

3.4.6.6 Simplified battery label

3.1

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

The simplified battery label shall contain the following.

a) Type designation

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

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

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

e) Battery chemistry (see 3.1) http://battery.army.mil/�

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

FIGURE 1.

Note: Battery nomenclature and values are fictitious

Sample simplified battery label

3.4.6.7 Color

a. Type I (Ni-Cd) batteries – black . The color of the marking shall be as specified below.

b. Type II (Ni-MH) batteries – white

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

3.4.6.8 Permanency and durability

4.7 . Marking shall be capable of withstanding all tests of

, except projectile (see 4.7.4.11), without evidence of any of the following:

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

3.4.7 Attitude

. Each battery shall be designed for operation in any position and shall meet the specified capacity, voltage and electrolyte leakage requirements (see ).

3.4.8 Battery condition for shipping

. Each battery shall be furnished fully charged as indicated by five state of charge segments where applicable. Batteries shall be supplied with instructions cards and a dust cap or cover over the connector.

http://battery.army.mil/�

3.4.8.1 Dust cap or cover 3.1. Each battery shall be furnished with a dust cap (see ), the dust cap or cover shall not fall off during normal handling and shall be removable by hand at temperatures from -20 to 55°C (-4 to 131ºF). The material used for the dust cap shall be non-toxic and non-flammable and shall withstand temperatures from -40 to 90°C (-40 to 195ºF) without shrinkage or cracking. The dust cap or cover shall not leave any residue on the battery contacts nor have any adverse affect on the connection interface. Dust cap or cover compliance to these requirements shall be certified (3.2.1).

3.5 Electrical requirements

3.5.1 Cell balance

4.7.2.1

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

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

b. Type III ( Li-ion) and Type IV (Li-Po) cells: ± 2.5%

3.5.2 Battery voltage

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

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

The minimum final voltage shall be the value listed in the applicable specification sheet. Inability to meet the specified minimum requirements shall constitute a failure.

3.5.4 Cycle life 4.7.2.4. When tested as specified in batteries shall be capable of retaining the specified capacity during and after 224 cycles (see 3.1).

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

3.5.6 Charge enable 3.1. When specified (see ), batteries shall be equipped with a charge enable circuit that allows charging (see 3.1) on approved chargers (see 6.3.12) and disallows charging when connected to a charger that doesn’t recognize the charge enable circuit protocol. Whenever a charger doesn’t recognize the charge enable protocol, the battery shall terminate any charge with current that exceeds the maximum specified (see 3.1). Unless otherwise specified, the charge enable pin shall have an equivalent input circuit of a resistor of specified value in series with a diode of specified VF (see 3.1). The circuit shall require activation current not less than the value specified (see 3.1). When tested as specified in 4.7.2.6, (1) the charge current shall not exceed the value specified without a charge enable circuit protocol being applied, and (2) battery current shall meet the preferred charging method while the charge enable is connected to a charge circuit equipped to allow the preferred charging method if the charge enable terminal or socket meets specified requirements (see 3.1).

3.5.7 Power consumption

4.7.2.13

. The power consumption for all electronics within the battery shall be less than 350µA, per battery or independent section where applicable, at 20oC. (See

3.5.8 State-of-charge indicator (SOCI)

3.1

. Each battery shall indicate its current state of charge. The state of charge display location shall be as specified (see ). The display shall have five distinct segments showing the ranges of state of charge of the battery. The segments shall be black in color on a white or pale gray background. The display shall be on continuously with no user action required except that it may go blank temporarily as it refreshes the display.

Dual section batteries require a separate display for each section. The value displayed shall compensate for use temperature, and discharge rate of the battery. As the battery ages and experiences capacity fade from use, the display shall compensate by showing the fully charged state as a percentage of the original fresh capacity (commonly referred to as “state of health” or “true capacity”). The state of charge ranges displayed shall be as follows (see 4.7.2.14):

SEGMENTS STATE OF CHARGE

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

3.5.8.1 Accuracy

3.5.8

. The state of charge ranges of the SOCI displayed shall be accurate within the tolerances stated above in . When tested as specified in 4.7.2.14, the indicator shall change state of charge indication within +0/-5% of the actual state of charge for the battery under test when compared to the range limits stated above.

3.5.9 SMBus 3.1. When specified (see ), each battery shall be compliant with System

Management Bus (SMBus) Specification Revision 1.1 and Smart Battery Data (SBData) Specification, version 1.1, with the exception that SBData safety signal hardware requirements therein shall be replaced with a charge enable when a charge enable is specified (see 3.1 and 3.5.6). Certification is required. Batteries shall be compatible with appropriate Level 2 and Level 3 chargers (see 6.3.9). When tested as specified in 4.7.2.14, SMBus data output shall be accurate within +0/-5% of the actual state of charge for the battery under test throughout the discharge. Manufacturer and battery data shall be correctly programmed (see 4.7.2.15).

3.5.10 Normal operating temperatures

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

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

3.5.10.1 Charge acceptance 4.7.2.9. When tested as specified in , batteries shall meet the capacity requirements 3.5.3 and the visual mechanical requirements of TABLE VIII.

3.5.10.2 Retention of charge

4.7.2.10

. Batteries shall be capable of maintaining the required minimum capacity after storage at 50oC (122oF) for 7 days. When tested as specified in

, batteries shall meet the capacity requirements 3.5.3 and the visual mechanical requirements of TABLE VIII.

3.6 Environmental requirements

TABLE I

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

a. Defects listed in TABLE VIII

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

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

d. Mechanical failure of any part.

e. Failure to mate with a corresponding part.

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

g. Electrical leakage.

h. Evidence of rupturing, burning or exploding.

TABLE I.

Environmental Requirements

Tests Req’t Paragraph Test Paragraph Extreme low temperature discharge 3.6.1 4.7.3.2 Extreme high temperature discharge 3.6.1 4.7.3.3 Altitude 3.6.2 4.7.3.4 Thermal Shock 3.6.3 4.7.3.5 Mechanical Shock 3.6.4 4.7.3.6 Vibration 3.6.5 4.7.3.7 Immersion 3.6.6 4.7.3.8 Transit drop 3.6.7 4.7.3.9 Battery storage life 3.6.8 4.7.3.10

3.6.1 Extreme discharging temperatures

4.7.3.2

. Type III (Li-ion) and Type IV (Li-Po) batteries shall be capable of discharging over a temperature range of -30°C (-22°F) to 55°C (131°F).

When tested as specified in and 4.7.3.3 the batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

3.6.2 Altitude

4.7.3.4 . Batteries shall experience no deleterious effects from high altitude.

When tested as specified in , batteries: (1) shall meet the requirements of 3.6; (2) batteries in the fully charge state shall meet the battery voltage requirements of 3.5.2.

3.6.3 Thermal shock

4.7.3.5

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

3.6.4 Mechanical shock

4.7.3.6

. Batteries shall be capable of withstanding mechanical shock environments without sustaining physical or electrical damage. When tested as specified in

, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

3.6.5 Vibration

4.7.3.7

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

3.6.6 Immersion

4.7.3.8.1

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

3.6.7 Transit drop

4.7.3.9.1

. Batteries shall be capable of withstanding drops at severe temperature conditions without sustaining physical or electrical damage. When tested as specified in or 4.7.3.9.2, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6 (with the exception of defects in 106 of TABLE VIII).

3.6.8 Battery storage life

4.7.3.10

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

3.7 Safety

. All protective devices employed shall not adversely affect battery performance or life.

3.7.1

Cell safety

3.7.1.1 Cell electrical safety

TABLE II

. Each cell when subject to the specified electrical tests of shall not:

a. Explode

b. Catch Fire

c. Rupture

d. Spark

e. Leak any material

f. Have a loss of mass greater than 0.1%

TABLE II.

Cell electrical safety tests

Tests Req’t Paragraph Test Paragraph Cell overcharge 3.7.1.1.1 4.7.3.4 Cell short circuit 3.7.1.1.2 4.7.3.5 Cell forced discharge 3.7.1.1.3 4.7.3.6

3.7.1.1.1 Cell overcharge

4.7.4.1

. Cells used to build batteries shall be capable of withstanding overcharge. When tested as specified in , surface temperatures shall not exceed 93°C (200°F).

3.7.1.1.2 Cell short circuit

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

3.7.1.1.3 Cell forced discharge

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

3.7.1.2 Nail penetration, cell 3.1. When specified (see ), cells shall not react violently when cell containers are penetrated by sharp objects. Cells tested in accordance with 4.7.4.4 shall not burn or explode, and the external temperature of each test sample shall be not greater than 170°C (338ºF).

3.7.1.3 Crush, cell 3.1. When specified (see ), cells shall not react violently when crushed. When subjected to the test of 4.7.4.5, no cell shall burn or explode.

3.7.2

Battery safety

3.7.2.1 Insulation resistance

3.1 . Terminals or contacts shall be as specified on the applicable specification sheet (see ) and insulation resistance shall be not less than 25 megohms when tested as specified in 4.7.4.6.

3.7.2.2 Overcharge/electrical leakage

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

3.7.2.3 Short circuit protection

4.7.4.8 . Each battery shall be protected against short circuits.

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

3.7.2.4 High temperature temporary cut off devices

4.7.4.9

. Each battery shall contain a minimum quantity of normally closed thermoswitches that shall open at 70 ± 5°C (158°F) and close at 50 ± 5°C (122°F) to insure safety under conditions of high temperature, overcharge, misuse, or any combination thereof. The minimum quantity shall be as specified in the applicable specification sheet. When tested as specified in , battery voltage shall be zero volts after each high temperature storage and batteries shall meet the voltage requirement of

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

3.7.2.5 High temperature permanent cut off devices.

4.7.4.10

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

Additionally, batteries shall not accept charge current during this test.

3.7.2.6 Projectile 3.1. When specified (see ), batteries shall not produce shrapnel when subjected to a flame. When tested as specified in 4.7.4.11, no part of a battery under test shall penetrate the wire screen such that some or all of the battery passes through the screen. When tested, the production of smoke and flames and the passing of small particles through the wire mesh are permitted; heat damage to the wire mesh is also permitted.

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

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

3.7.2.7.1 Destructive Lithium Battery Safety Program tests,

4.7.5.1 When tested in accordance

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

3.7.2.7.2 Non-destructive Lithium Battery Safety Program

4.7.5.4 tests When tested in accordance with or 4.7.5.5, no battery shall bulge, leak, vent, rupture, burn, or explode.

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

When tested as specified in 4.7.7, batteries connected to the system shall meet the requirements of MIL-STD-461 for each of the following: CS114; CS115; CS116; RE101; RE102;

RS101; RS103.

3.9 Transportation requirements

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

3.10 Interchangeability

4.7.6

. Batteries shall be capable of charging correctly on fielded chargers and adapters (see ).

4 VERIFICATION

4.1 Classification of Inspection

a. First article inspection (see

. The inspection requirements specified herein are classified as follows:

4.4).

b. Conformance inspection (see 4.5).

4.2 Test equipment and facilities

4.2.1 Electrical indicating instruments

. All voltmeters and ammeters shall be accurate within 1 percent of the full scale reading. The sensitivity of voltmeters shall be not less than 10 megohms per volt.

4.2.2 Resistor and current tolerances

. In all tests involving a resistor, such resistance shall be accurate within ± 0.5 percent. During the charging and discharging of batteries, conducted at various rates specified herein, the current shall be maintained within a tolerance of ± 3 percent of the specified value.

4.2.3 Timing

. The timing of discharges lasting not greater than one minute shall be maintained within ± 5 percent. All others shall be accurate within ± 1 percent.

4.3 Inspection conditions

. Unless otherwise specified herein, all examinations and tests shall be performed under ambient temperature, humidity, and atmospheric pressure conditions.

4.3.1 Normal conditions

. When normal conditions are specified, tests shall be conducted and measurements taken at 23 ± 5°C (73.4°F) and ambient atmospheric pressure and relative humidity with not less than 2 hours between charge and discharge except for cycle life test.

4.4 First article inspection

TABLE III

. First article inspection shall consist of the examinations and tests specified in and TABLE IV. Testing shall be performed in the order shown.

TABLE III tests require not greater than ten sample cells, the requisite amount of compound (see 4.7.1.5), two electronic component assemblies (ECA), two complete cell assemblies (CCA), (see 6.3.10 and 6.3.11 for definitions), and 40 sample batteries. Five pieces of battery cases may be required as well (see 3.4.5). These quantities may be less for some battery types based on applicability of the tests. All samples shall meet the requirements specified herein for each examination and test. Battery samples shall be as follows:

a. Group 1 (GR1) – Functional tests, shall contain 12 samples

b. Group 2 (GR2) – Electromagnetic interference tests, when specified (see 3.1) shall contain five samples

c. Group 3 (GR3) – Interchangeability tests, shall contain eight samples

d. Group 4 (GR4) – Lithium safety tests, when specified (see 3.1) shall contain 15 samples

TABLE III.

First article tests and certifications; cells, assemblies, and components

Inspection Requirement Paragraph

Test Method Paragraph

Samples

Cell balance 2/ 3.5.1 4.7.2.1 Cells: All Cell overcharge 2/ 3.7.1.1.1 4.7.4.1 Cells: 1, 2 Cell short circuit 2/ 3.7.1.1.2 4.7.4.2 Cells: 3, 4 Cell force discharge 2/ 3.7.1.1.3 4.7.4.3 Cells: 5, 6 Crush 1/ 2/ 3.7.1.3 4.7.4.5 Cells: 7, 8 Nail penetration 1/ 2/ 3.7.1.2 4.7.4.4 Cells: 9, 10 Power consumption 2/ 3.5.7 4.7.2.13 2 ECA & 2 CCA Insulating compounds, flow and shrinking 2/

3.3.4 4.7.1.5 By volume

Battery case 2/ 3.4.5 4.7.1.7 5 pieces or certification

Metals 3.3.1 Certification Dissimilar metals 3.3.2 Certification Resistance of elastomeric materials 3.3.5 Certification Electrical connection wires and tabs 3.3.6 Certification Electrical contacts 3.4.4.1 Certification State of charge indicator window 3.4.5.1 Certification Dust cap or cover 3.4.8.1 Certification Transportation requirements 3.9 Certification

NOTES

1/ Only when specified (see 3.1) 2/ Must be completed prior to tests of TABLE IV

TABLE IV.

First article tests, complete batteries

Inspection Req’t

Test Method

Samples or Group (GR)

GR1 GR2

(5 ea)

GR3

(8 ea)

GR4

(15 ea) 1 2 3 4 5,6 7,8 9,10 11,12 Visual and mechanical 3.4 4.7.1.1 Dimensions and weight 3.4.3 4.7.1.2 Battery open circuit voltage 3.5.2 4.7.2.2 Insulation resistance 3.7.2.1 4.7.4.6 Altitude 3.6.2 4.7.3.4 Charge enable 1/ 3.5.6 4.7.2.6 Charge acceptance 3.5.10.1 4.7.2.9 Capacity discharge (initial) 3.5.3 4.7.2.3 Cycle life 3.5.4 4.7.2.4 Battery storage life 3.6.8 4.7.3.10 Overcharge/electrical leakage 3.7.2.2 4.7.4.7 Low temperature discharge 3.5.3 4.7.2.7 High temperature discharge 3.5.3 4.7.2.8 Projectile 1/ 3.7.2.6 4.7.4.11 High rate discharge 3.5.3 4.7.2.5 Retention of charge 3.5.10.2 4.7.2.10 Pulse discharge 3.5.3 4.7.2.11 Motor inrush current 1/ 3.5.5 4.7.2.12 Thermal shock 3.6.3 4.7.3.5 Mechanical shock 3.6.4 4.7.3.6 Vibration (discharge) 3.6.5 4.7.3.7 Connector insertion 3.4.4.1.1 4.7.1.3 Flat terminal strength 3.4.4.1.2 4.7.1.4 Immersion, shallow 3.6.6 4.7.3.8 Transit drop, normal 1/ 3.6.7 4.7.3.9.1 Transit drop, severe 1/ 3.6.7 4.7.3.9.2 Immersion, shallow (post drop) 1/ 3.6.6 4.7.3.8.1 See note 2/ Immersion, deep (post drop) 1/ 3.6.6 4.7.3.8.2 See note 2/ State of charge 3.5.8 4.7.2.14 SMBus 1/ 3.5.9 4.7.2.15 Full capacity discharge 3.5.3 4.7.2.3 Extreme low temp. discharge 3/ 3.5.3 4.7.3.2 Extreme high temp. discharge 3/ 3.5.3 4.7.3.3 Battery case vent 3.4.5.3 4.7.1.6 Short circuit protection 3.7.2.3 4.7.4.8 High temperature temporary cut-off 3.7.2.4 4.7.4.9 High temperature permanent cut-off 3.7.2.5 4.7.4.10 Electromagnetic interference 1/ 3.8 4.7.7 Interchangeability 3.10 4.7.6 Lithium Battery Safety Program (US Navy) Tests 1/

3.7.2.7 4.7.5

NOTES

1/ Only when specified (see 3.1) (indicated in table as ) 2/ Immersion samples shall be the same samples having undergone transit drop 3/ Only Type III (Li-ion) and Type IV (Li-Po) batteries

4.5 Conformance inspection

4.5.3.1

. Inspection of product for delivery shall consist of groups A and B inspections, as well as Group C inspections when specified (see ).

4.5.1 Group A inspection

TABLE V

. Each battery on contract or delivery order shall be 100 percent inspected for conformance to the inspections in the order specified in . All failures shall be removed. In the event of failure, rework is permitted only as specified in TABLE VIII. Reworked batteries must be fully compliant after rework. Discrete lots shall be formed from batteries that pass these inspections.

TABLE V.

Group A inspection

Paragraph

Test Method paragraph

Visual and mechanical examination 3.4 4.7.1.1 Battery open circuit voltage 3.5.2 4.7.2.2

4.5.2 Group B inspection

4.5.1 . Group B inspections shall be performed on inspection lots that have passed Group A inspection (see ) and on samples selected from units that have been subjected to and met the Group A inspection. Group B samples selection shall be on not less than ten percent of the inspection lot or monthly quantity. Group B inspection shall consist of the test specified in TABLE VI and shall be conducted in the order shown. The sample size shall be four batteries for each inspection lot (see 6.5) or each month of production if an inspection lot spans more than one month. Samples 3 and 4, having successfully completed testing, are deliverable against the quantity on contract.

TABLE VI –

Group B inspection

Paragraph

Test Method Paragraph

Sample Number

1 2 3 4 Capacity discharge (initial)

3.5.3 4.7.2.3

Thermal shock 3.6.3 4.7.3.5 High rate discharge 3.5.3 4.7.2.5 Immersion, shallow 3.6.6 4.7.3.8.1

4.5.3 Group C inspection

4.5.1 . Group C inspections shall be performed on inspection lots that have passed Group A inspection (see ) and on samples selected from units that have been subjected to and met the Group A inspection. Group C samples selection shall be on not less than ten percent of the inspection lot or monthly quantity. This inspection is required during conformance inspection for the first inspection lot and repeated in accordance with 4.5.3.1. It shall consist of the tests listed in TABLE VII. Inspection shall be performed in the order shown.

The sample size shall be six batteries and six cells each time Group C is required.

4.5.3.1 Group C frequency

4.4 . Group C testing, or a complete first article inspection (see

), shall be performed within the 12 months prior to presenting the current inspection lot for acceptance.

TABLE VII.

Group C inspection

Inspection Paragraph Requirem ent Paragrap h

Test Paragraph

Sample Number

1 2 3 4

Dimensions and weight 3.4.3 4.7.1.2 Capacity discharge (initial) 3.5.3 4.7.2.3 High temperature discharge 3.5.3 4.7.2.8 Low temperature discharge 3.5.3 4.7.2.7 Thermal shock 3.6.3 4.7.3.5 Mechanical shock 3.6.4 4.7.3.6 Vibration 3.6.5 4.7.3.7 Immersion, shallow 3.6.6 4.7.3.8.1 Transit drop, normal 3.6.7 4.7.3.9 Immersion, shallow (post drop) 3.6.6 4.7.3.8.1 Capacity discharge (final) 3.5.3 4.7.2.3 Extreme low temp. discharge 1/ 3.5.3 4.7.3.2 Extreme high temp. discharge 1/ 3.5.3 4.7.3.3 Battery case vent 3.4.5.3 4.7.1.6 High temperature temporary cut-off

3.7.2.4 4.7.4.9

High temperature permanent cut-off

3.7.2.5 4.7.4.10

Cell balance 3.5.1 4.7.2.1 6 cells

NOTES

1/ Only Type III (Li-ion) and Type IV (Li-Po) batteries

4.6 Charge methods

4.6.1 Constant potential, current limited

4.3.1

. Where specified herein, Type III (Li-ion) and Type IV (Li-Po) batteries shall be charged by a constant potential (voltage) method with limited current at normal conditions in accordance with at a rate not less than specified (see 3.1) and for not greater than three hours. Voltages, current limits, and cut-off parameters are specified in the applicable specification sheet (see 3.1).

4.6.2 Constant current

. Where specified herein, Type I (Ni-Cd) and Type II (Ni-MH) batteries shall be charged by a constant current to the designated charge cut-off parameter.

Topping charges beyond the charge cut-off parameter shall be as specified. Charge and topping charge current and cut-off parameters are specified in the applicable specification sheet (see ).

4.6.3 Alternate charging

a. Where permitted herein, batteries may be charged by an approved charger as an alternative to the charge methods described above (see

6.3.12).

b. If an approved charger is not available, the alternate charging method described by the applicable specification sheet may be used whenever charging in accordance with 4.6.3 is permitted.

4.7 Test methods

4.7.1 Physical characteristics

4.7.1.1 Visual and mechanical

3.4

. Samples shall be examined to verify that the basic materials, component materials and parts, design and construction, marking and workmanship are in accordance with all the requirements of and TABLE VIII.

TABLE VIII.

Visual and mechanical inspection

Categories 1/ Rework Permitted

Defects

001 No Electrolyte leakage.

002 No Improper assembly causing parts to be inoperative or unsafe in service.

003 No Loose parts inside battery.

101 No Deformed or damaged parts which are inoperative or malfunction in service 102 Yes Contact surfaces obstructed so that electrical use is affected.

Rust, corrosion, or any type of non-conductive material on contact surfaces.

103 No Battery cases – any hole (not specified), tear, rip, or crack.

104 Yes Improper case closure.

105 Yes Sharp edges on exterior of battery.

106 No Pitting, blow-holes, rough spots, burrs, splits, dents, or other deformations on battery surface.

107 Yes Terminal, identification, or operating instructions markings not as specified (see 3.1 and 3.4.6).

108 Yes Marking defects of 3.4.6.8 are visible 109 Yes State of charge indicator does not display full state of charge

(Group A only).

110 No State of charge indicator does not display correct state of charge.

111 No State of charge indicator window is warped, punctured, separated from case, not transparent, or has visible condesation on the interior.

201 No Color not as specified.

NOTE:

1/ Category 0XX defects are critical; category 1XX are major, and category 2XX are minor.

These categories are used to qualify the levels of nonconformance. Critical defects affect safety; major categories affect use, batteries with minor defects may be serviceable with limitations.

4.7.1.2 Dimensions and weight

. Batteries shall be examined by gauging or measuring and by weighing to determine conformance. All measurements shall include any coating and labels which may be used. Battery dimensions shall be measured during the dimension inspections of first article. Dimensions may be checked by gauging whenever a first article test requires dimensional compliance as passing criteria following tests. Dimension inspections during conformance inspections may be accomplished by gauging. Batteries shall meet the requirements specified (see ).

4.7.1.2.1 Gauging

3.1

. When box or ring gauges are used, batteries, loaded with a weight not greater than five pounds, shall pass freely through the applicable gauge openings. The dimensions of the box or ring gauge shall be the specified maximum outside dimensions of the battery (see ).

4.7.1.3 Connector insertion test 3.1. Unless otherwise specified (see ), the following test shall be performed. Insert and withdraw each battery into a specified adapter or specified mating device (see 3.1) 500 times. Measure insertion and withdrawal force required on the first and last insertion/withdrawal cycles. Inspect the battery to verify that the screws (if any) are retained, the connector remains securely fastened and the connector remains fully functional.

Batteries shall meet the requirements of 3.4.4.1.1.

4.7.1.4 Flat terminal strength

3.4.4.1.2

. The following test shall be performed. Apply force of not less than 10 pounds to each battery terminal using 0.200 ± 0.050 inch diameter rod. Repeat force application for not less than a total of 250 applications. Maintain each application of force for not less than 1 second. Batteries shall meet the requirements of .

4.7.1.5 Insulating compounds, flow and shrinking

3.3.4

. The following test shall be performed on any insulating compounds that may be used in battery construction. Place compound in a container, approximately 3 inches wide by 6 inches long by 3/4 inch high, to within 1/2 inch of the top and allow curing in accordance with the manufacturer’s recommended procedures.

Place the container in an environmental chamber in an inverted position and raise the temperature to 93.3 ± 2.7ºC (200ºF). Keep the container inverted at these conditions for not less than 24 hours. Visually examine; the test sample shall meet the requirements of .

Place the container in an environmental chamber and lower the temperature to -40 ± 2.7ºC (- 40ºF); hold these conditions for not less than eight hours. Visually examine; the test sample shall meet the requirements of 3.3.4.

4.7.1.6 Battery case vent

3.4.5.3

. The following test shall be performed. Place a fully assembled battery into a fixture designed to contain possible bulging by the front, back and side faces of the battery case (see applicable specification sheet for face references). The fixture shall allow the battery to expand up to .010 inches over the specified maximum allowable dimensions. The fixture shall not cover the top and bottom of the battery. Tap an air line into the battery and increase the internal pressure of the battery 1.0 psi every 60 seconds until the battery case vent opens. Position the fixture with the pressurized battery so that it allows the battery to slide out through the bottom of the fixture. If the pressurized battery cannot slide out of the fixture, place weights on top of the battery. Measure and record the total weight used including the battery. Visually examine.