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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 Type
number
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 [email protected]. 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.

AMSC N/A FSC 6140

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

2.1 General. The documents listed in this section are specified in sections 3 and 4 of
this specification. This section does not include documents 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.)

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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. When specified (see 6.2), 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 PARAGRAPH
a. Metals 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. 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 4.7.1.5, 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. 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 6.3.8). Certification is required.

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

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. Cells used to build batteries shall have an individual
protective sleeving or coating. Material selected shall meet the requirements of 3.3.4; 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. Unless otherwise specified (see 3.1), 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. 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 4.7.1.4, battery terminals
shall not tear, rip, be displaced or separate from the battery case.

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3.4.4.1.3 Multilayer finish. When specified (See 3.1), 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. When specified (see 3.1), 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. 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 4.7.1.7 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. Unless otherwise specified (see 3.1), the battery shall
be designed to prevent dimensional expansion that will prevent its removal from equipment.

3.4.5.3 Battery case vent. 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 4.7.1.6, 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. The color of the battery case shall be as specified below, in accordance
with FED-STD-595.
a) Type I (Ni-Cd) and Type II (Ni-MH) batteries shall be lusterless green, chip number
34088.
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.

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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.

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

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3.4.6.5 Instructions / notes. Each battery shall be marked with complete instructions for
operation and charging of the battery, which shall include the following:
(Preferred charging method)
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. 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 3.1). 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)

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For more information see

http://battery.army.mil

FIGURE 1. Sample simplified battery label

Note: Battery nomenclature and values are fictitious

3.4.6.7 Color. The color of the marking shall be as specified below.

a. Type I (Ni-Cd) batteries – black
b. Type II (Ni-MH) batteries – white
c. Types III & IV (Li-ion & Li-Po) batteries – black

3.4.6.8 Permanency and durability. Marking shall be capable of withstanding all tests of
4.7, 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 3.1).

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.

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3.4.8.1 Dust cap or cover. Each battery shall be furnished with a dust cap (see 3.1), 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. 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 4.7.2.1, 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 3.1).

3.5.3 Capacity. The discharge in amperes hours or watt hours as required (see 3.1)
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. When tested as specified in 4.7.2.4 batteries shall be capable of
retaining the specified capacity during and after 224 cycles (see 3.1).

3.5.5 Motor inrush current. When specified (see 3.1), 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. When specified (see 3.1), 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. The power consumption for all electronics within the battery
shall be less than 350PA, per battery or independent section where applicable, at 20oC. (See
4.7.2.13)

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3.5.8 State-of-charge indicator (SOCI). Each battery shall indicate its current state of
charge. The state of charge display location shall be as specified (see 3.1). 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. The state of charge ranges of the SOCI displayed shall be accurate
within the tolerances stated above in 3.5.8. 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. When specified (see 3.1), 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. 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 4.7.2.7 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. When tested as specified in 4.7.2.9, batteries shall meet the
capacity requirements 3.5.3 and the visual mechanical requirements of TABLE VIII.

3.5.10.2 Retention of charge. Batteries shall be capable of maintaining the required

minimum capacity after storage at 50oC (122oF) for 7 days. When tested as specified in
4.7.2.10, batteries shall meet the capacity requirements 3.5.3 and the visual mechanical
requirements of TABLE VIII.

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3.6 Environmental requirements. Each battery when subjected to specified

environmental tests of TABLE I 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. 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 4.7.3.2 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. Batteries shall experience no deleterious effects from high altitude.
When tested as specified in 4.7.3.4, 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. 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 4.7.3.5, batteries shall meet the capacity
requirements of 3.5.3 and the requirements of 3.6.

3.6.4 Mechanical shock. Batteries shall be capable of withstanding mechanical shock

environments without sustaining physical or electrical damage. When tested as specified in
4.7.3.6, batteries shall meet the capacity requirements of 3.5.3 and the requirements of 3.6.

3.6.5 Vibration. Batteries shall be capable of withstanding vibration environments

without sustaining physical or electrical damage. When tested as specified in 4.7.3.7: (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.

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3.6.6 Immersion. Batteries shall be capable of withstanding water immersion without

sustaining physical or electrical damage. When tested as specified in 4.7.3.8.1 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. Batteries shall be capable of withstanding drops at severe

temperature conditions without sustaining physical or electrical damage. When tested as
specified in 4.7.3.9.1 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. 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 4.7.3.10, 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. Each cell when subject to the specified electrical tests of
TABLE II 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. Cells used to build batteries shall be capable of withstanding
overcharge. When tested as specified in 4.7.4.1, surface temperatures shall not exceed 93°C
(200°F).

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

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

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3.7.1.2 Nail penetration, cell. When specified (see 3.1), 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. When specified (see 3.1), 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. Terminals or contacts shall be as specified on the

applicable specification sheet (see 3.1) 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. Batteries shall be capable of withstanding

overcharge conditions without failure. When tested as specified in 4.7.4.7: 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. Each battery shall be protected against short circuits.
When tested as specified in 4.7.4.8, 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. 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 4.7.4.9, 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. 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 4.7.4.10, 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. When specified (see 3.1), 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.

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3.7.2.7 Lithium Battery Safety Program (US Navy). When specified (see 3.1), 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, When tested in accordance
with 4.7.5.1 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 tests When tested in

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

3.8 Electromagnetic compatibility. When specified (see 3.1), 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. Batteries shall be capable of charging correctly on fielded

chargers and adapters (see 4.7.6).

4 VERIFICATION

4.1 Classification of Inspection. The inspection requirements specified herein are

classified as follows:
a. First article inspection (see 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.

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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. First article inspection shall consist of the examinations
and tests specified in TABLE III 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 Test Method Samples

Paragraph Paragraph
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 3.3.4 4.7.1.5 By volume
shrinking 2/
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

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TABLE IV. First article tests, complete batteries

Inspection Req’t Test Samples or Group (GR)

Method GR1 GR2 GR3 GR4
1 2 3 4 5,6 7,8 9,10 11,12 (5 ea) (8 ea) (15 ea)
Visual and mechanical 3.4 4.7.1.1 3 3 3 3 3 3 3 3 5 3 5
Dimensions and weight 3.4.3 4.7.1.2 3 3 3 3 3 3
Battery open circuit voltage 3.5.2 4.7.2.2 3 3 3 3 3 3 3 3 5 3 5
Insulation resistance 3.7.2.1 4.7.4.6 3 3 3 3 3 3 3 3
Altitude 3.6.2 4.7.3.4 3 3 3 3 3 3 3 3
Charge enable 1/ 3.5.6 4.7.2.6 5
Charge acceptance 3.5.10.1 4.7.2.9 3
Capacity discharge (initial) 3.5.3 4.7.2.3 3 3 3 3 3 3 3 3
Cycle life 3.5.4 4.7.2.4 3
Battery storage life 3.6.8 4.7.3.10 3
Overcharge/electrical leakage 3.7.2.2 4.7.4.7 3
Low temperature discharge 3.5.3 4.7.2.7 3
High temperature discharge 3.5.3 4.7.2.8 3
Projectile 1/ 3.7.2.6 4.7.4.11 5
High rate discharge 3.5.3 4.7.2.5 3 3
Retention of charge 3.5.10.2 4.7.2.10 3 3 3 3
Pulse discharge 3.5.3 4.7.2.11 3 3
Motor inrush current 1/ 3.5.5 4.7.2.12 5
Thermal shock 3.6.3 4.7.3.5 3 3 3 3
Mechanical shock 3.6.4 4.7.3.6 3 3 3 3
Vibration (discharge) 3.6.5 4.7.3.7 3 3 3 3
Connector insertion 3.4.4.1.1 4.7.1.3 3 3
Flat terminal strength 3.4.4.1.2 4.7.1.4 3 3
Immersion, shallow 3.6.6 4.7.3.8 3 3 3 3
Transit drop, normal 1/ 3.6.7 4.7.3.9.1 5 5 5 5
Transit drop, severe 1/ 3.6.7 4.7.3.9.2 5 5
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 3
SMBus 1/ 3.5.9 4.7.2.15 5 5 5 5
Full capacity discharge 3.5.3 4.7.2.3 3 3 3 3
Extreme low temp. discharge 3/ 3.5.3 4.7.3.2 5 5
Extreme high temp. discharge 3/ 3.5.3 4.7.3.3 5 5
Battery case vent 3.4.5.3 4.7.1.6 3 3
Short circuit protection 3.7.2.3 4.7.4.8 3 3
High temperature temporary cut-off 3.7.2.4 4.7.4.9 3 3
High temperature permanent cut-off 3.7.2.5 4.7.4.10 3 3
Electromagnetic interference 1/ 3.8 4.7.7 5
Interchangeability 3.10 4.7.6 3
Lithium Battery Safety Program (US 3.7.2.7 4.7.5 5
Navy) Tests 1/
NOTES
1/ Only when specified (see 3.1) (indicated in table as 5)
2/ Immersion samples shall be the same samples having undergone transit drop
3/ Only Type III (Li-ion) and Type IV (Li-Po) batteries

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4.5 Conformance inspection. Inspection of product for delivery shall consist of

groups A and B inspections, as well as Group C inspections when specified (see 4.5.3.1).

4.5.1 Group A inspection. Each battery on contract or delivery order shall be 100
percent inspected for conformance to the inspections in the order specified in TABLE V. 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

Inspection Requirement Test Method

Paragraph 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. Group B inspections shall be performed on inspection lots

that have passed Group A inspection (see 4.5.1) 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

Inspection Requirement Test Method Sample

Paragraph Paragraph Number
1 2 3 4
Capacity discharge 3.5.3 4.7.2.3
3 3 3 3
(initial)
Thermal shock 3.6.3 4.7.3.5 3 3
High rate discharge 3.5.3 4.7.2.5 3 3
Immersion, shallow 3.6.6 4.7.3.8.1 3 3 3 3

4.5.3 Group C inspection. Group C inspections shall be performed on inspection lots

that have passed Group A inspection (see 4.5.1) 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. Group C testing, or a complete first article inspection (see
4.4), shall be performed within the 12 months prior to presenting the current inspection lot for
acceptance.

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TABLE VII. Group C inspection

Inspection Paragraph Requirem Test Sample

ent Paragraph Number
Paragrap
1 2 3 4
h
Dimensions and weight 3.4.3 4.7.1.2 3 3 3 3
Capacity discharge (initial) 3.5.3 4.7.2.3 3 3 3 3
High temperature discharge 3.5.3 4.7.2.8 3 3
Low temperature discharge 3.5.3 4.7.2.7 3 3
Thermal shock 3.6.3 4.7.3.5 3 3 3 3
Mechanical shock 3.6.4 4.7.3.6 3 3 3 3
Vibration 3.6.5 4.7.3.7 3 3 3 3
Immersion, shallow 3.6.6 4.7.3.8.1 3 3 3 3
Transit drop, normal 3.6.7 4.7.3.9 3 3 3 3
Immersion, shallow (post drop) 3.6.6 4.7.3.8.1 3 3 3 3
Capacity discharge (final) 3.5.3 4.7.2.3 3 3 3 3
Extreme low temp. discharge 1/ 3.5.3 4.7.3.2 5 5
Extreme high temp. discharge 1/ 3.5.3 4.7.3.3 5 5
Battery case vent 3.4.5.3 4.7.1.6 3 3
High temperature temporary cut- 3.7.2.4 4.7.4.9
3 3
off
High temperature permanent 3.7.2.5 4.7.4.10
3 3
cut-off
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. 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 4.3.1 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 3.1).

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.

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4.7 Test methods.

4.7.1 Physical characteristics.

4.7.1.1 Visual and mechanical. 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 3.4 and TABLE VIII.

TABLE VIII. Visual and mechanical inspection

Categories 1/ Rework Defects

Permitted
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 3.1).

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4.7.1.2.1 Gauging. 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 3.1).

4.7.1.3 Connector insertion test. Unless otherwise specified (see 3.1), 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. 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 3.4.4.1.2.

4.7.1.5 Insulating compounds, flow and shrinking. 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 3.3.4.
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. 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. Batteries shall meet the requirements of 3.4.5.3.

4.7.1.7 Battery case. When specified (see 3.4.5), the following test shall be performed
on 5 sample pieces of case material. Use the Horizontal Burning Test method of UL 94 to
determine the test apparatus criteria. Expose samples to a flame for not less than 30 seconds.
Samples shall meet the criteria of 3.4.5.

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4.7.2 Electrical performance tests.

4.7.2.1 Cell balance. The following test shall be performed. Fully charge the cells in any
appropriate manner at the normal conditions of 4.3.1. Stabilize cells at normal conditions after
charge termination for not less than 1 hour. Discharge cells at the C/5 rate to the cell
manufacturer’s recommended discharge cutoff voltage. Measure and record total capacity of
each cell to final voltage. Cells shall meet the requirements of 3.5.1.

4.7.2.2 Battery open circuit voltage. The open circuit voltage of the battery under test
shall be measured. In the case of multi-sectioned batteries, open circuit voltage shall be
measured in both series and independent modes (see 3.1). Batteries shall meet the
requirements of 3.5.2.

4.7.2.3 Capacity discharge. The following test shall be performed.

a. Charge batteries in accordance with 4.6; use of 4.6.3 is not permitted.
b. Stabilize the batteries at the conditions of 4.3.1 for not less than 2 hours.
c. Discharge at the rate specified; batteries shall meet full capacity discharge test
requirement (see 3.1 and 3.5.3).

4.7.2.3.1 Initial capacity discharge. Each battery subjected to the capacity discharge test
above (see 4.7.2.3) on its initial charge/discharge cycle is permitted up to three cycles to meet
the capacity discharge test requirement (see 3.1). Any battery not meeting the specified
capacity discharge requirement (see 3.1) during any of its first three cycles is considered a
failure.

4.7.2.4 Cycle life test. The following test shall be performed.

a. Cycles 1 through 26 - Charge the batteries in accordance with 4.6; use of 4.6.3 is
permitted. Allow batteries to rest for not less than 5 minutes. Discharge at the rate
specified to the specified final voltage (see 3.1). Allow batteries to rest for not less
than 5 minutes prior to the start of the next cycle.
b. Cycle 27 – Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted.
Allow batteries to rest for not less than 4 hours. Discharge at the rate specified to
the specified final voltage (see 3.1). Allow batteries to rest for not less than 4 hours
prior to the start of the next cycle.
c. Cycle 28 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted.
Perform the electric leakage test of 4.7.4.7d. Allow batteries to rest for not less than
4 hours. Discharge at the rate specified to the specified final voltage (see 3.1).
Record battery capacity.
d. Repeat steps a through c above until the total number of required cycles is obtained
(see 3.1).
e. After completion of the cycle life test, visually examine batteries for the criteria of
TABLE VIII. Batteries shall meet the cycle life and visual mechanical requirements
(see 3.1 and 3.5.3).

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4.7.2.5 High rate discharge. The following test shall be performed.

a. Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Stabilize the
batteries at ambient temperature for not less than 2 hours.
b. Discharge the batteries at the rate specified (see 3.1).
c. Record the following:
1. Battery open circuit voltage
2. The elapsed time for the voltage to drop to the final voltage specified on the
applicable specification sheet after the start of discharge.
d. After completion of the test, batteries shall meet the capacity requirements of 3.5.3
and the criteria of TABLE VIII.

4.7.2.6 Charge enable. When specified (see 3.1), the following test shall be performed.
Discharge each battery to final voltage. Using an ammeter in the charge circuit to record
resultant current slowly increase the charge current until the battery no longer accepts a charge
current. Once the charge current has been verified, discharge each battery to final voltage.
Apply a charge current to the battery terminals while connected to the charge enable terminal or
socket using a charge circuit equipped to provide the specified preferred charge method only if
the charge enable terminal or socket complies with requirements (see 3.1). After testing,
batteries shall meet the requirements of 3.5.6.

4.7.2.7 Low temperature discharge. The following test shall be performed. Charge
batteries in accordance with 4.6; use of 4.6.3 is not permitted. Store the batteries at -20°C (-
4°F) ± 1.1°C (± 2°F) for a minimum of 4 hours. Discharge under these conditions at the rate
specified to the specified final voltage (see 3.1). After testing, batteries shall meet the
requirements of 3.5.3 and 3.6.

4.7.2.8 High temperature discharge. The following test shall be performed. Charge
batteries in accordance with 4.6; use of 4.6.3 is not permitted. Store the batteries at 50°C
(122°F) ± 1.1°C (± 2°F) for a minimum of 4 hours. Discharge under these conditions at the rate
specified to the specified final voltage (see 3.1). After testing, batteries shall meet the
requirements of 3.5.3 and 3.6.

4.7.2.9 Charge acceptance. The following test shall be performed. After testing,
batteries shall meet the requirements of 3.1 and 3.5.10.1.
a. Discharge batteries in accordance with 4.7.2.3c.
b. Store the batteries at -20°C (-4°F) ± 1.1°C for a minimum of 4 hours.
c. Charge batteries in accordance with 4.6 at the same condition; use of 4.6.3 is not
permitted.
d. Stabilize batteries at the same condition for not less than 2 hours.
e. Discharge batteries in accordance with 4.7.2.3c at the same condition.
f. Store the batteries at 50°C (122°F) ± 1.1°C for a minimum of 4 hours.
g. Repeat steps c through e above.

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4.7.2.10 Retention of charge (at high temperature). The following test shall be performed.
After testing, batteries shall meet the requirements of 3.1, 3.5.3, and 3.5.10.2.
a. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.
b. Store batteries under 50°C (122°F) ± 1.1°C conditions for 7 days.
c. Return batteries to the normal conditions of 4.3.1 and stabilize for not less than 2
hours.
d. Discharge batteries at the same conditions at the rate specified to the specified final
voltage (see 3.1).

4.7.2.11 Pulse discharge. The following test shall be performed. After testing, batteries
shall meet the requirements of 3.1 and 3.5.3.
a. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted. Store batteries under
the normal conditions of 4.3.1.
b. Discharge each battery at the rate and for the time specified until the final voltage
specified is reached (see 3.1).

4.7.2.12 Motor inrush current. When specified (see 3.1), the following test shall be
performed. During and after testing batteries shall meet the motor surge requirement (see 3.1
and 3.5.5).
a. Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Stabilize the
batteries at ambient temperature for not less than two hours.
b. Discharge the batteries using current values not less than the profile specified (see
3.1)
c. Record the following:
1. Discharge current
2. Battery Voltage
d. After completion of the test, visually examine batteries for the criteria of TABLE VIII.
Batteries shall meet the motor surge and visual mechanical requirements (see 3.1
and 3.5.5).

4.7.2.13 Power consumption. The following test shall be performed. Connect an ammeter
between the ECA for the battery and the full CCA for the battery. Verify the current draw is in
accordance with paragraph 3.5.7.

4.7.2.14 State-of-charge indicator. When specified (see 3.1), the following tests shall be
performed.
a. Conduct this test at the normal conditions specified in 4.3.1, except that the
temperature tolerance shall be ± 1.1°C.
b. Discharge batteries at the C/5 rate to final voltage.
c. Charge batteries as specified in 4.6; use of 4.6.3 is not permitted.
d. Allow batteries to stabilize for not less than two hours.
e. Discharge batteries at the C/5 rate to final voltage.
f. Record capacity for each battery tested.
g. Charge batteries as specified in 4.6; use of 4.6.3 is not permitted.
h. Allow batteries to stabilize for not less than two hours.
i. Discharge batteries at the C/5 rate to final voltage while visually observing the state
of charge indicators. Monitor and record SMBus state of charge information
throughout the discharge where applicable.
j. Record the time of test when each state of charge indicator segment extinguishes.
k. Batteries shall meet the requirements of 3.5.8, 3.5.8.1 and 3.5.9.

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4.7.2.15 SMBus. When specified (see 3.1), verify the following data has been
programmed correctly using appropriate interface and software.
a. ManufacturerName
b. DeviceName (DoD type designation, e.g. BB-2590/U)
c. DeviceChemistry
d. SerialNumber
e. ManufactureDate
f. DesignCapacity
g. DesignVoltage
h. ChargingCurrent
i. ChargingVoltage

4.7.3 Environmental tests.

4.7.3.1 Sequential testing. When verification of the requirements of 3.6 or capacity

requirements of 3.5.3 are required for multiple environmental tests (see TABLE I) performed in
sequence on the same sample, single verifications may be used following the last test
performed in that sequence. (Note: reducing inspection frequency may result in increased
retesting in the event of a failure.)

4.7.3.2 Extreme low temperature discharge. For Type III (Li-ion) and Type IV (Li-Po)
batteries the following test shall be performed. Charge batteries in accordance with 4.6; use of
4.6.3 is not permitted. Store the batteries at -30°C (-22°F) ± 1.1°C (± 2°F) for a minimum of 4
hours. Discharge under these conditions at the rate specified to the specified final voltage (see
3.1). After testing, batteries shall meet the requirements of 3.5.3, 3.6, and 3.6.1.

4.7.3.3 Extreme high temperature discharge. For Type III (Li-ion) and Type IV (Li-Po)
batteries the following test shall be performed. Charge batteries in accordance with 4.6; use of
4.6.3 is not permitted. Store the batteries at 55°C (140°F) ± 1.1°C (± 2°F) for a minimum of 4
hours. Discharge under these conditions at the rate specified to the specified final voltage (see
3.1). After testing, batteries shall meet the requirements of 3.5.3, 3.6, and 3.6.1.

4.7.3.4 Altitude. The following test shall be performed. All battery types shall be
subjected to the altitude test for lithium batteries of the UN Manual of Tests and Criteria.
Prepare and fixture batteries as required by the manual prior to testing. Weigh batteries and
record OCV prior to and after the specified conditions. Upon completion, visually examine the
batteries in accordance with 4.7.1.1 and subject each battery in the fully charged state to the
battery voltage tests of 4.7.2.2. Batteries shall meet the requirements of 3.6 and 3.6.2.

4.7.3.5 Thermal shock. The following test shall be performed. Charge batteries in
accordance with 4.6; use of 4.6.3 is permitted. Subject batteries to temperature shock per
Method 503, Procedure 1-B of MIL-STD-810 at the temperature extremes of not less than 75°C
(167°F) and not greater than -59°C (-75°F), except that the time at the temperature extremes
shall be not less than 2 hours and diurnal cycling not required. Perform the capacity discharge
test of 4.7.2.3. Batteries shall meet the requirements of 3.5.3, 3.6, and 3.6.3.

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4.7.3.6 Mechanical shock. The following test shall be performed. Charge batteries in
accordance with 4.6; use of 4.6.3 is permitted. Rigidly attach the batteries to the test carriage
by mounting screws or other appropriate hardware and shock test at not less than 40g with a
pulse duration of not less than 18 milliseconds in accordance with test Method 516, Procedure
1, of MIL-STD-810. Apply three shocks per axis, on each of three orthogonal axes. Batteries
shall meet the requirements of 3.5.3, 3.6, and 3.6.4.

4.7.3.7 Vibration. The following test shall be performed. Charge batteries in accordance
with 4.6; use of 4.6.3 is permitted. While discharging at the rate specified (see 3.1), batteries
shall be subjected to minimum integrity vibration testing in accordance with MIL-STD-810
Method 514 using the general minimum integrity profile. Batteries shall meet the requirements
of 3.6, 3.6.5, and 3.4.7.

4.7.3.8 Immersion.

4.7.3.8.1 Immersion, shallow. When specified (see 3.1) batteries shall be tested as
follows. Weigh batteries and record their weight. Immerse the entire batteries to a depth of not
less than 3 feet in salt water substitute conforming to ASTM D-1141 for not less than 2 hours.
After immersion, remove the batteries and dry exterior surfaces. Reweigh the batteries.
Batteries shall meet the requirements of 3.6, 3.6.6, and the applicable specification sheet (see
3.1). For conformance testing (see 4.5.2), deionized water may be substituted for salt water.

4.7.3.8.2 Immersion, deep. When specified (see 3.1) batteries shall be tested as follows.
a. Weigh batteries and record their weight.
b. Immerse the batteries to an equivalent depth of not less than 33 feet in salt water
substitute conforming to ASTM D-1141 for not less than 5 minutes.
c. Reweigh the batteries. Batteries shall meet the requirements of 3.6, 3.6.6, and the
applicable specification sheet (see 3.1).
d. Repeat steps b and c with a depth of not less than 3 feet and time period of not less
than 12 hours.

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4.7.3.9 Transit drop.

4.7.3.9.1 Transit drop, normal. When specified (see 3.1), the following test shall be
performed.

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

b. Stabilize batteries for 4 hours at 55 ± 1.1ºC (130ºF).
c. Perform the drop at ambient conditions in not greater than 10 minutes after removal
from the preconditioning temperature.
d. Drop each battery once from a height of not less than 30 inches onto cured concrete.
The smallest side of the battery perpendicular to the plane of the connector face and
nearest to the connector (where applicable) shall be parallel to the concrete surface
and facing downward upon release, but need not be parallel upon impact. In the
case of cylindrical batteries, the axis of the cylinder shall be parallel to the concrete
surface upon release.
e. Visually examine batteries for the criteria in TABLE VIII.
f. Subject batteries to the battery voltage tests of 4.7.2.2 and the electrical leakage test
of 4.7.4.7d.
g. Stabilize batteries for 4 hours at -29 ± 1.1ºC (-20ºF).
h. Repeat steps c through f.
i. After test, batteries shall meet the requirements of 3.6 and 3.6.7

4.7.3.9.2 Transit drop, severe. When specified (see 3.1), the following test shall be
performed. Batteries shall be dropped on each face, edge and corner (see 3.1) (e.g. total of 26
drops for cubic batteries) for each temperature from a height not less than 30 inches onto cured
concrete. When specified (see 3.1), batteries shall be shall be dropped while mated to an
object having the same mass, mass distribution, dimensions, and physical interface as the end
item. Ten batteries shall be required for this test.

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

b. Stabilize five of the batteries for 4 hours at 55 ± 1.1ºC (130ºF) and the remaining five
batteries for 4 hours at -29 ± 1.1ºC (-20ºF) .
c. Perform drops specified in TABLE IX as follows. Perform the first requisite drop per
battery at ambient conditions in not greater than 10 minutes after removal from the
preconditioning temperature, and the final requisite drop not greater than 30 minutes
after removal from the preconditioning temperature. If greater than 30 minutes are
required, stabilize the battery for an additional 4 hours before proceding.
d. Subject batteries to the battery voltage tests of 4.7.2.2 and the electrical leakage test of
4.7.4.7d.
e. After test, batteries shall meet the requirements of 3.6 and 3.6.7

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TABLE IX. Transit drop, severe

Sample number
Drop Impact 1/ Mated 2/
-29 ºC 55ºC
1 Corner top-back-left YES 1 6
2 Edge bottom-back YES 1 6
3 Edge top-right YES 1 6
4 Edge top-front YES 1 6
5 Surface right YES 1 6
6 Corner bottom-back-left YES 2 7
7 Edge front-right YES 2 7
8 Edge bottom-front YES 2 7
9 Corner top-front-left YES 2 7
10 Corner bottom-front-left YES 2 7
11 Corner top-back-right NO 3 8
12 Edge bottom-left NO 3 8
13 Edge top-back NO 3 8
14 Surface front NO 3 8
15 Surface left NO 3 8
16 Corner bottom-back-right NO 4 9
17 Edge bottom-right NO 4 9
18 Edge back-left NO 4 9
19 Edge front-left NO 4 9
20 Surface bottom NO 4 9
21 Surface back NO 5 10
22 Surface top NO 5 10
23 Edge top-left NO 5 10
24 Corner bottom-front-right NO 5 10
25 Corner top-front-right NO 5 10
26 Edge back-right NO 5 10
Note:
1/ To determine surface definitions, the battery shall be oriented with the main
connector on the top. If the connector is off-center the battery shall be rotated so that the
connector is in the back leftmost position.
2/ When specified

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4.7.3.10 Battery storage life. The following test shall be performed.

a. Discharge each battery at the 0.5C rate to the specified final voltage. If the battery is
either Type III (Li-ion) or Type IV (Li-Po), proceed to the next step; if the battery is
either Type I (Ni-Cd) or Type II (Ni-MH), skip step b and proceed to step c.
b. Charge each Type III or Type IV battery with a constant current of not less than 100
milliamperes to not more than 220 milliampere-hours of capacity.
c. Store batteries at 60 ± 5°C (140°F) and not less than 85% relative humidity for not
less than 622 hours (approximately 26 days).
d. Return batteries to the normal conditions of 4.3.1 and store for not less than 2 hours.
e. Charge batteries at normal conditions in accordance with 4.6; use of 4.6.3 is
permitted.
f. Perform the electric leakage test of 4.7.4.7d.
g. Discharge each battery at the rate specified for capacity discharge of 4.7.2.3.
h. Repeat steps e, f, and g for two more cycles (a total of three charge/discharge
cycles).
i. After test, batteries shall meet the requirements of 3.6 and 3.6.8.

4.7.4 Safety tests.

4.7.4.1 Cell overcharge. The following test shall be performed. Weigh each cell to the
nearest tenth of a milligram. Attach a thermocouple to the side of each cell to be tested, and
attach current carrying and voltage monitoring leads to its terminals. Place each cell in a
temperature chamber set at 25 ± 2.7°C (77°F). Charge each cell at a constant current rate of
C/2 for not less than 8 hours continuously. Measure and record cell temperature, voltage, and
current. Visually examine the cells. Cells shall meet the requirements of 3.7.1.1and 3.7.1.1.1.

4.7.4.2 Cell short circuit. The following test shall be performed. Weigh each cell to the
nearest tenth of a milligram. Fully charge the cells in any appropriate manner at the normal
conditions of 4.3.1. Stabilize cells at the same conditions after charge termination for not less
than 1 hour. Short each cell individually by connecting the positive and negative terminals of
the cell with a copper wire, not greater than 8 inches in length and with a cross-sectional area
not less than AWG No. 16 wire. Discharge each cell to not greater than 0.2 volts. Visually
examine the cells and weigh each cell to the nearest tenth of a milligram. Cells shall meet the
requirements of 3.7.1.1and 3.7.1.1.2.

4.7.4.3 Cell forced-discharge. The following test shall be performed. Weigh each cell to
the nearest tenth of a milligram. Discharge each cell at the C/5 rate to not greater than 0.2 volts.
Connect each cell in series with a 12-volt DC power supply and force discharge it at the C/5 rate
for not less than 5 hours. Visually examine the cells and weigh each cell to the nearest tenth of
a milligram. Cells shall meet the requirements of 3.7.1.1and 3.7.1.1.3.

4.7.4.4 Nail Penetration, cell. When specified (see 3.1), the following test shall be
performed on cells between 50% and 71% state of charge. Insert a 2.5 mm DIA stainless steel
nail with a length that exceeds the width or diameter of the cell to be tested into each cell at
right-angles to the electrode surface close to the center of the cell. Drive the nail completely
through on one of the samples; Drive the nail to a depth of 2/3 of the width of the cell for the
other. Leave the nail in both cells for 24 hours. Monitor the voltage and external temperature of
the cell for the duration of the test. Cells shall meet the requirements of 3.7.1.2.

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4.7.4.5 Crush, cell. The following test shall be performed. Subject cells designated for
the crush test to the crush test of UL 1642. Crush each sample cell with its longitudinal axis
parallel to the flat surfaces of the crushing apparatus. Subject each sample cell to a crushing
force in only one direction. Cells shall meet the requirements of 3.7.1.3.

4.7.4.6 Insulation resistance. The following test shall be performed. Apply a direct-
current potential not less than 500 volts between any two battery terminals not electrically
connected and between battery terminals and the case of the battery. Measure the insulation
resistance of batteries by the use of a copper plate making physical contact with the case. The
plate shall exceed the dimensions of the surface to be tested. Place the battery under test on
the plate so that the plate is visible outside all edges of the surface under test. Test each
battery in not less than three locations. Test each battery on all surfaces with a case seam
other than that on which the battery terminals are located; for cylindrical batteries, test in not
less than three locations around the diameter including on seams if present. Batteries shall
meet the requirements of 3.7.2.1.

4.7.4.7 Overcharge/electrical leakage. The following test shall be performed. After

testing, batteries shall meet the overcharge and electrical leakage requirements (see 3.1).
a. Charge batteries in accordance with 4.6; use of 4.6.3 is not permitted.
b. Overcharge the batteries at the rate specified (see 3.1) for not less than 21 hours.
Measure and record battery voltages continuously or at a sampling rate of not less
once per 60 seconds during overcharge.
c. Stabilize batteries at ambient conditions for not less than 2 hours.
d. Connect a 1 megohm resistor to the following points: from the case or ground to
each battery terminal and between all electrically isolated terminals (example: on a
battery with two parallel sections, measure voltage from pin 1 to pins 2 and 5, from
pin 4 to pins 2 and 5, and vice versa). Measure and record voltages at each
connection point. Batteries shall meet the requirements of 3.7.2.2.
e. Discharge the batteries at the rate specified (see 3.1). Measure and record battery
voltages continuously or at a sampling rate of not less once per 60 seconds during
discharge.
f. Repeat steps a through e for a total of 10 cycles.
g. Visually examine the batteries for the criteria of TABLE VIII.
h. Examine batteries for the requirements of 3.6.
i. Examine batteries to insure compliance with the requirements of 3.5.3.

4.7.4.8 Short circuit protection. The following test shall be performed. Charge batteries
as specified in 4.6; use of 4.6.3 is permitted. Measure and record the OCV. Short each battery
across all the positive and negative terminals with a total external resistance not greater than 50
milliohms. After one hour remove the short from across the terminals. Measure and record the
OCV. Stabilize batteries at the normal conditions of 4.3.1 for not less than 2 hours. Charge
batteries in accordance with 4.6; use of 4.6.3 is permitted. Stabilize batteries at normal
conditions for not less than 2 hours, then discharge the battery in accordance with 4.7.2.3. The
battery shall meet the requirements of 3.7.2.3.

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4.7.4.9 High temperature temporary cutoff. The following test shall be performed.
Charge batteries as specified in 4.6; use of 4.6.3 is permitted.
a. Store the batteries at 75 ± 5oC for not less than 2 hours. Measure and record the
battery voltage.
b. Allow the battery to cool down to 40, +0/-5oC. Measure and record battery voltage.
c. Repeat steps a and b five (5) times.
d. Perform the capacity discharge test of 4.7.2.3.
e. Batteries shall meet the requirements of 3.7.2.4.

4.7.4.10 High temperature permanent cutoff. The following test shall be performed.
Charge batteries as specified in 4.6; use of 4.6.3 is permitted. Store the batteries at 95 ± 5oC
for not less than 2 hours. Measure and record the battery voltage. Allow batteries to cool down
to 40 +0/-5oC. Attempt to charge the battery in accordance with 4.6 (any specified manner),
then attempt to discharge the battery in accordance with 4.7.2.3. Measure and record any
resultant current from either attempt. Batteries shall meet the requirements of 3.7.2.5.

4.7.4.11 Projectile. The following test shall be performed. Subject each battery
designated for the projectile test to the projectile test of UL 1642. Batteries shall meet the
requirements of 3.7.2.6.

4.7.5 Lithium Battery Safety Program (US Navy) tests. When specified (see 3.1) the
following tests shall be performed on Types III and IV batteries. Test each battery in a test
vessel (see 6.8.2) in order to facilitate pressure readings in lieu of the “complete system”
described by NAVSEA S9310-AQ-SAF-010. Battery voltage, charge or discharge current, and
test vessel pressure shall be monitored continuously during testing. Test samples will be
subjected to testing as follows:

TABLE X. Lithium Battery Safety Program test and sample size

Inspection Sample Requirement Test Method

size Paragraph Paragraph
Visual mechanical 15 3.4 4.7.1.1
Battery open circuit voltage 15 3.5.2 4.7.2.2
Short circuit test 3 3.7.2.7 4.7.5.1
Overcharge/discharge test 3 3.7.2.7 4.7.5.2
Overcharge/charge test 3 3.7.2.7 4.7.5.3
Electrical safety device test 3 3.7.2.7 4.7.5.4
Aging safety test 3 3.7.2.7 4.7.5.5

4.7.5.1 Short circuit test. When specified (see 3.1), the short circuit test for rechargeable
batteries of NAVSEA S9310-AQ-SAF-010 shall be performed. Batteries shall meet the
requirements of 3.7.2.7.1.

4.7.5.2 Overcharge/discharge test. When specified (see 3.1), the overcharge/discharge

test for rechargeable batteries of NAVSEA S9310-AQ-SAF-010 shall be performed. Batteries
shall meet the requirements of 3.7.2.7.1.

4.7.5.3 Overcharge/charge test. When specified (see 3.1), the overcharge/charge test
for rechargeable batteries of NAVSEA S9310-AQ-SAF-010 shall be performed. Batteries shall
meet the requirements of 3.7.2.7.1.

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4.7.5.4 Electrical safety device test. When specified (see 3.1), the electrical safety
device test for rechargeable batteries of NAVSEA S9310-AQ-SAF-010 shall be performed.
Batteries shall meet the requirements of 3.7.2.7.2.

4.7.5.5 Aging safety test. When specified (see 3.1), the aging safety test for
rechargeable batteries of NAVSEA S9310-AQ-SAF-010 shall be performed. Batteries shall
meet the requirements of 3.7.2.7.2.

4.7.6 Interchangeability test. A battery charger interchangeability test shall be

performed. Batteries shall be charged on currently fielded standard Army chargers and
adapters. Verify no anomalies occur during charging and batteries meet 90% of their rated
capacity and meet the requirements of 3.10.

4.7.7 Electromagnetic interference. When specified (see 3.1), the tests specified in
MIL-STD-461 for the following parameters shall be performed on batteries connected to the
system specified in the applicable specification sheet: CS114, CS115, CS116, RE101, RE102,
RS101, and RS103.

5 PACKAGING

5.1 Packaging requirements. For acquisition purposes, the packaging requirements

shall be as specified in the contract or order (see 6.2). When packaging of materiel is to be
performed by DoD or in-house contractor personnel, these personnel need to contact the
responsible packaging activity to ascertain packaging requirements. Packaging requirements
are maintained by the Inventory Control Point’s packaging activities within the Military Service or
Defense Agency, or within the military service’s system commands. Packaging data retrieval is
available from the managing Military Department’s or Defense Agency’s automated packaging
files, CD-ROM products, or by contacting the responsible packaging activity.

6 NOTES

6.1 Intended use. Sealed, high energy density, rechargeable batteries covered
within this specification are used in military electronic and communications equipment, and for
other military power requirements. Some devices use these batteries to run electric motors.
These batteries are subjected to severe environmental conditions.

6.2 Acquisition requirements. Procurement documents should specify the following:

a. Title, number, and date of the specification
b. The specific issue of individual documents referenced, if required (see 2).
c. Packaging requirements (see 5.1).
d. When first article inspection and rough handling tests of equipment are required.
e. When certifications are required
f. If certification of parts, materials, or components are required (see 3.2.1).
g. Actions required relative to group C inspection failure.
h. Any additional case markings, dependent upon battery chemistry.

6.3 Definitions.

6.3.1 Fully charged batteries. Batteries will be considered fully charged when charged
in accordance with 4.6. In addition, the SOCI must indicate a fully charged battery.

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6.3.2 Discharged batteries. Batteries will be considered discharged when a specified

discharge rate was conducted until a specified final voltage was reached.

6.3.2.1 Discharge rate. The rate of discharge is defined as:

I = C/t
Where
I = current in amperes
t = hourly rate of discharge
C = rated ampere hour capacity

For example, the expression for the five hour discharge current for a 25 ampere hour
battery will be I = (1/5)(25) = 5 amperes

6.3.3 Final voltage. The final voltage of the battery is the specified final voltage
reached at the end of discharge.

6.3.4 Cycle. A cycle is a combination of a charge and a discharge.

6.3.5 Measured performance. The data obtained in conducting a test in accordance

with section 4 of this specification, such as capacity or cycle life, will be known as the measured
performance.

6.3.6 Specified performance. The numerical performance requirement specified in a

specification sheet covering parameters such as voltage, capacity, cycle life, storage life, etc.,
will be known as the specified performance.

6.3.7 Softening temperature. The softening temperature of insulation is the

temperature at which it will distort under a reasonable amount of pressure when tested per the
Heat Distortion Test of ASTM D 2633.

6.3.8 Non-flammable and non-toxic materials. Non-flammable and non-toxic materials

are those materials which will not support combustion, produce smoke, or be capable of
emitting toxic fumes, in a cured state, when subjected to the environmental conditions specified
herein.

6.3.9 Level 2 and 3 chargers. Smart Battery Charger Types are described by the
Smart Battery Charger Specification as:
Level 2 – Smart Battery Controlled Smart Battery Charger
Level 3 – Host Controlled Smart Battery Charger

Refer to the Smart Battery Charger Specification for a more complete description. Copies of
this document may be obtained from the System Management Interface Forum (SMIF), Inc, on-
line at http://powersig.org.

6.3.10 Electronic component assembly (ECA). An ECA is the total of all electronic
components, connectors and mounting boards used within a complete battery.

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6.3.11 Complete cell assembly (CCA). A CCA is the total number of cells used within a
complete battery along with the intercell connections; for testing purposes, it needs to be
connected to the ECA as a separate item in order to facilitate sensing connections between the
two assemblies.

6.3.12 Approved chargers. The following are the approved chargers that may be used
for the charge method of 4.6.3 above. Note that some of these chargers may be of an older
vintage and may not charge every battery described by the associated specification sheets.
Users of this document will need to assure compatibility with the products under test prior to
charging in accordance with 4.6.3. Individual specification sheets may list other chargers. This
listing is provided for reference only and does not constitute an endorsement of the products by
the Department of Defense.

TYPE DESIGNATION NSN PART NUMBER CAGEC

PP-8498/U 6130-01-495-2839 BTC-70801 51828
PP-8444A/U 6130-01-443-0970 BTC-UN108 51828
PP-8481B/U 6130-01-527-2726 BTC-70836 51828
PP-8481A/U 6130-01-494-9164 BTC-70840 51828
PP-8481/U 6130-01-467-9465 BTC-70440A 51828

6.4 Verification inspection. Verification by the Government will be limited to the

amount deemed necessary to determine compliance with the contract and will be limited in
severity to the definitive quality assurance provisions established in this specification and the
contract. The amount of verification inspection by the Government will be adjusted to make
maximum utilization of the contractor's quality control system and the quality history of the
product.

6.5 Inspection lot. The inspection lot is the quantity of batteries (exclusive of the
number of batteries required as samples) produced at any one place of manufacture on any one
contract presented to the Government for acceptance.

6.6 Test report data. The following data points will be necessary for Government
review and should be included in First Article and Conformance Test Reports:
Certifications, where required (see 3.2.1);
Whenever there is a service or ampere hour requirement, include the following:
Initial Open Circuit Voltage (IOCV)
Initial Loaded Voltage (ILV)
Battery or Cell Voltage and Current, recorded at regular intervals. Interval should be
Service Requirement or shorter.
The time elapsed between initial voltage and final voltage (FV).
Record how low a battery is discharged in volts, particularly whenever near zero volts.
Record date and time of day that any portion of test is initiated in the test report including
initiation of soak at test temperature.
When a requirement limit is specified, record the final quantitative figure.

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6.7 First Article. When a first article inspection is required, the contracting officer
should provide specific guidance to offerors whether the item(s) should be a preproduction
sample, a first article sample, a first production item, a sample selected from the first production
items, a standard production item from the contractor's current inventory (see 4.4), and the
number of items to be tested as specified in 4.4. The contracting officer should also include
specific instructions in acquisition documents regarding arrangements for examinations,
approval of first article test results, and disposition of first articles. Invitations for bids or
requests for proposal should provide that the Government reserves the right to waive the
requirement for samples for first article inspection to those bidders offering a product which has
been previously acquired or tested by the Government, and that bidders offering such products,
who wish to rely on such production or test, must furnish evidence with the bid that prior
Government approval is presently appropriate for the pending contract. Bidders should not
submit alternate bids unless specifically requested to do so in the solicitation.

6.8 Lithium Battery Safety Program (US Navy). Potential offerors and contractors
should be aware that passing the test criteria specified herein for the US Navy Lithium Battery
Safety Program will not constitute a “Safety Approval” for the battery by the US Navy. In
accordance with S9310-AQ-SAF-010, Navy department users must still apply for battery safety
approvals based on the NSN of the battery intended for use, as well as both the intended Navy
platform and each specific using end item.

6.8.1 Test data. The intent of including these test requirements in this specification are
primarily to give manufacturers visibility into the essential safety characteristics needed by the
Navy. Until now, the tests were performed in evaluating system or device safety without any
knowledge of these requirements by battery manufacturers. Additionally, these requirements
will provide the Navy with test data on file when assessing applications for safety approvals.
The data provided will be used for engineering assessments that are capable of providing
recommendations for safer battery compartments in battery-using devices.

6.8.2 Test vessel. Due to the need to record pressure changes during test, the Navy
safety tests require use of a test “vessel”, defined as a sealed container larger than the battery
under test. A “sealed container” could be something as simple as an unused paint can with the
lid on, provided that gaskets, plugs, or sealants are used around the access points for load and
sensing leads to preserve the seal. A calculation of the remaining void space inside the vessel
containing the battery under test will be needed for proper interpretation of the pressure
readings.

6.8.3 Navy test facility. The Department of Defense has a preference for having the
tests described by S9310-AQ-SAF-010 (see 4.7.5) conducted in a US Navy test facility.
Potential offerors are cautioned to review solicitations for such requirements. Should testing at
a Navy facility be required, offerors will need to obtain a quote for Navy testing from the Navy in
order to respond to the solicitation. Points of Contact in the Navy for the quote will be identified
in the solicitation documentation. Offerors will need to assure that Navy testing costs are
covered in their price proposal. Successful offerors will need to establish a Test Service
Agreement (TSA) with the Navy after award. Unsuccessful offerors will be under no obligation
to pay for anything associated with the quote obtained earlier. TSAs have expiration dates; if an
agreement is already established, check to make sure that it will still be in effect at the time
when testing may be required.

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6.8.4 Interchangeability testing. The Department of Defense has a preference for

having the tests described by 4.7.6 conducted in a US Army battery test facility. This test is to
ensure backwards compatibility with existing fielded chargers. Potential offerors are cautioned
to review solicitations for such requirements.

6.9 Electromagnetic compatibility. Some of the batteries described by this

specification are required to be electromagnetically compatible with specific systems (see the
applicable specification sheet for system identity). This compatibility is specific to the system
identified and should not be assumed for other systems as well. Any other system using such a
battery will need to have its electromagnetic compatibility with the battery evaluated separately,
and in the event the battery is not compatible, then either system modifications will be needed
or the system will need another battery.

6.10 Shelf life. This specification covers items where the assignment of a Federal
shelf-life code is a consideration. Specific shelf-life requirements should be specified in the
contract or purchase order, and should include, as a minimum, shelf-life code, shelf-life package
markings in accordance with MIL-STD-129 or FED-STD-123, preparation of a materiel quality
storage standard for type II (extendible) shelf-life items, and a minimum of 85 percent shelf-life
remaining at time of receipt by the Government. These and other requirements, if necessary,
are in DoD 4140.27-M, Shelf-life Management Manual. The shelf-life codes are in the Federal
Logistics Information System Total Item Record. Additive information for shelf-life management
may be obtained from DoD 4140.27-M, or the designated shelf-life Points of Contact (POC).
The POC should be contacted in the following order: (1) the Inventory Control Points that
manage the item and (2) the DoD Service and Agency administrators for the DoD Shelf-Life
Program. Appropriate POCs for the DoD Shelf-Life Program can be contacted through the DoD
Shelf-Life Management website: https://www.shelflife.hq.dla.mil/.

6.11 Subject term (key word) listing.

Advanced chemistry
Lithium ion
Nickel cadmium
Nickel metal hydride
Polymer

Custodians: Preparing Activity

Army – CR Army – CR
Navy – MC (Project Number 6140-2010-009)
Air Force – 99

Review activities:
Navy – AS,SH
Air Force – 71
DLA – CC

NOTE: The activities listed above were interested in this document as of the date of this
document. Since organizations and responsibilities can change, you should verify the currency
of the information above using the ASSIST Online database at https://assist.daps.dla.mil.

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