Interim Defence Standard 61-021

Supp 42
Issue 4 Date: 28 January 2017
______________________________________
General Specification for Batteries

Supplement: 42 : Sealed Lead Acid

Battery 12V 110 Ah (Minimum) NSN
6140-99-219-2903, NSN 6140-99-690-
6632, NSN 6140-12-369-8589, NSN
6140-99-738-0574, NSN 6140-01-485-
1472
______________________________________
This Defence Standard has been published as an INTERIM Standard and is provisional
because it has not been agreed by all authorities concerned with its use. It shall be applied
to obtain information and experience on its application which will then allow users to
submit observations and comments. Please consider if any part of the Standard creates
problem, requires interpretation or is restrictive in any way.
Users are asked to submit to DStan any beneficial and constructive comment that will
assist the author and/or working group to review prior to its being converted to a normal
Standard.
Please include; the page number, clause number(s) and wording that require attention; the
recommendation for correcting the deficiencies; any additional pertinent data which may
also be of use in improving the Standard should be submitted
 INT DEF STAN 61-021 Supp 42 Issue 4
Section 1

Foreword
Defence Standard Structure
Section 1 (Generated by the StanMIS toolset)
• Revision Note
• Historical Record
• Warning
• Standard Clauses
Section 2 (Technical information provided by Subject Matter Expert)
• Title
• Introduction (optional)
• Table of Contents
• Scope
• Technical Information to include Tables and Figures
• Annexes (as required)
Section 3 (Generated by StanMIS toolset)
• Normative References
• Definitions
• Abbreviation

REVISION NOTE
Additional NATO Stock Number (NSN) variants (6140-12-369-8589, 6140-99-738-0574 and 6140-
01-485-1472) have been added.

The cold cranking requirement has been increased to 1000A and the test method has been
revised.

HISTORICAL RECORD
This standard supersedes the following:
Def Stan 61-21 Supplement 42 Issue 3 dated 18 November 2011,
Def Stan 61-21 Supplement 042 Issue 2 dated 30 July 2009
Def Stan 61-21 Supplement 042 Issue 1 dated 30 November 2007
Bat Spec 264 Issue 3 Amd1 dated 12 November 1998

WARNING
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and
European laws regarding Health and Safety at Work. Many Defence Standards set out processes
and procedures that could be injurious to health if adequate precautions are not taken. Adherence
to those processes and procedures in no way absolves users from complying with legal
requirements relating to Health and Safety at Work.

STANDARD CLAUSES

a) This standard has been published on behalf of the Ministry of Defence (MOD) by UK Defence
Standardization (DStan).

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 INT DEF STAN 61-021 Supp 42 Issue 4
b) This standard has been reached following broad consensus amongst the authorities concerned with its
use and is intended to be used whenever relevant in all future designs, contracts, orders etc. and
whenever practicable by amendment to those already in existence. If any difficulty arises which prevents
application of the Defence Standard, DStan shall be informed so that a remedy may be sought.
c) Please address any enquiries regarding the use of this standard in relation to an invitation to tender or to
a contract in which it is incorporated, to the responsible technical or supervising authority named in the
invitation to tender or contract.
d) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations
imposed upon them.
e) This standard has been devised solely for the use of the MOD and its contractors in the execution of
contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability whatsoever
and howsoever arising (including, but without limitation, liability resulting from negligence) for any loss or
damage however caused when the standard is used for any other purpose.

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 INT DEF STAN 61-021 Supp 42 Issue 4

Section 2

General Specification for Batteries

Sealed Lead Acid Battery 12V 110 Ah (Minimum)
NSN 6140-99-219-2903, NSN 6140-99-690-6632,
NSN 6140-12-369-8589, NSN 6140-99-738-0574 and
NSN 6140-01-485-1472

Preface

a) This supplement shall be read in conjunction with Def Stan 61-21.

b) This supplement provides a definitive specification for the electrical, physical, performance and
nomenclature requirements for a 12V 110Ah (Minimum) Sealed Lead Acid battery.

c) This supplement has been agreed by the authorities concerned with its use and is intended to
be used whenever relevant in all future designs, contracts, orders etc. and whenever practicable
by amendment to those already in existence. If any difficulty arises which prevents application
of this Defence Standard and its associated supplements, the UK Defence Standardization
(DStan) shall be informed so that a remedy may be sought.

d) Any enquiries regarding this standard in relation to an invitation to tender or a contract in which
it is incorporated are to be addressed to the responsible technical or supervising authority
named in the invitation to tender or contract.

e) Compliance with this Defence Standard shall not in itself relieve any person from any legal
obligations imposed upon them.

f) This standard has been devised solely for the use of the Ministry of Defence (MOD) and its
contractors in the execution of contracts for the MOD. To the extent permitted by law, the MOD
hereby excludes all liability whatsoever and howsoever arising (including, but without limitation,
liability resulting from negligence) for any loss or damage however caused when the standard is
used for any other purpose.

GENERAL REQUIREMENTS

0 Introduction

It is Ministry of Defence (MOD) policy to purchase batteries against performance specifications

whenever possible. Defence Standard 61-21 and its series of supplements has been generated to
address the current requirements for batteries. This supplement is applicable when invoked directly by
a MOD invitation to tender, contract, or when referred to by other MOD battery specifications.

1 Scope

This supplement provides a definitive specification for the electrical, physical, performance and
nomenclature requirements for a 12V 110Ah (Minimum) Sealed Lead Acid battery, NSN’s 6140-99-
219-2903, 6140-99-690-6632, 6140-12-369-8589, 6140-99-738-0574 and 6140-01-485-1472. It is
essential that the battery be operated only within its design and performance parameters. This
supplement invokes Major Product Conformity Certification.

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Table of Contents

Preface ................................................................................................................................................. 2-1

GENERAL REQUIREMENTS .............................................................................................................. 2-1
0 Introduction ................................................................................................................................ 2-1
1 Scope .......................................................................................................................................... 2-1
ELECTRICAL CHARACTERISTICS ................................................................................................... 2-3
2 Electrochemical System ........................................................................................................... 2-4
3 Nominal voltage ......................................................................................................................... 2-4
4 Capacity ...................................................................................................................................... 2-4
PHYSICAL CHARACTERISTICS ........................................................................................................ 2-4
5 Materials and Construction ...................................................................................................... 2-4
5.1 All Variants ............................................................................................................................. 2-4
5.2 6140-99-219-2903 (UK Manifold Variant) ............................................................................. 2-5
5.3 6140-99-690-6632 and 6140-12-369-8589 (Non-Manifold Variant) ..................................... 2-5
5.4 6140-99-738-0574 (Dual Terminal Variant) .......................................................................... 2-5
5.5 6140-01-485-1472 (USA Variant) ........................................................................................... 2-5
6 Dimensions ................................................................................................................................. 2-5
7 Mass ............................................................................................................................................ 2-5
8 Temperature Range ................................................................................................................... 2-6
PERFORMANCE REQUIREMENTS ................................................................................................... 2-6
9 Electrical Requirements ............................................................................................................ 2-6
9.1 Charging Procedure .............................................................................................................. 2-6
9.2 Commissioning Procedure. .................................................................................................. 2-6
9.3 Immediate Discharge. ........................................................................................................... 2-6
9.4 Capacity Discharge (20 Hour Rate at +25°C). ..................................................................... 2-6
9.5 Capacity Discharge (20 Hour Rate at +55°C). ..................................................................... 2-7
9.6 Capacity Discharge (High Rate at –40°C). .......................................................................... 2-7
9.7 Capacity Discharge (High Rate at +25°C). .......................................................................... 2-7
9.8 Capacity Discharge (High Rate at +55°C). .......................................................................... 2-8
9.9 Charge Retention Test. ......................................................................................................... 2-8
9.10 Cycle Life Test. ...................................................................................................................... 2-8
9.11 Short Circuit Test. ................................................................................................................. 2-9
9.12 Shelf Life. ............................................................................................................................... 2-9
9.13 Cranking Performance Test. ................................................................................................ 2-9
9.13.1 Method 1............................................................................................................................. 2-9
9.13.2 Method 2........................................................................................................................... 2-10
9.14 Overcharge Endurance Test. ............................................................................................. 2-10

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9.15 Deep Discharge Test. .......................................................................................................... 2-10

9.16 Polarity of Battery................................................................................................................ 2-10
10 Mechanical & Environmental Requirements ......................................................................... 2-11
10.1 Efficiency of Sealing. .......................................................................................................... 2-11
10.2 Electrolyte Retention........................................................................................................... 2-11
10.3 Vibration. .............................................................................................................................. 2-11
10.4 Drop And Topple. ................................................................................................................ 2-12
PRODUCT CONFORMITY CERTIFICATION.................................................................................... 2-12
11 General requirements .............................................................................................................. 2-12
11.1 Product Conformity Test Requirements ........................................................................... 2-12
11.2 Interim Certification ............................................................................................................. 2-12
11.3 Batch Certification ............................................................................................................... 2-12
11.4 Periodic Verification of Critical Performance ................................................................... 2-12
11.5 Performance Assessment Sheets (PAS)........................................................................... 2-13
12 Hazard Classification and Transportation Requirements ................................................... 2-14
MARKING REQUIREMENTS ............................................................................................................ 2-15
13 MARKING .................................................................................................................................. 2-15
14 Cell Age Requirements ........................................................................................................... 2-15
15 Packaging and Labelling Requirements ............................................................................... 2-15
Annex A Performance Assessment Sheets ................................................................................... 2-21

Tables
Table 1 - Periodic Verification of Critical Performance ...................... 2-Error! Bookmark not defined.
Table 2 - Product Conformity Test Schedule....................................... 2-Error! Bookmark not defined.

Figures
Figure 1 - Battery Outline Drawing for Battery 6140-99-219-2903 (UK Manifold Variant). ........ 2-16
Figure 2 - Battery Outline Drawing for Battery 6140-99-690-6632 and 6140-12-369-8589
(Non-Manifold Variants) ................................................................................................. 2-17
Figure 3 - Battery Outline Drawing for Battery 6140-99-738-0574 (Dual Terminal Variant). ..... 2-18
Figure 4 - Battery Outline Drawing for Battery 6140-01-485-1472 (USA Variant). ...................... 2-19
Figure 5 - Preferred handle type for the UK variants (rope and solid handle). ......................... 2-20
Figure 6 - Vent Nozzle for Battery 6140-99-219-2903 .................................................................... 2-20

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ELECTRICAL CHARACTERISTICS

2 Electrochemical System

The electrochemical system shall be sealed Lead Acid.

3 Nominal voltage

The battery shall have a nominal voltage of 12V.

4 Capacity

The battery shall have a 20 hour rate capacity of at least 110Ah.

PHYSICAL CHARACTERISTICS

5 Materials and Construction

5.1 All Variants

a) The battery is a sealed Lead Acid battery similar to NATO battery “Type 2”.

b) The battery shall not require routine maintenance (i.e. topping up with water) during its service
life.

c) Different battery labels are used (in-line with country requirements).

d) The battery case and lid material shall meet the “Elasticity” requirements of Para 7.3.6.3 of VG
96 924 Part 2.

e) The colour of the battery case shall correspond with "Stone Grey" RAL 7030 according to the
RAL colour chart (managed by the German Institute for Quality Assurance and Identification).

f) The material shall be self-extinguishing when subjected to a simple flammability test such as
that in UL 94.

g) The case shall be sufficiently resilient so as to withstand abusive effects such as being dragged
over ground.

h) The terminals shall be standard taper post to BS EN 50342-2.

i) The preferred UK handle design (i.e. rope and solid handle) is shown in figure 5. However,
alternative designs may be acceptable to the Authority with prior agreement. The handles shall
be attached in such a manner that they cannot become accidentally detached from the battery
during use or testing to the specified requirements.

j) The strength of the handles must not be affected by application of the following fluids:

i) Silicone based Hydraulic Oil to Def Stan 00-35 Part 3 (Dimethyl Silicone ZX42, NATO S1714).

ii) Mineral Oil based Hydraulic Fluid to Def Stan 00-35 Part 3 (NATO H-515).

iii) Kerosene to Def Stan 00-35 Part 3 (ISO 1817 Liquid F)

iv) Petrol to Def Stan 00-35 Part 3 (ISO 1817 Liquid B)

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v) Acid battery electrolyte – diluted sulphuric acid of relative density 1.25.

k) Alternative test fluids and test temperatures may be acceptable to the Authority with prior
agreement.

l) Once unpacked, it is not intended that batteries of this type should be stacked on top of each
other.

m) The battery shall be compliant with UN2800 and IATA Special Provision A67.

5.2 6140-99-219-2903 (UK Manifold Variant)

a) The battery shall incorporate a manifold with two outlet nozzles through which all cells should
vent. The manifold should be sufficiently substantial to enable its use for battery hold-down
purposes. The manufacturer shall demonstrate, using a method acceptable to the Authority,
that the manifold arrangement fitted to the top of the battery does not impair the functionality of
the cell vents. Vent nozzles shall be fitted with user removable plug(s).

b) The handle mounting points are located on the battery lid.

5.3 6140-99-690-6632 and 6140-12-369-8589 (Non-Manifold Variant)

a) The battery is a sealed Lead Acid battery similar to NATO battery “Type 2”.

b) The handle mounting points are located on the battery lid.

5.4 6140-99-738-0574 (Dual Terminal Variant)

a) The dual terminals shall include standard taper post to BS EN 50342-2 with additional 3/8”-16
UNC Studs.

b) The handle mounting points are located on the battery lid.

5.5 6140-01-485-1472 (USA Variant)

a) The terminals are standard taper post to BS EN 50342-2 but feature knurled annular sections.

b) There are four locating features on the bottom four corners of the battery box.

c) The handle mounting points are located on the battery box.

6 Dimensions

a) The dimensions of the battery will be in accordance with the outline drawings of Figures 1 to 4.
The positive terminal post shall be clearly identified.

b) Critical vent nozzle dimensions for Battery NSN 6140-99-219-2903 are shown in Figure 6.
Alternative designs may be acceptable to the Authority, with prior agreement.

7 Mass

The battery mass, in the charged state, shall not exceed 40kg.

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8 Temperature Range

The battery operational temperature range shall be -40°C to +55°C.

PERFORMANCE REQUIREMENTS

9 Electrical Requirements

For test purposes the battery must be capable of being charged at constant voltage but it must also be
capable of being charged with existing in service equipment - some of which are constant current. In
service the battery is charged at constant voltage of 14.25V ± 0.25V and it must be capable of
accepting, without adverse effects, current surges of 100A for periods of 20 minutes particularly at the
end of deep discharge with occasional pulses of 350A for 3 seconds.

9.1 Charging Procedure

The following procedure shall be used:

a) The battery temperature shall be stabilised at +25°C ± 5°C before charging commences. The
period of open circuit stand following discharge is not to exceed 15 hours.

b) Generally, the charging or recharging of the battery shall be carried out using a constant voltage
of 14.25V ± 0.25V with a charging current limit of 0.1C20A.

However, for tests 9.5, 9.10 and 9.14 (where charging or recharging of the battery is carried out
at +55°C) a constant voltage of 14.25V +0 -0.25V with a charging current limit of 0.1C20A shall
be used.

c) The charge shall be terminated when the voltage and charge current have remained stable for
three consecutive hourly readings.

9.2 Commissioning Procedure.

The battery shall be commissioned in accordance with the manufacturer’s instructions.

9.3 Immediate Discharge.

a) After commissioning the battery, allow the battery to stabilise at a test temperature of –18°C ±
2°C for at least 24 hours.

b) Discharge the battery at a constant current of 3C20A (330A in the case of a 110Ah rated
battery).

c) The voltage after 5 seconds of discharge shall be greater than 8.5V.

d) The duration of discharge to an end-point voltage of 6.0V shall be greater than 90 seconds.

e) The battery shall be charged in accordance with clause 9.1.

9.4 Capacity Discharge (20 Hour Rate at +25°C).

a) The ambient temperature during this test shall be +25°C ± 2°C.

b) The battery shall be discharged continuously at a constant current of 0.05C20A to an on-load

voltage end-point of 10.5V.

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c) Up to three cycles of discharge/charge may be applied. The duration of discharge shall be not
less than 18 hours for the first and second discharge and not less than 20 hours for the third.

d) If the battery yields more than 20 hours on the initial or second cycle then subsequent
discharge(s) need not be carried out.

e) If the discharge duration exceeds 20 hours then the test may be halted even if the battery
voltage remains above the specified end-point.

f) The final cycle should be such that the battery has been recharged in accordance with clause
9.1.

9.5 Capacity Discharge (20 Hour Rate at +55°C).

a) The battery shall be stored for at least 24 hours at +55°C ± 2°C. Throughout the test, the battery
shall be maintained at a temperature of +55°C ± 2°C.

b) The battery shall be discharged continuously at a constant current of 0.05C20A to an on-load

voltage end-point of 10.5V.

c) Up to three cycles of discharge/charge may be applied. The duration of discharge shall be not
less than 18 hours for the first and second discharge and not less than 20 hours for the third.

d) If the battery yields more than 20 hours on the initial or second cycle then subsequent
discharge(s) need not be carried out.

e) If the discharge duration exceeds 20 hours then the test may be halted even if the battery
voltage remains above the specified end-point.

f) The final cycle should be such that the battery has been recharged in accordance with clause
9.1.

9.6 Capacity Discharge (High Rate at –40°C).

a) The battery shall be stored for at least 24 hours at –40°C ± 2°C and then discharged at that
temperature.

b) The discharge current shall be 3C20A.

c) The voltage at five seconds shall be not less than 8.5V.

d) The duration of discharge to an on-load voltage end-point of 6.0V shall be greater than 85
seconds.

e) After discharge, the battery shall be recharged as specified in clause 9.1.

9.7 Capacity Discharge (High Rate at +25°C).

a) The battery shall be allowed to stabilise at an ambient temperature of +25°C ± 2°C before being
discharged at that temperature.

b) The discharge current shall be 3C20A.

c) The voltage at five seconds shall be not less than 10.0V.

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d) The duration of discharge to an on-load voltage end-point of 8.5V shall be greater than 350
seconds.

e) After discharge, the battery shall be recharged as specified in clause 9.1.

9.8 Capacity Discharge (High Rate at +55°C).

a) The fully charged battery shall be stored for at least 24 hours at +55°C ± 2°C and then
discharged at that temperature.

b) The discharge current shall be 3C20A.

c) The voltage at five seconds shall be not less than 10.0V.

d) The duration of discharge to an on-load voltage end-point of 8.5V shall be greater than 350
seconds.

e) After discharge, the battery shall be allowed to stabilise at an ambient temperature of +25°C ±
2°C before being recharged as specified in clause 9.1.

9.9 Charge Retention Test.

a) After completion of charge, the battery shall be stored open circuit for 28 days in an ambient
temperature of +25°C ± 2°C.

b) At the end of the 28-day stand, and without further recharge, the battery shall be placed into an
ambient temperature of –40°C ± 2°C for 24 hours.

c) The battery is then to be discharged at that temperature.

d) The discharge current shall be 3C20A.

e) The duration of discharge to an on-load voltage end-point of 6.0V shall be not less than 45
seconds.

f) After discharge, the battery shall be recharged as defined in clause 9.1.

9.10 Cycle Life Test.

The battery shall be capable of withstanding a minimum of four seven-day test cycles using the
following procedure:

a) Throughout the test, the battery shall be maintained at a temperature of +55°C ± 2°C.

b) The battery shall be discharged for one hour at 0.1C20A followed by an immediate charge for
two hours, in accordance with clause 9.1. Repeat for 8 cycles per day for 4 days followed by 60
hours open-circuit stand.

c) The battery shall be discharged, without further charge, at a constant current of 3C20A to an
on-load voltage end-point of 8.0 volts. The duration of discharge shall exceed 4 minutes.

d) On completion of discharge, the battery shall be recharged in accordance with clause 9.1. This
charge shall be completed within 12 hours from the end of the open-circuit stand.

e) The seven-day test cycle shall be repeated to a total of four times.

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f) Upon completion of the Cycle Life Test the battery shall meet the requirements of the Cranking
Performance Test (9.13.2 Method 2).

9.11 Short Circuit Test.

Warning: This is a hazardous test and appropriate precautions must be taken.

The battery shall be capable of withstanding the following short circuit test:

a) If the battery has just been charged it shall be allowed to stand on open circuit for a minimum of
four hours.

b) The battery shall then be left to stabilise at an ambient temperature of +25°C ± 2°C.

c) A test circuit shall be applied to the battery, which incorporates mating connectors, a suitable
switch and a minimum length of interconnecting cable. The maximum resistance of the circuit
shall be less than 2.0 milliohms.

d) The battery shall be short circuited, by means of the switch, for a minimum of 15 seconds.

e) There shall be no evidence of physical damage to the battery as a result of this test.

f) After having been allowed to stabilise at an ambient temperature of +25°C ± 2°C, the battery
shall be recharged in accordance with clause 9.1 and then re-tested for one cycle of the 20 hour
rate capacity discharge as defined in clause 9.4. Discharge duration shall be consistent with
that originally obtained.

9.12 Shelf Life.

a) The battery shall be stored for two years at +25°C ± 5°C and with a relative humidity in the
range 35% to 80%.

b) Test requirements subsequent to two years storage remain as for new units with the exception
of the Immediate Discharge Test, see clause 9.3d, where the discharge duration to an end-point
voltage of 6.0V is reduced to a minimum of 60 seconds.

9.13 Cranking Performance Test.

In order to assess the performance of the battery at low temperature, it shall be tested as follows:

9.13.1 Method 1

a) Charge the battery in accordance with clause 9.1.

b) With the battery at a stabilised temperature of –18°C ± 2°C measure the battery terminal
voltage whilst being discharged at 1000A. After 30 seconds on load, the terminal voltage shall
be a minimum of 7.2 volts.

c) The battery shall then be recharged in accordance with clause 9.1.

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9.13.2 Method 2

Note: This test method is used for Cycle Life (9.10) and Overcharge Endurance (9.14) testing.

a) Charge the battery in accordance with clause 9.1.

b) With the battery at a stabilised temperature of –18°C ± 2°C measure the battery terminal
voltage whilst being discharged at 600A. After 30 seconds on load, the terminal voltage shall
be a minimum of 6.0 volts.

c) The battery shall then be recharged in accordance with clause 9.1.

9.14 Overcharge Endurance Test.

To establish the performance of the battery in an overcharge situation, it shall be subjected to the
following test:

a) Fully charge the battery in accordance with clause 9.1.

b) Place the battery in a water bath maintained at +55°C ± 2°C and immerse it such that the water
is within 25mm of the top of the case and the minimum distance between the case and the
sides of the bath and/or other batteries is at least 25mm.

c) Charge the battery in accordance with clause 9.1 for a period of 1488 hours (62 days).

d) Upon completion of the Overcharge Endurance Test the battery shall meet the requirements of
the Cranking Performance Test (9.13.2 Method 2).

9.15 Deep Discharge Test.

To establish the performance of the battery and its ability to recover from a deep discharge, the
following test shall be applied:

a) This test shall be carried out at +25°C ± 5°C.

b) Charge the battery in accordance with clause 9.1.

c) Connect a circuit with a 1.0-Ohm resistor between the positive and negative terminals of the
battery. The resistor shall remain connected for two weeks.

d) Remove the resistor circuit and leave the battery to stand in the discharged condition for a
further two weeks.

e) Charge the battery in accordance with clause 9.1.

f) Carry out a Capacity Discharge Test (20 Hour Rate) in accordance with clause 9.4.

g) The battery shall have passed this test if the obtained discharge duration is equal to or greater
than the result obtained from the original test to clause 9.4.

9.16 Polarity of Battery.

The battery will be tested for correct polarity using a suitable electrical method.

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10 Mechanical & Environmental Requirements

10.1 Efficiency of Sealing.

The battery (when equipped with a vent manifold) shall be checked for sealing by applying a pressure
of 70mbars, above atmosphere, for 15 seconds to one outlet of the vent manifold. The remaining
outlet shall be blocked during this exercise. There shall be no pressure drop indicative of leakage.

10.2 Electrolyte Retention.

a) After having been charged in accordance with clause 9.1, the following sequence of tests shall
be applied:

i) The battery shall be tilted 90° from the vertical in a plane normal to its major axis and so held
for 15 minutes.

ii) The battery is then to be tilted 90° from the vertical in a plane normal to its minor axis and
so held for 15 minutes.

iii) The battery shall be inverted for 15 minutes.

b) No electrolyte shall escape from the battery during the above tests.

10.3 Vibration.

a) The battery shall be fully charged in accordance with clause 9.1.

b) The battery shall be placed in an ambient temperature of +55°C ± 2°C for 24 hours.

c) On completion of the above conditioning the battery shall be stabilised at +25°C ± 5°C.

d) The battery shall be secured to a vibration test machine by means of a suitable holding device,
which does not bear on vents or terminals. The battery is then to be vibrated for 2 hours (40
minutes in each of three mutually perpendicular planes) at a frequency of 33 to 35 Hertz at an
amplitude of 1.14 to 1.27 millimetres (total excursion 2.29 to 2.54 millimetres). Throughout this
test, the battery shall be under discharge at 0.05C20A.

e) The battery shall be removed from the vibration test machine and placed in a chamber
regulated to –40°C ± 2°C for 24 hours. The battery is then to be replaced immediately on the
vibration test machine and tested in accordance with clause 10.3(d) - (except that durations are
decreased to 20 minutes per axis, which will result in a total test time of 1 hour at the lower
temperature). Throughout this period, the battery shall be under discharge at 0.05C20A.

f) Voltage and discharge current of the battery shall be monitored throughout the vibration test.
There shall be no evidence of instability. On completion of the vibration tests, the battery shall
show no signs of external damage or leakage of electrolyte.

g) After having been allowed to stabilise at +25°C ± 2°C, the battery shall be recharged in
accordance with clause 9.1. The battery shall then be discharged at the 20-hour rate as
specified in clause 9.4. Results should be consistent with those previously obtained for this
test.

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10.4 Drop And Topple.

a) The battery shall be tilted on one bottom edge so that the distance between the opposite edge
and the test surface is 50mm. The battery shall be dropped, freely, onto a rigid steel test
surface. The battery shall be subjected to one further drop from each of its remaining bottom
edges.

b) The battery, standing on its bottom surface, is tilted about one bottom edge until a position of
instability is reached and then allowed to fall over freely onto an adjacent face. It is then
subjected to one topple about each remaining underside edge in turn.

c) The drop and topple tests are to be carried out on the battery whilst it is at a temperature of
+25°C and then when it is at –40°C. Cables are not to be connected during testing.

d) The battery shall be charged in accordance with clause 9.1 and checked for capacity as
specified in clause 9.4 before and after the drop and topple test.

e) After testing, the battery shall be examined and any evidence of damage or leakage reported.

PRODUCT CONFORMITY CERTIFICATION

11 General requirements

The Product Conformity Certification requirements are defined in Section 2 of Def Stan 61-21.

11.1 Product Conformity Test Requirements

The test schedule shown in table 2 shall apply for product conformity certification. Ten batteries are to
be provided, two for each of the sub groups, and tested to the requirements and sequence of Table 2.

11.2 Interim Certification

Interim certification may be considered after the satisfactory completion of sub-groups 1-4 in the
schedule shown in Table 2.

11.3 Batch Certification

Batch Certification is not applicable for Major PCC.

11.4 Periodic Verification of Critical Performance

a) All supplied batteries shall meet the requirements for Polarity, Efficiency of Sealing and
Marking.

b) The tests in Table 1 shall be carried out in accordance with the contractor’s quality procedures.
Alternative tests may be adopted by the contractor, with the prior agreement of the Authority.

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 INT DEF STAN 61-021 Supp 42 Issue 4

TEST SPECIFICATION

CLAUSE

Mass 7

Immediate Discharge 9.3

Capacity Discharge (20Hr Rate) 9.4

Table 1 - Periodic Verification of Critical Performance

11.5 Performance Assessment Sheets (PAS)

To assist the acquirer during the tender assessment stages, a typical PAS is provided at annex A.
The PAS augments the PCC and formal test report by summarising the technical compliance data and
displaying the data in a common format.

Notes for PAS completion:

• * Delete as appropriate.
• The PAS should be printed on Company Headed/Logo paper.
• The PCC test schedule indicates the minimum number of samples/results required and the
test sequence.
• Limitations of the design shall be described and any instances of Sample/Test equipment
failures shall be fully reported. Any Deviations from the defined test procedures shall be
disclosed.
• Performance data shall clearly indicate whether it originates from the certification exercise or
production/release testing following contract award.
• Interim Certificates shall clearly indicate test “due dates” for Full Certification.

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 INT DEF STAN 61-021 Supp 42 Issue 4

TESTS IN SEQUENCE CLAUSE SUB-GROUPS

1 2 3 4 5
a) Battery Marking 13 * * * * *
b) Efficiency of Sealing 10.1 * * * * *
c) Polarity of Battery 9.16 * * * * *
d) Shelf Life 9.12 - - - - *
e) Immediate Discharge 9.3 * * * * *
f) Mass 7 * * * * *
g) Capacity Disch. (20Hr Rate +25°C) 9.4 * * * * *
h) Capacity Disch. (20Hr Rate +55°C) 9.5 * * * * *
i) Electrolyte Retention 10.2 * * * * *
j) Capacity Discharge (HR @ -40°C) 9.6 * * * * *
k) Capacity Discharge (HR @ +25°C) 9.7 * * * * *
l) Capacity Discharge (HR @ +55°C) 9.8 * * * * *
m) Charge Retention 9.9 * * - - -
n) Cranking Performance 9.13 * * * * *
o) Short Circuit 9.11 (1)* (1)* - - -
p) Overcharge Endurance 9.14 - - - * -
q) Deep Discharge 9.15 - (1)* - - -
r) Vibration 10.3 - - (1)* - -
s) Drop and Topple 10.4 - - (1)* - -
t) Cycle Life 9.10 (1)* - - - -

Table 2 - Product Conformity Test Schedule.

Notes : * Battery requires test.

- Test may be omitted.

(1) These tests should be carried out on different samples so that a battery which has
been "abuse" tested is not then subjected to an additional test.

Sub-Groups 1 to 4 - Tests are to commence within 60 days of manufacture of the sample

batteries.

12 Hazard Classification and Transportation Requirements

For transportation considerations the manufacturer shall state within the Declaration of Conformity the
following:

a) The manufacturer shall declare that the battery is tested to and is compliant with Hazard
Classification UN2800 (Wet Non-spillable) and IATA Special Provision A67.

b) Compliance with the range of UK National and Multi-National mode specific transport
regulations stipulated in Def Stan 61-21.

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 INT DEF STAN 61-021 Supp 42 Issue 4

c) Reference to the manufacturing data package (build standard) for materials, piece parts and
processes used in the battery construction.

MARKING REQUIREMENTS

13 MARKING

a) Different battery labels are used (in-line with country requirements).

b) However, marking shall be in accordance with DEF STAN 61-21 with the addition of the
following:

Battery Serial Number

Polarity indication

Statement of compliance to UN2800 and IATA Special Provision A67

NATO Type (or item name) i.e. UK6TNMF

Voltage / Ah

Month and Year of Manufacture

Instructions for Use (where appropriate)

14 Cell Age Requirements

The battery/cell age (at the time of delivery) shall be less than 6 months.

15 Packaging and Labelling Requirements

a) In addition to the packaging and labelling requirements stated in the contract, all packaging and
labelling shall comply with the requirements of the civil dangerous goods transport regulations
governing land, sea and air modes of transport. Except where specified in the contract or
excluded within the regulations this shall include packaging requirements for mixed passenger
and cargo aircraft.

b) All levels of packaging shall also include:

The product NATO Stock Number.

The date of manufacture.

The battery storage life in the format “NOT TO BE STORED BEYOND MM,YYYY

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 INT DEF STAN 61-021 Supp 42 Issue 4

Figure 1 - Battery Outline Drawing for Battery 6140-99-219-2903 (UK Manifold Variant).

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 INT DEF STAN 61-021 Supp 42 Issue 4

Figure 2 - Battery Outline Drawing for Battery 6140-99-690-6632 and 6140-12-369-8589 (Non-Manifold Variants)

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 INT DEF STAN 61-021 Supp 42 Issue 4

Figure 3 - Battery Outline Drawing for Battery 6140-99-738-0574 (Dual Terminal Variant).

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 INT DEF STAN 61-021 Supp 42 Issue 4

Figure 4 - Battery Outline Drawing for Battery 6140-01-485-1472 (USA Variant).

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 INT DEF STAN 61-021 Supp 42 Issue 4

manifold

6.50±0.50 DIA

14.50±0.50

8.75±0.25 DIA

3.75±0.25 DIA

Showing critical dimensions in mm

Not to scale.

Figure 5 - Preferred handle type for the

UK variants (rope and solid handle).
Figure 6 - Vent Nozzle for Battery 6140-99-219-2903

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 INT DEF STAN 61-021 Supp 42 Issue 4

Annex A
Performance Assessment Sheets

Performance Assessment Sheet In Accordance with:

Def.Stan. 61-21/Issue 3 dated 20/03/2009

General Specification for Batteries

Def.Stan. 61-21 Supplement 042/Issue 4 dated 28/01/2017

Sealed Lead Acid Battery 12V, 110Ah
NSN 6140-99-219-2903, NSN 6140-99-690-6632
NSN 6140-12-369-8589, 6140-99-738-0574 and 6140-01-485-1472

Status Interim/Full Contract Ref:

Certificate Nos:

Supplier Product Type & Data

Name: Manufacturer:
Place of Manufacture:
Battery Type:
Address & Tel: Battery Manufacturing Data Pack/Build Standard
Ref:
Issue:
Date
ISO 9000 Status Cell Manufacturing Data Pack/Build Standard
Accreditation Body: Ref:
Certificate Ref: Issue:
Date
Quality Plan Test Report(s)
Ref: Ref(s):
Issue: Date(s):
Date:
Test Laboratory (if applicable) Compliant with UN2800 and IATA A67
Name: Yes/No
Address

Additional Information, Limitations, Test Deviations:

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 INT DEF STAN 61-021 Supp 42 Issue 4

Interim Product Certification

All Sub-Groups

Supp Test Rep

Attribute Criteria Result(s)/Comments
Ref Ref &Date
110Ah
4 Capacity

Figure 1, 2, 3
6 Dimensions or 4
NATO Type 2
Manifold Assembly (if fitted) Pass/fail

Maintenance Required YES/NO

Case & Lid Material Compliant with Elasticity requirement of VG

96 924 Part 2 YES/NO
5 Construction
Case Colour RAL 7030
YES/NO
Self-extinguishing material UL94
YES/NO
Handles. Compliant to Style and Material (DS 00-35 Part 3)
YES/NO

13 Marking Pass/Fail

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 INT DEF STAN 61-021 Supp 42 Issue 4

Interim Product Certification

Sub-Group 1

10.1 Sealing Pass/fail

9.16 Polarity Pass/fail

Immediate >8.5V After 5

9.3
Discharge. seconds
Imm. Disch.
9.3 > 90 secs
Duration
Mass Range &
7
< 40kg Mean (kg)
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.4 Discharge
+25°C
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.5 Discharge
+55°C

Electrolyte
10.2 Pass/fail
Retention
High Rate, >8.5V @ 5 seconds Min Duration > 85 seconds
9.6 Discharge @
-40°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.7 Discharge @
+25°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.8 Discharge @
+55°C
Charge
9.9 > 45 secs
Retention
Cold >7.2V
9.13 Cranking @ 30
Performance seconds
9.11 Short Circuit Observation

9.10 Cycle Life Pass/fail

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 INT DEF STAN 61-021 Supp 42 Issue 4

Interim Product Certification

Sub-Group 2

10.1 Sealing Pass/fail

9.16 Polarity Pass/fail

Immediate >8.5V After 5

9.3
Discharge. seconds
Immediate
9.3 Discharge > 90 secs
Duration
Mass Range &
7
< 40kg Mean (kg)
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.4 Discharge
+25°C
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.5 Discharge
+55°C

Electrolyte
10.2 Pass/fail
Retention
High Rate, >8.5V @ 5 seconds Min Duration > 85 seconds
9.6 Discharge @
-40°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.7 Discharge @
+25°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.8 Discharge @
+55°C
Charge
9.9 > 45 secs
Retention
Cold >7.2V
9.13 Cranking @ 30
Performance seconds
9.11 Short Circuit Observation
Deep ≥
9.15
Discharge para 9.4

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 INT DEF STAN 61-021 Supp 42 Issue 4

Interim Product Certification

Sub-Group 3

10.1 Sealing Pass/fail

9.16 Polarity Pass/fail

Immediate >8.5V After 5

9.3
Discharge. seconds
Immediate
9.3 Discharge > 90 secs
Duration
Mass Range &
7
< 40kg Mean (kg)
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.4 Discharge
+25°C
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.5 Discharge
+55°C

Electrolyte
10.2 Pass/fail
Retention
High Rate, >8.5V @ 5 seconds Min Duration > 85 seconds
9.6 Discharge @
-40°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.7 Discharge @
+25°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.8 Discharge @
+55°C
Cold >7.2V
9.13 Cranking @ 30
Performance seconds

10.3 Vibration Observation

10.4 Drop & Top Observation

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 INT DEF STAN 61-021 Supp 42 Issue 4

Interim Product Certification

Sub-Group 4

10.1 Sealing Pass/fail

9.16 Polarity Pass/fail

Immediate >8.5V After 5

9.3
Discharge. seconds
Immediate
9.3 Discharge > 90 secs
Duration
Mass Range &
7
< 40kg Mean (kg)
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.4 Discharge
+25°C
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.5 Discharge
+55°C

Electrolyte
10.2 Pass/fail
Retention
High Rate, >8.5V @ 5 seconds Min Duration > 85 seconds
9.6 Discharge @
-40°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.7 Discharge @
+25°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.8 Discharge @
+55°C
Cold >7.2V
9.13 Cranking @ 30
Performance seconds
>6.0V
Overcharge
9.14 @ 30
Endurance
seconds

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 INT DEF STAN 61-021 Supp 42 Issue 4

Full Product Certification

Sub-Group 5 (Post 2 Years Storage)

10.1 Sealing Pass/fail

9.16 Polarity Pass/fail

Discharge >8.5V After 5

9.3
seconds
Discharge
9.3 > 90 secs
Duration
Mass < 40kg Range &
7
Mean (kg)
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.4 Discharge
+25°C
st rd
Capacity >18hrs for 1 & 2nd Disch >20 hrs for 3 Disch
9.5 Discharge
+55°C

Electrolyte
10.2 Pass/fail
Retention
High Rate, >8.5V @ 5 seconds Min Duration > 85 seconds
9.6 Discharge @
-40°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.7 Discharge @
+25°C
High Rate, >10V @ 5 seconds Min Duration > 350 seconds
9.8 Discharge @
+55°C
Cold >7.2V
9.13 Cranking @ 30
Performance seconds
All above tests
9.12 Shelf Life completed and
passed

With the exception of any Limitations/Test deviations (described above) the product
( ) conforms to the specification requirements.

The supporting data, calculations and performance test reports are a true and accurate record.

Signatory(s) and Date(s):

Position/Function:

2-27
 DEF STAN 61-021 Supp 42 Issue 4

Section 3

Normative References
1 The publications shown below are referred to in the text of this standard. Publications are
grouped and listed in alpha-numeric order.
Note: Def Stan’s can be downloaded free of charge from the DStan web site by visiting
<http://dstan.uwh.diif.r.mil.uk/> for those with RLI access or <https://www.dstan.mod.uk> for all other
users. All referenced standards were correct at the time of publication of this standard (see A.2, A.3 & A.4
below for further guidance), if you are having difficulty obtaining any referenced standard please contact the
DStan Helpdesk in the first instance.

Def Stans

Number Title
81-041, Pt 5, Iss Packaging of Defence Materiel - Packaging Processes
8

61-017, Iss 5 The Selection and Introduction of Batteries and Fuel Cells for Service Use

81-041, Pt 1, Iss Packaging of Defence Materiel - Introduction to Defence Packaging

9 Requirements

81-041, Pt 2, Iss Packaging of Defence Materiel - Design

9

81-041, Pt 4, Iss Packaging of Defence Materiel - Service Packaging Instruction Sheet (SPIS)
8

81-041, Pt 6, Iss Packaging of Defence Materiel - Package Marking

09

81-041, Pt 3, Iss Packaging of Defence Materiel - Environmental Testing

06

00-035, Pt 3, Iss Environmental Handbook for Defence Materiel - Environmental Test Methods
4

STANAGs

Number Title
4107 Edition 9 MUTUAL ACCEPTANCE OF GOVERNMENT QUALITY ASSURANCE AND
USAGE OF THE ALLIED QUALITY ASSURANCE PUBLICATIONS (AQAP)

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 DEF STAN 61-021 Supp 42 Issue 4
Allied Publications

Number Title
AQAP-2110 NATO QUALITY ASSURANCE REQUIREMENTS FOR DESIGN,
Edition 3 DEVELOPMENT AND PRODUCTION

Other References

Standard Type Standard Name

CIVIL BS EN 50342-2 - Lead-acid starter batteries. Dimensions of batteries and
dimensions and marking of terminals.

Other UL 94 - Standard for Tests fo Flammability of Plastic Materials for Parts in

Devices and Appliances.

Other VG 96 924 Part 2 - Valve Regulated Lead-acid Batteries - Generic Standard.

Other AOF - Acquisition Operating Framework

CIVIL BS EN ISO/IEC 17050 - Conformity Assessment - Supplier's declaration of

conformity.

CIVIL BS EN 60068: (series) - Environmental testing.

CIVIL BS EN 60086: (series) - Primary batteries.

CIVIL BS EN 60095: (series) - Lead-acid starter batteries.

CIVIL BS EN 60622 - Sealed nickel cadmium prismatic single cells.

CIVIL BS EN 60896: (series) - Stationary lead-acid batteries.

CIVIL BS EN 60952: (series) - Aircraft batteries.

CIVIL BS EN 61056: (series) - Portable lead-acid cells and batteries.

CIVIL BS 2G 239 - Primary active lithium batteries for use in aircraft.

Other JSP 335 - Dangerous Air Cargo Regulations.

CIVIL 2006/66/EC - EU Directive Waste Battery Collection / Recycling Provisions.

2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. Care should be taken when referring out to specific portions of other standards to ensure that they
remain easily identifiable where subsequent amendments and supersession’s might be made. For some
standards the most recent editions shall always apply due to safety and regulatory requirements.

3-2
 DEF STAN 61-021 Supp 42 Issue 4
3 In consideration of clause A.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Correct identification of standards is as defined in the ITT or contract.

4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.

3-3
 DEF STAN 61-021 Supp 42 Issue 4
Definitions

For the purpose of this standard, ISO/IEC Guide 2 ‘Standardization and Related Activities –
General Vocabulary’ and the definitions shown below apply.

Definition Description
Generic Standard Defined as a standard that combines the general requirements and procedures
applicable to a number of battery types.

Supplement Defined as a supplement to the generic standard for an individual battery type,
that invokes or tailors, the relevant sections from the standard as required.

Mandatory Defined as clauses that use the word "shall". Optional or non-madatory
Clauses in clauses use the word "should".
Defence
Standards

Acquirer Governmental and/or NATO Organisations, who enter into a contractual

relationship with a supplier, defining the product and quality requirements.

Supplier Organisation that acts in a contract as the provider of products to the acquirer.

Standard Defined as the MoD Sponsor for the preparation of a Defence Standard.
Sponsor

Defence Battery The DBSC is made up of representatives from DStan, MoD user groups,
Standardization Acquirers/Provisioners, Subject Matter Experts (SME's), Technical and QAR
Committee support groups.
(DBSC)

Quality Quality Assurance Representatives (QAR) are the personnel with responsibility
Assurance for Quality Assurance, acting on behalf of the Acquirer.
Representatives

Storage Life and Cells and batteries are required to meet the minimum specified storage life
Cell Age performance stated in each supplement. In addition, the supplement may also
state the maximum cell age that can be used within a new battery.

The storage life of a battery is defined as the number of years of temperate

storage at the end of which a battery retains its ability to perform a specified
service output (typically discharge life or capacity).

The cell age is defined as the expired time from when the cell was
manufactured.

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 DEF STAN 61-021 Supp 42 Issue 4
Abbreviations

Abbreviation Description
ADR European Agreement concerning the International Carriage of Dangerous
Goods by Road

ADN UN Regulations for the Carriage of Dangerous Goods by Inland Waterways.

AP Allied Publication (NATO)

AQAP Allied Quality Assurance Publication (NATO)

BS British Standard

BS EN European Standard

BSI British Standards Institute

Def Stan Defence Standard

DBSC Defence Battery Standardization Committee

DMSC Defence Material Standardization Committee

IATA International Air Transport Association

ICAO International Civil Aeronautics Organisation

IEC International Electro-technical Commission

IMO IMDG International Maritime Organisation International Maritime Dangerous Goods

Code

ISO International Standards Organisation

JSP Joint Service Publication.

MoD Ministry of Defence

PAS Performance Assessment Sheet

PCC Product Conformity Certification

PM/ESM Project Manager/Equipment Support Manager

RID European Agreement concerning the International Carriage of Dangerous

Goods by Rail

UN United Nations

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 ©Crown Copyright 2017

Copying Only as Agreed with DStan

Defence Standards are published by and obtainable from:

Defence Equipment and Support

UK Defence Standardization

Kentigern House

65 Brown Street

GLASGOW

G2 8EX

DStan Helpdesk

Tel: +44 (0) 141 224 2531

Fax: +44 (0) 141 224 2503

Internet e-mail: [email protected]

File Reference
The DStan file reference relating to work on this standard is D/DSTAN/61/21/4.

Contract Requirements
When Defence Standards are incorporated into contracts, users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.

Revision of Defence Standards

Defence Standards are revised as necessary by an up-issue or amendment. It is important that users
of Defence Standards ensure that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Websites https://www.dstan.mod.uk
and http://dstan.uwh.diif.r.mil.uk/, updated weekly. Any person who, when making use of a Defence
Standard, encounters an inaccuracy or ambiguity is encouraged to notify UK Defence Standardization
(DStan) without delay in order that the matter may be investigated and appropriate action taken.