JSS 6140-03 : 2019

(Fifth Revision)
CAPT (IN) P Digitally signed
by CAPT (IN) P
Kishore JD Kishore JD (Tech
(Tech Coord)
Date: 2020.11.05
Coord) 11:57:43 +05'30'

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GOVERNMENT OF INDIA
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MINISTRY OF DEFENCE

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JOINT SERVICES SPECIFICATION

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BATTERIES, SECONDARY, PORTABLE,

NICKEL-CADMIUM

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DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’ BLOCK, NIRMAN BHAWAN PO
NEW DELHI–110011
 JSS 6140-03 : 2019
(Fifth Revision)

LIST OF MEMBERS ASSOCIATED WITH REVISION OF THIS SPECIFICATION

1. The fifth revision of this Joint Services Specification 6140-03 has been approved by
Cmde (EE) Indrajit Dasgupta, EE, Chairman, Electrical Standardisation Sub-committee by
circulation.

2. The following members have been present/consulted in approving the document:

S. Name & Designation Organisation Email

No.
1. Rahul Gupta (E&I), Jt Dir/E & I DGAQA [email protected]
2. Shri Y A Kambali, JAG (NFSG) CQA (L)/DGQA, cqalbang-dgqa @nic.in
Bangalore
3. Cdr Tias Thakur JDEE [email protected]
4. Cdr Maneesh Singh, JDLS DLS/NHQ
5. Shri M K Roy, Sc ‘D’ R & DE (Engrs), [email protected]
Pune
6. Shri KM Madhusudhanan, CQA (EE), Pune [email protected]
SSO II
7. Shri H R Meena, Dy Dir Eqpt Management [email protected]
(STD), MGO
Branch, New
Delhi
8. Gp Capt A Bhattacharyya, Dir DES, Air HQ, -
ES New Delhi
9. Maj Naveen Siddhu, TSO-I HQ TG EME, -
New Delhi
10. Dr Ram Varma, ACE offg Jt Director of Utility, -
DGW (U) E-in-C’s Branch,
New Delhi
11. SS Dullat (Maj) JD OS (L&E) DGOS (OS-17B) -
12. Shri V Ravi Chandran, Addl GM BEL, Bangalore -
13. Shri DAV Satyanarayan, NSO Service STD Cell -
(Navy)
14. Wg Cdr R Muralidhar, Service STD Cell -
JD TETTRA (IAF)
15. Col Neeraj Arora, OIC DSC, Badarpur dscbadarpur.defstand@
gov.in
16. Lt Col S Tripathi DSC, Pune [email protected]
17. Lt Col Tushir Mukherjee DSC, Bangalore dscbanglore.defstand@
gov.in
18. Shri Deendayal Singh, AE (QA) CQA (R)
19. Cdr N Jain JDQA(WP) DQA(WP), [email protected]
New Delhi
20. Shri BN Guruprasad, PScO DQA(L), [email protected]
Bangalore
21. Shri Girish Chandra Agnihotri, OFB, Kolkata [email protected]
DDG/R&D

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LIST OF MEMBERS ASSOCIATED WITH REVISION OF THIS SPECIFICATION

(CONCLUDED)

S. Name & Designation Organisation Email

No.
22. Shri Rajeev Bhardwaj, Directorate of [email protected]
Staff Captain StandardisaNtion

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RECORD OF AMENDMENTS

Amendment Amendment pertains Authority Amended by Signature

No. Date to S. No./Para No./ Name & &
Column No. Appointment Date
(In Block Letters)

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TABLE OF CONTENTS

S. Topic Page No.

No.

0. FOREWORD 1

1. SCOPE 3

2. RELATED SPECIFICATIONS AND DOCUMENTS 3

3. STANDARD PATTERN 3

4. TERMINOLOGY 4

5. MATERIAL 6

6. MANUFACTURE/CONSTRUCTION 6

7. WORKMANSHIP AND FINISH 7

8. MARKING 8

9. QUALITY ASSURANCE 9

10. MISCELLANEOUS 25

11. PACKAGING, STORAGE AND TRANSIT 26

12. DEFENCE STORES CATALOGUE NUMBER/NATO STOCK 27

NUMBER

13. SUGGESTIONS FOR IMPROVEMENT 29

14. SUPPLEMENTS 1 to 13 30-93

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0. FOREWORD

0.1 This Joint Services specification 6140-03 has been prepared by the Electrical
Standardisation Sub-committee on the Authority of Standardisation Committee, Ministry of
Defence by circulation.

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

0.3 This JSS 6140 -03 : 2019 (Fifth Revision):

a) was revised in the years 1993, 1998, 2008 and 2013.
b) is revision of JSS 6140-03 : 2013 (Fourth Revision) and supersedes the same.

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

0.5 Quality Assurance Authorities for the items covered by this specification are the
Controller, Controllerate of Quality Assurance (Electronics), Bangalore-560006, e-mail id-
[email protected]. 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 Secy ESSC by email at [email protected] or
by post to:

The Director,
Directorate of Standardisation,
Ministry of Defence,
‘H’ Block, Nirman Bhawan PO,
New Delhi-110011.

0.6 Non-registered users can obtain the following on payment:

a) Copies of IS from:

Bureau of Indian Standards,

Manak Bhawan,
9, Bahadur Shah Zafar Marg,
New Delhi-110002,
or
their regional/branch offices.

b) Copies of JSSs/JSGs/JSRLs/JSPRs/ANs from:

The Director,
Directorate of Standardisation,
Standardisation Documents Centre,
Ministry of Defence,
Room No. 05, ‘J’ Block, Nirman Bhawan PO,
New Delhi-110011.

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0.7 Indian Standard (IS) specifications are available free of cost for registered users on:

Directorate of Standardisation Website:

www.ddpdos.gov.in
for registration visit our website.

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

0.9 Directorate of Standardisation Website - All the approved JSSs/JSGs/JSRLs/

JSPRs/ANs are available on the Directorate of Standardisation Website www.ddpdos.gov.in.
Defence organisations desirous of accessing a copy of this document are requested to
approach the Directorate of Standardisation for obtaining user id/password to access the
website.

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1. SCOPE

1.1 This specification covers the general requirements, electrical performance

requirements, test details, test procedures and acceptance criteria for Battery, Secondary,
Nickel-Cadmium for use in Defence. The characteristics of individual batteries are listed in
supplements to this specification.

1.2 The batteries are required to meet the following basic requirements:
a) Temperature for storage - –30ºC to +70ºC

b) Temperature for operation - –30ºC to +55ºC

2. RELATED SPECIFICATIONS AND DOCUMENTS

References are made in this specification to:

Table 1 Related Specifications

S. No. Spécification No. Nomenclature

a) JSS 55555 : 2012 Environmental Test Methods for Electronic and
(Third Revision) Electrical Equipment
Amd 1
b) JSS 0251-01 : 2015 Procedure for Preparation and Production of
(Second Revision) Technical Publication for Electronic and
Electrical Equipment
c) JSG 015 : 2018 Registration of Manufacturer for Defence
(Fourth Revision)
d) IEC 61951-1 Secondary Cells and Batteries Containing
(2006-01) Alkaline or other Non-Acid Electrolytes-Portable
Sealed Rechargeable Single Cells
Part 1 Nickel-cadmium

3. STANDARD PATTERN

3.1 The standard pattern, if held by the purchasing agency or the Quality Assurance
Authority may be obtained and shall constitute a general guide only. The stores shall
otherwise conform to this specification.

3.2 The drawings applicable to each battery can be obtained from the Quality Assurance
Authority. These are meant to ensure mechanical interchangeability and proper fitment.
Detailed drawings are to be prepared by the manufacturer and submitted for approval of the
Quality Assurance Authority before undertaking bulk production.

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4. TERMINOLOGY

4.1 *Initial Charge

4.1.1 This charge is given at the time of commissioning the battery for the first time or
whenever the battery is to be recommissioned after long period of idle storage.

4.1.2 The battery which is first discharged to less than 1 volt per cell average, is charged for
a period of 16 h at a current corresponding to approximately 1/10 of the rated capacity of the
battery and the exact value selected from the current ratings available in the intended
chargers.

4.2 *Capacity Charge

4.2.1 This charge is given prior to testing the battery for assessing its Ah capacity output.

4.2.2 The battery which has been discharged to less than 1 volt per cell average, is charged
for a period of 14 h at a current corresponding to approximately 1/10 of the rated capacity of
the battery and the exact value selected from the current ratings available in the intended
chargers.

4.3 *Normal Charge

4.3.1 This charge is given during the course of actual use or during the laboratory test.

4.3.2 The battery which has been discharged to the end voltage as indicated in the relevant
supplement to this specification is charged at a current corresponding to approximately 1/5 of
the rated capacity of the battery and the exact value selected from the current ratings available
in the intended chargers. The duration of the normal charge shall be such that the battery is
fully charged and fit for immediate use within 8 h including rest period if any, from the time
of commencing the charge.

4.4 *Accelerated Charge

4.4.1 This is a fast mode of charging adopted when the battery is required to be brought into
use within a short time.

4.4.2 This charge is done at twice the normal charge current and the duration shall be such
that a battery which has been discharged to its end voltage (as indicated in the supplements to
this specification) shall be fully charged and ready for use within 4 h.

*NOTE - The details of recommended chargers and applicable charging rates & durations have been indicated
in the relevant supplements for individual batteries.

4.5 Over Charge

Extra charge given to the battery in continuation of normal charge.

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4.6 Retention of Charge

When left in open circuit the capability of a fully charged battery to retain its charge for a
specified duration with specified tolerance.

4.7 Capacity

The duration of discharge at 5 h rate upto end voltage of 1 volt per cell average yielded by a
fully charged battery is the capacity life of the battery. The product of above duration of
discharge and the discharge current in amperes is the Ampere-hour (Ah) capacity output of
the battery.

4.8 Service Life

The number of hours of continuous operation, a fully charged battery is capable of providing
at specified loads/currents simulating the operating conditions of main equipments is termed
as Service life of the battery.

4.9 Cycle Life

The number of charge-discharge cycles which a battery is capable of providing before the
duration of discharge falls below 85% of the nominal value specified.

4.10 Shelf Life/Storage Life

The number of years for which the battery can be preserved in the idle storage under ambient
conditions without affecting its rated level of the performance is termed as the shelf life of the
battery

4.11 Short Circuit Test

Tests conducted to assess the capability of the battery to withstand accidental short circuit for
a very limited period.

4.12 High Rate Discharge Test

Test conducted to assess the capability of the battery to deliver high current for a specified
duration.

4.13 On Load Voltage Test

Test to assess the capability of the battery to provide the required voltages to the main
equipment under the specified current drains/load conditions.

4.14 Electrolyte Retention Test

Test to ensure that there is no leakage of electrolyte even when the battery is kept in inverted
position.

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4.15 Acceptance Tests

Tests conducted to assess the quality of a batch of batteries before acceptance of the same
against a contract.

4.16 Product Confirmatory Tests

Tests conducted to ensure that the design of the battery type is such that it meets the
specification requirements in full from the manufacturer.

5. MATERIAL

5.1 The materials used in the manufacture of the battery shall conform to the relevant
Indian and other standards.

5.2 As far as possible only LCSO Qualification approved components shall be used and
where such approved components are not available, the manufacturer shall provide the
required number each of the unapproved components for tests and approval separately as
required by the Quality Assurance Authority.

5.3 Where use of imported components/sub assemblies are inescapable, it shall be

ensured that these are of the type which have been approved by the respective governments
for use in the military equipments.

5.4 Adequate under rating of components, connecting wires and connectors shall be
adopted so as to ensure sufficient factor of safety. Input/Output connections will be provided
with dust caps.

5.5 The mechanical and electrical parts of the battery shall be sufficiently robust to
withstand rough use and are to be resistant to Corrosive elements.

5.6 The venting arrangement shall be such that excess pressure is released but there shall
be no leakage of electrolyte or bulging of cells.

6. MANUFACTURE/CONSTRUCTION

The design of the battery shall aim at the following:

a) Minimum mass/volume to Ah capacity ratio (optimum energy density).

b) Capability to withstand possible physical and electrical abuses under field

condition.

c) Essential electrical performance. Characteristics like long shelf life, good

charge retention, long cycle life and excellent reliability with least maintenance.

d) Capability for storage, transportation, handling and operation under wide

range of climatic conditions.

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e) Capability to accept charge from the existing Service chargers with minimum
technical supervision.

f) Capability to operate in any position without spillage of electrolyte.

g) Sufficient accessibility, ease of inspection, testing and maintenance of

batteries/battery packs.

h) Uniform Quality and proper matching of cells in each battery pack.

7. WORKMANSHIP AND FINISH

7.1 All parts shall be manufactured and assembled in accordance with the latest
engineering practice and with excellent workmanship.

7.2 The hardware items like terminals, studs, intercell connectors, fasteners etc, shall be
Nickel/Cadmium plated and subjected to bichromate passivation to render them resistant to
rusting and corrosion.

7.3 The outer container (box/lid/tray) of the battery shall be painted with Alkali resistant
paint and the external surface of these shall be finished in olive green scamic 314 shade.

7.4 The electrical wiring shall be with PTFE insulated type having adequate current
carrying capacity and good insulation. Correct colour coding, sleeving/lacing and clamping
will be adopted so that these are routed neatly and there is no strain or tension. Grounding of
one of the terminals to the battery casing shall be done, if called for.

7.5 Soldering shall be such that no acid or salts are used for preparation during soldering.
There shall be no rough surfaces or sharp points resulting from insufficient heating. The
minimum amount of flux under solder shall be used and temperature controlled to safe guard
insulation. The soldered parts shall be immediately subjected to thorough cleaning with a
natural cleaning agent. The soldered joints shall be protected with correct sleeves.

7.6 The bonding of moulded parts shall be such that bounded joints are firm, leak-proof
and are not affected by action of alkali, mechanical stress and strain, temperature variation
and ageing.

7.7 Where cell containers are made of steel, these shall be provided with insulating
jackets.

7.8 Dropper resistances where used shall be of insulated type and these shall be properly
mounted with sufficient safeguard for effective electrical and thermal insulation to other parts
of the battery.

7.9 The cell assemblies shall be tightly packed inside the outer case of the battery so that
there is no relative movement and the cells are adequately protected on all sides from
mechanical shocks.

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7.10 The intercell connectors are to be so arranged/protected with insulating sleeves where
possible so that possibilities of accidental short circuits are minimised.

7.11 After fabrication/assembly, batteries shall be cleaned thoroughly and shall be free
from particles of solder, flux and other foreign material and corrosive material shall be
removed completely. The cleaning process shall have no deleterious effect.

7.12 Lock washers and locknuts will be used on terminal studs and for other fasteners one
or more free threads (safety threads) shall be available after tightening the locknuts on
studs/screws.

7.13 Where metallic containers are used, in addition to the application of Alkali resistant
paint, the inner side of the battery box and lid shall be bounded with thin sheet of PVC.

8. MARKING

8.1 Polarity of cell terminals shall be marked legibly and indelibly.

8.2 Cell type, serial No., Batch No./Date of manufacture and manufacturer’s
identification may be marked on individual cells where possible.

8.3 The schematic diagram of the battery assembly should be inserted on the battery
case/lid preferably in the form of anodised aluminium label or any other type of label to be
approved by the Quality Assurance Authority.

8.4 The anodised aluminium name plate/label of the battery shall have the following
information:
a) Nomenclature of the battery.

b) DS Cat No./Nato Stock No.

c) Serial No.

d) Month and year of manufacture.

e) Defence Services Acceptance mark (↑).

f) Charging instructions.

g) Cautions and reference to User Hand Book.

h) Manufacturer’s name and address.

j) Circuit Diagram.

8.5 Pre-Inspection of Supplies by Supplier

8.5.1 Supplier shall satisfy themselves that the stores manufactured are in accordance with
the contract and fully confirm to the specification by carrying out thorough pre-inspection of
each lot/batch before actually tendering for inspection to QA Authority.

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8.5.2 A declaration by the contractor that necessary pre-inspection tests have been carried
out on the stores tendered and the same are fit for inspection. Results of tests and findings if
any shall be tendered along with the challan. The declaration shall include the method
followed in pre-inspection showing features checked, tested and also accompanied by the
tests reports.

8.5.3 In case of supply against Defence order, the Supplier shall ensure that incoming
materials and products are not used or processed until it has been inspected or otherwise
verified as confirming to specified requirements. Quality records shall be maintained by the
Supplier to demonstrate achievement of the required quality and effective operation of the
Quality system.

8.5.4 The inspecting Officer or his representative shall be afforded the right to verify at
such contractor’s premises or upon receipt that the purchased incoming materials conform to
specified design requirements. In order to ensure monitoring and verification of materials,
production process etc, a Quality Audit and a Quality Surveillance Plan in consultation and
concurrence with the inspecting officer will be drawn before production/commencement of
supply.

9. QUALITY ASSURANCE

9.1 Product Confirmatory Test

9.1.1 The onus of building quality into the product will rest with the supplier/manufacturer,
since he is the first party assurer. The sample picked up from the production lot should be
able to demonstrate the stated performance as per the specification. Control sample testing
will be done from the samples picked up from the production lot and I/Note issued.

9.1.2 The manufacturer/supplier shall demonstrate by virtue of having been assessed as

complying with the requirements of JSG 015-03-2007 and being currently registered on the
defence contractors list of OES as recommended by OEM that the control exercised in his
works over materials, components, manufacturing process, manufacturing locations and
product testing is such that the batteries in bulk production will comply in all respects with
the requirements of the specification.

9.1.3 On receipt of supply order, the supplier shall prepare production schedule and QA
plan and submit to regional quality assurance establishment.

9.1.4 The Supplier shall produce the quality reports received from the supplier of
components and materials and these shall be produced to QA agency during quality audit.

9.1.5 The Supplier shall carry out inward goods inspection of the components, materials
procured from outside as well as quality checks on the components fabricated in - house. The
quality records shall be maintained and produced to QA agency during quality audit.

9.1.6 The Supplier shall intimate Regional Quality Assurance Establishment as soon as
40% to 50% of the raw materials/components for the lot likely to be offered are available
with him.

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9.1.7 Regional Quality Assurance Establishment shall verify conformance of the bill of
materials by auditing the procurement records of the firm. Regional Quality Assurance
Establishment shall carry out surveillance checks, which may also include testing of some of
the components/materials. The Supplier shall make test facilities available either in house or
at any of the reputed test laboratories.

9.1.8 The Supplier shall intimate Regional Quality Assurance Establishment detailed
production schedule well in advance so that they can plan and carry out process audit.

9.1.9 The Supplier shall carry out in-house tests as given in Table 2 below on the assembled
batteries to verify conformance to the specification and shall offer the stores to QA agency
only when he is satisfied that the stores meet the requirements. The Supplier will have all the
necessary test equipments to demonstrate the conduct of the tests. The stores shall be
tendered for QA checks along with the pre-inspection report.

Table 2

S. No. Tests
a) Detailed physical examination (Overall dimensions, weight & fitment with
the main eqpt)
b) Capacity test at Room Temperature
c) Electrolyte retention test (for vented type only)
d) On-load voltage and service life test
e) High rate discharge test at room temperature

9.2 Application for Product Confirmatory Test

Requisition for product Confirmatory test shall be made to the QAO supported by the
following:
a) Details of construction with drawings and 2 sets of all components/fabricated
parts used in battery.

b) Details of Tests conducted by the manufacturer and the results obtained.

c) The manufacturer shall provide the test sample batteries and their components
alongwith details of components as required in the proforma to be provided by
concerned AHSP free of charges unless otherwise contractually agreed to determine
their compliance with the requirements of the specification. The necessary testing
charges are also liable to be paid to the QA Authority if so required.

9.3 Product Confirmatory Test

The manufacturers/supplier will carry out the product confirmatory tests on the samples on
their own confirming to specified requirements and the records of carrying out the tests may
be submitted to QA authority whenever being asked.

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9.4 Quality Assurance Procedure

The manufacturer/supplier shall ensure quality of conformance to the specified requirements

by the following methods:
a) Inspection of materials, components and batteries, in the course of
manufacture and completed batteries, to ensure that the requirements are being met
and that the necessary standard of workmanship and process control is being
maintained and proper records on the above materials are being kept.

b) Inspection of batteries and representative samples for the tests as specified in

the relevant supplement to this specification.

9.5 Classification of Tests

9.5.1 Product Confirmatory Tests

Conducted for purpose of evaluation for specific type of battery.

9.5.2 Acceptance Tests

Class A, B & C tests carried out for the purpose of bulk acceptance.

9.5.3 Control Sample Tests

Conducted on samples drawn from the bulk to ascertain conformity with cycle life specified
in the contract.

9.6 Standard Conditions of Tests

Unless otherwise specified, all tests shall be carried out at room temperature within the range
of 15ºC to 40ºC under prevailing atmospheric pressure and relative humidity of the same type
and ratings.

9.7 Test details for Product Confirmatory Test

a) 14 samples of batteries of the same type and ratings from the same batch of
production will be subjected to type tests as under groups ‘A’ to ‘G’.

b) This test will be carried out against payment as per JSS specifications, on
approval of the concerned authority.

c) The results of evaluation will be valid provided there is no change in raw

materials, construction, design, drawing and it complies with JSS specification.

d) The firm should have all the test facility for carrying out testing/evaluation on
the subject battery packs. However in case the firms are not having any test facility, it
can be tested at any of the approved test laboratory.

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e) The following tests will be carried out by the supplier in addition to other test
being carried out on each supply order and the results will be submitted to QA agency
along with the call letter:

1) On All 14 Samples (Group ‘A’ to Group ‘G’ of two Battery Each):

i) Visual examination - check for marking, dimension, mass and

fitment (Clause 9.10.1, 9.10.3, 9.10.4).

ii) Capacity test at room temperature (Clause 9.10.5.1).

iii) Electrolyte retention test (Clause 9.10.5.8).
iv) On load voltage test (Clause 9.10.5.13).
v) Service life test (Clause 9.10.5.14).
vi) High rate discharge test at room temperature
(Clause 9.10.5.11).
2) On 2 Samples (Group ‘A’)

i) Capacity test at &20ºC after charge at room temperature

(Clause 9.10.5.2).

ii) Capacity test at &20ºC after charge &20ºC (Clause 9.10.5.3).

iii) Capacity test at &30ºC after charge at room temperature (Clause

9.10.5.4).

iv) Capacity test at &30ºC after charge at &30ºC (Clause 9.10.5.5).

3) On 2 Samples (Group ‘B’)

i) Detailed physical examination (Clause 9.10.2).

ii) Capacity test at &55°C after charge at room temperature

(Clause 9.10.5.6).

iii) Capacity test at &55ºC after charge at +55ºC

(Clause 9.10.5.7).
iv) Permanent charge endurance (Clause 9.10.5.19).
4) On 2 Samples (Group ‘C’)
i) Environmental tests (Clause 9.10.5.18).
5) On 2 Samples (Group ‘D’)
i) Cycle life test (Clause 9.10.5.16).

6) On 2 Samples (Group ‘E’)

i) Accelerated charge/discharge test (Clause 9.10.5.15).

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7) On 2 Samples (Group ‘F’)

i) Retention of charge test (Clause 9.10.5.9).

ii) Over charge test (Clause 9.10.5.10).

iii) Short circuit test (Clause 9.10.5.12).

8) On 2 Samples (Group ‘G’)

i) Storage test (Clause 9.10.5.17).

9.7.1 Criteria for Satisfactory Performance

All samples shall successfully complete the respective test sequences as detailed above.
Should any of the samples fails in type tests, the cause for the failure is to be ascertained and
due remedial action taken after which the Quality Assurance Authority at his discretion may
call for fresh samples not exceeding twice the original number and subject them to all the
tests or to the tests in which failure has occurred. Not even a single failure shall be permitted
in the repeat test.

9.8 Acceptance Tests

On receipt of bulk production clearance from the competent authority against a contract, the
manufacturer shall give advance intimation to the Quality Assurance Officer mentioned in the
contract about the production programme for the stores ordered. The manufacturer shall make
available to the Quality Assurance Officer all facilities to oversee the in-house quality control
checks. The stores shall be tendered in convenient lots to the Quality Assurance Officer for
his Acceptance Inspection as specified in clauses (9.8.1 to 9.8.3).

9.8.1 Class ‘A’ tests on 100% of the Bulk:

a) Fitment with the main equipment where relevant.

b) Prepack checks.

c) On load voltage test.

9.8.1.1 Criteria for acceptance

Only batteries conforming to the requirements will be accepted. The bulk will be released
only on satisfactory completion of class ‘B’ tests detailed in Clause 9.8.2.

9.8.2 Class ‘B’ Tests

(On random samples selected as per sampling procedure given below):

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9.8.2.1 Test sequence

a) Detailed physical examination.

b) Measurement of mass.

c) Capacity test at room temperature.

d) Electrolyte retention test.

e) On-load voltage and service life test.

f) High rate discharge test at room temperature.

g) Overall dimensional Check.

h) On load voltage test.

9.8.2.2 Sampling procedure

The following sampling procedure shall be followed for selecting random samples for class
‘B’ tests:

Table 3 Showing Lot Size, Sample Size and Criteria for Conformity

Sample Size
(No. of Samples to be Selected) Criteria for Conformity
Lot Size
First Second Total (No. of Defective Samples)
Stage Stage
N n n 2n C1 C2 C3
(1) (2) (3) (4) (5) (6) (7)
Up to 50 2 - 2 0 1 0
51 to 300 3 - 3 0 1 0
301 to 500 5 5 10 0 2 2
501 to 1000 8 8 16 0 2 2
1001 and above 13 13 26 0 3 4

NOTES
1. Each of the sample battery selected in the first stage as per column 2 of Table above will be subjected
to all the class ‘B’ acceptance tests. A battery shall be declared defective if it fails in one or more of the
class ‘B’ tests.

2. If the number of defective sample is zero (C1 at column 5), the lot shall be considered as conforming to
the specified requirements and shall be accepted.

3. If the number of the defective is equal to or greater than C2 (Column 6), the entire lot shall be rejected.

4. If the number of defective is greater than zero (C1 at column 5) but less than C2 (column 6), a further
sampling of the same size (column 3) is done and these second stage samples are subjected to all the class ‘B’
tests as done before.

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5. If the number of defective in first and second stages combined is less than C3 (Column 7), the lot shall
be accepted. Otherwise, the entire lot shall be rejected.

6. The above sampling plan shall be made applicable only when smooth production flow of the battery
has started and supply of not less than 200 batteries is made or if the firm has supplied the same type of batteries
in bulk (of not less than 200) earlier and the last consignment has been supplied not earlier than one year before
tendering the present lot. For others, the following rate of sampling will be carried out.

Total No. Percentage Decision on Acceptance

of batteries of batteries
to be tested
First 25 100% Acceptance of only those samples which are
conforming to specification.
25 to 200 10% Acceptance of lot if no defect noticed .If defects are
noticed in one or more samples, carry out double
sampling plan of 8 No. each and acceptance limits as
per table given above. (The 10% samples tested may
be taken as first and second stage sampling. If the
number of batteries comes less than 16 the
remaining samples may be taken. If already tested
samples exceed 16, double sampling plan with
13 samples for each stage may be carried out).

9.8.3 Class ‘C’ tests

(On random samples upto a maximum of 1% of the bulk as required by the Quality
Assurance Authority).

The samples after completion of class ‘A’ and ‘B’ tests are subjected to the following tests:
a) Capacity test at &30ºC after charge at &30ºC.

b) Capacity test at +55ºC after charge at +55ºC (Clause 9.10.5.7).

c) Environmental (complete) tests (Clause 9.10.5.18).

9.8.3.1 Criteria for acceptance

Since class ‘C’ tests are time consuming, release of the lot will not await completion of class
‘C tests. However, when failures are noticed, the matter shall be taken up with the
manufacturer for evolving and implementing corrective measure forthwith. The acceptance of
batches tendered after failures in Class ‘C’ tests are noticed, shall be subject to satisfactory
implementation of the corrective measures. The samples on completion of class ‘C’ tests will
be returned to the firm for re-offering and the same if found acceptable in class ‘A’ tests will
be released as part of the bulk as yellow banded (not fit for operational deployment) model.

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9.9 Control Sample Tests (Warranty Clause and Cycle Life Tests)

9.9.1 As per conditions normally laid down in the contract, the manufacturer shall render a
warranty that the batteries being supplied will be repaired/replaced free of cost if found
defective within a period of 15 months from the date of supply. The batteries shall also be
warranted by the contractor for storage at any temperature from &30ºC to +70ºC for a period
of 4 years from the date of despatch and give the required number of cycle life as specified in
the relevant supplement to this specification.

9.9.2 To ensure that the batteries fulfil the cycle life requirements as stipulated in the
warranty clause, random samples will be drawn from the bulk supplies and subjected to cycle
life test as per the terms of the contract.

9.10 Test Details, Procedure and Acceptance Criteria

9.10.1 Visual Examination

The battery will be checked for conformity with the relevant drawings in respect of overall
dimensions, general details of construction, finish and markings. All parts/components and
the battery as a whole should be free from damage and the cells inside the battery will be
tightly packed to prevent internal movements. All connectors & vented type cells (in case of
vented type batteries) shall be provided with dust caps.

9.10.2 Detailed Physical Examination

Details of individual cells, components and other constructional features will be compared
with the relevant detailed drawings and conformity ensured.

9.10.3 Fitment Checks

The mechanical/fitment aspects will be ensured with the main equipment. There shall be no
difficulty in proper fitment, clamping and effecting electrical connection with the main
equipment. If a carrying arrangement is called for, the same will be checked for correctness
and completeness.

9.10.4 Measurement of Weight

The weight of battery shall be measured with suitable scale. This shall be within the
maximum value specified in the relevant supplement.

9.10.5 Electrical Test Performance Checks

Detailed test procedure for conducting electrical and performance checks to ensure
compliance with the specification is given as specified in Clause 9.10.5.1 to Clause 9.10.5.18.

9.10.5.1 Capacity test at room temperature

The battery is first discharged at 5 h rate to end voltage of 1 V per cell average.

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a) The discharged battery is given capacity charge as per clause 4.2.

b) On completion of charge the battery is given rest for not less than 1 h
and not more than 4 h.

c) The battery is then discharged at 5 h rate to end voltage of 1 V per cell

average.

d) The duration of discharge shall not be less than 5 h, thereby yielding

the full rated Ah capacity.

9.10.5.2 Capacity test at &20ºC after charge at room temperature

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell is given
capacity charge as per clause 4.2 at room temperature.
a) On completion of charge, the battery is conditioned at &20ºC ±3ºC for
16 h.

b) The battery is then discharged at &20ºC ±3ºC at 5 h rate to end voltage

of 1 V per cell average. The duration of discharge at &20ºC shall not less than
3 h thereby yielding minimum 60% of the rated capacity.

c) The battery is allowed a recovery time of 2 h to 4 h at room

temperature and discharged further at 5 h rate to end voltage of 1 V per cell
average at room temperature.

9.10.5.3 Capacity test at &20ºC after charge at &20ºC

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell average at
room temperature is conditioned at &20ºC ±3ºC for 16 h.
a) The battery is then charged at capacity charge rate as per clause 4.2 at
&20ºC ±3ºC. The charged battery is allowed a rest of not less than 1 h and not
more than 4 h at –20ºC ±3ºC.

b) The battery is then discharged at 5 h rate to end voltage of 1 V per cell

average at –20ºC ±3ºC.

c) The duration of discharge at &20ºC shall not less than 3 h thereby

yielding a minimum of 60% of the rated capacity.

d) The battery is allowed a recovery time of 2 h to 4 h at room

temperature and discharged further at 5 h rate to end voltage of 1 V per cell
average at room temperature.

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9.10.5.4 Capacity test at &30ºC after charge at room temperature

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell average at
room temperature is given capacity charge as per clause 4.2 at room temperature.
a) On completion of charge, the battery is conditioned at &30ºC ±3ºC for
16 h. The battery is then discharged at –30ºC ±3ºC at 5h rate to end voltage of
1 V per cell average.

b) The duration of discharge at –30ºC shall be not less than 2 h,

30 minutes there by yielding a minimum of 50% of the rated capacity.

c) The battery is allowed recovery time of 2 h to 4 h at room temperature

and discharged further at 5 h rate to end voltage of 1 V per cell average at
room temperature.

9.10.5.5 Capacity test at &30ºC after charge at &30ºC

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell average at
room temperature is conditioned at &30ºC ±3ºC for 16 h.
a) The battery is then charged at capacity charge rate as per clause 4.2 at
&30ºC ±3ºC. The battery is allowed a rest of not less than 1 h and not more
than 4 h at &30ºC ±3ºC and discharged at the same temperature at 5 h rate to
end voltage of 1 V per cell average.

b) The duration of discharge at &30ºC shall be not less than

2 h 30 minutes thereby yielding a minimum of 50% of the rated capacity.

c) The battery is allowed a recovery time of 2 h to 4 h at room

temperature and discharged further at 5h rate to end voltage 1 V per cell
average.

9.10.5.6 Capacity test at +55ºC after charge at room temperature

The battery which has been discharged at room temperature at 5 h rate to end voltage of 1 V
per cell average is given capacity charge as per Clause 4.2 at room temperature.
a) On completion of charge the battery is conditioned at +55ºC ±3ºC for
16 h. The battery is then discharged at +55ºC ±3ºC at 5 h rate to end voltage of
1 V per cell average.

b) The duration of discharge at +55ºC shall be not less than 3 h thereby

yielding a minimum of 60% of the rated capacity. The battery is allowed
recovery time of 2 h to 4 h at room temperature and discharged further at 5 h
rate to end voltage of 1 V per cell average at room temperature.

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9.10.5.7 Capacity test at +55ºC after charge at +55ºC

The battery which has been discharged at room temperature at 5 h rate to end voltage of 1 V
per cell average is conditioned at +55ºC ± 3ºC for 16 h. The battery is then given capacity
charge as per Clause 4.2 at +55ºC ±3ºC.
a) On completion of charge, the battery is allowed a rest of not less than
1 h and not more than 4 h at +55ºC ±3ºC and then discharged at same
temperature at 5 h rate to end voltage of 1 V per cell average.

b) The duration of discharge at 55ºC shall not be less than 3 h thereby

yielding a minimum of 60% of the rated capacity. The battery is allowed a
recovery time of 2 h to 4 h at room temperature and discharged further at 5 h
rate to end voltage of 1 V per cell average at room temperature.

9.10.5.8 Electrolyte retention test at room temperature

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell average at
room temperature is given normal charge as per clause 4.3. On completion of charge, the
battery is allowed 1 h rest and then kept in inverted position for 2 h. At the end of this period
the battery is brought to upright position and checked thoroughly for any traces of leakage of
electrolyte. There shall be no sign of leakage of electrolyte from the cells.

9.10.5.9 Retention of charge test at room temperature

9.10.5.9.1 On completion of capacity charge after the capacity discharge as per

Clause 9.10.5.1. The battery is left in open circuit for 21 days at room temperature at the end
of which, a capacity test as per Clause 9.10.5.1 is conducted on the battery to ascertain the
extent of loss in Ah capacity due to self discharge.

9.10.5.9.2 The loss in Ah capacity during 21 days storage in charged condition shall not
exceed 30% of the rated Ah capacity.

9.10.5.10 Overcharge test at room temperature

The battery which has been discharged at 5 h rate to end voltage of 1 V per cell average at
room temperature is given continuous charge at 5 h rate for 24 h.
a) On completion of the charge, the battery is allowed a rest of not less
than 1 h and not more than 4 h and then tested for capacity at 5 h rate to end
voltage of 1 V per cell average at room temperature.

b) The duration of discharge shall not be less than 5 h thereby yielding

the full rated capacity.

9.10.5.11 High rate discharge test at room temperature

9.10.5.11.1 The battery which has been discharged at 5 h rate to end voltage of 1 V per
cell average is given capacity charge as per clause 4.2 at room temperature. The battery is
then allowed a rest of not less than 1 h and not more than 4 h.

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9.10.5.11.2 On completion of rest period the battery is discharged continuously at a

current in amperes numerically equal to the rated Ah capacity mentioned for the battery till
the end voltage of 1 V per cell average is reached. The duration of discharge shall be not less
than 45 minutes.

9.10.5.12 Short circuit test at room temperature

9.10.5.12.1 The battery which has been discharged at 5 h rate to the end voltage of 1 V per
cell average is given normal charge as per clause 4.3.

9.10.5.12.2 On completion of normal charge the battery is given a rest of not less than 1 h
and not more than 4 h and then discharged through the input/output connector for one minute
at a current in amperes numerically equal to three times the rated Ah capacity value
mentioned for the battery. If the battery has more than one connector, the above one minute
discharge will be done through every available connector one after the other. There shall be
no overheating or damage to any part of the battery. On completion of above high discharge
when the battery is further discharged, charged and tested for capacity as per Clause 9.10.5.1,
it shall yield the rated capacity thereby indicating that there has been no deleterious effect on
the performance of the battery as a result of the short circuit test.

9.10.5.13 On load voltage test at room temperature

9.10.5.13.1 Depending upon the input requirements of the main equipment, this test is
carried out to ensure the capability of the battery to deliver the onload voltage within the
limits specified.

9.10.5.13.2 The battery which has been discharged at 5 h rate to end voltage of 1 V per
cell average is given normal charge as per clause 4.3, and allowed a rest for 30 minutes.
Immediately on completion of rest period, the battery is connected to the resistive loads
corresponding to simulating the operational modes of the main equipment. The onload
voltages recorded shall be within the limits specified.

9.10.5.14 Service life test at room temperature

9.10.5.14.1 The capability of the battery to continuously power the main equipment for the
required number of hours is assessed by means of this test.

9.10.5.14.2 The battery which has been discharged at 5 h rate to end voltage of 1 V per
cell average is given normal charge as per clause 4.3.

9.10.5.14.3 On completion of normal charge, the battery is allowed a rest of not less than
1 h and not more than 4 h, and then discharged continuously across resistive loads simulating
the operational modes of the main equipment till the minimum specified operating voltage
limit is reached.

9.10.5.14.4 In the case of batteries used for powering communication equipments, the
transmit-receive ratio of 1 : 9 (1 min Tx & 9 min Rx) will be adopted and the discharge
terminated when the end point reaches in transmit condition.

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9.10.5.14.5 The discharge duration obtained shall be not less than that specified in the
relevant supplement.

9.10.5.15 Accelerated charge/service life discharge test

9.10.5.15.1 The capability of the battery to accept charge at fast/accelerated charge rate
and perform satisfactorily inspite of repeated resort to this mode of charging is verified by the
following test procedure:

9.10.5.15.2 The battery shall be charged as per accelerated charge procedure at clause 4.4
at double the normal charge rate for a duration so that the charging process including the
subsequent rest period, if any does not exceed 4 h. Immediately on completion of the above
4 h period, the battery shall be subjected to service life test discharge as per clause 9.10.5.14
or capacity test discharge as per clause 9.10.5.1 depending upon the usage of the battery.

9.10.5.15.3 The above sequences shall be repeated for 50 cycles continuously and the
duration obtained in these discharges shall be not less than 80% of the nominal rated value.

9.10.5.15.4 During the above tests, the maintenance/care received by the battery shall
conform to the following:
a) Periodic checks and adjustment of electrolyte level in case of vented
type batteries.

b) If required after every 10th cycle, battery will be further discharged at

5 h rate to 1 V per cell average and a conditioning cycle of charge at Capacity
charge rate as per Clause 4.2, followed by a rest for not less than 1 h and not
more than 4h a discharge at 5h rate upto 1 V per cell average will be carried
out.

9.10.5.16 Cycle life test at room temperature (not less than 400 cycles)

9.10.5.16.1 For batteries using vented type cells

On satisfactory completion of all tests mentioned at Clause 9.7 (a) the samples for cycle life
test shall be subjected to continuous cycles of charge and discharge as under after being
discharged to 1 V per cell average.

Cycle Charge Rest Discharge

1 0.2 C5 a for 7 h Nil 0.25 C5 A for 2 h 30 min
2 to 26 0.25 C5 a for Nil -do-
7 h 30 min
27 -do- Nil 0.2 C5 A upto 1 V per cell
average
28 0.2 C5 a for 7 h 1 h to 4 h -do-

a) Cycle No. 1 to 28 shall be repeated until duration of discharge in any

28th cycle falls below 4 h 15 min corresponding to 85% of rated A output. For

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computing the cycle life obtained the No. of cycles up to the last 28th cycle
with a discharge duration not less than 4 h 15 min shall be counted.
b) The cycle life thus obtained shall be not less than that specified in the
relevant supplement to this specification.

c) In the case of vented type of batteries the level of electrolyte shall be

checked and adjusted after the 28th cycle charge, during the rest period prior
to the 28th cycle discharge. After the level adjustment, the external surfaces of
all the cells shall be thoroughly cleaned and dried before continuing with the
test.

9.10.5.16.2 Procedure is as per IEC 61951-1 (2001-01) CI : 4.4.1 Table 11 is given below
before the endurance in cycle test, the cell shall be discharged at 0.2It A to a final voltage of
1.0 V/cell.

9.10.5.16.3 The following endurance test shall be carried out irrespective of cell
designation, in a ambient temperature of 20ºC ±5ºC. Charge and discharge shall be carried
out at constant current in accordance with conditions specified in Table 11, 11a, 11b and 12.
Precautions shall be taken to prevent the cell case temperature from rising above 35ºC during
the test, by providing a forced air draught, if necessary.

NOTE - Actual cell temperature, not the ambient temperature determines cell performance. Table 11 Endurance
in cycles for small prismatic cells and for cylindrical cells.

Cycle Charge Stand in Charged Discharge

Number Condition
1 0.1 It for 16 h None 0.25 It for 2 h 20 min
2-48 0.25 It for 3h 10 min None 0.25 It for 2 h 20 min
49 0.25 It for 3h 10 min None 0.25 It to 1 V/cell
50 0.1 It for 16 h 1 h-4 h 0.20 It to 1 V/cell
It is permissible to allow sufficient open circuit rest time after the completion
of discharge at cycle 50, so as to start cycle 51 at an exact two week interval.
A similar procedure may be adopted at cycles 100, 150, 200, 250, 300 and
350.

Cycles 1 to 50 shall be repeated until the discharge duration on any 50th

cycle becomes less than 3 hrs (not less than 60% of rated Ah). At this stage,
a repeat capacity measurement as specified for cycle 50 shall be carried out.
The endurance test is considered complete when two successive capacity
measurement cycles give a discharge duration less than 3 h (not less than
60% of rated Ah). The number of cycles successfully completed shall be not
less than 400 for small prismatic cell and for cylindrical cell.

9.10.5.17 Storage/Shelf life test

The battery which has been discharged at 5 h rate to 1 V per cell average is kept in idle
storage at room temperature for 4 years. On completion of the above storage period, the
battery is subjected to the following tests.

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a) Initial charge as per clause 4.1 followed by a rest for not less than 1 h
and not more than 4 h and capacity discharge at 5 h rate upto 1 V per cell
average.

NOTE - A maximum of 3 such cycles of charge and discharge are allowed within which the
battery shall yield the rated Ah capacity.

b) Electrolyte Retention test as per clause 9.10.5.8 (for vented type

batteries).

c) High rate discharge test as per clause 9.10.5.11.

d) On load voltage test as per clause 9.10.5.13.

e) Service life test as per clause 9.10.5.14.

9.10.5.18 Environmental tests

9.10.5.18.1 The following sequence of the environmental tests are specified for batteries
used with ground equipments partly protected (Class L2).
a) Before commencement of each environmental test, the battery will be
in fully charged condition. The physical condition of the battery, individual
cell voltages and terminal voltage will be recorded before and after each of the
following tests.

b) There shall be no leakage of electrolyte, physical damage/deterioration

or abrupt drops in voltage. Functional checks, if any required will be detailed
in the respective supplements.

9.10.5.18.1.1 Vibration test (test no. 28 of JSS 55555)

a) (Endurance by sinusoid with frequency sweep) Clause 3.4.2 (c),
clause 3.4.6, Table 4.28.2 Serial 1(b), Frequency 8 Hz to 500 Hz

b) Amplitude ±15 m/s2, constant acceleration. Duration 6 h total for all

3 planes.

9.10.5.18.1.2 High temperature test (test no. 17 of JSS 55555)

(High temperature exposure)

Clause 3.2.5 procedure 5 test condition H
Temperature +70ºC ±3ºC - Duration 24 h
Relative humidity not greater than 50%

9.10.5.18.1.3 Damp heat test (test no. 10 of JSS 55555)

Clause 3.2, Temperature +40ºC ±2ºC

Relative humidity 93 ±5% - Duration 16 h
Lab temperature
Humidity saturation Not less than 3 h

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9.10.5.18.1.4 Dust test (test no. 14 of JSS 55555)

Duration 1 h

9.10.5.18.1.5 Altitude test (test no. 3 of JSS 55555)

Clause 3.2.5, procedure 5 - Test condition L2 A2

Temperature - 30ºC ±3ºC
Air pressure 60 kPa³ Exposure for 16 h Exposure for 16 h
(Altitude 4160 m)³

9.10.5.18.1.6 Drop test (test no. 13 of JSS 55555)

Clause 3.2, Test condition ‘C’.

Height of drop 100 mm/250 mm as given in the relevant supplements. No. of drops 3, one
each on mutually perpendicular faces.

9.10.5.18.1.7 Toppling test (test no. 26 of JSS 55555)

Clause 3.2.

9.10.5.18.1.8 Bump test (test no. 5 of JSS 55555)

Clause 3.3.

To be mounted without isolators, in vertical position. No. of bumps 4000 ±10 at peak
acceleration of 400m/s2.

9.10.5.18.1.9 Tropical exposure test (test no. 27 of JSS 55555)

Clause 3.2.

Test condition B, No. of cycles 14.

9.10.5.18.2 On conclusion of the complete sequences of environmental tests listed above,

the battery shall yield the rated capacity when tested for capacity at room temperature as per
clause 9.10.5.1.

9.10.5.19 Permanent charge endurance test

The procedure as per Clause 4.4.2.3 of IEC 61951 (2001-01) is given below:

9.10.5.19.1 The permanent charge endurance test shall be performed in three steps
according to the conditions specified in Table 15.

9.10.5.19.2 It consists of
a) A charge efficiency test.

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b) An ageing period of six months at +70ºC.

c) A final charge efficiency test to check the cells performance after
ageing.

NOTE - The temperature of +70ºC is estimated to stimulate four years of permanent charge at +40ºC.

9.10.5.19.3 Prior to the test, the cell shall be discharged at 0.2 It A at 20ºC ±5ºC to a final
voltage of 1 Volt/cell and stored at an ambient temperature of +40ºC ± 2ºC, for not less than
16 h and not more than 24 h.

9.10.5.19.4 The cell shall then be charged and discharged at constant currents under the
conditions specified while maintained in an ambient temperature of +40ºC ±2ºC or +70ºC
±2ºC Respectively as appropriate.

9.10.5.19.5 The discharge condition A or B may be chosen to suit the user’s requirements.
The discharge is carried out immediately on completion of charging.

9.10.5.19.6 After performing the first charge efficiency test at +40ºC the cell is stored, at
an ambient temperature of +70ºC ±2ºC, for not less than 16 h and not more than 24 h.

9.10.5.19.7 During the ageing period of 6 months +70ºC, precautions shall be taken to
prevent the cell-case temperature from raising above +75ºC by providing forces air drought,
if necessary.

NOTE - Actual cell case temperature, not the ambient temperature, determines the cell performance.

9.10.5.19.8 The discharge duration of the three cycles at +70ºC shall be recorded. Leakage
of electrolyte shall not occur during this test.

9.10.5.19.9 After completion of ageing period, the cells shall be stored for not less than
16 h and not more 24 h at an ambient temperature of +40ºC ±2ºC. Three cycles at +40ºC of
the initial charge efficiency test are then repeated using the conditions specified in table 15.
Duration of the discharge shall be not shall less than the minimum specified in Table 15.

10. MISCELLANEOUS

Supply of Accessories, Carried Spares, Tools, User Hand Book and other Technical
Documents:

10.1 Accessories

When periodic adjustment of electrolyte level is required to be carried out, a graduated

syringe shall be supplied with each battery. Any other accessories like charging cable, mating
connector etc, where called for, will be supplied alongwith the batteries in quantities
specified in the supply order/relevant paper particulars.

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10.2 Carried Spares

Each battery shall be supplied with a set of carried spares like vent plugs, diaphragms, sealing
gasket etc as applicable. The scaling shall be at approximately 25% of the quantity used on
each battery.

10.3 Tools

Basic tools required for maintenance of the battery while in service, shall be supplied in
matching quantities.

10.4 User Hand Book

User hand book containing technical data, precaution and instructions for packing, transit,
storage, installation, use, care and maintenance shall be supplied with each battery. The
scaling shall be indicated in the relevant supply order.

10.5 Technical Documents

Detailed procurement drawings and other technical documents as called for in the relevant
contract shall be supplied. These shall be prepared and supplied as per JSS 0251-01 unless
otherwise stipulated in the contract.

11. PACKING, STORAGE AND TRANSIT

11.1 State of Charge of the Battery at the Time of Despatch

Unless otherwise called for in the relevant contract, the batteries shall be discharged fully
before packing for shipment. The batteries shall be transported and stocked in the discharged
condition only.

11.2 Packing

Individual battery shall be packed and sealed in poly theme cover and then put in
corrugated/cardboard carton before being packed in wooden packing case lined with
rubberised coir/Thermocole. All associated items accompanying the battery shall be packed
and put in the same carton case along with the battery.

11.2.1 The total No. of batteries that are accommodated in a packing case shall be such that
the total mass of the complete case shall not exceed 25 kg or the mass of a battery plus
8 kg, whichever is more.

11.2.2 The design of the wooden packing case shall be such that it is sturdy and easy to
handle. These shall be of reusable type.

11.2.3 The supply order No., Nomenclature and DS Cat No./NSN of stores, make, date of
manufacture, quantity and serial No. of the batteries inside and handling instructions shall be
marked on the packing cases in addition to consignee and consignor addresses.

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11.3 Transit and Storage

11.3.1 The battery shall be placed with adequate packing on all sides and transported in
upright position only.

11.3.2 The battery can be stored at any temperature from &30ºC to +75ºC but shall be
protected against rain, dust, mist, snow and direct sun while in transit and storage. As far as
possible, it shall be stored in a cool dry atmosphere away from sources of heat and fumes.

11.3.3 The manufacturer shall be responsible for the safe delivery of the stores at
consignee’s end transit damage if any shall be promptly attended to by him.

11.4 Receipt Inspection by the Consignee

The receipt inspection by the consignee will be carried out through the visual examination to
ensure the correctness and completeness of the items received against each Inspection Note.
Discrepancies and transit damage, if any will be taken up with the supplier under intimation
to all concerned.

11.5 Stocking and Issue

11.5.1 The stores shall be stocked for the barest minimum period in depots. These shall be
stored in cool, dry atmosphere well protected from direct sun, rain, dust, snow etc. The
batteries shall be stored in the packing cases supplied by the contractor.

11.5.2 The batteries shall be issued to the units as soon as possible on first- in first-out basis
and it shall be ensured that the full benefits accruing from the warranty clauses
(Clause 9.9.1) are made available to the users.

11.5.3 The batteries shall be issued to the users alongwith all associated items like UHB,
accessories (if any), carried spares and tools as originally supplied by the contractor.

11.5.4 Under no circumstances the battery shall be stocked beyond the warranted shelf life
period of 4 years. The design of the battery shall be such that no maintenance is required
during stocking period at the depots.

12. DEFENCE STORES CATALOGUE NUMBER/NATO STOCK NUMBER

12.1 Each type of battery shall bear DS Cat No./NSN before it is supplied or accepted in
Defence Services. The DS Cat No./NSN shall be as per the allotment by the Defence
Codification Authority.

12.2 The following DS Cat No./NSN have been allotted to the batteries Secondary, Nickel
Cadmium:

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S. No. Nomenclature DS Cat No. NSN

a) Batteries Secondary, Portable, Nickel- 6140-000201 6140720025062
Cadmium 2.4 V, 10 Ah
b) Batteries Secondary, Portable, Nickel- 6140-000378 NA
Cadmium (Sealed Cylindrical) 12 V,
2 Ah
c) Batteries Secondary, Portable, Nickel- 6140-000393 6140720025039
Cadmium (Sealed Cylindrical) 24 V,
4 Ah
d) Batteries Secondary, Portable, Nickel- 6140-000467 6140720025020
Cadmium (Sealed Cylindrical) 12 V,
7 Ah
e) Batteries Secondary, Portable, Nickel- 6140-000468 6140720025019
Cadmium (Sealed Cylindrical) 12 V,
1.6 Ah
f) Batteries Secondary, Portable, Nickel- 6140-000475 6140720025017
Cadmium (Sealed Cylindrical) 12 V,
10 Ah
g) Batteries Secondary, Portable, Nickel 6140-000483 6140720025016
Cadmium 2.5 V, 9 Ah
h) Batteries Secondary, Portable, Nickel- 6140-000113 NA
Cadmium (Sealed Cylindrical) 1.2 V,
6.5 Ah*
j) Batteries Secondary, Portable, Nickel- 6140-000117 6140720025076
Cadmium (Spring Cylindrical) 2.4 V,
10 Ah*
k) Batteries Secondary, Portable, Nickel- 6140-000176 NA
Cadmium (Semi Cylindrical) 2.4 V,
7 Ah
m) Batteries Secondary, Portable, Nickel- 6140-005173 6140720024967
Cadmium (Sealed Cylindrical) 2.4 V,
4 Ah
n) Batteries Secondary, Portable, Nickel- 6140-005171 6140720024969
Cadmium (Sealed Cylindrical) 12 V,
4 Ah
p) Batteries Secondary, Portable, Nickel- 6140-005172 6140720024968
Cadmium (Sealed Cylindrical) 24 V,
4 Ah
*Pertains to DQA(N)

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13. SUGGESTIONS FOR IMPROVEMENTS

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

The Director,
Directorate of Standardisation,
Ministry of Defence,
‘H’ Block, Nirman Bhawan PO,
New Delhi-110011.

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SUPPLEMENT No. 1

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM, 2.4 V, 10 Ah
(DS Cat No./NSN 6140-000 201/6140720025062)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 2 No. of 1.2 V 10 Ah non spillable
cells connected in series to form a 2.4 V block. The battery assembly is housed in mild steel
box provided with a hinged lid on which a 2 pin plug is fixed. An outline sketch and the
schematic diagram are attached as Appendices ‘A’ and ‘B’ to this supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with 130 mm Gun (Russian) for
powering its illumination set LUCH-C71M.

2.2 The following are the input requirements of the main equipment:

Input Voltage Limits

Equipment Operating Conditions
Max Min
130 mm Gun Continuous drain at 1.25 A 3.5 V 2.0 V
(LUCH-C71M)

3. TECHNICAL DATA
a) Nominal Voltage - 2.4 V.

b) Rated Ah Capacity - 10 Ah at 5 h rate.

c) Construction and layout - As per drawing No CIL SK-781 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx ‘A’ to this supplement).

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions in mm:

1) Length - 188

2) Width - 61

3) Height - 173.5

g) Mass - 2 kg (Max).

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h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact with the input connector of the main equipment.

j) Service Life - Shall be capable of powering the Illuminating set LUCH-C71 M

of the main equipment 130 mm Gun (Russian) continuously for a minimum period of
8 h.

k) Cycle Life - Minimum 504 cycles.

m) Recommended Charging Currents.

1) Initial Charge - 1 A for not more than 16 h.

2) Capacity Charge - 1 A for not more than 14 hours

3) Normal Charge - 2 A for not more than 7 hours

4) Accelerated Charge - 4 A for not more than 3-1/2 hours

4. PARAMETRIC REQUIREMENTS

Table 4 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current in Voltage Capacity
mA in volts in Ah
a) Capacity test at room 9.10.5.1 2.0 2.0 10.0
Temperature
b) Capacity test at &20ºC 9.10.5.2 2.0 2.0 6.0
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 2.0 2.0 5.0
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 2.0 2.0 6.0
& 9.10.5.7
e) Capacity test at room 9.10.5.9 2.0 2.0 7.0
temperature to assess
retention of charge
f) Capacity test at room
temperature after 9.10.5.10 2.0 2.0 10.0
overcharge
g) Capacity test at room 9.10.5.12 2.0 2.0 10.0
temperature after short
circuit test
h) Capacity test at room 9.10.5.17 2.0 2.0 10.0
temperature after
4 years shelf life

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Table 4 Parametric Requirements (Concluded)

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current in Voltage Capacity
mA in volts in Ah
j) Capacity test at room 9.10.5.18 2.0 2.0 10.0
temperature on
completion of
environmental tests
k) High Rate Discharge 9.10.5.11 10.0 2.0 7.5
test
m) Electrolyte Retention 9.10.5.8 No leakage of electrolyte
test
n) On load voltage Test 9.10.5.13
The on load voltage shall be within the following limits:
On Load Voltages
Simulated Load Conditions
Max Min
1.25 A continuous 3.5 V 2.4 V
p) Accelerated Charge/Continuous Discharge Test (As per Clause 3.11) - Discharge at
1.25 A continuous to an end voltage 2.0 V. The duration of discharge shall not be
less than 6 h 30 min for 50 cycles.
q) Cycle Life test 9.10.5.15 Not less than 504 cycles

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APPX ‘A’ TO SUPPLEMENT No. 1

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APPX ‘B’ TO SUPPLEMENT No. 1

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SUPPLEMENT No. 2

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL), 12 V, 2 Ah
(DS Cat No./NSN 6140-000 378/NA)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 10 No. of 1.2 volts 2 Ah sealed
cylindrical cells. These are connected in series to form a 12 volts block and is housed in a
black colour ABS moulded outer casing provided with Silicon rubber pads. The battery
output terminals are wired to a 3 pin socket which mates with the battery plug provided on
the main equipment. An outline sketch and a schematic diagram are attached as Appendices
‘A’ & ‘B’ to this supplement.

2. USED ON DATA

2.1 This is special purpose battery intended for powering the Interface Equipment Analog
Code Multiplex Encryption (ACME) unit (DS Cat No./NSN Z1/5820-003703/NA) in
manpack/truck version.

2.2 The following are the input requirements of the main equipment:

Current Drains at Nominal Input voltage limits

Equipment
Voltage of Operating Conditions Max Min
ACME Send (for 1 min) 160 mA at 12 V 15 V 10.8 V
Receive (for 9 min) 130 mA at 12 V

3. TECHNICAL DATA
a) Nominal Voltage - 12 V.

b) Rated Ah Capacity - 2 Ah at 5 h rate.

c) Construction and layout - As per drawing No CQAL 4410 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx ‘A’ to this supplement).

d) Overall Dimensions in mm:

1) Length - 213 ±2

2) Width - 44 ±2

3) Height - 73 ±2

e) Mass - 1.4 kg (Max).

f) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is mounted on the main equipment, after enclosing in the
battery box (Z1/6140-000 342) which is then clamped to the main equipment.

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g) Service Life - Shall be capable of powering the main equipment ACME

continuously for a minimum period of 10 hours at send to receive ratio of 1 : 9.

h) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

j) Charges Recommended - Dual Battery Charger DS Cat

No. X2/6130-000442 or equivalent.

k) Recommended Charging Currents:

1) Initial Charge - 200 mA for not more than 16 hours.

2) Capacity Charge - 200 mA for not more than 14 hours.

3) Normal Charge - 400 mA for not more than 7 hours.
4) Accelerated Charge - 800 mA for not more than 3-1/2 hours.

4. PARAMETRIC REQUIREMENTS

Table 5 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current in Voltage Capacity
mA in volts in Ah
a) Capacity test at room 9.10.5.1 400 10 2.0
Temperature
b) Capacity test at &20ºC 9.10.5.2 400 10 1.2
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 400 10 1.0
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 400 10 1.2
& 9.10.5.7
e) Capacity test at room 9.10.5.9 400 10 1.4
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 400 10 2.0
temperature after
overcharge
g) Capacity test at room 9.10.5.12 400 10 2.0
temperature after short
circuit test
h) Capacity test at room 9.10.5.17 400 10 2.0
temperature after 4 years
shelf life

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Table 5 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current in Voltage Capacity
mA in volts in Ah
j) Capacity test at room 9.10.5.18 400 10 2.0
temperature on
completion of
environmental tests
k) High Rate Discharge 9.10.5.11 2.0 A 10 1.5
test
m) Electrolyte Retention 9.10.5.8 Not applicable
Test
n) On load voltage Test 9.10.5.13
The on load voltage shall be within the following limits:
Simulated Load Conditions On Load Voltages
Tx Rx Max Min
75 Ω 92.3 Ω 15.0 V 12 V
p) Service Life test 9.10.5.14
(1 : 9 ratio)
Simulated load Conditions End Voltage Min Duration
As per 4.12 of this supplement 10.8 V 10 h
q) Accelerated Charge/ 9.10.5.15 Discharge condition as per clause 4.13 of
Service life Discharge this supplement. Duration of discharge not
Test to be less than 8 h for 50 cycles.
r) Cycle Life test 9.10.5.16 Not less than 400 cycles.

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APPX ‘A’ TO SUPPLEMENT No. 2

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APPX ‘B’ TO SUPPLEMENT No. 2

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SUPPLEMENT No. 3

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL), 24 V, 4 Ah
(DS Cat No./NSN 6140-000 393/NA)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 20 No. of 1.2 volts 4 Ah sealed
cylindrical cells. These are connected in series to form a 24 volts block which is enclosed in a
moulded outer container. The end terminal is connected to a MIL type free female connector.
An outline sketch and the schematic diagram are attached as Appendices ‘A’ and ‘B’ to this
supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with the equipments:
a) Radio Set UA (LUP 321) (Z1/6820-003026) and

b) V/UHF Radio Set (LUP 322) (Z1/5820-003940)

2.2 The following are the input requirements of the main equipment:

Current Drains at Nominal

S. Voltage of 24 V Input Voltage Limits
Equipment
No. Operating Conditions
Tx Rx Max Min
a) RUSA 2.6 A 550 mA 28 V 21 V
(LUP321)
b) V/UHF 3.6 A 580 mA 28 V 21 V
(LUP322)

3. TECHNICAL DATA
a) Nominal Voltage - 24 V

b) Rated Ah Capacity - 4 Ah at 5 hours rate

c) Construction and layout - As per drawing No. CQAL 4383 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx ‘A’ to this supplement)

d) General Requirement - As per this specification

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

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f) Overall Dimensions (Max):

1) Length - 238 mm

2) Width - 93 mm

3) Height - 68 mm

g) Mass - 4 kg (Max)

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when contacted to the main equipment.

j) Service Life - Shall be capable of powering the main equipment continuously

for a minimum period of 5 h for RS UA (LUP 321) and minimum 4 h for V/UHF
(LUP 322) at the Send/Receive ration of 1: 9.

k) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

m) Charges Recommended - Battery charger with BEL Part No. 1100 003 854 24
DS Cat No. X2/6130-000442 or equivalent.
n) Recommended Charging Currents:

1) Initial Charge - 400 mA for not more than 16 hours

2) Capacity Charge - 400 mA for not more than 14 hours

3) Normal Charge - 800 mA for not more than 7 hours or 700 mA for
8 hours

4) Accelerated Charge - 1.6 A for not more than 3-1/2 hours or

1.4 A for 4 hours

4. PARAMETRIC REQUIREMENTS

Table 6 Parametric Requirements

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current Voltage Capacity
in mA in Volts in Ah
a) Capacity test at room 9.10.5.1 800 20.0 4.00
Temperature
b) Capacity test at &20ºC 9.10.5.2 800 20.0 2.4
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 800 20.0 2.0
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 800 20.0 2.4
& 9.10.5.7

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Table 6 Parametric Requirements (Concluded)

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current Voltage Capacity
in mA in Volts in Ah
e) Capacity test at room 9.10.5.9 800 20.0 2.8
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 800 20.0 4.00
temperature after overcharge
g) Capacity test at room 9.10.5.12 800 20.0 4.00
temperature after short
circuit test
h) Capacity test at room 9.10.5.17 800 20.0 4.00
temperature after 4 years
shelf life
i) Capacity test at room 9.10.5.18 800 20.0 4.00
temperature on completion
of environmental tests
j) High Rate Discharge test 9.10.5.11 4A 20.0 3.00
k) Electrolyte Retention test 9.10.5.8 Not
applicable
m) On load voltage Test 9.10.5.13
n) The on load voltage shall be within the following limits:
Simulated Load Conditions On Load Voltages
Tx Rx Max Min
1) RS UA (LUP 321) 9.23 Ω 43.6 Ω 28 V 24 V

2) V/UHF RS (LUP 322) 6.67 Ω 41.37 Ω 28 V 24 V

p) Service Life test (1 : 9 ratio) 9.10.5.14
Simulated Load Conditions
Tx Rx End Voltage Min
Duration
1) RS UA (LUP 321) 9.23 Ω 43.6 Ω 21.0 V 5h
2) V/UHF (LUP 322) 6.67 Ω 41.37 Ω 21.0 V 4h
q) Accelerated Charge/ 9.10.5.15 Discharge condition as per clause 4.13 of
Service life Discharge Test this supplement. Duration of discharge not
to be less than 80% of the rated value for
50 cycles
r) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 3

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APPX ‘B’ TO SUPPLEMENT No. 3

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SUPPLEMENT No. 4

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL) 12 V, 7 Ah
(DS Cat No./NSN 6140-000 467/6140720025020)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 10 No. of 1.2 volts 7 Ah sealed
cylindrical cells. These are connected in series to form 12 a volts block which is enclosed in a
moulded outer container which can be latched directly to the main equipment. The end
connections are brought to a two pin connector mounted on the top side of the battery. An
outline sketch and the schematic diagram are attached as Appendices ‘A’ and ‘B’ to this
supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with the equipment RADIO SET
STARS ‘V’-FF/05 (LVP 235).

2.2 The following are the input requirements of the main equipment:

Current Drains at Nominal

Voltage of 12 V Input Voltage Limits
Equipment
Operating Conditions
Tx Rx Max Min
RS STARS ‘V’ 3.2 A 400 mA 15.25 V 10.8 V

3. TECHNICAL DATA
a) Nominal Voltage - 12 V.

b) Rated Ah Capacity - 7 Ah at 5 hours rate.

c) Construction and layout - As per drawing No. CQAL 4384 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx ‘A’ to this supplement).

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions in mm:

1) Length - 259 ±2

2) Width - 89 ±2

3) Height - 118 ±2

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g) Mass - 3.4 kg (Max).

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when latched to the main equipment.

j) Service Life - Shall be capable of powering the STARS ‘V’ continuously for a
minimum period of 8 h at the Send/Receive ration of 1 : 9.

k) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

m) Charges Recommended - Battery charger with DS Cat No. X2/6130-000514

or equivalent.

n) Recommended Charging Currents:

1) Initial Charge - 700 mA for not more than 16 hours.

2) Capacity Charge - 700 mA for not more than 14 hours.

3) Normal Charge - 1.4 A for not more than 7 hours.

4) Accelerated Charge - 2.8 A for not more than 3-1/2 hours.

4. PARAMETRIC REQUIREMENTS

Table 7 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test /Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
a) Capacity test at room 9.10.5.1 1.4 10.0 7.0
Temperature
b) Capacity test at &20ºC 9.10.5.2 1.4 10.0 4.2
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 1.4 10.0 3.5
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 1.4 10.0 4.2
& 9.10.5.7
e) Capacity test at room 9.10.5.9 1.4 10.0 4.9
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 1.4 10.0 7.0
temperature after
overcharge
g) Capacity test at room 9.10.5.12 1.4 10.0 7.0
temperature after short
circuit test

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Table 7 Parametric Requirements (Concluded)

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
h) Capacity test at room 9.10.5.17 1.4 10.0 7.0
temperature after 4 years
shelf life
j) Capacity test at room 9.10.5.18 1.4 10.0 7.0
temperature on
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 7.00 10.0 5.25
m) Electrolyte Retention test 9.10.5.8 Not
applicable
n) On load voltage Test 9.10.5.13
p) The on load voltage shall be within the following limits:
Simulated Load Conditions On Load Voltages
Max Min
Tx 4Ω 15.25 V 12 V
Rx 37.5 Ω 15.25 V 12 V
q) Service Life test 9.10.5.14
(1 : 9 ratio)
Simulated load conditions End Voltage Min Duration
r) Tx 4.0 Ω 10.8 V 8h
(Tx Rx Ratio 1 : 9)
s) Rx 37.5 Ω
t) Accelerated Charge/ 9.10.5.15 Discharge condition as per clause 4.13 of
Service life Discharge this supplement. Duration of discharge
Test not to be less than 6 h 30 min for
50 cycles
u) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 4

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APPX ‘B’ TO SUPPLEMENT No. 4

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SUPPLEMENT No. 5

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL), 12 V, 1.6 Ah
(DS Cat No./NSN 6140-000 468/6140720025019)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 10 No. of 1.2 volts 1.6 Ah sealed
cylindrical cells. These are connected in series to form a 12 volts block which is enclosed in
an ABS moulded outer container. The end terminals are connected to two reed contacts
provided on the top surface of the battery outer case to facilitate connections to the main
equipment when the battery is fitted in the battery compartment. An outline sketch and the
schematic diagram are attached as Appendices ‘A’ and ‘B’ to this supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with the equipments SMART and
programmer COMET MK-II.

2.2 The following are the input requirements of the main equipment:

Input Voltage Limits

Equipment Current Drain Conditions
Min Max
SMART 500 mA 10.8 V 13.6 V
COMET MK-II 500 mA 10.8 V 13.6 V

3. TECHNICAL DATA
a) Nominal Voltage - 12 V.

b) Rated Ah Capacity - 7 Ah at 5 hours rate.

c) Construction and layout - As per drawing No. CQAL 4385 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx ‘A’ to this supplement).

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 100 mm.

f) Overall Dimensions in mm:

1) Length - 295

2) Width - 54

3) Height - 33

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g) Mass - 1 kg (Max).

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when fitted in the battery compartment of the main equipment.

j) Service Life - Shall be capable of powering the main equipment continuously

for a minimum period of 3 h 12 minutes.

k) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

m) Charges Recommended - Charger Battery DS Cat No. X2/6130-000515.

n) Recommended Charging Currents:

1) Initial Charge - 160 mA for not more than 16 hours.

2) Capacity Charge - 160 mA for not more than 14 hours.

3) Normal Charge - 320 mA for not more than 7 hours.

4) Accelerated Charge - 640 mA for not more than 3-1/2 hours.

4. PARAMETRIC REQUIREMENTS

Table 8 Parametric Requirements

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current in Voltage Capacity
mA in volts in Ah
a) Capacity test at room 9.10.5.1 320 10.0 1.6
Temperature
b) Capacity test at &20ºC 9.10.5.2 320 10.0 0.96
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 320 10.0 0.8
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 320 10.0 0.96
& 9.10.5.7
e) Capacity test at room 9.10.5.9 320 10.0 1.12
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 320 10.0 1.6
temperature after
overcharge
g) Capacity test at room 9.10.5.12 320 10.0 1.6
temperature after short
circuit test

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Table 8 Parametric Requirements (Concluded)

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current in Voltage Capacity
mA in volts in Ah
h) Capacity test at room 9.10.5.17 320 10.0 1.6
temperature after 4 years
shelf life
j) Capacity test at room 9.10.5.18 320 10.0 1.6
temperature on completion
of environmental tests
k) High Rate Discharge test 9.10.5.11 1.6 A 10.0 1.2
m) Electrolyte Retention test 9.10.5.8 Not
applicable
n) On load voltage Test 9.10.5.13
p) The on load voltage shall be within the following limits:
q) Simulated Load Conditions
Equipment Current Drain Continuous
Smart 500 mA
Comet MK-II
r) Service Life test at 500 mA Continuous
s) Equipment End Voltage Min Duration
Smart 10.8 V 3 h 12 min
Comet 10.8 V
MK-II
t) Accelerated Charge/ 9.10.5.15 Discharge test condition as per Clause
Service life Discharge Test 4.13 of this supplement. Duration of
discharge to be not less than 2 h
30 min for 50 cycles.
u) Cycle Life test 9.10.5.16 Not less than 400 cycles.

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APPX ‘A’ TO SUPPLEMENT No. 5

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APPX ‘B’ TO SUPPLEMENT No. 5

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SUPPLEMENT No. 6

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL), 12 V, 10 Ah
(DS Cat No./NSN 6140-000 475/6140720025017)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 10 No. of 1.2 volts 10 Ah sealed
cylindrical cells. These are connected in series to form a 12 volts block which is enclosed in
an Aluminium outer container. The positive end is connected to two 3 pin adaptor contacts
connected in parallel and the negative is connected to the other two 3 pin adaptor contacts.
The battery can be latched directly to the main equipment. An outline sketch and the
schematic diagram are attached as Appendices ‘A’ and ‘B’ to this supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with the equipment RADIO LOCAL
EXTENSION UNIT (which is a portable Radio Trans Receiver) of the Radio Local System.

2.2 The following are the input requirements of the main equipment:

Current Drains at Nominal

Input Voltage Limits
Equipment Voltage of 12 V Operating Conditions
Tx Rx Max Min
RLE Unit 8A 1A 13.2 V 10.8 V

3. TECHNICAL DATA
a) Nominal Voltage - 12 V.

b) Rated Ah Capacity - 10 Ah at 5 hours rate.

c) Construction and layout - As per drawing No CQAL 4388 (See outline sketch
at Appx ‘A’ to this supplement).

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions in mm:

1) Length - 272 ±2

2) Width - 98 ±2

3) Height - 132 ±2

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g) Mass - 7.0 kg (Max).

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when latched to the main equipment RLE Unit or the designated charger.

j) Service Life - Shall be capable of powering the RLE UNIT continuously for a
minimum period of 8 hours at the Send/Receive ratio of 1 : 9.

k) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

m) Charges Recommended - Battery charger with DS Cat No./NSN

X2/6130-000503/6130720093186 or equivalent.

n) Recommended Charging Currents:

1) Initial Charge - 1 A for not more than 16 hours.

2) Capacity Charge - 1 A for not more than 16 hours.

3) Normal Charge - 2 A for not more than 7 hours.

4) Accelerated Charge - 2 A for not more than 3-1/2 hours.

4. PARAMETRIC REQUIREMENTS

Table 9 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
a) Capacity test at room 9.10.5.1 2.0 10.0 10.0
Temperature
b) Capacity test at &20ºC 9.10.5.2 2.0 10.0 6.0
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 2.0 10.0 5.0
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 2.0 10.0 6.0
& 9.10.5.7
e) Capacity test at room 9.10.5.9 2.0 10.0 7.0
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 2.0 10.0 10.0
temperature after
overcharge
g) Capacity test at room 9.10.5.12 2.0 10.0 10.0
temperature after short
circuit test

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Table 9 Parametric Requirements (Concluded)

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
h) Capacity test at room 9.10.5.17 2.0 10.0 10.0
temperature after 4 years
shelf life
j) Capacity test at room 9.10.5.18 2.0 10.0 10.0
temperature on
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 10.0 10.0 7.50
m) Electrolyte Retention test 9.10.5.8 Not
applicable
n) On load voltage Test 9.10.5.13
The on load voltage shall be within the following limits:
On Load Voltages
Simulated Load Conditions
Max Min
Tx 12 Ω 13.2 V 12 V
Rx 4Ω 13.2 V 12 V
p) Service Life test 9.10.5.14
(1 : 9 ratio)

Simulated Load Conditions End Voltage Min Duration

Tx 12 Ohms; Rx 4 Ohms (Tx : Rx Ratio 1 : 9) 10.8 V 8h
q) Accelerated Charge/ 9.10.5.15 Discharge condition as per clause 4.13
Service life Discharge of this supplement. Duration of
Test discharge not to be less than 6 h 30 min
for 50 cycles
r) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 6

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APPX ‘B’ TO SUPPLEMENT No. 6

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SUPPLEMENT No. 7

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM, 2.5 V, 9 Ah
(DS Cat No. 6140-000 483)

1. GENERAL FEATURES

This rechargeable Nickel cadmium battery consists of 2 No. of 1.2 volts 9 Ah non spillable
cells connected in series to form a 2.5 volts block. The special twin cell configuration is such
that the interconnection between the cells is achieved by means of welding the positive
terminal of one cell and negative terminal of the second cell to their respective cell containers
(made of MS), which are welded together thus bringing out only the two end terminals of the
battery for connections. An outline sketch and the schematic diagram are attached as
Appendices ‘A’ and ‘B’ to this supplement.

2. USED ON DATA

2.1 This is a special purpose battery intended for use with 23 mm Twin Gun Mount
Model ZU 23 (M2/IMB/RUS/Twin/0461) for illuminating the instruments therein.

2.2 The following are the input requirements of the main equipment:

Input Voltage Limits

Equipment Operating Conditions
Max Min
23 mm Twin Continuous drain at 0.6 A 3.5 V 2.0 V
Gun mount ZU 23

3. TECHNICAL DATA
a) Nominal Voltage - 2.5 V.

b) Rated Ah Capacity - 9 Ah at 5 hours rate.

c) Construction and layout - As per drawing No CQAL 4370 and firm’s drawing
as approved by CQA(L) (See outline sketch at Appx A to this supplement).

d) General Requirement - As per this specification

e) Environmental Specification - JSS 55555 as applicable to ground equipments

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions in mm:

1) Length - 80 ±1.

2) Width - 60 ±1.

3) Height - 122 ±1.

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g) Mass - 1.4 kg (Max).

h) Fitment - Not applicable.

j) Service Life - Shall be capable of Illuminating the Instruments on the gun

continuously or a minimum period of 15 h.

k) Cycle Life - Minimum 504 Cycles as per JSS.

m) Recommended Charging Currents

1) Initial Charge - 1 A for not more than 16 hours.

2) Capacity Charge - 1 A for not more than 14 hours.

3) Normal Charge - 2 A for not more than 7 hours.

4) Accelerated Charge - 4 A for not more than 3-1/2 hours.

4. PARAMETRIC REQUIREMENTS

Table 9 Parametric Requirements

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current Voltage Capacity
in mA in Volts in Ah
a) Capacity test at room 9.10.5.1 1.8 2.0 9.0
Temperature
b) Capacity test at &20ºC 9.10.5.2 1.8 2.0 5.4
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 1.8 2.0 4.5
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 1.8 2.0 5.4
& 9.10.5.7
e) Capacity test at room 9.10.5.9 1.8 2.0 6.3
temperature to assess
retention of charge
f) Capacity test at room 9.10.5.10 1.8 2.0 9.0
temperature after
overcharge
g) Capacity test at room 9.10.5.12 1.8 2.0 9.0
temperature after short
circuit test
h) Capacity test at room 9.10.5.17 1.8 2.0 9.0
temperature after 4 years
shelf life

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Table 9 Parametric Requirements (Concluded)

Specified Performance
Requirements
S. Clause in
Test/Parameter Discharge End Minimum
No. Specification
Current Voltage Capacity
in mA in Volts in Ah
j) Capacity test at room 9.10.5.18 1.8 2.0 9.0
temperature on
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 9.0 2.0 6.75
m) Electrolyte Retention test 9.10.5.8 No leakage of electrolyte
n) On load voltage Test 9.10.5.13
p) The on load voltage shall be within the following limits
Simulated Load Conditions On Load Voltages
Max Min
0.6 A Continuous 3.5 V 2.5 V
q) Service Life test 9.10.5.14
Simulated Load Conditions End Voltage Min Duration
As per 4.12 of this supplement 2.0 V 15 h
r) Accelerated Charge/ 9.10.5.15 Discharge condition as per clause 4.13
Service life Discharge Test of this supplement. Duration of
discharge not to be less than 12 h for
50 cycles
s) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 7

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APPX ‘B’ TO SUPPLEMENT No.7

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SUPPLEMENT No. 8

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEALED CYLINDRICAL), 1.2 V, 65 Ah
(DS Cat No./NSN 6140-000 113/NA)
AHSP : DQA(N)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of 1 number of 1.2 V sealed cylindrical
cell. This is housed in a steel container. Output terminal is made of steel stud and nut.
DQA(N) drawing is attached to this supplement.

2. TECHNICAL DATA
a) Nominal Voltage - 1.2 V

b) Rated Ah Capacity - 65 Ah at 5 hours rate

c) Construction and layout - As per DQA(N) drawing No. DPIN/11387

d) General Requirement - As per this specification

e) Environmental Specification - JSS 55555, As applicable to ground equipments

partly protected.

f) Overall Dimensions in mm:

1) Length - 144.4

2) Width - 45

3) Height - 292

f) Mass - 3.855 kg, Unfilled 4.5 kg with electrolyte

g) Cycle Life - 500 cycles.

3. PARAMETRIC REQUIREMENTS

Table 10 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
a) Capacity test at room 9.10.5.1 65
* *
Temperature
b) Capacity test at &20ºC 9.10.5.2 39
* *
& 9.10.5.3

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Table 10 Parametric Requirements (Concluded)

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in Volts in Ah
c) Capacity test at &30ºC 9.10.5.4 33
* *
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 46
* *
& 9.10.5.7
e) Capacity test at room 9.10.5.9 45.5
temperature to assess * *
retention of charge
f) Capacity test at room 9.10.5.10 76
temperature after * *
overcharge
g) Capacity test at room 9.10.5.12 65
temperature after short * *
circuit test
h) Capacity test at room 9.10.5.17 65
temperature after 4 years * *
shelf life
j) Capacity test at room 9.10.5.18
temperature on
* * *
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 * * *
m) Electrolyte Retention test 9.10.5.8 No leakage of electrolyte
n) On load voltage Test 9.10.5.13 * 1.2 *
p) Service Life test (1 : 9 9.10.5.14
* * *
ratio)
Simulated load conditions
As per 4.12 of this supplement
q) Accelerated Charge/ 9.10.5.15 500 cycles
Service life Discharge
Test
r) Cycle Life test 9.10.5.16 500 cycles
* NOTES
1. Qualifications Approval is being done as per drawing held with DQA(N).

2. Information to be provided by DQA(N) at the time of testing.

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SUPPLEMENT No. 9

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SPRING LOADED), 2.4 V, 10 Ah
(DS Cat No./NSN 6140-000 117/6140720025076) AHSP : DQA(N)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of 2 numbers of 1.2 V sealed cylindrical
cells connected in series to form a 2.4 V. DQA(N) drawings are attached to this supplement.

2. USED ON DATA

This battery is intended for powering old type of Automatic Emergency Lantern.

3. TECHNICAL DATA
a) Nominal Voltage - 2.4 V.

b) Rated Ah Capacity - 10 Ah.

c) Construction and layout - As per DQA(N) drawing No. DPIN/11936, 11937

and 11938 and specification IN/EL/IL.

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555, as applicable to ground equipments

partly protected.

f) Overall Dimensions in mm:

1) Length - 67

2) Width - 56

3) Height - 163

g) Mass -1.25 kg, with electrolyte filled.

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is mounted on the Automatic Electrical Lantern.

j) Cycle Life - 400 cycles.

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4. PARAMETRIC REQUIREMENTS

Table 11 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. Specification Current Voltage Capacity
in mA in volts in Ah
a) Capacity test at room 9.10.5.1 10
* *
Temperature
b) Capacity test at &20ºC 9.10.5.2 6
* *
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 5
* *
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 7
* *
& 9.10.5.7
e) Capacity test at room 9.10.5.9 10
temperature to assess * *
retention of charge
f) Capacity test at room 9.10.5.10 10
temperature after * *
overcharge
g) Capacity test at room 9.10.5.12 10
temperature after short * *
circuit test
h) Capacity test at room 9.10.5.17 10
temperature after 4 years * *
shelf life
j) Capacity test at room 9.10.5.18 10
temperature on
* *
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 * * 8
m) Electrolyte Retention test 9.10.5.8 No leakage of electrolyte
n) On load voltage Test 9.10.5.13 * 2.4 *
p) Service Life test 9.10.5.14
* * *
(1 : 9 ratio)
Simulated load conditions
As per clause 4.12 of this supplement
q) Accelerated Charge/Service life 9.10.5.15 400 cycles
Discharge Test
r) Cycle Life test 9.10.5.16 400 cycles
s) *NOTES

1. Qualifications Approval is being done as per drawing held with DQA(N).

2. Information to be provided by DQA(N) at the time of testing.

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SUPPLEMENT No. 10

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (SEMI SEALED CYLINDRICAL), 2.4 V, 7 Ah
(DS Cat No./NSN 6140-000 176/NA)
AHSP : DQA(N)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of 2 numbers of 1.2 V sealed cylindrical
cells connected in series to form a 2.4 V block and is housed in a steel moulded casing the
battery output terminals are made of steel stud and nut. DQA(N) drawings are attached to this
supplement.

2. USED ON DATA

This battery is intended for powering Automatic Emergency Lantern with trickle charging
facility.

3. TECHNICAL DATA
a) Nominal Voltage - 2.4 V.

b) Rated Ah Capacity - 7 Ah.

c) Construction and layout - As per DQA (N) Drawing No. DPIN/12275, 12276
and 12277.

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555, as applicable to ground equipments

partly protected.

f) Overall Dimensions in mm:

1) Length - 75 ±2.

2) Width - 55 ±2.

3) Height - 128 ±2.

g) Mass - 0.9 kg, with electrolyte filled.

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is mounted on the Automatic Electrical Lantern.
Clamping/fitment of the battery on AEL should be effective.

j) Cycle Life - 500 cycles.

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4. PARAMETRIC REQUIREMENTS

Table 12

Specified Performance Requirements

S. Clause in Discharge Minimum
Test/Parameter End Voltage
No. Specification Current Capacity
in volts
in mA in Ah
a) Capacity test at room 9.10.5.1 9.97
* *
Temperature
b) Capacity test at &20ºC 9.10.5.2 6.475
* *
& 9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 7.233
* *
& 9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 7.7
* *
& 9.10.5.7
e) Capacity test at room 9.10.5.9 7
temperature to assess * *
retention of charge
f) Capacity test at room 9.10.5.10 8.98
temperature after * *
overcharge
g) Capacity test at room 9.10.5.12 8.4
temperature after short * *
circuit test
h) Capacity test at room 9.10.5.17 9
temperature after 4 years * *
shelf life
j) Capacity test at room 9.10.5.18
temperature on
* * *
completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 * * *
m) Electrolyte Retention test 9.10.5.8 No leakage of electrolyte
m) On load voltage Test 9.10.5.13 * 2.4 *
n) Service Life test (1:9 9.10.5.14
* * *
ratio)
p) Simulated load conditions
q) As per 4.12 of this supplement
r) Accelerated Charge/Service life Discharge 9.10.5.15 500 cycles
Test
s) Cycle Life test 9.10.5.16 500 cycles
* NOTES
1. Qualifications Approval is being done as per drawing held with DQA(N).

2. Information to be provided by DQA(N) at the time of testing.

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SUPPLEMENT No. 11

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM, 2.4 V, 4 Ah
(DS Cat No./NSN 6140-005173/6140720024967)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of Qty 2 Cells of 1.2 V 4 Ampere Hour
(Ah) Non-spillable cells connected in series to form a 2.4 V block. The two wires (Red for
positive and Blue for negative) are brought out from the cells and terminated at the (Male)
2 pin terminal for connections. The battery pack is enclosed in an polycarbonate outer
container. The battery pack latched directly to the main equipment Aiming circle PAB 2M
(used on Tank T-72 Mk, ICV BMP-II K, OS A-AK weapon systems and KVADRAT
weapon system). An outline sketch and the schematic diagram are attached as Appendices
‘A’ and ‘B’ respectively to this supplement.

2. USED ON DATA

This is a special purpose battery intended for use with Aiming Circle PAB 2M (used on Tank
T-72 Mk, ICV BMP-II K, OS A-AK weapon systems and KVADRAT weapon system). The
following are the input requirements of the main equipment:

Equipment Operating Conditions Input Voltage Limits

Aiming Circle PAB Illumination of 3 lamps of Min Max
2M 0.25W each for 8 hour 2.70 V 2.40 V
48 min.

3. TECHNICAL DATA
a) Normal Voltage - 2.40 V.

b) Rated Ah Capacity - 4 Ah at 5 hours rate.

c) Construction and layout - As per firms drawing FN 3 as approved by CQAL.

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipment

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.
f) Overall Dimensions:

1) Length - 124.0 ±2 mm.

2) Width - 55.0 ±2 mm.

3) Height - 166.5 ±2 mm.

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g) Mass - 750 g (Max)

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is attached to the main equipment.

j) Service Life - Shall be capable of illuminating Aiming circle PAB 2M (used

on Tank T-72 Mk, ICV BMP-II K, OS A-AK weapon systems and KVADRAT
weapon System) continuously for a period of 8 hours 48 minutes.

k) Cycle Life - Minimum 504 cycles as per JSS 6140-03.

m) Chargers Recommended - Any suitable constant current dc source.

n) Recommended Charging Currents:

1) Initial Charge - 400 mA for not more than 16 hours.

2) Capacity Charge - 400 mA for not more than 14 hours.

3) Normal Charge - 800 mA for not more than 7 hours.

4) Accelerated Charge - 1.6 A for not more than 3 hours 30 minutes.

4. PARAMETRIC REQUIREMENTS

Table 13 Parametric Requirements

Specified Performance Requirements

Minimum
S. Clause in Discharge End
Test/Parameter Specified
No. JSS Current Voltage
Capacity
(mA) (Volts)
(Ah)
a) Capacity test at room temp 9.10.5.1 800 2.0 4.0
b) Capacity test at &20ºC 9.10.5.2 & 800 2.0 2.4
9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 & 800 2.0 2.0
9.10.5.5
d) Capacity test at &55ºC 9.10.5.6 & 800 2.0 2.4
9.10.5.7
e) Capacity test at room temp 9.10.5.9 800 2.0 2.8
to assess retention of
charge
f) Capacity test at room temp 9.10.5.10 800 2.0 4.0
after overcharge
g) Capacity test at room temp 9.10.5.12 800 2.0 4.0
after short circuit test
h) Capacity test at room temp 9.10.5.17 800 2.0 4.0
after 4 years shelf life

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Table 13 Parametric Requirements (Concluded)

Specified Performance Requirements

Minimum
S. Clause in Discharge End
Test/Parameter Specified
No. JSS Current Voltage
Capacity
(mA) (Volts)
(Ah)
j) Capacity test at room temp 9.10.5.18 800 2.0 4.0
on completion of environ
mental tests
k) High Rate discharge test 9.10.5.11 4000 2.0 3.0
m) Electrolyte Retention Test 9.10.5.8 Not Applicable
n) On load voltage test 9.10.5.13
p) The on load voltage shall be within the following limits: On load voltages
Simulated Load Conditions Min Max
315 mA continuous 2.40 V 2.70 V
q) Service Life test 9.10.5.14 End voltage Minimum Duration
r) Simulated Load Conditions: 2.0 V 8 hours 48 minutes
315 mA continuous
s) Accelerated Charge and 9.10.5.15 & 2.0 V Discharge duration shall
Service life test 4.13 of this not be less than 7 hours
Supplement 02 minutes for 50 cycles
t) Cycle Life test 9.10.5.16 504 cycles

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APPX ‘A’ TO SUPPLEMENT No. 11

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APPX ‘B’ TO SUPPLEMENT No. 11

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SUPPLEMENT No. 12

DETAILED SPECIFICATION FOR BATTERY, SECONDARY, PORTABLE,

NICKEL-CADMIUM (Sealed Cylindrical), 12 V, 4 Ah
(DS Cat No./NSN 6140-005171/6140720024969)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of 10 No. of 1.2 volts ‘D’ size Sealed
Cylindrical Cells connected in series to form a 12 volts block. The positive and negative
connections are terminated at the 2 pin female connector at the top of the battery for
discharging and 3 in female contact at the bottom of the battery for charging. The battery pack
is enclosed in an ABS moulded outer container. The battery pack is housed in metal container
that is latched directly to the main equipment Radio station PRC 6020 (CAT No. Z1/5820-
007515), Radio station PRC 6020A (CAT No. Z1/5820-007514), Radio station PRC 730M 5W
(CAT No. Z1/Misc-PRC-730M and Radio station PRC 730MHP 20W (CAT No. Z1/Misc-
PRC-730MHP. OR Z1/Misc-110 016 001 55 High speed Data Modem). An outline sketch and
the schematic diagram are attached as Appendices ‘A’ and ‘B’ respectively to this supplement.

2. USED ON DATA

This battery is intended for use with the equipment RADIO STATION PRC 6020. The
following are the input requirements of the main equipment:

Current drains at nominal

Input Voltage Limits
Voltage of 12.0 V
Equipment
Operating conditions (cyclic)
Min Max
TX (1 minute) RX (9 minutes)
Radio station PRC 6020, 4.40 A 0.25 A 12.0 V 14.0 V
6020 A, 730M 5 W and
730 MHP 20 W

3. TECHNICAL DATA
a) Normal Voltage - 12.0 V.

b) Rated Ah Capacity - 4 Ah at 5 hours rate.

c) Construction and layout - As per firms drawing No. CQAL 4443.

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipment

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions in mm:

1) Length - 186.5 ±1 mm.

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2) Width - 70.6 ±1 mm.

3) Height - 65.0 ±1 mm.

g) Mass - 2.20 kg (Max).

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is attached to the main equipment.

j) Service Life - Shall be capable of powering the Radio Set PRC 6020
continuously for a minimum period of 4 hours 31 minutes at the Send/Receive ratio of
1 : 9.

k) Cycle Life - Minimum 400 Cycles (as per IEC 61951-1).

m) Chargers Recommended - Battery Charger DS Cat No./NSN

X2/6130-003923/6130720093417.

n) Recommended Charging Currents:

1) Initial Charge - 400 mA for not more than 16 hours.

2) Capacity Charge - 400 mA for not more than 14 hours.

3) Normal Charge - 800 mA for not more than 7 hours.

4) Accelerated Charge - 1.6 A for not more than 3 hours 30 minutes.

4. PARAMETRIC REQUIREMENTS

Table 14 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. JSS Current Voltage Specified
(mA) (volts) Capacity (Ah)
a) Capacity test at room 9.10.5.1 800 10.0 4.0
temp
b) Capacity test at &20ºC 9.10.5.2 & 800 20.0 2.4
9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 & 800 10.0 2.0
9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 & 800 10.0 2.4
9.10.5.7
e) Capacity test at room 9.10.5.9 800 10.0 2.8
temp to assess retention
of charge
f) Capacity test at room 9.10.5.10 800 10.0 4.0
temp after overcharge

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Table 14 Parametric Requirements (Concluded)

Specified Performance
Requirements
S. Minimum
Test/Parameter Clause in JSS Discharge End
No. Specified
Current Voltage
Capacity
(mA) (Volts)
(Ah)
g) Capacity test at room 9.10.5.12 800 10.0 4.0
temp after short circuit
test
h) Capacity test at room 9.10.5.17 800 10.0 4.0
temp after 4 years shelf
life
j) Capacity test at room 9.10.5.18 800 10.0 4.0
temp on completion of
environmental tests
k) High Rate Discharge test 9.10.5.11 4000 10.0 3.0
m) Electrolyte Retention 9.10.5.8 Not Applicable
Test
n) On load voltage test 9.10.5.13
The on load voltage shall be within the following limits:
Simulated Load Conditions On Load Voltages
TX RX Min Max
2.7  48  12 V 14 V
p) Service Life test (1 : 9) 9.10.5.14
Simulated Load End Minimum Duration
Conditions voltage
TX : RX 10.80 V 4 hours 31 minutes
(1 mm) : (9 mm)
2.70  : 48 
q) Accelerated Charge and 9.10.5.15 & 10.80 V Discharge duration
Service life test 4.13 of this shall not be less than
Supplement 3 hours 41 minutes for
50 cycles
r) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 12

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APPX ‘B’ TO SUPPLEMENT No. 12

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SUPPLEMENT No. 13

DETAILED SPECIFICATION FOR BATTERY SECONDARY PORTABLE

NICKEL-CADMIUM (SEALED CYLINDRICAL), 24 V, 4 Ah
(DS Cat No./NSN 6140-005172/6140720024968)

1. GENERAL FEATURES

This rechargeable Nickel Cadmium Battery consists of 20 No. of 1.2 volts ‘D’ size Sealed
Cylindrical Cells connected in series to form a 24 volts block. These cells are connected in
series internally with the positive and negative connections are terminated at the female two
pin connector at the top of the battery. The battery pack is enclosed in a glass filled Nylon
moulded outer container that can be latched directly to the main equipment Transmitter
Receiver Radio set STARS V 25 W Mk 1 (CAT No./NSN Z1/5820-007483/NA). An outline
sketch and the schematic diagram are attached as Appendices ‘A’ and ‘B’ respectively to this
supplement.

2. USED ON DATA

2.1 This battery is intended for use with the equipment Transmitter Receiver Radio set
STARS V 25 W Mk 1 (CAT No./NSN Z1/5820-007483/NA).

2.2 The following are the input requirements of the main equipment:

Current Drains at Nominal Input Voltage Limits

Voltage of 24.0 V
Equipment Operating Conditions (cyclic)
TX RX Min Max
(1 minute) (9 minutes)
STARS V 25 W MK 1 4.70 A 0.36 A 24.0 V 31.0 V

3. TECHNICAL DATA
a) Normal Voltage - 24.0 V.

b) Rated Ah Capacity - 4 Ah at 5 hours rate.

c) Construction and layout - As per firms drawing No CQAL 4442.

d) General Requirement - As per this specification.

e) Environmental Specification - JSS 55555 as applicable to ground equipment

partly protected. Test sequences and test severities as per Clause 9.10.5.18 of this JSS.
Drop height 250 mm.

f) Overall Dimensions:

1) Length - 261 ±2 mm.

2) Width - 89.5 ±2 mm.

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3) Height - 131.3 ± 2 mm.

g) Mass - 3.80 kg (Max).

h) Fitment - Shall engage and disengage smoothly and establish firm electrical
contact when the battery is attached to the main equipment.

j) Service Life - Shall be capable of powering the Transmitter Receiver Radio set
STARS V 25 W Mk 1 (CAT No./NSN Z1/5820-007483/NA) Continuously for a
minimum period of 4 hours at the Send/Receive ratio of 1: 9.

k) Cycle Life - Minimum 400 cycles (as per IEC 61951-1).

m) Chargers Recommended - Battery Charger with DS Cat No./NSN

X2/6130-003857/6130720093377 or X2/6130-007867/NA.

n) Recommended Charging Currents:

1) Initial Charge - 400 mA for not more than 16 hours.

2) Capacity Charge - 400 mA for not more than 14 hours.

3) Normal Charge - 800 mA for not more than 7 hours.

4) Accelerated Charge - 1.6 A for not more than 3 hours 30 minutes.

4. PARAMETRIC REQUIREMENTS

Table 15 Parametric Requirements

Specified Performance Requirements

S. Clause in Discharge End Minimum
Test/Parameter
No. JSS Current Voltage Specified
(mA) (Volts) Capacity (Ah)
a) Capacity test at room temp 9.10.5.1 800 20.0 4.0

b) Capacity test at 20ºC 9.10.5.2 & 800 20.0 2.4

9.10.5.3
c) Capacity test at &30ºC 9.10.5.4 & 800 20.0 2.0
9.10.5.5
d) Capacity test at +55ºC 9.10.5.6 & 800 20.0 2.4
9.10.5.7
e) Capacity test at room temp 9.10.5.9 800 20.0 2.8
to assess retention of charge
f) Capacity test at room temp 9.10.5.10 800 20.0 4.0
after overcharge
g) Capacity test at room temp 9.10.5.12 800 20.0 4.0
after short circuit test

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Table 15 Parametric Requirements (Concluded)

Specified Performance Requirements

S. Discharge End Minimum
Test/Parameter Clause in JSS
No. Current Voltage Specified
(mA) (Volts) Capacity (Ah)
h) Capacity test at room 9.10.5.17 800 20.0 4.0
temp after 4 years shelf
life
j) Capacity test at room 9.10.5.18 800 20.0 4.0
temp on completion of
environ mental tests
k) High Rate Discharge 9.10.5.11 4000 20.0 3.0
test
m) Electrolyte Retention 9.10.5.8 Not Applicable
Test
n) On load voltage test 9.10.5.13
The on load voltage shall be within the following limits:
Simulated Load Conditions On load voltages
TX RX Min Max
5.11  66.67  24 V 31 V
p) Service life test (1 : 9) 9.10.5.14
Simulated Load End Minimum Duration
Conditions Voltage
TX : RX 21.60 V 4 hours
1 mm : 9 mm
5.11  : 66.67 
q) Accelerated Charge and 9.10.5.15 & 4.13 21.60 V Discharge duration shall
Service life test of this not be less than 3 h
Supplement 12 min for 50 cycles
r) Cycle Life test 9.10.5.16 Not less than 400 cycles

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APPX ‘A’ TO SUPPLEMENT No. 13

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APPX ‘B’ TO SUPPLEMENT No. 13

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