Defence Standard 61-021 Supp 41
Issue 3
Date: 14 December 2016
______________________________________
General Specification for Batteries
Supplement: 41 : Lithium Sulfur
Dioxide Battery 12/24V NSN 6135-99749-7054
______________________________________
AMENDMENT RECORD
Amd No
Date
Text Affected
Signature and Date
REVISION NOTE
This supplement has been revised to align its content with Def Stan 61-21 Issue 3 and the
inclusion of a PAS.
The technical content from Issue 2 to Issue 3 has not changed the technical authority have
deemed the content as fit for continued use.
HISTORICAL RECORD
This standard supersedes the following:
Bat Spec 276 Issue 3 dated 04/11/1999
Def Stan 61-21 Supplement 041/Issue 1
Def Stan 61-21 Supplement 041 Issue 2 Amendment 1 dated 08 May 2009
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
CONTENT
Description
Page
Content
Preface
Main Text
SECTION 1
0
1
2
3
4
5
13
14
15
16
17
7
7
7
7
PERFORMANCE REQUIREMENTS
General Requirements
Duty Discharge Capacity Requirements
Storage Requirements
SECTION 5
6
6
6
PHYSICAL CHARACTERISTICS
Materials and Construction
Dimensions
Mass
Temperature Range
SECTION 4
4
4
4
5
5
5
ELECTRICAL CHARACTERISTICS
Electrochemical System
Off-load Voltage
On-load Voltage
SECTION 3
9
10
11
12
GENERAL REQUIREMENTS
Introduction
Scope
Warning
Related Documents
Definitions
Abbreviations
SECTION 2
6
7
8
1
3
4
8
8
9
PRODUCT CONFORMITY CERTIFICATION
General Requirements
Hazard Classification and Transportation Requirements
10
13
1
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
CONTENT
Description
SECTION 6
18
14
PACKAGING REQUIREMENTS
General Requirements
Table 1
Duty Discharge Capacity Requirements
Fig 1
Fig 2
Product Conformity Test Schedule
Photo of a typical BA-5590/U battery
Annex A
Performance Assessment Sheet (PAS)
2
14
CELL AGE
General Requirements
SECTION 8
20
MARKING REQUIREMENTS
General Requirements
SECTION 7
19
Page
15
8
11
16
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
PREFACE
Standards for Defence
Specification for
Lithium Sulfur Dioxide Battery
12/24V, NSN 6135-99-749-7054
a.
This supplement shall be read in conjunction with Def Stan 61-21.
b.
This supplement provides a definitive specification for the electrical, physical,
performance and nomenclature requirements for a 12/24V Lithium Sulfur Dioxide battery.
c.
This supplement has been agreed by the authorities concerned with its use and is
intended to be used whenever relevant in all future designs, contracts, orders etc. and
whenever practicable by amendment to those already in existence. If any difficulty arises
which prevents application of this Defence Standard and its associated supplements, the UK
Defence Standardization (DStan) shall be informed so that a remedy may be sought.
d.
Any enquiries regarding this standard in relation to an invitation to tender or a
contract in which it is incorporated are to be addressed to the responsible technical or
supervising authority named in the invitation to tender or contract.
e.
Compliance with this Defence Standard shall not in itself relieve any person from any
legal obligations imposed upon them.
f.
This standard has been devised solely for the use of the Ministry of Defence (MOD)
and its contractors in the execution of contracts for the MOD. To the extent permitted by
law, the MOD hereby excludes all liability whatsoever and howsoever arising (including,
but without limitation, liability resulting from negligence) for any loss or damage however
caused when the standard is used for any other purpose.
3
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
STANDARDS FOR DEFENCE
Specification for
Lithium Sulfur Dioxide Battery
12/24V, NSN 6135-99-749-7054
SECTION 1
0
GENERAL REQUIREMENTS
INTRODUCTION
It is Ministry of Defence (MOD) policy to purchase batteries against performance
specifications whenever possible. Defence Standard 61-21 and its series of supplements has
been generated to address the current requirements for batteries. This supplement is
applicable when invoked directly by a MOD invitation to tender, contract, or when referred
to by other MOD battery specifications.
1
SCOPE
This supplement provides a definitive specification for the electrical, physical, performance
and nomenclature requirements for a 12/24V Lithium Sulfur Dioxide battery, NSN 613599-749-7054. It is essential that the battery is operated only within its design and
performance parameters. This supplement invokes Major Product Conformity Certification.
2
WARNING
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom
and European laws regarding Health and Safety at Work, without exemption. All Defence
Standards either directly or indirectly invoke the use of processes and procedures that could
be injurious to health if adequate precautions are not taken. Defence Standards or their use
in no way absolves users from complying with statutory and legal requirements relating to
Health and Safety at Work.
4
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 1
3
GENERAL REQUIREMENTS
RELATED DOCUMENTS
3.1
For the purposes of this supplement all related documents are listed in Defence
Standard 61-21 with the exception of:
MIL-PRF-49471B
PERFORMANCE SPECIFICATION
BATTERIES, NON-RECHARGEABLE, HIGH PERFORMANCE
MIL-PRF-49471/3A
PERFORMANCE SPECIFICATION SHEET
BATTERIES, NON-RECHARGEABLE,
HIGH PERFORMANCE, BA-X590/U
3.2
Reference in this standard to any related document means in any invitation to
tender or contract the edition and all amendments current at the date of such tender or
contract unless a specific edition is indicated.
3.3
In consideration of 3.2 above, users shall be fully aware of the issue and
amendment status of all related documents, particularly when forming part of an invitation
to tender or contract. Responsibility for the correct application of standards rests with
users.
3.4
DStan can advise regarding where related documents are obtained from. Requests
for such information can be made to the DStan Helpdesk. How to contact the helpdesk is
shown on the outside rear cover of Defence Standards.
4
DEFINITIONS
Def Stan 61-21 definitions shall apply.
5
ABBREVIATIONS
Def Stan 61-21 abbreviations shall apply.
5
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 2
6
ELECTRICAL CHARACTERISTICS
ELECTROCHEMICAL SYSTEM
The electrochemical system shall be Lithium Sulfur Dioxide LiSO2.
7
OFF-LOAD VOLTAGE
The Off-Load voltage shall be a maximum of:
8
33V
(in 24V mode)
16.5V
(in 12V mode)
ON-LOAD VOLTAGE
The on load voltage shall be measured between socket holes 1&4 and 2&5. Whilst applying
a load of 5Ω±2% at 20°C ±5°C the voltage shall be greater than 10V within 10 seconds.
6
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 3
9
PHYSICAL CHARACTERISTICS
MATERIALS AND CONSTRUCTION
The battery shall comprise two series strings of Lithium Sulfur Dioxide cells enclosed
within a plastic moulded case, in accordance with MIL-PRF-49471/3A battery type BA5590/U with the following exception:
The complete discharge device or “kill-switch” shall be removed or disabled.
Each cell shall incorporate a pressure relief mechanism that will relieve excessive internal
pressure at a value and rate that will preclude explosion or self-ignition. If encapsulation is
necessary to support the cells within the case, the type of encapsulant and the method of
encapsulation shall not cause the battery to overheat under normal operation nor inhibit the
operation of the pressure relief mechanism.
Each series string of cells shall be protected against discharge currents in excess of 3A by a
slow blow fuse. Additionally the battery shall be protected against excessive temperature by a
thermal fuse(s). The battery shall be protected from charging from an external source by a
suitably rated series diode(s). The battery shall not present a hazard during over-discharge.
Shutdown separators, suitably rated shunt diodes, or alternative methods to protect the battery
during over-discharge shall be employed at the manufacturer’s discretion.
The safety devices shall be an integral part of the battery and not susceptible to shorting or
any failure that would allow them to be bypassed. The devices shall not be replaceable by the
user.
The battery case material and/or its final assembly should be so designed that in the event of
one or more cells venting, the battery case shall not present a hazard in its own right.
10
DIMENSIONS
The dimensions and interface of the battery shall be in accordance with MIL-PRF-49471/3A
battery type BA-5590/U.
11
MASS
The nominal mass of the battery is 1kg.
12
TEMPERATURE RANGE
The battery operational temperature range shall be -30°C to +55°C. The battery shall not be
deranged by exposure to temperature extremes in the range -40°C to +70°C.
7
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 4
13
PERFORMANCE REQUIREMENTS
GENERAL REQUIREMENTS
The batteries shall meet the requirements of performance specification MIL-PRF-49471B
and its associated performance specification sheet MIL-PRF-49471/3A for battery type BA5590/U with the following exception:
The complete discharge device or “kill-switch” shall be removed or disabled.
14
DUTY DISCHARGE CAPACITY REQUIREMENTS
The batteries shall be allocated to the discharge regime and test temperature in accordance
with the Product Conformity test schedule, figure 1.
The batteries shall be conditioned at the stated test temperature for a minimum of 16 hours
prior to discharge. Throughout the test, the temperature shall be controlled to within ±3°C.
The batteries shall have the two 12V sections connected in series and subjected to
continuous discharge loads of 2A±10mA to an end-point of 20V, except at +55°C when the
load shall be applied for 5 minutes on and 5 minutes off in a continuously repeated cycle.
The discharge duration shall be recorded and the capacity calculated. The minimum
discharge capacity requirements are given in Table 1.
The voltage throughout the discharge shall be recorded. The “initial voltage delay” shall be
measured and recorded and shall not exceed 5 seconds to reach 20V (when discharged at
+20°C and +55°C) and shall not exceed 60 seconds (when discharged at -30°C).
Table 1
Duty Discharge Capacity Requirements
Discharge Temperature and
Storage Regime
Minimum capacity (Ah)
to 20 Volts
-30°C
+20°C
+55°C
8
Immediate
5.5
7.0
7.0
4 Weeks HT Storage
5.23
6.65
6.65
260 Weeks Temperate Storage
4.68
5.95
5.40
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
15
STORAGE REQUIREMENTS
15.1
Examination During Storage
At the start, and on completion of each storage test, the off-load voltage test (clause 7) shall
be carried out, and the batteries examined. Any battery showing signs of leakage, corrosion
or distortion shall be deemed to have failed.
15.2
Temperate Storage
Batteries shall be stored in an ambient temperature of 20 ± 5°C and a relative humidity
between 45% and 75% for the specified duration.
15.3
4 Weeks High Temperature Storage
Batteries shall be stored at +70°C±5°C for 4 weeks. Alternative tests may be adopted by
the contractor, with the prior agreement of the Authority.
9
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 5
16
PRODUCT CONFORMITY CERTIFICATION
GENERAL REQUIREMENTS
The Product Conformity Certification requirements are defined in Section 2 of Def Stan 6121.
16.1
Product Conformity Test Requirements
The test schedule shown in figure 1 shall apply for product conformity certification. All of
the tests shall be carried out in the stated order. The number of samples for each test shall be
in accordance with the supplier’s quality procedures, but shall be not less than the minimum
quantities shown in figure 1.
16.2
Interim Certification
Interim certification may be considered after the satisfactory completion of the tests marked
‘#1’ in the schedule shown in figure 1.
16.3
Batch Certification
Batch Certification is not applicable for Major PCC.
16.4
Periodic Verification of Critical Performance
Duty Discharge Capacity tests (clause 14) shall be carried out in accordance with the
contractor’s quality procedures. Alternative tests may be adopted by the contractor, with the
prior agreement of the Authority.
16.5
Performance Assessment Sheets (PAS)
To assist the acquirer during the tender assessment stages, a PAS is provided at annex A.
The PAS augments the PCC and formal test report by summarising the technical
compliance data and displaying the data in a common format.
Notes for PAS completion:
• * Delete as appropriate.
• The PAS should be printed on Company Headed/Logo paper.
• The PCC test schedule indicates the minimum number of samples/results required
and the test sequence.
• Limitations of the design shall be described and any instances of Sample/Test
equipment failures shall be fully reported. Any Deviations from the defined test
procedures shall be disclosed.
• Performance data shall clearly indicate whether it originates from the certification
exercise or production/release testing following contract award.
• Interim Certificates shall clearly indicate test “due dates” for Full Certification.
10
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
Figure 1 Product Conformity Test Schedule
27 Batteries
General Performance #1
Requirements
Clause 13
27 Batteries
Duty Discharge
Capacity Tests
Clause 14
Transport Tests #1
Clause 17
9 Batteries #1
Immediate
9 Batteries #1
4 Weeks HT Storage @+70°C
9 Batteries
260 Weeks Temperate Storage
Discharge
3@-30°C
3@+20°C
3@+55°C
Discharge
3@-30°C
3@+20°C
3@+55°C
Discharge
3@-30°C
3@+20°C
3@+55°C
Note This schedule excludes any requirements for sample testing to demonstrate compliance with Dangerous Goods Legislation.
#1 Indicates the tests to be carried out for interim certification (see clause 16.2).
11
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
17
HAZARD CLASSIFICATION AND TRANSPORTATION REQUIREMENTS
For transportation considerations, lithium cells and batteries are designated as UN 3090 and
may be either classified as Class 9 Dangerous Goods or are exempt, in either case compliance
with various constructional and safety test requirements are mandatory within a range of
transport regulations.
Within the Declaration of Conformity, the manufacturer shall state:
1. The UN hazard Classification (i.e. either Class 9 Dangerous Goods or Exempt from Class
9)
2. Compliance with the range of UK National and Multi-National mode specific transport
regulations stipulated in Def Stan 61-21.
3. The maximum lithium contents of an individual cell and battery (expressed in grams).
4. Reference to a test report demonstrating compliance to UK National and Multi-National
mode specific transport regulations stipulated in Def Stan 61-21. The report shall also
indicate the date of assessment.
5. Reference to the manufacturing data package (build standard) for materials, piece parts
and processes used in the battery construction.
6. Safety devices incorporated at cell and battery level shall be defined (these include: vents,
fuses, diodes and positive temperature coefficient resistors etc).
12
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
SECTION 6
18
MARKING REQUIREMENTS
GENERAL REQUIREMENTS
Marking shall be in accordance with MIL-PRF-49471/3 battery type BA-5590/U with the
exception that the label for the complete discharge device or “kill-switch” shall be omitted.
SECTION 7
19
CELL AGE
GENERAL REQUIREMENTS
The cell age (at the time of delivery) shall be less than 12 months.
SECTION 8
20
PACKAGING AND LABELLING REQUIREMENTS
GENERAL REQUIREMENTS
In addition to the packaging and labelling requirements stated in the contract, all packaging
and labelling shall comply with the requirements of the civil dangerous goods transport
regulations governing land, sea and air modes of transport. Except where specified in the
contract or excluded within the regulations this shall include packaging requirements for
mixed passenger and cargo aircraft.
All levels of packaging shall also include:
1.
2.
3.
The product NATO Stock Number.
The date of manufacture.
The battery storage life in the format “NOT TO BE STORED BEYOND
MM,YY” which shall be 5 years from date of manufacture
13
DEF STAN 61-21 SUPPLEMENT 041 ISSUE 3
Figure 2. Photo of a typical BA-5590/U battery.
14
Annex A
Performance Assessment Sheet in Accordance with:
Def. Stan. 61-21/Issue 3 dated 20/03/2009
General Specification for Batteries
Def. Stan. 61-21 Supplement 041/Issue 2 Amendment 1dated
17/12/2010
Lithium Sulfur Dioxide Battery 12/24V
NSN 6135-99-749-7054
Status Interim/Full*
Contract Ref:
Certificate Nos:
Supplier
Name:
Address & Tel
ISO 9000 Status
Accreditation Body:
Certificate Ref:
Quality Plan
Ref:
Issue:
Date
Test Laboratory (if applicable)
Name:
Address:
Product Type & Data
Manufacturer:
Place of Manufacture:
Battery Type:
Manufacturing Data Pack/ Build
Standard
Ref:
Issue:
Date
Cell Manufacturing Data Pack/ Build
Standard
Ref:
Issue:
Date
Test Report(s)
Ref(s)
Date(s)
Cell Transport Certificate
Ref:
Date:
Battery Transport Certificate
Ref:
Date:
Additional Information, Limitations, Test Deviations:
Interim Product Certification
Spec
MIL3A
MIL3A
041
MIL3A
041/14
041/14
041/14
041/14
041/14
041/14
49471B
49471B
49471B
49471B
MIL3A
MIL3A
MIL3A
Attribute
Dimensions
& Interface
Mass (Nom)
1kg
Construction
& Marking
Off Load 24V
Off Load 12V
On Load V
Imm.Disch
-30°C
Imm.Disch
+20°C
Imm.Disch
+55°C
Post HTS
Disch @-30
Post HTS
Disch @+20
Post HTS
Disch @+55
Vibration
Shock
Drop
Altitude
Forced
Discharge
Overload
Abuse
Test Rep
Ref &
Date:
Criteria
Result(s)/Comments
Pass/Fail
Range &
Mean (kg)
Pass/Fail
<33V
<16.5V
>10V in 10s
>5.5Ah
& V Delay
>7.0Ah
& V Delay
>7.0Ah
& V Delay
>5.23Ah
& V Delay
>6.65Ah
& V Delay
>6.65Ah
& V Delay
Functional
Functional
Functional
Functional
Observation
Observation
Observation
Full Product Certification
041/14
Disch: Post
260 Wk T.S
Value (Ah)
(V delay)
Or Due Date
@-30°C
@+20°C
@+55°C
Full Product Certification
Spec
Attribute
Test Rep
Ref &
Date:
Criteria
041/14
260 Week
Discharge
-30°C
>4.68Ah
& V Delay
041/14
260 Week
Discharge
+20°C
>5.95Ah
& V Delay
041/14
260 Week
Discharge
+55°C
>5.40Ah
& V Delay
Result(s)/Comments
With the exception of any Limitations/Test Deviations (described above) the product
(
) conforms to the specification requirements.
The supporting data, calculations and performance test reports are a true and
accurate record.
Signatory(s) and Date(s):
Position/Function:
©Crown Copyright 2016
Copying Only as Agreed with DStan
Defence Standards are published by and obtainable from:
Defence Equipment and Support
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
DStan Helpdesk
Tel: +44 (0) 141 224 2531/2
Fax: +44 (0) 141 224 2503
Internet e-mail: enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is 61/21/41.
Contract Requirements
When Defence Standards are incorporated into contracts, users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a
Defence Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards
Defence Standards are revised as necessary by an up-issue or amendment. It is important that
users of Defence Standards ensure that they are in possession of the latest issue or
amendment. Information on all Defence Standards can be found on the DStan Websites
https://www.dstan.mod.uk and http://dstan.uwh.diif.r.mil.uk/, updated weekly. Any person who,
when making use of a Defence Standard, encounters an inaccuracy or ambiguity is encouraged
to notify UK Defence Standardization (DStan) without delay in order that the matter may be
investigated and appropriate action taken.
®
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