GOVERNMENT OF INDIA

MINISTRY OF DEFENCE

JOINT SERVICES SPECIFICATION

ON

BATTERY NICKEL-CADMIUM, RECHARGEABLE SEALED

CYLINDRICAL, PORTABLE (GENERAL)

JSS 6140-05: 2005

(Revision No. 1)
(Reaffirmed 2012)

ISSUED BY

DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’-BLOCK, NIRMAN BHAWAN P.O.
NEW DELHI – 110 011
 GOVERNMENT OF INDIA
MINISTRY OF DEFENCE

JOINT SERVICES SPECIFICATION

ON

BATTERY NICKEL-CADMIUM, RECHARGEABLE SEALED

CYLINDRICAL, PORTABLE (GENERAL)

JSS 6140-05: 2005

(Revision No. 1)
(Reaffirmed 2012)

ISSUED BY

DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’-BLOCK, NIRMAN BHAWAN P.O.
NEW DELHI – 110 011
 MEMBERS ASSOCIATED WITH FORMULATION OF THIS STANDARD

1. This “Joint Services Specification” has been re-affirmed by Dr. K Tamilmani,

Chief Executive, Centre for Military Airworthiness And Certification (CEMILAC), and
Chairman, Aeronautical Stores Standardisation Sub Committee in the 45th Aero SSSC
meeting held on 13 Dec 2011.

2. The following members have been associated in preparation of the document.

Sl. No. Name Organisation

1. Gp Capt. S.B. Sharma, JD (E&I) DGAQA, New Delhi
(Coordinator, Working Group)
2. Shri J.M. Rewalliwar, DD (E&I) -do-
(Member Secretary, Aero-SSSC)
3. Shri ML Chopra, Director BIS, New Delhi
4. Shri V.N. Ray Sc ‘F’ Defence Standardisation Cell,
(Member Secretary, Aero-SSC) Bangalore
5. Cdr. BB Khilari, Tech Staff Officer -do-
6. Shri KM Ramchandran, Tech -do-
Officer
7. Shri S.K. Yaji Sc ‘É’ CEMILAC, Bangalore
8. Shri P.R. Venugoplan ADA, Bangalore
9. Dr. Shiv Kumar, general Manager M/S HBL, Hyderabad
10. Shri Surenderpal, Dy GM -do-
11. Shri T.M. Tikku, Sr. Manager (ABP) HAL, Hyderabad
12. Shri Veera Kumar, Manager -do-
13. Shri Venkata Saubramanian, GM M/S HEB, Trichy
14. Shri S Mathur Bootham, Sr Manager -do-
15. Shri Rakesh Mehta, Vice President PPPL, Chandigarh
16. Shri K Marriyappa, Director ALISDA, Bangalore
Chairman Working Group
17. Shri G Pari, SSO I ALISDA, Bangalore
18. Col SL Kapoor, OIC DS Cell, Bangalore
Member Secy Aero SSC
19. Wg Cdr DK Sharma, TSO DS Cell, Bangalore
 RECORD OF AMENDMENTS

Amendment Amendment Pertains Authority Amended by Signature

No. Date to: Sl.No./ Para Name & Appointment & Date
No.Column No. (IN BLOCK
LETTERS)
 CONTENTS

Sl.
No.
0. FOREWORD
1. SCOPE
2. RELATED SPECIFICATIONS
3. STANDARD PATTERN
4. TERMINOLOGY
5. MATERIALS
6. MANUFACTURE/CONSTRUCTION
7. WORKMANSHIP AND FINISH
8. MARKING
9. PRE-INSPECTION OF STORES/CONSIGNMENT
10. QUALITY ASSURANCE
11. LITERATURE
12. TOOL KIT
13. WARRANTY
14. PACKAGING
15. DEFENCE STORES CATALOGUE NUMBER
16. SUGGESTIONS FOR IMPROVEMENT
TABLE I – ENVIRONMENTAL REQUIREMENTS
TABLE II – VISUAL AND MECHANICAL INSPECTION
TABLE III – TYPEAPPROVAL TESTS IN ORDER OF APPLICATION
& DISTRIBUTION OF SAMPLES
TABLE IV – ACCEPANCE TESTS IN ORDER OF APPLICATION
TABLE V - ROUTINE TESTS
0. FOREWORD

0.1 This specification has been prepared by Working Group for Airborne batteries under
the aegis of Aeronautical Stores Standardisation Sub Committee (Aero SSC) on the authority
of the Standardisation Committee, Ministry of Defence.

0.2 This specification has been approved by the Ministry of Defence and is mandatory for
use by the Defence Services.

0.3 This specification is the reaffirmation of the earlier issued Specification No.
JSS: 6140-05:2005, (Revision No. 1).

0.4 This specification shall be read in conjunction with individual specification sheets.

0.5 This specification shall be used for general manufacture, quality assurance and
procurement of the item.

0.6 Quality Assurance Authority for the item covered by this specification is the Director
General, Directorate General of Aeronautical Quality Assurance, (DGAQA) Ministry of
Defence, ‘H’ Block, Nirman Bhawan P.O., New Delhi-110 011.

0.7 Enquiries regarding this specification relating to any contractual condition shall be
addressed to the Quality Assurance Authority named in the tender or contract. Other
enquiries shall be referred to:

The Director
Directorate of Standardisation
Ministry of Defence
‘H’ Block, Nirman Bhawan P.O.
New Delhi-110 011

0.8 Copies of this specification are obtainable on payment from: -

The Director,
Directorate of Standardisation,
Ministry of Defence, Standardisation Document Centre,
Room No. 5, ‘J’ Block, Nirman Bhawan P.O.,
New Delhi-110 011

0.9 This specification holds good only for the supply order for which it is issued.

0.10 Directorate of Standardisation Website All the approved JSS/JSGs are available
on the Directorate of Standardisation Website www.defstand.gov.in. Defence Organisation
desirous of procuring a copy of this document are requested to approach Director, Directorate
of Standardisation for obtaining user id/password to access the website.

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

1. SCOPE

1.1 This specification covers the general constructional details, manufacture, test
procedure and quality assurance of “Battery Nickel cadmium Rechargeable Sealed
Cylindrical, Portable: for use on aerobatic and non- aerobatic aircraft. The detailed physical
and electrical requirements of a particular type of a battery are given in the individual
specification sheets.

2. RELATED SPECIFICATIONS The following specifications / standards have

been referred / consulted while preparing this specification:-

(a) IS 5:1994 Colours for Ready Mixed Paints and Enamels

(Sixth Revision)

(b) IS 1248: Direct Acting Indicating Analogue Electrical Measuring

Part 2:2003 Instruments and their Accessories - Part 2:
(Reaffirmed Ammeters and Voltmeters (Third Revision)
2008)

(c) MIL-STD- Test Method Standard Electronic and Electrical Component

202G Parts
8 February
2002
(d) MIL-STD- Environmental Test Methods and Engineering Guidelines
810E
31 July 1995

(e) MIL-PRF- Performance specification, Batteries, Rechargeable, Sealed,

32052 (CR) General Specification For

2.1 Copies of the Indian Standards are obtainable on payment from:-

Bureau of Indian Standards,

Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi – 110 002

2.2 Copies of MIL Standards / Specifications are obtainable on payment from

Book Supply Bureau,

A-68, South Extension Part-I,
New Delhi – 110 049.

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3. STANDARD PATTERN The Standard Pattern if held, with the purchasing or the
Quality Assurance Authority, may be obtained and shall constitute a general guide only. The
stores shall otherwise confirm to this specification.

4. TERMINOLOGY For the purpose of the specification, the following definitions

shall apply: -

4.1 Type Tests Tests carried out to prove conformity with the requirements of this
specification. These are intended to prove the quality of design, manufacture and
workmanship of a given type of battery.

4.2 Acceptance Tests Tests carried out on samples selected at random from a lot for
the purpose of verifying the acceptability of lot.

4.3 Routine Tests Tests carried out on each battery to check the requirements,
which are likely to vary during production.

4.4 Lot All batteries of the same type, design, and rating, manufactured by the same
factory during the same period using the same process and materials and offered for
inspection at a time shall constitute a lot.

4.5 Re-chargeable Cell A voltaic cell that after discharge, can be brought back to its
initial (charged) chemical state by passing a current through it in a reverse direction to that of
discharge.

4.6 Re-chargeable Battery An assembly consisting of more than one re-chargeable cell.

4.7 Nominal Cell Voltage Nominal cell voltage per cell of Nickel Cadmium
Battery system is 1.2 V.

4.8 Nominal Battery Voltage Nominal Cell voltage multiplied by the number of cells
in series in the battery.

4.9 Charged Battery A battery that has been fully charged in accordance with the
battery manufacturer’s instructions or as laid down in the individual specification sheets.

4.10 Normal Servicing Battery servicing including cleaning, and charging as specified
in the manufacturer’s instruction book / sheet but not replacement of cells.

4.11 Serviceable Battery A battery that in all respects meets the requirement stated in the
manufacturer’s instructions for continued use on aircraft

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

4.12 Sealed Cell Sealed Cells are in which products of electrolysis are not consumed
during the course of charging. Provision for venting of gases evolved during overcharging is
provided. Sealed cells, which do not require addition of electrolyte during use. They are
designed to operate throughout their life in the original sealed condition. Such cells forming
battery may be operated in any attitude of the aircraft in which they are fitted.

4.13 Manufacturer’s Instruction The service instructions contained in the

operating and maintenance manual provided by the battery manufacturer and approved by
the Quality Assurance Authority.

4.14 Individual Specifications Specifications for individual batteries aircraft wise

provided by the Quality Assurance Authority or Purchasing Authority.

5. MATERIALS

5.1 Metals All metals which do not enter into the basic electro- chemical reaction of the
cell shall resist, or be treated to resist corrosion.

5.1.1 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.

5.2 Electrical Connection Wires and Tabs All electrical connecting wires and tabs for
the cells and the battery shall be able to carry the current specified in specification sheets and
shall be covered by an insulation with the following characteristics:

Softening Temperature: 150°C minimum

Lengthwise shrinkage 3% maximum after application
Thickness: 1.3mm minimum
The material shall be non-flammable and non-toxic

5.3 Hardware The mounting screws shall be furnished with the battery connector.
Mounting screws shall be tightened so as not to impede the side ways movement of the
connector.

5.4 Pressure Release Device Unless specified otherwise in the individual

specification sheet a pressure release device shall be incorporated into the battery. This
device shall be designed to release below the bursting pressure of the container and above the
normal operating pressure of the battery. The device is intended to function only as an
emergency release to protect the battery against abnormal pressure build- up. 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.

4
5.5 Battery Case

5.5.1 Battery case shall be capable of maintaining the specified dimensions during the life
of the battery. The surfaces of cases 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. The battery case
shall be a material that does not support combustion when subjected to flame.

5.5.2 The battery case (container) and lid shall be aluminum or stainless steel material
unless otherwise specified in the individual specification sheet. Any approved materials may
be used on obtaining permission of Inspection Authority.

5.5.3 The metal container and lid shall be Alkali resistant epoxy coated inside and outside
to prevent short circuit.

5.6 Marking Each battery shall be provided with a permanent, legible hot-stamped or
printed identification label. Direct printing on the battery is the preferred method. For
rectangular batteries, the marking may be placed on more than one surface.

5.6.1 Identification Label The identification label shall contain the following
information. The information in parentheses shall be filled in by the manufacturer.

BATTERY, RECHARGEABLE, (Battery Nomenclature)

(Battery Voltage) (Full Capacity Rating)
(Contract Number)
(Date Code) (Serial Number)
(Manufacturer)
(Charging Instructions)
BATTERY TEMPERATURE SHOULD BE BETWEEN
5°C AND 38°C DURING CHARGE.
LOWER TEMPERATURE CHARGING IS PERMITTED
BUT RUNTIMES WILL BE LOWER.

WARNING / STORAGE
DO NOT STORE ABOVE 50°C,
CRUSH, MUTILATE, REVERSE POLARITY,
DISASSEMBLE, OR DISPOSE OF IN FIRE.

5.6.2 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 proceeded by “O”. 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.

5.6.3 Terminal Marking Where applicable, 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. A schematic drawing shall
be placed as close as possible to the receptacle as shown on the individual specification sheet.

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

5.7 Instruction Each battery shall be furnished with complete instructions for
operation and charging of the battery either on a label or printed on the battery. Direct
printing on the battery is the preferred method.

5.8 Connectors Battery connector shall be as shown on the individual specification

sheet.

5.9 Colour The colour of the battery container shall be lusterless green as per clause 15
of IS-5 or as stated on the individual battery drawings or on the individual specification sheet.

5.10 Battery Condition for Shipping The battery shall be furnished in a charged state
with instructions attached to each battery and a dust cap or cover over the receptacle.

5.11 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 25 mm x 2 mm.

5.12 Cells/Cell Container/Plates/Separators

5.12.1 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. When two or more cells are connected in parallel together in the
battery, they are considered as a single cell.

The cell container shall be of cylindrical design made of steel with Nickel-plating unless
otherwise specified in the individual specification sheets.

5.12.2 The manufacturer may also use any other approved material with the permission of
Inspection Authority.

5.12.3 The positive electrode shall made of Nickel Powder and Negative Electrode of
Cadmium as per the manufacturers designs. The positive and negative plates shall be
sufficiently robust to withstand the normal stresses likely to be expected in service.

5.12.4 The separators shall be of un woven Nylon or any other approved material highly
absorbent to alkaline electrolyte, permeable to oxygen and dimensionally stable without
deformation at the temperature of use.

6
5.13 Cell Balance The capacities of the individual cells used in each battery shall not vary
by more than 5% from the average capacity value of the cells in that particular battery.

5.14 Protective Coverings Batteries shall be fabricated of cells, which have an individual
protective sleeves or coating.

5.15 Cell Safety A single cell that does not contain ay electronics shall meet all the
safety requirement listed below:

5.15.1 Cell Overcharge After being subjected to the test as specified in 10.10.2 the cell
shall not explode or catch fire or spark. No electrodes or separator material of the cell shall
be outside of the cell case.

5.15.2 Cell Short Circuit After being subjected to the test as specified in 10.10.3, the
cell shall not explode or catch fire or spark.

5.15.3 Cell Forced-Discharge After a single cell in the string has been subjected to the test
as specified in paragraph 10.10.4, there shall be no leaking, venting, fire or explosion.

5.15.4 Cell Leakage Individual Cell used in the battery shall be free of electrolytes leakage
indicated by presence of liquid or white or brown deposits or the smell of either at the vent or
closure area of the cells. The seals between cell terminals and cell covers shall be so
constructed that the batteries assembled from these cells shall be capable of meeting the
electrical leakage requirements and the life requirements of the individual specification.

5.16 Dimensions and Weights The dimensions and weights of batteries shall be as per the
individual specification sheets.

5.17 Attitude The battery shall be designed for operation in any position and shall meet
the specified capacity, voltage and electrolyte leakage requirements as specified in the
individual specification sheets.

5.18 Chemical Requirements

5.18.1 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.

5.18.2 Resistance of Elastomer Materials All elastomer materials used in the battery shall
show no cracks, blisters or other deterioration, or cause degradation of battery performance.

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

5.19 Temperature Requirements

5.19.1 Operating The battery shall meet the temperature performance requirements of
the individual specification sheet.

5.19.2 Non-Operating The battery shall show no evidence of breaking or cracking of the
case or cover when subjected to thermal shock temperature cycling in the range of +70°C to -
60°C.

5.20 Electrical Requirements

5.20.1 Electrical Leakage Unless otherwise specified, no potential in excess of 0.5 volts
shall be obtained from the case or non-connected terminal to any terminal when tested in
accordance with 10.21.

5.20.2 Battery Voltage When charged briefly, the battery voltage at 10 seconds of
charge shall be no greater than the number of cells in series per battery, (N), times 1.2 V per
cell.

5.21 Performance The discharge current in amperes for each discharge shall be the value
listed in the individual specification sheets. The temperature of discharge and the minimum
end voltage shall be the value listed in the individual specification sheet. Inability to meet the
specified minimum requirements shall constitute a failure.

5.22 Environmental Requirements The battery when subjected to the tests listed in
Table I that are required by the individual specification sheets shall show no:

Dimensional distortion beyond specified limits

Sharp current over voltage fluctuations during any charge or discharge period

Mechanical failure of any part.

Failure to mate with a corresponding part.
Diminution of the rated capacity specified in the individual specification sheet
following the performance of each test.
Electrical leakage (10.21)
Safety hazard
Battery case cracked.

8
 TABLE - I Environmental Requirements

Tests Reference clause Number

Thermal Shock 10.26

Mechanical Shock 10.27

Vibration 10.28

Transient Drop Test 10.29

Overcharge 10.20

5.23 Immersion The batteries shall show no evidence of leakage of water into cases or
leakage of gas from the cases after being subjected to the immersion or alternate leakage tests
of 10.30.

5.24 Battery Case Expansion The battery shall be designed to prevent dimensional
expansion that will prevent its removal from equipment during and after battery case venting.
The battery shall not require more than 5.5 Kg of force for removal when tested as per
Battery Case-Vent Test 10.35.

5.25 Battery Storage Life The battery shall be capable of at least 5 years of warehouse
storage during which storage temperature may vary between the limits of -20°C to + 50°C.
The battery when removed from storage shall show no:

Dimensional distortions beyond the specified limits

Mechanical failure of any part.
Evidence of marking, pitting, chipping, scaling, corrosion or other deleterious effects
on external parts of battery.
Electrical leakage 5.20.1
Cell leakage 5.15.4

Inability to provide the rated capacity specified in the individual specification sheet
after a full charge for 2 hours followed by discharge as per Clause 10.18

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

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

5.26.1 Temporary Cut off Devices If required to ensure safety under conditions of
overcharge and/ or misuse, the battery, unless otherwise specified, shall contain at a
minimum a normally closed thermo switch that shall open at 70°C ± 5 deg C and close at
50°C ± 5 deg C. Each two to three single cells in series arrangement shall have at least one
temporary cut off devices. The device shall be located as close as possible to the geometric
center of the cluster. The devices for a cluster arrangement of three or more cells shall be
distributed evenly across at the geometric center of the cluster.

5.26.2 Permanent Cut off Devices The battery shall be permanently shut off when the
temperature of the battery reaches 90°C ± 5 deg C. Each two to three single cells in series
arrangement shall have at least one permanent cut off devices. The device shall be located as
close as possible to the geometric center of the cluster. The devices for a cluster arrangement
of three or more cells shall be distributed evenly across at the geometric center of the cluster.
The devices shall prevent charging and discharging of the battery.

5.26.3 Short Circuit Protection The battery shall be a short-circuit protected device.
When shorted across the battery terminals with total external resistance less than 50 milli-
ohms, there shall not be any damage to the battery. When the short is removed, the battery
shall be able to meet the full discharge capacity requirement after full charge.

5.27 State-of-Charge Display and Power Requirement All of the batteries shall contain
a state of charge display. Unless otherwise specified, the state of charge display location is
optional.

5.28 Power Consumption The power consumption for the state of charge display and
internal charge and discharge circuit shall be less than 50 mAh or less than 2% of the battery
capacity for seven days operation when the state-of-charge display illuminates at least 5 times
a day for 7 days at 25°C ± 5 deg C, whichever is less.

5.29 State-of-charge Display Characteristics As a minimum, the state of charge shall

be displayed as two distinct ranges of remaining capacity in the battery. The two ranges shall
be:
(a) between 40 and 70 percent
(b) greater than 70 percent

5.30 Altitude After the batteries have been tested as specified in Clause 10.16 they
shall meet the Physical and Visual Examination (10.11) and battery voltage (10.15)
requirements.

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6. MANUFACTURE / CONSTRUCTION

6.1 Cells The battery shall be made up of the required number of individual series and /
or parallel connected cells, which have met the capacity test and other electrical
requirements. The individual cells shall be provided with protective sleeving or coating. The
cells shall not contain any electronics and shall meet all the safety requirements listed in 5.26.
The battery case / compartment shall not expand that will prevent its easy removal from
equipment.

6.2 Terminal Marking Where applicable, 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. A schematic drawing shall
be placed as close as possible to the receptacle as shown on the individual specification sheet.

6.3 Connector The battery connector shall be as per the individual specification sheet.

6.4 Carrying Handles The carrying handles shall be provided as per the individual
specification sheet.

6.5 Design Requirements

6.5.1 The battery shall be generally designed for operation under the following
environmental conditions:-
(a) Application : Fitted inside the aircraft

(b) Temperature :

(i) Operation : - 30°C to + 50°C or as per individual specification

sheet

(ii) Storage : -60°C to +75°C or as per individual specification

sheet.

(c) Altitude : Sea level to 15 Km

(d) Mechanical shock : As per Clause 10.27

tests

(e) Vibration : As per Clause 10.28

(f) Transient drop test : As per Clause 10.29

(g) Thermal Shock : As per Clause 10.26

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 JSS 6140-05: 2005
(Revision No. 1)
(Reaffirmed 2012)

6.5.2 The specific environment for particular aircraft shall be as per individual specification
for that aircraft.

6.5.3 The battery shall be protected so that it is not adversely affected by rain and dust
storm conditions prevailing in the field areas.

6.5.4 The battery shall consist of number of cells connected in series and or parallel as
specified in the individual specification and shall be assembled in a container. The battery
container shall meet the requirements stated in this specification.

6.5.5 The manufacturer shall make his own design of the cells but at the time of approval
two sets of representative components used in the manufacture of the cells should be
submitted to the Type Approval Authority for their record. This will be a guide for
component inspection at the time of assembly during production. Once the set of
components and cell container is approved, no change in design of the cell and components
shall be permitted during bulk production without the prior approval of the Type Approval
Authority.

6.5.6 The mass of the battery in full charged condition shall not exceed the mass stated in
the individual specification.

6.5.7 The construction and dimension of the battery shall be as per drawing indicated in the
individual specification.

6.5.8 Pressure Release Device

6.5.8.1 Unless specified otherwise in the individual specification sheet, a pressure release
device shall be incorporated into the battery. This device shall be designed to release below
the bursting pressure of the container and above the normal operating pressure of the battery.
The device is intended to function only as an emergency release to protect the battery against
abnormal pressure build-up. 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.

7. WORKMANSHIP AND FINISH The battery and its components shall be

manufactured and processed in best workmanship like manner in accordance with the design
and sound engineering practice and to the entire satisfaction of the Quality Assurance
Authority.

12
8. MARKING Each battery shall be marked legibly and indelibly with the following
particulars:

DS Cat Number

Description of the battery including nominal voltage and rated ampere-hour capacity.

Manufacturer’s code

Month and year of manufacture

Battery Sl. No.

Contract/supply order number

Charging and other special instructions

Defence Acceptance Mark

9. PRE-INSPECTION OF STORES/CONSIGNMENT

9.1 Manufacturers/Contractors must satisfy themselves that the stores are in accordance
with the terms of the contract and fully conform to the required specification by carrying out
a thorough pre-inspection of each lot before actually tendering the same for inspection to the
Quality Assurance Officer nominated under the terms of the contract. A declaration by the
contractor that a necessary pre-inspection has been carried out on the stores tendered, will be
submitted along with the challan. The declaration will also indicate the method followed in
carrying out pre-inspection showing the features checked/tested and will have the test
certificate attached to the challan/declaration.

9.2 If the Quality Assurance Officer finds that pre-inspection of the consignment as
required above has not been carried out, the consignment is liable for rejection.

9.3 The store shall be inspected at the supplier’s premises for satisfactory performance
and proper packaging before despatch to the destination.

9.4 In addition to above, requirements as mentioned in the contract shall also apply.

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(Reaffirmed 2012)

10. QUALITY ASSURANCE

10.1 The manufacturer shall be fully responsible for performance of all inspection
requirements as specified herein and shall ensure compliance with the specified requirements
by the following methods.

10.2 Inspection of materials, components and completed batteries in the course of

manufacture to ensure that the specified requirements are being met and that the necessary
standard of workmanship and process control is being maintained.

10.3 The manufacture shall prepare a quality assurance plan to be applied to the total
process of producing the specified type of battery. The Quality Assurance Authority shall
approve the quality assurance plan.

10.4 The manufacturer’s quality control organization shall apply this quality assurance
plan during production and maintain records thereof.

10.5 Quality Assurance plan shall also list the tests that are to be carried out on completed
battery. Electrical tests shall be included where appropriate.

10.6 Representative battery samples shall be subjected to the specified tests.

10.7 Classification of Tests The batteries shall be evaluated/tested at various stages under
following classification of tests: -

Type Tests

Acceptance Tests

Routine Tests

10.7.1 Type Tests The tests specified in Table II shall be carried out as type tests. Qty.8
(Eight) numbers of samples shall be submitted by the manufacturer for carrying out the tests.
The distribution of samples is shown in Table III Additional samples required for user trials
shall be as indicated in the individual specification.

10.7.1.1 Criteria for Compliance All samples shall successfully pass all the type tests
including user trials for proving conformity with the requirements of this specification. If
any of the samples fail in any of the Type tests including user trials, the battery shall not
qualify for Type Approval. The Quality Assurance Authority may investigate the reasons for
failure and the manufacturer may resubmit fresh samples after incorporating necessary
improvements for further evaluation.

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10.7.2 Acceptance Tests The tests specified in Table IV shall constitute acceptance tests.
The Quality Assurance Authority at their discretion may also subject the sample batteries to
tests listed in Table II including environmental tests.

10.7.2.1Sampling Plan The acceptance tests are intended for checking the quality of batches
of batteries selected at random and shall be applied on minimum four samples or upto
maximum of two percent in a batch. However, the Quality Assurance Authority at his
discretion may select more number of samples for carrying out acceptance tests.

10.7.2.2 Criteria for Acceptance The complete batch of batteries shall be cleared on
successful completion of acceptance tests. If any of the samples fail in any of the acceptance
tests, the entire batch shall be liable for rejection. The batch (es) may be re-submitted for
inspection after removal of defects and/or reworking to correct the fault.

10.7.3 Routine Tests The tests specified in Table V shall constitute routine tests.

10.8 Test Equipment

10.8.1 Accuracy of Measuring Instruments

10.8.1.1 The measuring instruments used for the tests shall have at least the following
degree of accuracy and shall be periodically calibrated.

10.8.1.2 Voltmeters shall comply with class 0. 5 of IS 1248 (Part 2).

10.8.1.3 Ammeters shall comply with class 0.5 of IS 1248 (Part 2).

10.8.1.4 Thermometers shall have a maximum calibration error of ± 1 deg C.

10.8.1.5 Time measurement shall be to a minimum accuracy of 0.5%

10.8.1.6 The range of the measuring instruments shall correspond to the values being
measured.

10.9 Method of Tests Method of tests to be carried out for proving conformity of the
batteries with the requirements of this specification are described in sub-clauses 10.30.2 to
10.30.3

10.10 Cell Safety The cell/component level tests shall be carried out on Qty. 6
Nos. of cells. The test details and distribution of samples for various tests are given below.

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 JSS 6140-05: 2005
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10.10.1. Cell Balance (All cells) The manufacturer shall measure and record the
capacities of individual cells (or sub-assemblies of cells). The records shall show that the
capacities of the individual cells used in the battery shall not vary by more than 5% from the
average capacity value of the cells in that particular battery.

10.10.2 Cell Overcharge (Cell No. 3,4) A single cell shall be placed in a temperature
chamber set at 25 deg.C. A thermo couple shall attach to the side of the cell, and current
carrying and voltage monitoring leads shall be attached to the terminals. Using a power
supply that provides at least 24Volts, a constant C/2 current charging rate shall be applied for
8 hours continuously. Cell temperature, voltage and current shall be recorded. A single cell
shall meet the requirement of not to explode or catch fire or spark. No electrodes or separator
material of the cell shall be outside of the cell case.

10.10.3 Cell Short Circuit (Cell No.5, 6) A single cell shall be shorted by
connecting the positive and negative terminals of the cell with a less than 20 cm in length of
No.16 AWG or higher copper wire. The cell shall be completely discharged. The cell shall
not explode or catch fire or spark.

10.10. 4 Cell Forced-Discharge (Cell Nos. 1,2) A completely discharged single cell (less
than 0.2 volts) is to be forced –discharge in accordance with method 2 of the forced discharge
test of UL-1642. One cell for each cell string shall be discharged at the rate specified in the
individual specification sheet to a test end voltage of two-thirds of its open circuit voltage.
It shall then be connected in series with the appropriate number of charged cells, which shall
then be discharged at the rate specified in individual specification sheet to a test end voltage
of the individual specification sheet. There shall be no leaking, venting, fire or explosion.

10.10.5 Electrical Connection Wires and Tabs All electrical connecting wires and tabs
for the cells and the battery shall be able to carry the current specified in specification sheet
and shall be covered by an insulation with the following characteristics:

Softening temperature : 150 deg. C minimum

Lengthwise shrinkage : 3% maximum after application
Thickness : 1.3 mm minimum

10.11 Physical and Visual Examination

10.11.1 Cells The manufacturer shall carry out the physical examination of the cells
and record of the same shall be maintained for verification purpose.

10.11.2 Batteries The batteries shall be physically examined for its general conditions,
design and construction and workmanship including basic materials, components materials
and parts, Hardware, connector,, mounting screws. The batteries shall also be examined to
verify the requirements of the Table II

16
 TABLE - II VISUAL AND MECHANICAL INSPECTION

DEFECTS METHOD OF
INSPECTION

Zero (o) Voltage Voltmeter

Contact surfaces obstructed by insulation compounds so that electrical Visual

use is affected

Improper assembly causing parts to be inoperative or unsafe in service. Visual

Weight not within specified limits Scale

Location and polarity of receptacle not specified Visual

Terminal markings, identification label and operating instructions not as Visual

specified.

Corrosion, which could cause mechanical, operational or electrical Visual

failure.

Particles of solder, flux or other foreign material, which could cause Visual
mechanical, operational or electrical failure.

Free movement of floating connection restricted. Visual

Burrs or imperfections, which interfere with proper, use in operation, Visual

assembly or disassembly or cause an unsafe condition in service.

Contact surfaces of the terminals obstructed by insulation compounds Visual

Insulators or insulation damaged Visual

State of charge indicator displays state of charge Visual

10.12 Dimensions and Weights The dimensions and weights of batteries shall be as per
the individual specification sheets.

10.13 Marking The marking on the battery shall be as per the clause 8

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 JSS 6140-05: 2005
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10.14 Insulation Resistance The insulation resistance test shall be carried out on the
individual battery and cell series string unless otherwise specified in the individual
specification sheet. The batteries/cell series shall be stored for a period of 48 hrs at 20°C ± 2
deg C and a relative humidity of 50 ± 15%. After storage and while at these conditions the
insulation resistance shall be measured by applying 500V ± 20 VDC between any of the two
battery terminals or cell series string terminations (not electrically connected) and between all
ungrounded terminals and the container of the battery. The insulation resistance shall be more
than 25 megohms.

10.14.1For Routine inspection, it is not necessary to store the battery in above mentioned
conditions. The insulation values can be measured at room temperatures.

10.15 Battery Voltage The battery at 25ºC ± 5 deg C shall be given a charge pulse at
the C rate for 10 ± 3 seconds. The voltage shall be constantly monitored and it shall not be
greater than the number of cells in series per battery(N) times 1.2V/cell. For Routine
inspection, it is not necessary to pulse charge the battery, however, the battery voltage shall
meet the requirements stated above.
10.16 Altitude Test The Batteries shall be placed in an altitude chamber, in which the
pressure is maintained at a value corresponding to an altitude of 15 KM and the temperature
is kept at 24°C ± 3 deg C, for a period of six (6) hours. Upon completion of the altitude test,
the battery voltage as per Clause 10.15 shall be tested and the battery shall be examined for
Physical and Visual Examination defects as per Clause 10.11
10.17 State of Charge Display The battery shall be charged by at constant current
method or constant potential (voltage) at 25°C ± 5 deg C at ambient atmosphere pressure and
RH at a minimum C/2 rates for a period of 2 hours or as specified in the individual
specification sheet. The battery shall then be discharged at C/5 rate. The state of charge shall
be displayed as two distinct ranges of remaining capacity in the battery. The two ranges shall
be:
(a) between 40 and 70 percent

(b) greater than 70 percent.

10.18 Capacity Discharge (Nominal) The battery shall be charged by a constant

current method or constant potential (Voltage) at normal temperature conditions at a
minimum of C/2 rates and for a period of 2 hrs or as specified in the individual specification
sheets. The battery shall then be stabilized for a period of 2 hrs.

10.18.1 It shall then be discharged at the rate specified by the individual specification
sheet including to the specified final voltage.

10.18.2 The battery shall meet the capacity discharge test requirement of individual
specification sheet.

18
10.18.3 In case the capacity obtained in the first cycle is less than the specified value, the
battery may be subjected to three cycles of capacity discharge tests. The capacity obtained in
any one of the above cycles shall not be less than the capacity specified in the individual
specification.

10.19 Cycle Life Test The battery shall be tested as follows at 25°C ± 5 deg C at
ambient atmospheric pressure.

(a) Cycle 1 – Charge the battery as per Cl.10.17 and discharge at 0.5 C5 rate to
the discharge cut off voltage of 1V /cell or as specified in the individual specification
sheet.

(b) Cycles 2- 26: Charge at C/2 or higher for 2 hours as per Cl., 10.17
Discharge at the rate as specified in the individual specification sheet for a minimum
of 100% of initial full discharge capacity and shall continue until the battery internal
circuit cuts off. Allow 5 minutes maximum rest time between charge and discharge.
Allow 30 minutes maximum rest time between discharge and charge.

(c) Cycle 27: Charge as per (b) above. Discharge as per the current specified in
the individual specification. Allow minimum of two hour of storage time at ambient
temperature between charge and discharge.

(d) Cycle 28 – Charge as per Cl. 10.17, discharge as per the current specified
in the individual specification sheets. Allow minimum of two hours of storage time at
ambient temperature.

(e) Check for electrical leakage 10.21.

(f) Repeat cycles 1-28 until any of the following conditions occur :

(i) The capacity on any 28th cycle is lower than that specified on the cycle
life test of the individual specification sheet

(ii) The battery fails to pass the electrical leakage inspection of 10.21

(iii)The number of satisfactory cycles completed equals that specified on

the individual specification sheet.

10.20 Over Charge

10.20.1 Batteries shall be charged as per Cl.10.17 or at the rate specified in the individual
specification sheet for the specified number of hours. Voltage readings shall be recorded and
shall not show sharp current and over voltage fluctuations during any charge or discharge
period. The battery shall then be discharged and meet the overcharge test of the individual
specification sheets. The battery shall be examined to ensure compliance with all
Environmental requirements as per clause 5.18.

10.20.2 Repeat this test for 10 cycles. The battery shall then be discharged and shall meet
the over charge test of individual specification sheets.

10.20.3 The battery shall then be examined to ensure compliance with all requirements of
Cl. 5.18

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10.21 Electrical Leakage The battery voltage readings shall be taken from the case or
ground to either terminal and between all electrically isolated terminals with a voltmeter
having a 1 Meg ohm impedance. For example, on a battery with two parallel sections
measure voltage from pin 1 to pins 2 to 5, etc. The battery shall not show potential in excess
of 0.5V.

10.22 High Rate Discharge Test

(a) The battery shall be charged as per Cl.10.17 and stored under the specified
temperature and storage conditions

(b) The battery shall then be discharged at the rate specified in the individual
specification sheet.

(c) The following shall be recorded.

(i) The terminal voltage, 5 seconds after the start of discharge.

(ii) The elapsed time for the voltage to drop to the final voltage specified
in the individual specification sheet after the start of discharge. The
battery shall meet the high rate discharge test of the individual
specification sheet.

10.23 Low Temperature Test The battery shall be Charged as specified in

Clause 10.17. The battery shall then be stored for a minimum storage time of 16 hours
between charge and discharge at the temperature indicated in the individual specification
sheet.

10.23.1 Discharge the battery as specified at the low ambient temperature to the specified
final voltage.

10.23.2 The duration obtained shall not be less than the value as specified in the individual
specification sheet.

10.24 Retention of Charge Test (at high temperature)

10.24.1 The battery shall be charged as specified in 10.17. It shall then be stored under
high temperature conditions for the number of days as specified in the individual
specification sheet.

20
10.24.2 It shall then be discharged at ambient temperature at the rate specified on the
individual specification sheet to the specified final voltage and shall meet the requirement of
retention of charge test of the individual specification sheet.

10.24.3 The subsequent discharge capacity shall be at least 94% of the capacity discharge
as specified in the individual specification sheet.

10.25 High Rate Pulse Test

10.25.1 The battery shall be charged as specified in Clause 10.17 and stored under the
normal specified temperature and storage conditions.

10.25.2 The battery shall then be discharged at the rate and for the times specified in pulse
discharge test of the individual specification sheet until the specified end voltages are
reached.

10.26 Thermal Shock (Charge after this Test) With the battery in a discharged
condition, it shall be subjected thermal shock temperature cycling in the range of +70°C to
–60°C as per Method 503, Procedure 1 of MIL-STD-810, except the duration at the
temperature extremes shall be 2 hours and diurnal cycling not required.

10.26.1 The container shall be examined for breaks, cracks, or other defects resulting from
this storage.

10.26.2 The requirements as specified in Cl.5.18 shall be met

10.27 Mechanical Shock Tests The batteries in a charged condition shall be

rigidly attached to the test carriage by the mounting screws and shock tested at 40g for an 18
millisecond duration in accordance with test Method 516, Procedure 1, MIL-STD-810.

10.27.1 Three shocks per axis, on each of the three orthogonal axis, shall be applied.

10.27.2 The requirements as specified in Clause 5.18 shall be met.

10.28 Vibration (Discharge)

10.28.1 With the battery fully charged, it shall be tested in accordance with Method 201
for low frequency conditions and Method 204, Test Condition C, Part 2 only for high
frequency conditions of MIL-STD-202, with the following exceptions:

(a) The battery may be vibrated in one plane through both low and high
frequencies before being changed to the next plane on the vibration table.

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 JSS 6140-05: 2005
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(b) The low frequency vibration may be varied either uniformly or logarithmically
between the limits of 10 and 55 Hz and return to 10 Hz. The entire frequency
range from 10 to 55 Hz and back to 10Hz shall be traversed in approximately one
(1) minute.

(c) The length of time for low frequency vibration in one plane shall be 90-100
minutes (270-300 minutes for the complete test).

(d) The battery shall be discharged at the rate specified on the individual
specification sheet in each plane during the low frequency vibration and the
discharge continued to the specified final voltage. The capacity specified in the
individual specification sheet shall be met.

(e) The voltage shall be recorded on a recording voltmeter during both high and
low frequency vibration, and shall meet the requirements of 5.18
10.29 Transient Drop Test

10.29.1 With the battery fully charged, it shall be dropped once, for each temperature,
from a height of 76 ± 5 cm onto a hard surface consisting of 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.

10.29.2 The drop test shall be performed on batteries preconditioned at +55°C to –70°C.

10.29.3 The batteries shall be stabilized a minimum of 4 hours at each test temperature
and dropped within 10 minutes after removal from the temperature chamber.

10.29.4 The battery shall meet all the requirement as per clause 5.18 upon completion of
the drop test.

10.30 Immersion Test

10.30.1 The battery shall be tested for leakage by either one of the test methods below and
shall meet the requirements of 5.19 and the individual specification sheet.

10.30.2 Method One The battery with terminals protected against electrolytic action
shall be immersed to a depth of 90 cm in fresh water for 2 hours. After 2 hours of immersion,
the battery shall be removed and wiped dry on exterior surfaces. There shall be no evidence
of leakage.

22
10.30.3 Method Two Pressurize the battery with a minimum of 1.3 psig of gaseous
N2 for a minimum of 2 hours. Release the pressure and immediately transfer the battery into
an immersion vessel. The battery shall be immersed in an upright position to a depth of 8 cm
in fresh water. Carefully observe the battery (particularly the seals) for a total of 5 minutes
for indication of leakage. Leakage shall be indicated by the emission of gas bubbles from the
interior of the battery.

10.31 Electrical Leakage Test

10.31.1 The battery Voltage readings shall be taken from the case or ground to either
terminal and between all electrically isolated terminals with a voltmeter having a 1 Meg Ohm
impedance. For example, on a battery with two parallel sections measure voltage from pin
1 to pins 2 to 5, etc.

10.31.2 The battery shall show no voltage in excess of 0.5V.

10.32 Power Consumption

(a) Connect the ammeter between the electronics within the batter and the battery.

(b) Measure and record the current flow between the battery and internal control
and state of charge device.

(c) If it is a push ON state-of-Charge display, push ON to display the state of

charge device for 35 minutes, and record the current flow.

(d) Calculate the total ampere-hour.

(e) The total ampere-hour shall be less than 50 mAh or less than 2% of the
batteries initial capacity whichever is less.

10.33 State Of Charge Display Characteristics Charge the battery fully as

specified in 10.17. The battery shall then be discharged at C/5 rate.

10.33.1 The state of charge shall be displayed as two distinct ranges as a minimum of
remaining capacity in the battery. The two ranges shall be

(a) Between 40 and 70 % &

(b) Greater than 70%.

10.34 State Of Charge Accuracy

10.34.1 Four fully charged batteries shall be discharged at the 5 ± 1 hour rate to the
minimum voltage specified. If parallel discharge is specified for the battery under test, then
two batteries shall be discharged in parallel and two in series configuration. Calculate the
average capacity.

10.34.2 Discharge the four fully charged batteries (2 parallel, 2 series when specified) at
the 5 hour rate to 80+0, -5 percent of average capacity.

Record the status indication.

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 JSS 6140-05: 2005
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Discharge the batteries at the same rate to 50+ 5, -0% of average capacity.

Record the indication.

Discharge the batteries at this rate to 25+5, -0% capacity.

Record the status indication

Discharge the batteries to 5+5, -0% capacity

Activate the state of charge indicator and record the status indication.

Discharge the batteries to the cut-off voltage as specified in the individual

specification.

Record the status indication.

10.35 Battery Case-Vent Test

10.35.1 A fully assembled battery shall be inserted into a fixture designed to contain
possible bulging by the front, back and side faces of the battery case (see individual
specification sheet for face references).

10.35.2 The fixture shall allow the battery to expand upto 0.25mm inches over the
specified maximum allowable dimensions. The fixture shall not cover the top and bottom of
the battery.

10.35.3 An airline shall be tapped into the battery and the internal pressure of the battery
shall be increased 1.0 psia every 60 seconds until the battery case vent opens.

10.35.4 The battery shall meet the requirement as specified in clause 6.5.8.1

10.35.5 The fixture with the pressurized battery shall be lifted or positioned to allow the
battery to slide out through the bottom of the fixture,

10.35.6 If, the pressurized battery cannot slide out of the fixture, weights shall be placed
on top of the battery

10.

24
35.7 The total force required to allow the battery to slide out of the mount shall not
exceed 5.5 Kgs.

10.35.8 The battery shall meet the requirements of clause 6.5.8.1

10.36 Battery Safety Tests

10.36.1 High Temperature Temporary Cut off The battery shall be Charged as
specified in 10.17. The battery shall then be stored at 75°C ± 5 deg C. Measure and record
the battery voltage. Allow the battery to cool down to 50°C ± 5 deg C. The battery voltage
shall return as specified in the individual specification sheet. The battery shall meet the
capacity discharge test requirement as per clause 10.18.

10.36.2 High Temperature Permanent Cut off The battery shall be charged as
specified. The battery shall then be stored at 90 deg C. Measure and record the battery
voltage. Allow the battery to cool down to 50°C. The battery voltage shall be less than 1
volt and not be able to be charged as per clause 10.17.

10.36.3 Short Circuit Protection The battery shall be shorted across all the
positive and negative terminals with a total external resistance less than 50 mill ohms for one
hour. Then remove the short across the terminals. The battery shall meet the capacity
discharge test.

10.37 Storage Life Test

10.37.1 The battery shall be capable of at least 5 years of warehouse storage during which
storage temperatures may vary between the limits of -20°C to + 50°C. The battery when
removed from storage shall show no:

(a) Dimensional distortions beyond the specified limits

(b) Mechanical failure of any parts.

(c) Evidence of marking, pitting, chipping, scaling, corrosion or other deleterious

effects on external parts of battery.

(d) Electrical leakage

(e) Cell leakage

(f) Inability to provide the rated capacity specified in the individual specification
sheet after a full charge.

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 JSS 6140-05: 2005
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10.38 User Trials

10.38.1 User Trials including Flight Trials on the battery shall be carried out as detailed in
the individual specification of the battery. This shall include the following: -

(a) Physical Checks

(b) Fitment Trials

(c) Ground Performance Trials

(d) Flight Performance Tests

10.38.2 The No. of samples required for user trials shall be as per individual specification.

10.39.3 The User Trials shall be carried out as per the “Task Directives” issued by Air
HQ/CEMILAC.

10.39 Type Approval Authority

10.39.1 Type Approval Authority for granting Type Approval for the items covered under
this specification shall be CEMILAC, Ministry of Defence, Marathalli Colony PO,
Bangalore – 560 037. The manufacturer shall prepare a type test plan/ procedure document
and submit the same to CEMILAC for their approval.

11. LITERATURE The manufacturer shall supply the following documents free of
cost along with the battery:

11.1 Operating and maintenance manual – This should cover the following aspects: -

(a) General Information

(b) Operating guidelines

(c) Charging

(d) Maintenance

(e) Overhaul and repair

(f) Storage and shipping

(g) Trouble shooting

(h) Service log sheets

26
12. TOOL KIT

12.1 The manufacturer shall supply the tool kit for removal and maintenance of the
batteries. The manufacturer shall list the essential tool kit in their quotation/tender.

13. WARRANTY

13.1 The stores supplied shall bear a warranty as per the contract. In absence of such
clause in contract, the following clause shall apply

“ The stores supplied against this specification shall be deemed to bear a

warranty of the contractor against defective design, material, workmanship and performance
for a period of 12 months from the date of initial commissioning of the battery by the
consignee. During this period if any of the items is found defective during use, the same
shall be replaced by the supplier free of cost at the consignee’s place but not later than 3
months on receipt of such intimation”.

14. PACKAGING

14.1 The battery shall be suitably packed to withstand transit hazards. The battery may be
packed in cardboard box or wooden case. While packing, precautions must be taken to keep
batteries in upright position. The packing case shall be legibly and indelibly marked to read
“THIS SIDE UP”, “TOP” OR “BOTTOM” as the case may be.

14.2 In addition to above, the packaging shall be in accordance with the terms of the
contract.

15. DEFENCE STORES CATAGLOGUE NUMBER

15.1 The stores shall bear a DS Cat No. before they are supplied / accepted in Defence
Services. The DS Cat No. for the individual battery aircraft wise shall be as per allotment by
the Defence Codification Authority.

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 JSS 6140-05: 2005
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16. SUGGESTIONS FOR IMPROVEMENT

16.1 Any suggestion for improvement in this document may be forwarded to:

The Director,
Directorate of Standardisation
Ministry of Defence
‘H’ Block, Nirman Bhawan P.O.,
New Delhi - 110 011.

28
 TABLE – III

TYPE APPROVAL TESTS IN ORDER OF APPLICATION AND DISTRIBUTION

OF SAMPLES

SL.No. TEST DETAILS CLAUSE REFERENCE BATTERY

No. SRL.No.
1 Cell Safety 5.15 1 to 6
2. Physical and Visual Examination 10.11 1 to 6
3. Dimensions and weight 10.12 1 to 6
4. Marking 10.13 1 to 6
5. Insulation Resistance 10.14 1 to 6
6. Battery voltage 10.15 1 to 6
7 Altitude 10.16 1 to 6
8. State of charge display 10.17 1 to 6
9. Capacity discharge test 10.18 1 to 6
10. Cycle life 10.19 5, 6
11. Over charge 10.20 2,3
12 Electrical leakage 10.21 1 to 6
13 High Rate discharge test 10.22 1, 3
14 Low Temperature test 10.23 2, 4
15. Retention of charge test 10.24 1, 2, 3 4
16. High rate pulse 10.25 1, 3
17 Thermal shock (charge after this 10.26 1, 2, 3 4
test)
18 Mechanical shock 10.27 1, 2, 3, 4
19 Vibration (discharge) 10.28 2, 3
20 Transient drop 10.29 1, 2, 3, 4
21 Immersion 10.30 1, 2, 3, 4
22 Electrical leakage 10.31 1, 2, 3, 4
23 State of charge accuracy 10.34 1, 2, 3, 4
24 Capacity discharge test 10.18 1, 2, 3, 4
25 Battery case - vent 10.35 1, 4
26 Battery safety tests 10.36 2, 3
27 Storage life test 10.37 7,. 8 (see Note
1)
28 User Trials 10.38 9, 10 (see Note
2)

Note: (1) The number of samples required for carrying out user trials shall be as specified
in the individual specification for the battery.
(2) Basic cells may be subjected to storage life test instead of batteries unless
otherwise specified in the individual specification.

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 JSS 6140-05: 2005
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TABLE – IV

ACCEPTANCE TEST IN ORDER OF APPLICATION

Sl.No. TEST DETAILS CLAUSE REFERENCE

1. Physical and Visual Examination 10.11
2. Dimensions and weight 10.12
3. Marking 10.13
4. Insulation Resistance 10.14
5. Battery voltage 10.15
6. State of charge display 10.17
7. Capacity discharge 10.18
8. High rate discharge 10.22
9. Low Temperature test 10.23
10. High rate pulse 10.25
11. Over charge 10.20
12. Electrical leakage 10.21
13. Battery Safety Tests 10.36

Note: The Quality Assurance Authority at his discretion may also subject the battery
samples to tests listed in Table III including Environmental tests.

TABLE –V

ROUTINE TESTS

Sl.No. Tests Details Clause Reference No.

1. Physical and Visual examination 10.11
2. Marking 10.13
3. Insulation Resistance 10.14
4. Battery voltage 10.15

Note: The insulation resistance test at Sl.No.3 may be carried out at room temperature
without storage.

30