MIL-PRF-32383-4A_19_Feb_2019.pdf

AMSC N/A FSC 6140

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

INCH-POUND

MIL-PRF-

32383/4A(CR)

1 February 2019

DRAFT SUBJECT TO

CHANGE WITHOUT

NOTICE

SUPERSEDING

MIL-PRF-32383/4

6 March 2013

PERFORMANCE SPECIFICATION SHEET 4

BATTERY, RECHARGEABLE, SEALED, LITHIUM-ION, BB-2525 and BB-3525 6 The requirements for acquiring the product herein shall consist of this specification sheet and 8

MIL-PRF-32383 9

FIGURE 1. M32383/4-3 (BB-2525) Lithium Ion and M32383/4-4 (BB-3525) Lithium Polymer 13 Conformal Batteries (See Figure 7 for dimensions) 14

Note: Depicted battery segmentation is representative of a potential solution but is not a 15 requirement within this document. 16

NOTE: This draft, dated 1 February 2019 has been prepared by US Army PM SWAR and CERDEC, and it has not been approved and is subject to modification. DO NOT USE PRIOR TO APPROVAL. (Project 6140-2015-001)

MIL-PRF-32383/4A DRAFT

Unless otherwise specified, paragraph numbers are in reference to MIL-PRF-32383. Note that 18 the requirement and verification paragraphs included in this document that are in addition to 19 MIL-PRF-32383 are highlighted in BOLD. Their numbering is based on MIL-PRF-32383. 20

2 APPLICABLE DOCUMENTS 22

2.2. Government documents. 24

2.2.1. Specifications, standards, and handbooks. 26

Add the following: 27

DEPARTMENT OF DEFENSE SPECIFICATIONS 29

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), 31 NATO F-35, and JP-8 + 100 32

DEPARTMENT OF DEFENSE STANDARDS 34

MIL-STD-461 Requirements for the Control of Electromagnetic Interference 36

Characteristics of Subsystems and Equipment 37

MIL-STD-1275 Characteristics of 28 Volt DC Electrical Systems in Military Vehicles 39

MIL-STD-1472 Human Engineering 41 (Copies of these documents are available online at http://quicksearch.dla.mil/ or from the 43 Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 44 19111-5094.) 45

2.2.2. Other Government documents, drawings, and publications. 47 Add the following: 48

ADS-37A-PRF Electromagnetic Environmental Effects (E3) Performance and 50 Verification Requirements (Relevant pages of this document can 51 be found in APPENDIX A herein) 52

NWPAN-WP-01112013 Nett Warrior Interconnect Architecture White Paper 54

(Available from: Product Manager Ground Soldier Systems (PdM 55 GSS) Attn: SFAE-SDR-SWAR, 5966 12th Street, Building 1024, 56 Ft. Belvoir, VA. 22060) – Approved Nett Warrior compatible 57 connectors. 58

2.3. Non-Government publications. 60

Add the following: 61

IEC 61000-4-5 Electromagnetic compatibility (EMC) – Part 4-2: Testing and 63 measurement techniques - Electrostatic discharge immunity test 64

IEC 61000-4-9 Electromagnetic compatibility (EMC) – Part 4-9: Testing and 66 measurement techniques Pulse magnetic field immunity test 67

(Copies of this specification available online from International Electrotechnical Commission 69 https://webstore.iec.ch ) 70

ASTM G115-10 Standard Guide for Measuring and Reporting Friction Coefficients 72 (Copies of this specification are available online from ASTM International http://astm.org ) 74 Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 76 (Copies of this specification are available online from SBS Implementers Forum (SBS-IF) at: 77 www.sbs-forum.org) 78

REQUIREMENTS 81

Type – III or Type IV (see 1.2 for classification) 82 PIN – M32383/4-3 or M32383/4-4 (see 1.2 for PIN) 83 Specification requirements and test methods: The following requirements and test methods of 85 MIL-PRF-32383, identified therein as “when specified”, are applicable as indicated below: 86

“When Specified” Requirements 88

Requirement Requirement Paragraph

Test Method Paragraph

Applicability

Multilayer finish 3.4.4.1.3 Certification Yes Gold plating 3.4.4.1.4 Certification No Motor inrush current 3.5.5 4.7.2.12 Yes Charge enable 3.5.6 4.7.2.6 No SMBus 1/ 3.5.9 4.7.2.14;

4.7.2.15 Yes

Immersion, shallow 1/ 3.6.6 4.7.3.8.1 Yes Immersion, deep 3.6.6 4.7.3.8.2 No Transit drop, normal 3.6.7 4.7.3.9.1 Yes Transit drop, severe 3.6.7 4.7.3.9.2 Yes Drop while mated 1/ 3.6.7 4.7.3.9.2 Yes Nail penetration, cell 3.7.1.2 4.7.4.4 Yes Crush, cell 3.7.1.3 4.7.4.5 Yes Projectile 3.7.2.6 4.7.4.11 Yes Lithium Battery Safety Program (US Navy) Tests 3.7.2.7 4.7.5 Yes Electromagnetic interference 3.8 4.7.7 Yes

1/ As modified herein, both mated and unmated configurations. 89

3.2. First Article Requirements. 91

3.2.1. Certifications. 93

Add the following: 95

REQUIREMENT PARAGRAPH 96

Connector force disconnect 3.4.4 98 Connector 3.4.4.1.1 99 Battery Case 3.4.5 100 Smart Battery Identity 3.5.6 101 State-of-charge/Sate of Health 102 Display characteristics 3.5.8Error! Reference source not found. 103 Overvoltage protection 3.7.2.2 104

3.4. Physical characteristics. 106

3.4.3. Dimensions and weight. 108

Width shall be 7.60 +/- 0.06 inches. 109 Height shall be 8.65 +/- 0.05 inches. 110 Depth shall be no less than 0.50 inches and not greater than 0.70 inches. 111 Weight shall be no greater than 2.6 pounds. 112 All other dimensions shall be accordance with FIGURE 7 Conformal Battery Dimension. 114

3.4.4. Battery connector and electrical interfaces. 116

3.4.4.1. Electrical contacts. 118

3.4.4.1.1. Connector. Glenair connector Part Number 8070-1939-07ZNU6.7SY (printed 120 circuit board tails or colder cup) or TE Connectivity Part Number: 2828420-2 (7 position). The 121 primary (master) keyway shall be oriented downward, facing the charge terminal contacts. 122 Note: Other connectors may be approved by Project Manager Soldier Warrior Ground Soldier 124 System. Any proposed connector shall have the ability to mate with TE Connectivity and Glenair 125 Part Numbers identified in the Nett Warrior Interconnect Architecture White Paper (NWPAN-126 WP-01112013) and be approved by Project Manager Soldier Warrior Ground Soldier System 127 before implementation. 128 The connector shall provide a shell to shell shield impedance of not greater than 4 milliohms 130 when mated with any of the mating connectors listed below. 131

Sockets 1, 2, and 3 shall be capable of carrying not less than 5 amps continuous each. 133 Connector shall be capable of mating with plugs having the 6-6 or 6-7 pin configuration. The 135 connector shall be sealed to meet the requirements of section 3.6.6 (Immersion). The connector 136 shall be sealed in a way such that insertion of a plug with a 6-7 pin configuration does not 137 compromise the ability to meet Immersion and other requirements herein. 138 The pinout for the connector shall be as follows in “Connector Pinout Description” with socket 140 numbering depicted in FIGURE 2. Cerification is required 141

Connector Pinout Description 146

SOCKET DESCRIPTION TERMINAL MARKINGS

1 V+ Battery Voltage Batt +

2 V- Battery Ground Batt -

3 Charge + 1/ Charge +

4 SMBus Data Data

5 SMBus Clock Clock

6 SMBus ID (‘T-pin’) 2/ SB ID

7 No Connection (N/C) N/C 1/ Charge + shall be input only 148 2/ Safety Signal IAW Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 149

FIGURE 2. Connector Pinout Assignment 153

3.4.4.1.1.1. Connector disconnect pull force. The connector shall have a 15.0 +/- 5.0 155 pounds of force disconnect. Test per 4.7.1.3.1 156

3.4.4.1.2. Flat terminal. Add: The charge terminals shall be as shown in FIGURE 3, 158 Charge Terminal Pinout Assignment. Charge terminals shall be electrically protected against 159 short circuit and shall not source battery current. All four contacts shall be recessed 0.020 +/- 160

0.005 inches. 161

The battery shall be capable of being charged via both the main connector and the charge 163 contacts. The battery shall be capable of “wake up” charging via both the main connector and 164 the charge contacts. Wake up charge charging via the main connector shall be IAW the Smart 165 Battery Specified behavior for the Safety Signal. Wake up charging via the bottom contacts shall 166 be performed by accepting +5V between terminal 1 and 2 and responding to SMBus commands 167 before charging voltage is provided. 168

Charge Terminal Descriptions 170

POSITION (Left to Right)

DESCRIPTION TITLE

1 Charge Terminal, Positive CHG +

2 Charger Terminal, Negative (Ground) CHG -

3 SMBus Data DATA

4 SMBus Clock CLK

FIGURE 3. Charge Terminal Pinout Assignment 173

3.4.5. Battery case. 174

Delete from MIL-PRF-32383 the following sentences: “When plastics are used for the battery 176 case, the material shall be classified in accordance with UL Standard 94, Test for Flammability 177 of Plastic Materials for Parts in Devices and Appliances, except as otherwise noted herein. 178 Acceptable ratings include: HB; V-0; V-1; V-2; 5VA; 5VB; VTM-0; VTM-1; and VTM-2.” 179

Add: “The case material shall be classified in accordance with UL Standard 94, Test for 181 Flammability of Plastic Materials for Parts in Devices and Appliances, except as otherwise noted 182 herein. Acceptable ratings include V-0, 5VA, or 5VB.” 183

3.4.5.1 Replace reference to SOCI with SOCI/SOH 185

3.4.5.6. Surface friction. Batteries shall slide easily in and out of their pouch. When 187 tested as specified in 4.7.1.8 batteries shall have a coefficient of static friction of not greater 188 than 0.40 against a Cordura® fabric containing meta-aramid, nylon and cotton in a blend ratio of 189 43/30/27 percent by weight. 190

3.4.5.7. Battery case edges. The battery case edges, seams, and corners shall be 192 smooth. 193

3.4.6. Marking. All marking and labels shall be in accodance with MIL-STD-1472 195

3.4.6.6.1. Power interface marking. The location of the power interface marking shall be 197 adjacent to the power connector and clearly identify socket assignments. 198

3.4.6.6.2. Warning marking. 200

Add: Warning labels shall be not less than a 12 font; other labels shall not be less than a 10 201 point font.. 202

3.4.6.6.3. Terminal marking. The terminal (connector) marking shall be as shown in 204 FIGURE 4 and orientated as in FIGURE 7 205

FIGURE 4 Connector marking details 209

3.4.6.5. Instructions / notes. 210

The following charging instructions shall be marked on each battery: 212

CHARGE CONSTANT VOLTAGE AT 16.8V AT 5 AMPS MAX THROUGH CONNECTOR 214

BATTERY TEMPERATURE SHOULD BE BETWEEN 32°F (0°C) AND 113°F (45°C) DURING 215

CHARGE. 216

LOWER TEMPERATURE CHARGING IS PERMITTED BUT RUNTIMES WILL BE LOWER. 217

WARNING/STORAGE 218

DO NOT STORE ABOVE 160°F (71°C), CRUSH, MUTILATE, REVERSE POLARITY, 219

DISASSEMBLE, OR DISPOSE OF IN FIRE.” 220

3.4.6.6. Simplified battery label. The simplified battery label location shall be located on 222 the same surface as the charging instructions. 223

3.4.8. Battery condition for shipping. 225

Delete MIL-PRF-32383 3.4.8 in its entirety and replace with the following: 226

Each battery shall be shipped with an instruction card that shall contain instructions for 228 operation, charging, and maintenance of the battery to include long term storage/shipping 229 requirements per 3.4.6.5 (SDS, class of shipping, and shipping markings). 230

3.5. Electrical requirements. 232

3.5.2. Battery voltage. Battery must operate within the range of 10.0 volts to 20.0 volts. 234

3.5.3. Capacity. Minimum final voltage: 10 volts. 236

When subjected to the specific test listed below and discharged at the specified rate to minimal 238 final voltage, the battery shall have the following minimum capacity: 239

Test Capacity Requirements 241

Test Requirement Paragraph

Test Method Paragraph

Discharge Rate

Minimum Capacity

Capacity Discharge 3.5.3 4.7.2.3 See 4.7.2.3 148 WH Cycle life (224th cycle) 3.5.4 4.7.2.4 See 4.7.2.4 125 WH High rate discharge 3.5.3 4.7.2.5 5 A 9.0 AH Low temperature discharge 3.5.3 4.7.2.7 18 W 75 WH High temperature discharge 3.5.3 4.7.2.8 18 W 140 WH Motor inrush current 3.5.5 4.7.2.12 See 3.5.5 148 WH Charge acceptance 3.5.10.1 4.7.2.9 18 W 148 WH High temperature charge acceptance 3.5.10.1 4.7.2.9 18 W 130 WH Low temperature charge acceptance 3.5.10.1 4.7.2.9 18 W 130WH Retention of charge 3.5.10.2 4.7.2.10 18 W 135 WH Pulse discharge 3.5.3 4.7.2.11 See 4.7.2.12 7.0 AH Extreme low temperature discharge 3.6.1 4.7.3.2 18 W 75 WH Extreme high temperature discharge 3.6.1 4.7.3.3 18 W 130 WH Thermal shock (post-test) 3.6.3 4.7.3.5 18 W 130 WH

Mechanical shock (post-test) 3.6.3 4.7.3.6 18 W 135 WH Vibration (during test) 3.6.5 4.7.3.7 18 W 148 WH Vibration – Loose Cargo 3.6.5 4.7.3.7.1 N/A 148 WH Battery storage life 3.6.8 4.7.3.10 See 4.7.2.3 100 WH Impact 3.6.8 4.7.3.11 18W 148 WH Conformability 3.6.13 4.7.3.16 18W 148 WH Flexibility 3.6.9 4.7.3.12 18W 148 WH Electrostatic discharge 3.6.12 4.7.3.15 18W 148 WH Salt Fog 3.6.11 4.7.3.14 18W 148 WH Overcharge/electric leakage (post-test) 3.7.2.2 4.7.4.7 18W 140 WH Short circuit protection (post-test) 3.7.2.3 4.7.4.8 18 W 135 WH High temperature temporary cut off 3.7.2.4 4.7.4.9 18 W 105 WH Electromagnetic compatibility / interference

3.8 4.7.7 18W 148 WH

3.5.5. Motor inrush current. The discharge profile shall be as follows. (Note: this pulse is 243 modeled after the end item and not a motor.) Verify values in accordance with 4.7.2.12. 244

STEP Start time End time Current (A) (second:millisecond:microsecond)

1 00:000:000 00:000:400 65 2 00:000:400 00:000:915 33 3 00:000:915 00:025:000 25 4 00:025:000 05:000:000 6.5 5 05:000:000 10:000:000 5.5 6 10:000:000 Until Cutoff Voltage 5

3.5.8. State-of-charge- (SOCI)/State of Health (SOH) Display. 248 Delete 3.5.8 from MIL-PRF-32383 and replace with the following: 249

3.5.8 State-of-charge/State of Health indicator display characteristics. 251

The display shall have the following characteristics: 252

a. There shall be a single digital SOCI/SOH display located on the top central edge of 253 the battery pack (see Figure 7) The SOCI/SOH actuator shall be recessed and 254 shall be protected from inadvertent operation. 255

b. The load applied by the SOCI/SOH circuitry on the battery shall be not greater than 256 50 micro-amperes in the non-operating mode. 257

c. The device shall be designed to compensate for usage temperature and discharge 258 rate and shall monitor and adjust for changes in both during battery use. 259

d. In the event that an open-circuit condition should occur in a battery (within the pack 260 prior to the fuel gage) – ground or V+, the SOCI/SOH shall indicate 0% remaining 261 capacity. 262

e. The accuracy of the information displayed shall be +0%/-5%. 263

f. The SOCI/SOH shall provide readings of 0 to 100% in 1% increments and not less 264 than ¼ inch in height. The display shall visually distinguish between SOCI and 265 SOH and shall be discernable from any direction (i.e. distinguish between readings 266 of 001 and 100 or 85 and 58) 267

g. The display must be compatible with Night Vision Imaging Systems. The output of 268 the display at full intensity, measured in a direction normal to the display shall be 269

1.0 to 10.0 millicandelas. The display shall be capable of providing the correct 270 information in a temperature range of −30 to 55ºC and be capable of surviving 271 temperature extremes of −40ºC to 93ºC. Certification to the full intensity output and 272 storage temperature range requirements is required. 273

h. The SOCI/SOH display shall normally be in the ‘off’ mode and shall require a push-274 button actuator to activate the display. The push-button shall be capable of 275 operation by Soldiers wearing Mission Oriented Protective Posture (MOPP) IV and 276 cold weather gloves. The words “PRESS FOR REMAINING CAPACITY” shall 277 appear in close proximity to the actuator or the actuator shall be clearly visible to 278 ensure its function is known. The push-button actuator shall comply with the 279 following displacement and resistance requirements: 280

Push Button Requirements 282

DISPLACEMENT RESISTANCE

Not less than 0.008 in. 0.25 lbs.

Not greater than 0.050 in. 5.50 lbs.

i. At full intensity, the display shall only illuminate the state of charge level 284 appropriate to its usage level when viewed from a direction normal to the indicator 285 (i.e., no light bleed-through to levels/spaces meant for higher states of charge). 286 Time to full light intensity shall be not greater than two seconds. The display shall 287 remain at full intensity for not less than 3 seconds and shall self-extinguish in not 288 greater than 7 seconds of actuation when the actuator is held down. The display 289 shall extinguish any time the actuator is released in not greater than 7 seconds. 290

3.5.9. SMBus 292

Delete 3.5.9 from MIL-PRF-32383 and replace with the following: 293

Each battery shall be compliant with System Management Bus (SMBus) Specification Revision 294

1.1 and Smart Battery Data (SBData) Specification, version 1.1. Batteries shall be compatible 295 with appropriate Level 2 and Level 3 chargers (see 6.3.9). When tested as specified in 4.7.2.14, 296 Relative State of Charge value shall be accurate within +0/-5% of the actual state of charge for 297 the battery under test throughout the discharge. Manufacturer and battery data shall be correctly 298 programmed (see 4.7.2.15). 299

SMBus shall use 5V logic circuitry. Pull-up resistors will be provided by the charger. SMBus 301 circuitry shall respond to a SMBus query in not greater than 45 seconds. 302

3.5.11. Concurrent charge / discharge. 304

The battery shall be capable of being charged via pin 3 and simultaneously discharged via pin 1 305 of the connector (3.4.4.1.1). The battery shall disable the connector when being charged 306 through the charge terminal contacts. 307

3.6. Environmental requirements. 309

3.6.5. Vibration. 311

Replace “When tested as specified in 4.7.3.7” with “When tested as specified in 4.7.3.7 and 312 4.7.3.7.1” 313

3.6.8. Impact. Batteries shall be capable of being impacted without sustaining physical or 315 electrical damage. When tested as specified in 4.7.3.11 batteries shall meet the impact test 316 capacity requirements of 3.5.3 and the requirements of 3.6 (with the exception of defects in 106 317 of TABLE VIII). 318

3.6.9. Flexibility. Batteries shall be capable of flexing 800 times with a 1 inch displacement 320 in both directions on each axis without sustaining physical or electrical damage. When tested as 321 specified in 4.7.3.12 batteries shall meet the flexibility test capacity requirements of 3.5.3 and 322 the requirements of 3.6 323

3.6.10. Solar radiation. Batteries shall be capable of withstanding prolonged exposure to 325 sunlight without sustaining physical or electrical damage. When tested as specified in 4.7.3.13 326 batteries shall meet the requirements of 3.6. 327

3.6.11. Salt fog. Batteries shall withstand a salt fog atmosphere. When tested as specified in 329

4.7.3.14 batteries shall meet the salt fog test capacity requirements of 3.5.3 and the 330 requirements of 3.6. 331

3.6.12. Electrostatic discharge (ESD). Batteries shall withstand ESD to ±8kV, contact 333 discharge and ±15kV air discharge on any surface, panel component (including vent) or 334 connector, including exposed pins, in both operating and non-operating mode. When tested as 335 specified in 4.7.3.15 batteries shall meet the ESD capacity requirements of 3.5.3 and the 336 requirements of 3.6. 337

3.6.13. Conformability. Batteries shall be capable of bending under not greater than 35 339 pounds of force around curved surfaces of a 7 inch radius. Batteries shall conform to the 340 curvature of the above cited curved surface and maintain no greater than 3/16 inch distance 341 between the curved surface and entire battery surface while conformed. When tested in 342 accordance of 4.7.3.16 batteries shall meet the conformability capacity requirements of 3.5.3 343 and the requirements of 3.6. 344

3.6.14. Chemical resistance. Batteries shall not be affected by common chemicals in the 346 operational environment such as military decontamination or fuel. When testing in accordance 347 of 4.7.3.17 batteries shall meet the requirements of TABLE VIII. 348

3.7. Safety. 350

3.7.2. Battery safety. 352

3.7.2.2. Overcharge / electrical leakage. 354

Add: Batteries shall have three levels of protection between each set of charge contacts (both 355 primary connector and charge contacts) and the battery pack that shall withstand not less than 356 50V continuous. There shall be not less than two different circuit types and a single mode of 357 failure shall not allow the cells to see an overvoltage condition. Certification is required. 358 Replace: 4.7.4.7 step f with: “F. Repeat steps a through e for a total of 1 cycles. 359

3.7.2.4. High temperature temporary cutoff devices. 361

Add: The quantity of thermoswitches shall be not less than 1. 362

3.7.2.8. Nail Penetration. Batteries shall be capable of safely withstanding penetration by 364 sharp objects. 365

3.7.2.8.1. Safety. Batteries shall not exhibit any unsafe conditions when penetrated by a 367 sharp object(s). An unsafe condition is defined as excessive heat, flame, and/or smoke 368 generation, violent reaction or ejection of materials when tested as specified in 4.7.4.8. The 369 battery shall exhibit any of the aforementioned unsafe conditions for not less than two minutes 370 after the completion of the test. 371

3.7.2.8.2. Protective Devices. The battery shall include protective 373 devices/circuitry/material to prevent thermal event propagation between cells. 374

3.8. Electromagnetic compatibility. 376

Add: The battery shall be appropriately filtered and shielded to comply with the applicable 377 emissions and susceptibility requirements of MIL-STD-461 Table V, Aircraft, Army, including 378 Flight Line and as tailored herein. When tested as specified in 4.7.7 the batteries and system 379 shall function properly. 380

3.9. Transportation requirements. 382

Replace with “Batteries shall be prepared for shipping IAW UN ST/SG/AC.10/11 current 383 revision or 49 CFR Parts 171, 172, 173, 175 Hazardous Materials: Transportation of Lithium 384 Batteries.” 385

3.10. Interchangeability. 387

Add: Applicable “currently fielded” chargers are listed under 4.6.3 388

3.11. System level integration. The battery shall be capable of supplying voltage (volts) as 390 defined in Section 3.5.2 to a connected Nett Warrior system IAW with current (amps) 391 requirements in Section 3.5.5. 392

4. VERIFICATION 394

4.4. First article inspection. 396

Modify MIL-PRF-32383 sample sizes as defined below: 397

a. Group 1 (GR1) – Functional tests: increase sample size from 12 samples to 16 399 samples. 400

b. Group 2 (GR2) – Electromagnetic interference tests: decrease sample size from five 401 samples to two samples. 402

Add: 403

e. Group 5 (GR5) – Nail penetration tests: create group with sample size of 20 404

Replace TABLE IV. First article tests, complete batteries with the following noting the sequential 405 order of sequence of testing in order of that provided in the table: 406

Inspection/Test Req’t

Test Method

Samples or Group (GR)

GR1 GR

(2 ea)

GR

(8 ea)

GR4

(15 ea)

GR5

(20 ea)

C/T(1

1 2 3 4 5,6 7,8

9, 11, 13, 15, Visual and mechanical 3.4 4.7.1.1 C Dimensions and weight 3.4.3 4.7.1.2 C Battery open circuit voltage 3.5.2 4.7.2.2 C Insulation resistance 3.7.2.1 4.7.4.6 C Altitude 3.6.2 4.7.3.4 C Charge acceptance 3.5.10.1 4.7.2.9 C Concurrent charge / discharge 3.5.11 4.7.2.16

C

Capacity discharge (initial) 3.5.3 4.7.2.3 C,G Cycle life 3.5.4 4.7.2.4 C Battery storage life 3.6.8 4.7.3.10 C Overcharge/electrical leakage 3.7.2.2 4.7.4.7 C

Overvoltage protection 3.7.2.2.1

Certifica tion & 4.7.4.7.

Low temperature discharge 3.5.3 4.7.2.7 C,G High temperature discharge 3.5.3 4.7.2.8 C,G Nail Penetration 3.7.2.6 4.7.4.11 C High rate discharge 3.5.3 4.7.2.5 C Retention of charge 3.5.10.2 4.7.2.10 C Pulse discharge 3.5.3 4.7.2.11 C

Motor inrush current 3.5.5 4.7.2.12 C Thermal shock 3.6.3 4.7.3.5 C Mechanical shock 3.6.4 4.7.3.6 C Vibration (during test) 3.6.5 4.7.3.7 C Vibration (loose cargo)

3.6.5 4.7.3.7.

Conformability 3.6.13 4.7.3.16 C Chemical resistance 3.6.14 4.7.3.17 C Connector insertion 3.4.4.1.

1 4.7.1.3

Connector disconnect pull force

3.4.4.1.

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 C Transit drop, severe

3.6.7 4.7.3.9.

C,G

Surface friction 3.4.5.6 4.7.1.8 C FlexibilityTest 3.6.9 4.7.3.12 C Impact 3.6.9 4.7.3.11 C Salt Fog 3.6.11 4.7.3.14 C Electrostatic Discharge (ESD) 3.6.12 4.7.3.15 C Solar radiation 3.6.10 4.7.3.13 C Immersion, shallow (post drop & flex) 3.6.6

4.7.3.8.

State of charge/State of Health 3.5.8 4.7.2.14

SMBus 3.5.9 4.7.2.15 C Full capacity discharge 3.5.3 4.7.2.3 C,G Concurrent charge / discharge 3.5.11 4.7.2.16

Extreme low temp. discharge 3.5.3 4.7.3.2 C Extreme high temp.

discharge 3.5.3 4.7.3.3

Battery case vent 3.4.5.3 4.7.1.6 C Short circuit protection 3.7.2.3 4.7.4.8 C High temp. temporary cut-off 3.7.2.4 4.7.4.9 C High temp. permanent cut-off 3.7.2.5 4.7.4.10 C Electromagnetic compatibility/interference 3.8 4.7.7

Interchangeability 3.10 4.7.6 G US Navy Safety Tests 3.7.2.7 4.7.5 G SMBus 3.5.9 4.7.2.15 C System Level Integration 3.11 4.7.8 G

(1) – Contractor( C) or Government conducted test 408

4.5. Conformance inspection. 410

Add to MIL-PRF-32383 sample sizes as defined below: 411

4.5.1. Group A inspection. 413

Add to TABLE V of MIL-PRF-32383 the following rows: 414

Capacity discharge (initial)

3.5.3 4.7.2.3

SMBus 3.5.9 4.7.2.15

4.5.2. Group B inspection. 416

Remove from TABLE VI of MIL-PRF-32383 the following row: 417

Capacity discharge (initial)

3.5.2 4.7.2.3

Add to TABLE VI of MIL-PRF-32383 the following rows: 419

Concurrent charge / discharge

3.5.11 4.7.2.16

FlexibilityTest 3.6.10 4.7.3.12

Electrostatic discharge

(ESD)

3.6.14 4.7.3.16

4.5.3. Group C inspection. 422

4.5.3.1. Group C frequency. 424

Add to TABLE VII of MIL-PRF-32383 the following rows: 425

Impact 3.6.8 4.7.3.11 Salt Fog 3.6.11 4.7.3.14 Flexibility Test 3.6.13 4.7.3.16 Overcharge/Electrical Leakage

3.7.2.2 4.7.4.7

Nail penetration 3.7.2.8 4.7.4.8

4.6. Charge methods. 428

4.6.1. Constant potential, current limited. 430

Add: A constant potential of 16.8 volts (or a voltage as approved by PM SWAR GSS and 431 requested via the SMBus interface) shall be applied with current limited to 5.0 amperes, to a 432 charge cut off of 750 milli-amperes. 433

4.6.3. Alternate charging. 435

Add: The following charger may be used whenever the requirement allows use of alternate 436 charging: 437

ITEM PART NUMBER NSN CAGE 439

Charger (Ultralife) CH0008 6130-01-545-1983 0UU59 440 Charger (Thales UBC) 4102871-501 6130-01-659-7090 23386 441 Charger (Thales eMUBC) 1100743-1672 6130-01-643-5527 23386 442 Squad Power Mgr. (Protonex) SPM-612 6130-01-617-5294 3B0F7 443 Squad Power Mgr. (Protonex) SPM-622 6130-01-626-9656 3B0F7 444 SPC Charger, PP-8498 (Bren-Tronics) BTC-70801 5310014952839 51828 445 ABC Charger (Bren-Tronics) BTC-70100 6310016603696 51828 446 CWB General Adapter (Bren-Tronics) BTA-70910A 5940016594717 51828 447

4.7. Test methods. 449

4.7.1. Physical characteristics. 451

4.7.1.3. Connector insertion test. 453

Add: Mate and un-mate the connector with a plug having the 6-7 pin configuration. Perform a 454 visual inspection on the plug and socket and verify no pins or sockets are crushed, recessed, or 455 otherwise damaged. 456

4.7.1.3.1. Connector disconnect pull force test. 458

a. Secure battery in a stationary holding device and grip the cable 6 to 12 inches 460 away. 461

b. The grip should not slip or damage the cable during the test. 462

c. Apply a static force of between 6 and 12 pounds. 463

d. Verify that the quick disconnect breaks. 464

e. Examine {Battery} for no damage or connector separation. 465

f. Repeat process with force below 5 pounds and verify item does not disconnect. 466

g. Repeat process with force above 12 pounds and verify item disconnects without 467 any damage. 468

h. Mate and un-mate the connector with a plug having the 6-7 pin configuration. 469

Perform a visual inspection on the plug and socket and verify no pins or sockets 470 are crushed, recessed, or otherwise damaged 471

4.7.1.8. Surface friction. Verify battery surface is dry and free of any lubricants prior to 473 test. Measure and report the coefficient of static friction per test method D2394 of ASTM G115-474 10, Standard Guide for Measuring and Reporting Friction Coefficients. Verify that the value is 475 not greater than 0.4. 476

4.7.2. Electrical performance tests. 478

4.7.2.3. Capacity discharge 480

Replace: a. with: “Charge batteries IAW 4.6. Use of 4.6.3 is acceptable.” 481

For c.: Use a constant rate of 18W. 482

Add: Press and release SOCI/SOH actuator. Observe display and verify operability. 484

4.7.2.4. Cycle life test. 486

Delete 4.7.2.4 from MIL-PRF-32383 in its entirety and replace with the following: 487

a. Cycles 1 through 27 - Charge the batteries in accordance with 4.6; use of 4.6.3 is 489 permitted. Allow batteries to rest for not greater than one hour. Discharge at 18W to 490 cutoff voltage. Allow batteries to rest for not greater than one hour prior to the start of 491 the next cycle. Every seventh cycle a rest of not greater than five hours is permitted 492 before and after charge. 493

b. Cycle 28 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. 494 Perform the electric leakage test of 4.7.4.7d. Allow batteries to rest for not less than 4 495 hours. Discharge at 2A to cutoff voltage. Record battery capacity. 496

c. Repeat steps a through c above until the 224 cycles are obtained. 497

d. After completion of the cycle life test, visually examine batteries for the criteria of 498 TABLE VIII. Batteries shall meet the cycle life and visual mechanical requirements (see 499

3.1 and 3.5.3) 500

4.7.2.9. Charge acceptance. 502

Modify MIL-PRF-32383 as defined below: 503

a. Change Step C to charge batteries with SMBus compliant charger. 504

b. Change the temperature in Step F to 55°C from 50°C. 505

4.7.2.11. Pulse discharge. 507

Add:Discharge with 5 amperes for 5 seconds, rest for 25 seconds. Continue discharge to final 508 voltage. 509

4.7.2.14. State-of-charge/State of Health (SOCI/SOH) Display 511 Delete 4.7.2.14 from MIL-PRF-32383 in its entirety and replace with the following: 512

The following test shall be performed. 514

a. Charge each battery in accordance with 4.6; use of 4.6.3 is permitted. 515

b. Verify location and marking. 516

c. Press and release the SOCI/SOH actuator. 517

d. Measure and record the following to the nearest tenth of a second: (1) time from 518 actuation to full intensity of the lights or digital display; (2) time from reaching full 519 intensity until the lights extinguish; and (3) the total time from actuation until the 520 lights extinguish. 521

e. Measure displacement and resistance values for the actuator and record the 522 results. 523

f. Press each sample against a flat, transparent surface with not less than 5 lbs. of 524 force, with the face including the actuator against the surface. 525

g. Observe whether or not the display illuminate in accordance with 3.5.8; record and 526 verify the response(s) as applicable. 527

h. Discharge batteries at the C/10 rate as follows: one battery at −10 ± 2ºC (+14ºF) 528 and one at 55 ± 2ºC (130ºF). 529

i. Continuously discharge batteries to the following approximate states of charge, 530 stopping the discharge at each state: 90%; 70%; 50%; 30%; 10%. 531

j. Obtain the SOCI/SOH readings while the test battery is not subject to discharge. 532 For each of the states of charge states in (i), observe the indication of the state of 533 charge indicator, read the SMBus data output, and record both indications after 534 each partial discharge. Environmental chambers may be paused or shut off while 535 accessing batteries to obtain the SOCI/SOH readings. For samples tested at 536 −10°C, care is needed to limit the freezing of condensation at the battery to test 537 circuit interface. 538

k. Once the SOCI/SOH readings have been obtained, restart the environmental 539 chamber and restart the discharge in not less than 15 minutes after return to the 540 required test temperature (for samples tested at −10°C, allow sufficient time to 541 clear the frost if condensation has frozen on batteries). 542

l. Discharge the batteries to final voltage. 543

m. Observe the indication of the state of charge indicator, read the SMBus data 544 output, and record the indications. Batteries shall meet the requirements of 3.5.8. 545

4.7.2.16. Concurrent charge / discharge. 547

Perform the following charge & discharge tests. Verify that no charge condition or battery failure 548 occurs: 549

a. Test A. Connect a 100% SOC battery to a 2 Amp load at pin 1 of the battery 551 main power connector. Apply a 16.8 VDC 1 Amp current limited supply at pin 3 552 of the battery main power connector. Allow charge to continue for 2 hours at 553 room temperature. Verify that for 2 hours that the battery does not take in a 554 charge current less than 0.95 Amps at pin 3 and that the battery SOC is not less 555 than 80% (+/- 10%). 556

b. Test B. Connect battery from Test A to a 1 Amp load at pin 1 of the battery main 557 power connector. Apply a 16.8 VDC 2 Amp current limited supply at pin 3 of the 558 battery main power connector. Allow charge to continue for 2 hours at room 559 temperature. Verify that after 2 hours the battery does not take in a charge 560 current greater than 1.0 Amps at pin 3 and that the battery SOC is greater than 561 90%. Continue charge/discharge conditions for another 4 hours and verify that 562 the battery SOC is at 100% and verify that SMBus current never exceeds 0 563 Amps. 564

c. Test C. Connect a 90% SOC battery to a 0.9 Amp load at pin 1 of the battery 565 main power connector. Apply a 16.8 VDC 1 Amp current limited supply at pin 3 of 566 the battery main power connector. Allow charge to continue for 2 hours at room 567 temperature. Verify that after 2 hours the battery SOC is equal to or greater than 568 90%. 569

d. Test D. Connect an 80% SOC battery to a 2 Amp load at pin 1 of the battery 570 main power connector. Apply a 16.8 VDC 1 Amp current limited supply at the 571 Charge + contact of the battery. Allow charge to continue for 2 hours at room 572 temperature. Verify during test that no voltage/current is available at pin 1. Verify 573 after 2 hours that the battery SOC is greater than 80%. 574

e. If a rapid charge technology is employed, any alternate charging regime shall be 575 vetted with and pre-approved by PM SWAR GSS. 576

4.7.3. Environmental tests. 578

4.7.3.7. Vibration. 580

4.7.3.7.1 Vibration, loose cargo transportation. Charge batteries in accordance with 582 4.6; use of 4.6.3 is permitted. Batteries shall be subjected to loose cargo testing in accordance 583 with MIL-STD-810 Method 514 Procedure II for not less than 20 minutes duration. Batteries 584 shall initially be placed stacked one on top of another in the package tester with no other 585 equipment present. After Step 4 of Procedure II, proceed to Step 9. Batteries shall meet the 586 requirements of para 3.6. 587

4.7.3.8. Immersion. 589

4.7.3.8.1 Immersion, shallow. 591

Delete MIL-PRF-32383 4.7.3.8.1 in its entirety and replace with the following: 592

Mate and un-mate the connector with a plug having the 6-7 pin configuration. Perform a 594 visual inspection on the plug and socket and verify no pins or sockets are crushed, 595 recessed, or otherwise damaged. 596

Test ten batteries in accordance with MIL-STD-810, Method 512, Procedure I. The test 598 samples shall be fully charged and configured as follows: 4 CWB in operating 599 configuration (with sealed mating connector attached to 18W load) and three without 600 dust cap and three with supplied dust cap attached. Note, cleaning procedures allowed 601 in accordance with Appendix B for systems under test without any dust cap or connector 602 attached are allowed post immersion. 603

For Step 6, use a duration of 2 hours in saltwater per ASTM D-1141. 605 As applicable, during the immersion period verify that the batteries provide a constant 607 18W to the load for the connected (mated) CWBs. 608 For Step 9, conduct Capacity Discharge Test in 3.5.3. Note, immersion testing shall be 610 conducted post other battery stress testing such as drop or flexibility as required here for 611 test sequences. 612

4.7.3.8.2 Immersion, deep. 614

Delete 4.7.3.8.2 from MIL-PRF-32383 in its entirety. 615

4.7.3.9. Transit drop. 617

4.7.3.9.2. Transit drop, severe. 619

Modify MIL-PRF-32383 as follows: 620

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted and 622 verify that the State of Charge Indicators are properly functioning. 623

b. Replace “height not less than 30 inches onto cured concrete” with “height not 624 less than 48 inches onto surface specified in MIL-STD 810 Method 516 625 Procedure IV” 626

c. Perform drops 1 – 10 in Table IX on both mated and unmated batteries (4 627 mated, 3 unmated, and 3 with supplied dust caps). The mated battery tests 628 shall utilize the Nett Warrior battery input mating cable. 629

d. Verify that here are no indications of potential start of structural or mechanical 630 damage that could further lead to system failures. At a minimum verify each 631 pack with visual inspection of pack skin, contact terminals, Connectors, and 632 SOCI/SOH indicators for any physical damage, also verify that capacity 633 meets that of section 3.5.3. 634

4.7.3.11. Impact. 636

The following test shall be performed: 637

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted and verify 638 that the State of Charge Indicators are properly functioning. 639

b. Place the battery on an ESAPI side plate backed by a sandbag. 640

c. Drop a 16 lb. (+/- 2oz.) weight with rounded edges from not less than 36 inches 641 onto the center-point of the battery +/-one inch. 642

d. Repeat step c for the left and right sides of the horizontal centerlines of the 643 battery not less than one half inch and not greater than two inches from the edge. 644

e. Perform the capacity discharge of 4.3.7.2 and verify that capacity is not below 645 that of 3.5.3 for Capacity Discharge minimum. 646

f. Verify that here are no indications of potential start of structural or mechanical 647 damage that could further lead to system failures. At a minimum verify each 648 pack with visual inspection of pack skin, contact terminals, Connectors, and 649 SOCI/SOH indicators for any physical damage, 650

Batteries shall meet the requirements of 3.5.3, 3.6, and 3.6.8. 652

4.7.3.12. Flexibility Test. 654

The following test shall be performed. Refer to Figure 7. 655

a. Fully charge batteries in accordance with 4.6; use of 4.6.3 is permitted. 656

b. Soak the battery for not less than four hours at not greater than -20oC. 657

c. Place the battery in a fixture which allows the center of the battery to bend while 658 holding the edges. The edges can pivot in the direction of the bend. 659

d. At a distance equidistant between the centerline edges of the battery provide 660 sufficient force to move the battery up and down 1 inch in each direction 200 661 times. One flex consists of an upward and a downward motion. 662

e. Rotate the centerline of the battery 90 degrees in the fixture. 663

f. Repeat steps d and e for 200 flexes 664

g. Soak the battery for not less than four hours at not less than 60oC. 665

h. Repeat steps c through f. 666

i. Verify proper SOCI/SOH functionality with 4.7.2.14. Charge battery IAW 4.7.2.6 667

j. Verify that here are no indications of potential start of structural or mechanical 668 damage that could further lead to system failures. At a minimum verify each 669 pack with visual inspection of pack skin, contact terminals, Connectors, and 670 SOCI/SOH indicators for any physical damage, 671

Batteries shall meet the requirements of 3.5.3, 3.6, and 3.10. 673

FIGURE 5 Battery Flexibility 676

Note: Figure not to scale 677

4.7.3.13. Solar radiation. Fully charge batteries in accordance with 4.6; use of 4.6.3 is 679 permitted and verify that the State of Charge Indicators are properly functioning. The following 680 test shall be performed. Test batteries per MIL-STD-810, Method 505, Procedure II using the 681 spectral power distribution below for seven days. Position one battery with the front face up and 682 one battery with the front face down Wind speed shall be sufficient to maintain the battery 683 surface temperature below 75⁰C. Below 65°C surface temperature wind speed shall be 0 mph. 684 Batteries shall meet the requirements of 3.6.12 and 3.6. 685

Spectral power distribution 687

Spectral

Bandwidt h

Natural

Radiation (% of

Tolerance

(% of total)

Irradianc e

Spectral Region Min Max

Ultraviolet - B 280-320 0.5 0.3 0.7 5.6 5.6

Ultraviolet - A 320-360 2.4 1.8 3 26.9

62.7 360-400 3.2 2.4 4.4 35.8

Visible 400-520 17.9 16.1 19.7 200.5

580.

520-640 16.6 14.9 18.3 185.9 640-800 17.3 12.8 19 193.8

Infrared 800-3000 42.1 33.7 50.5 471.5 471.

Totals 1120 1120

4.7.3.14. Salt fog. The following test shall be performed. Test batteries per MIL-STD-810, 689 Method 509 for four 24 hour cycles alternating 24-hour periods of salt fog exposure and drying 690 conditions for a minimum of four 24-hour periods (two wet and two dry). The water used for the 691 saltwater solution shall have a resistivity of not greater than 5 mega-ohms per cm. The battery 692 shall meet the requirements of 3.6, 3.6.15, and 3.5.3. Note, posttest battery cleaning is allowed 693 as described in accordance with Section 6 notes - Appendix B and/or approved by PM SWAR 694 GSS, for cleaning of an unconnected, un plugged - unprotected power connector, prior to the 695 verification of the requirements of 3.6, 3.6.15, and 3.5.3. 696

4.7.3.15. Electrostatic discharge (ESD). Charge batteries in accordance with 4.6; use of 698

4.6.3 is permitted. Subject the batteries to both the contact and air discharge test of IEC 61000-699 4-2, Level 4, to include each contact (both charge and main connector), connector shield, 700 battery case, seams, and the SOCI/SOH. The battery shall be tested with no load and under an 701 18W load. Verify that a load of 18W can be sustained for 1 minute following the test. Fully 702 charge the battery via the SMBus and perform the discharge test of 4.7.2.3 once with the 703 primary connector and once with the bottom charge contacts. The battery shall meet the 704 requirements of 3.6, 3.6.13, and 3.5.3. 705

4.7.3.16. Conformability. An Electrical Mechanical (EM) load frame equipped with a 707 reversible load cell (capacity not to exceed 200 lb-f) shall be used to measure the compressive 708 force required to conform the battery to the 7 inch radius curved surface. Refer to Figure 6. 709

FIGURE 6 Conformability test fixture 713

Note: Figure not to scale. 714

Battery primary side will be with the power connector positioned in the upper left corner coming 716 out the left side and charge contacts coming out the bottom (refer to FIGURE 7). Top to bottom 717 will be considered the vertical axis and left to right the horizontal axis. The other side of the 718 battery will be the secondary side. 719

The following test shall be performed: The rollers shall roll freely on the battery while the upper 720 fixture moves vertically downward. The rollers shall be spread at a fixed distance when the 721 battery is centered over the lower fixture to minimize friction as it curves the battery. 722

a. Ensure that the batteries are not tested in a prior conformed, pre-stressed 724 condition, each battery shall be placed on a flat surface between each 725 compressive trial to allow it to return to a flat condition. 726

b. Center the upper fixture above the lower fixture. 727

c. Place the battery on the center of the lower fixture, oriented primary side (power 728 connector to left and contacts out of front of the fixture) along the vertical axis. 729

d. Move the upper fixture to just above or to touch the battery. 730

e. Ensure that the rollers are within ½ inch of the edges of the battery (+/- ¼ inch). 731

f. Once the battery is in position for test, allow no than 1 minute time to start test. 732

Note: Battery relaxation might start and roller contact may be lost when the battery 733 is placed on curved surface for an excessive amount of time. 734

g. Perform test by lowering the upper fixture with a compressive cross head rate of 2 735 inches per minute. 736

h. Record load, displacement, and time measurements at a data acquisition rate of 737 100 ms. 738

i. Stop the test when the compressive load threatens to crush the battery. 739

j. Remove the tension of the upper fixture and lay the battery down flat on a table 740 for 2 minutes between each measurement. 741

k. Repeat steps b. through i. in each of the other three orientations (secondary side 742 horizontal axis, primary side horizontal axis, and secondary side vertical axis) and 743 record data for each orientation. Each test set shall be performed by alternating 744 the battery orientation after each measurement. 745

l. Repeat the same procedure for each orientation a total of five (5) times for a total 746 number of 20 runs for the battery. 747

Verify batteries meet requirements of 3.6.13. 749

Verify discharge capacity as part of 4.7.2.3. 751

4.7.3.17. Chemical resistance. The following test shall be performed. Batteries shall be 753 sprayed separately with each of the following substances below. The substance shall cover not 754 less than 50% of the surface area of the battery and include portions of all seams, SOCI/SOH, 755 vent, label, charge terminal contacts, and connector. After standing for not less than 10 minutes, 756 the batteries shall be rinsed with soap and water. Batteries shall meet the requirements of 757

3.6.14. 758

a. JP-8 per MIL-DTL-83133G or commercial diesel fuel. 760

b. Sodium Hypochlorite 5.25% (household bleach). 761

4.7.4. Safety tests. 763

4.7.4.7. Overcharge / electrical leakage. 765

Add: Charge at 2.36 amperes with a charge voltage limit of 50 volts minimum during the 21-766 hour overcharge period of 4.7.4.7b. Discharge batteries at a constant 28W load to final voltage 767 in step 4.7.4.7e. One sample shall be tested via the main connector and one sample shall be 768 tested via the charge contacts. Verify that the battery meets the overcharge/electrical leakage 769 capacity requirements of 3.5.3. 770

4.7.4.8. Nail Penetration Test 772

The following test shall be performed. The batteries under test shall be recorded using video (at 774 not less than 1080p 30 frames per second) and thermal cameras while subject to the following 775 nail penetration tests. Recordings shall not cease until 10 minutes following the impact of the 776 last nail in the test. 777

Single penetration test 779

a. Fully charge the battery in accordance with 4.6; use of 4.6.3 is permitted. 781

b. Place the batteries on a surface that will not inhibit the movement of the nail 782

c. Mark a random location on each test sample to be penetrated, avoiding any 783 critical areas. 784

d. Batteries shall be placed on a resistive load of 30Ω +/- 10%. 785

e. Use a 2.5 mm DIA stainless steel nail with a length that exceeds the width or 786 diameter of the battery. Drive the nail completely through the samples. 787

f. Record for each test: the date, time, place, ambient and battery temperatures, 788

(not less often than once per 15 seconds), and any events (e.g. smoke, fire, cell 789 activity, and disassembly) along with the event time and associated event 790 severity. 791

g. Batteries shall meet the requirements of section 3.7.2.8. 792

Multiple nail penetration test: 794

a. Fully charge the battery in accordance with 4.6; use of 4.6.3 is permitted. 796

b. Place the batteries on a surface that will not inhibit the movement of the nail 797

c. Randomly mark no less than three location on each test sample to be 798 penetrated, avoiding any critical areas. 799

d. Batteries shall be placed on a resistive load of 30Ω +/- 10%. 800

e. Use a 2.5 mm DIA stainless steel nail with a length that exceeds the width or 801 diameter of the battery. Drive the nail completely through the samples. 802

f. Record for each test: the date, time, place, ambient and battery temperatures, 803

(not less often than once per 15 seconds), and any events (e.g. smoke, fire, cell 804 activity, and disassembly) along with the event time and associated event 805 severity. 806

g. Batteries shall meet the requirements of section 3.7.2.8. 807

4.7.7. Replace: Electromagnetic interference. 809

CWB EMI shall be characterized with a PM SWAR GSS approved U.S. Army system such as a 810 Nett Warrior System as a load for the CWB. Conducted tests shall reflect battery contributions 811 shall be recorded and verified to not exceed that of MIL-STD-461. Note, the Government may 812 require personnel with security clearance or may conduct independent testing and adjudication 813 of independent test results. 814

CS114: Applicable if permanently integrated power cable is part of battery. Testing shall utilize 816 Aircraft (External or Safety Critical) level limits 817

CS115: Applicable if permanently integrated power cable is part of battery. Testing shall utilize 819 Aircraft (External or Safety Critical) level limits 820

CS116: Use limits of FIGURE CS116-2. 822

RE101: Use the limites of FIGURE RE 101-1 824

RE102: Use the limits of FIGURE RE102-4 from 2 MHz to 18 GHz for the Nett Warrior 826 application 827

RS101: Not applicable 829

RS103. Testing shall utilize Aircraft (External or Safety Critical) level limits for2 MHz to 18 GHz. 831

4.7.8. System level integration. Verify through test that battery meets requirements of 3.11 833 while connected to Nett Warrior Extended Mission Configuration. 834 Repeat testing in 4.7.7 with battery connected to NW system. Radios shall be tested at a 836 minimum of 20 frequencies or 10 frequencies per operational band for any multi-band radio. 837

ADDITIONAL FIGURES 839

FIGURE 7 Conformal Battery Dimensions 840

NOTE: Dimensions are in inches and degrees. Unless otherwise specified, tolerances are: 842 For distances +/- 0.01 inches 843 For angles +/- 0.05 degrees 844

6 NOTES 845

Changes from previous issue: Marginal notations are not used in this revision to identify 847 changes with respect to the previous issue due to the extent of the changes. 848 Add: (This section contains information of a general nature which may be helpful but is not 850 mandatory) 851

6.1. Intended use. This battery is intended…