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SPECIFICATION FOR BATTERY SECONDARY, LEAD ACID,
LOW MAINTENANCE FOR MT PURPOSES
Specification No. CQAL/637
0. FOREWORD
0.1 This Specification has been prepared by Controllerate of Quality Assurance (Electronics) on behalf
of Director General of Quality Assurance, Ministry of Defence, New Delhi.
0.2 This specification supersedes specification CQAL/540A : 1996 (MT Battery)
0.3. This specification shall be used for tender enquiry and Quality assurance.
0.4. Quality Assurance Authority for this store is Controller, Controllerate of Quality assurance
Electronics. Enquires regarding this specification relating to technical or any other contractual
conditions shall be referred to the Quality Assurance Authority (QA authority).
0.5. All clauses of this specification shall be complied within every respect irrespective of the source of
supply of the material and/or components.
0.6. Should any discrepancy exist between this specn and any sample or pattern loaned for any
purpose, the specification and/or other connected specifications of drawings shall be taken as
correct.
0.7. The contractor shall offer the QA authority or his authorized representative free of cost, all
reasonable facilities including test equipments for satisfying himself that the stores are being
manufactured in accordance with the specification and for this purpose QA authority or authorized
representative must have free access to the contractor‟s /sub contractor‟s work at all reasonable
times during the run of contract. The contractor is required to notify the QA Authority the sub-
contracts placed by him.
0.8 The general workmanship, finish and performance of the batteries shall be of high standard.
1.0 SCOPE
This specification lays down the general/mechanical, electrical and functional requirements of
Battery Secondary Lead Acid (low maintenance) and is to be read in conjunction with the relevant
supplement for individual Battery. In line with current usage and practical reference, Batteries
covered in the specification are rated at 5 Hour rate only.
1.1 This specification covers the requirements of Battery, Secondary, Lead Acid, and Low
Maintenance and provides guidance to contractors/s, Supplier‟s. Quality Assurance Agencies and
stockiest /indentors.
1.2 The Batteries should give good performance in the temperature range from –30°C to
Specification No. CQAL/637 :2006
+50°C. Storage in the temperature range from–30°C to +70°C shall not affect the battery.
1.3 For purpose of interpretation in case of any omission, conflicts, ambiguities or inconsistencies to
the extend that the contract includes any or all of the following documents, each documents shall
rank in the following order or precedence:-
(a) This Specification and
(b) Applicable documents and/or patterns
1.4. Copies of Indian standard can be obtained on payment from Bureau of Indian Standard, 9 Bahadur
Shah Zafar Marg, New Delhi 110 002.
1.5 Reference in this specification to Defence specification or any other specification or documents in
any tender or contract means the edition “current” at the date of tender or contract, unless
specifically, stated otherwise.
2. RELATED SPECIFICATIONS
Specification/drawing Title
a) IS : 14257-1995 Lead acid storage batteries for motor vehicle with
lightweight and high cranking performance.
b) JIS – D5301: 1999 Lead Acid starter battery for water consumption test.
c) IS 266 : 1977 Sulphuric acid (second revision)
d) IS 1069 : 1964 Water for storage batteries (revised)
e) IS : 1146-1981 Specification for Rubber & Plastic
Containers For Lead Acid Storage Batteries.
f) IS 6071 : 1986 Glass mat Separators for lead-acid batteries (first
revision)
g) JSS 55555: 2000 Environmental Test methods of Service
Electronic & Electrical Equipment.
h) CQAL/586 Package Container Of Battery SLA
j) DIN-VDE-0304-3 (Part 3) Battery Container
k) IS 12292 : 1988 Impurity level of Lead sub Oxide
l) IS 1654 : 1992 Lead Antimonial Alloys
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Specification No. CQAL/637 :2006
m) IS-4905 Methods for random sampling
n) IS-2102 Allowable deviation for dimensions without specification
o) IS-1300 Phenolic moulding materials
p) IS-1885 (Part VIII) Electro-technical vocabulary secondary cell a btys
q) CQAL drawings For individual Batteries
r) IS 3025 (Part II) Quality of water for batteries
2.1 ILLUSTRATION AND DRAWINGS
2.1.1 Third angle projection is used.
2.1.2 Dimensions are given in International system of units (SI-units).
2.1.3 Where official drawings are quoted, they are mandatory. Copies of such drawings can be obtained
from QA-authority.
2.1.4 Patent or design rights or copy right may subsist in connection with items defined as standards and
issue of this specification does not convey or imply any license to use information, which is the
subject of such rights.
2.1.5 For the purpose of this specification the term battery shall be taken to cover patterns consisting one
or more cells. In addition, definitions indicated in IS 1885 (Part VIII) – Electro technical
vocabulary, secondary cells and batteries shall apply.
3. TERMINOLOGY, DEFINITIONS & SYMBOLS
As per definitions given in IS 1885(Part 8): 1986
3.1 Battery
A battery consists of six/three elements connected in series and housed in a plastic monoblock
container. Each element consists of a +ve plate, a -ve plate and separators. The lid shall be
of
one piece construction sealed to the container by heat sealing or ultrasonic sealing or by
adhesion with sealing material with one positive and one negative terminal.
3.1.1 Battery Assembly. A battery assembly is defined as a unit consisting of batteries as defined
above which can be connected together in multiple, in a separable fashion and fitted in a common
container.
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Specification No. CQAL/637 :2006
3.2 Dry Charged Bty. A bty intended for use as soon as it has been filled with electrolyte, without
any initial charging or alternatively with additional activation charging according to Supplier‟s
recommendation.
3.3 Initial Charge
3.3.1 This charge is for commissioning the Battery for the first time or whenever the battery is to be re-
commissioned after a long period of idle storage.
3.3.2 The Battery, which has been discharged to 9 V, is charged at a constant voltage/current and
duration as specified by the Supplier.
3.4 Normal Charge:
3.4.1 This charge is given during the course of actual use or during Laboratory tests.
3.5 Charging of battery
3.5.1 Fully charged battery
A battery is deemed to be fully charged when the terminal voltage and specific gravity of
electrolyte (corrected for temperature) measured every 30 min towards end of charging at the
recommended current shows a constant value three times consecutively.
3.6 Accelerated charge:
3.6.1 This is a fast mode of charging adopted when the battery is required to be brought into use within a
short time.
3.6.2 The battery, which has been discharged to the end voltage of 10.5 V, is charged at a
voltage/current and time as specified by the 5 hr rating as per IS 14257: 1995.
3.7 Over Charge:
3.7.1 Extra Charge given to the battery in continuation of normal charge.
3.8 Retention of Charge:
3.8.1 When left in open circuit, the capability of fully charged battery to retain its charge within
specified tolerances for a specified duration.
3.9 Rated Capacity:
3.9.1 The 5 hr rating is the ampere-hour obtainable when the battery is discharged at a constant current I
= 0.2C5 amperes down to a final terminal voltage of 10.50V, the capacity being corrected to an
electrolyte temperature of 27°C(see15.5.1).
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Specification No. CQAL/637 :2006
3.10 Nominal Voltage
3.10.1 The nominal voltage of the battery is defined as 12 Volts/6Volts
3.11 Life Cycle: As per Para 13.3.10 (IS: 14257: 1995).
3.12 Shelf Life/Storage Life:
3.12.1 The number of years for which the battery can be preserved in idle storage under ambient
conditions without affecting its rated level of performance is termed as the shelf life of the battery.
3.13 High Rate Discharge Test:
3.13.1 Test conducted to assess the capability of a battery to deliver high current for a specified duration.
3.14 Specific Gravity.
3.14.1 For the purpose of the tests, with the battery fully charged and the electrolyte level corresponding
to the upper level marked on the battery, a specific gravity of 1.280 +0.01 (corrected to 27°C) shall
be used.
The temperature correction shall be made by the following formula:
SG27 = SGt + 0.0007(t-27)
Where
SG27 = specific gravity at 27° C.
SGt = specific gravity at t° C.
t = temperature of electrolyte at the time of measurement, °C
3.15 Water Consumption Test
3.15.1 Batteries used should necessarily be with low maintenance characteristics, a procedure for
assessing the topping up requirement of a distilled water has been included. It is recognized that
the loss of water from the battery is a function of several factors like alloy composition, electrolyte
volume, venting system, ambient temperature, the overcharge current and the charging system
(with good voltage regulation). These are taken into account while designing the test procedure.
A minimum of 350 cycles are stipulated before any topping-up is done on the battery
4. MATERIALS, CONSTRUCTION AND WORKMANSHIP:
4.1 Container and Lid.
The container and lid shall be of plastic, such as polypropylene, ABS, etc, conforming to IS 1146:
1981.
4.2 Separator
Separators shall be envelope type, with glass mat conforming to IS 6071: 1986.
4.3 Sealing Material
The Lid shall be sealed to the container by heat sealing or by ultrasonic welding as per IS-
3116-2002 or by addition of Sealing material with one + ve and one – ve terminal .Sealing material
employed shall be an acid resistant adhesive.
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Specification No. CQAL/637 :2006
4.4 Terminals.
The terminals shall be made of lead alloy and shall conform in shape and dimensions to Table
II.
.
4.5 Lead Alloys and Active Materials : Lead alloys used shall not contain impurities in excess
of those shown below. Reclaimed lead if used shall be refined, to a degree of purity equivalent to
the minimum required for alloys. Active material shall be prepared from the best grade Lead Oxide
suitable for the performance of the battery. The inspectors may test for absence of impurities
beyond the limit given. Specification of impurities and free lead in lead suboxide shall be as
below. A typical limiting percentage % of impurities in lead suboxide is shown below:
Element Maximum Percentage
Iron 0.002
Antimony 0.00 1
Arsenic 0.0001
Bismuth 0.030
Copper 0.002
Silver 0.00 1
Tin 0.001
Zinc 0.001
Nickel 0.0001
Sum of all these impurities may not exceed 0.04 percent, when analysed in accordance with IS : 403-1996
or by spectro-photometric method.
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Specification No. CQAL/637 :2006
Notes : 1. The limits of Arsenic and tin shall be subject to agreement between the
Supplier and the purchaser and grades except grade PbSbSn.
2. Other impurities do not preclude the possible presence of other unnamed
elements. However analysis shall regularly be made only for the impurities
tested in the table.
Table for lead Calcium alloys
----------------------
Dimensions of Tapered Terminals
TABLE II
Terminal Type Dimensions of D (mm) Types
(+) (-)
Small 14.7 + 0 13.0 + 0 12 V 32 AH
- 0.3 - 0.3
Standard 19.5 + 0 17.9 + 0 12 V 60 AH
-0.3 - 0.3 12 V 70 AH
12 V 88 AH
12 V 92 AH
12 V 100 AH
12 V 110 AH
12 V 120 AH
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Specification No. CQAL/637 :2006
12 V 177 AH
12 V 180 AH
12 V 200 AH
Note:- Tolerance on D may be taken as +/- .03mm at present
4.7 Electrolyte
The sulphuric acid and water used for the preparation and maintenance of electrolyte shall conform
to IS 266: 1977and IS 1069 Pt-II respectively.This shall also be reflected in respective SO.
4.8 General Construction Requirements : The batteries consists of six elements, connected in series
and in housed in a plastic monobloc container. Each element consists of + ve plate ,- ve plate and
separators. The construction of batteries and the choice of the materials used therein shall be
governed by consideration of the preference required.
4.9 Battery containers and Cell Lids: Normally materials for a particular type of battery container and
cell lids shall be of Polypropylene. The material shall comply with the requirements of IS 1146.
The material must resist action by sulphuric acid and shall not liberate any substance which will
contaminate the electrolyte and impair the life and efficiency of the battery. The material must be
capable of withstanding temperature between minus 30 deg C to plus 75 deg C.
4.10 Connecting bars and Terminal posts : Connecting Bars and terminal posts must be made of
antimonial Lead or antimonial lead coated brass or copper.
4.11 Packing material : The packing material for crates, trays and cases, if required, shall be of
appropriate strength and Quality.
4.12 Phenolic moulding material when used shall comply with the requirements of IS : 1300/94
4.13 Components parts and Assembly: The materials, constructions, dimensions and finish of the
components shall be as per the relevant detail specification/drawings. General requirement and
their assembly shall be governed by the following :-
a) Grid Plates : Plates shall not be used which have missing pellets of active material. It will be
verified during assembly that all plates of a group are of the same polarity. Plates shall be of the
number, thickness size and weight necessary for specified performance and shelf life.
b) Inter cell connectors: The inter cell connector shall be of lead alloy. They shall be of such cross
section so as to conduct the current flow during High Discharge tests safely. It should be free from
the blowholes and other deterioration.
c) Containers: Containers shall not be scarred, clipped, cracked, or distorted. The surfaces shall
have a smooth finish being free from blowholes, rough spots, blisters, other flaws or defects.
d) Elements: The place elements when assembled in the containers, shall be so close fitting that the
end plates are firmly supported. The element should not come out even if the container is inverted
after assembly.
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Specification No. CQAL/637 :2006
e) Terminal : The terminals shall be of the type required by the drawing, battery terminal post will
be tapered and of a section to suit the cable connectors. The indication of polarity + and – OR “P”
and “N” shall be clearly moulded/punched on the upper surface of the terminal posts and finished
with RED and BLUE paint over it, as shown below:-
All terminal shall be correctly and securely positioned. They shall be free from corrosion surface
irregularities or other defects which should impair their contact making properties.
POSITIVE TERMINAL NEGATIVE
TERMINAL
+ or P
- or N
g) Vent plug : Vent plugs shall be of the anti splash/ non spillable/semi non spillable type with
more that one exit hole and shall allow the gases to escape freely.
4.14 Mass : The mass of the completed batteries/cells filled with electrolyte shall not exceed the limit
if specified in table VI. Mass shall be measured when the battery is fully charged and electrolyte is
adjusted to the level specified by the Supplier.
4.15 Dimensions & Tolerances : Dimensions of batteries are given in the relevant drawings where
official drawings are quoted they are to be taken as mandatory. Copies of each drawing may be
obtained from Authority Holding Sealed Particulars (AHSP) Viz., Controllerate of Quality
assurance Electronics, Bangalore on payment.
4.16 Normal engineering tolerances as per IS 2102 shall be applicable on all dimensions which are
without specified tolerance in the relevant drawings of Batteries.
5.0 CONSTRUCTION
5.1 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 conditions.
(c) Essential electrical performance characteristics like long Shelf life, good charge retention,
long life cycle and excellent reliability with least maintenance.
(d) Capability for storage, transportation, handling and operations under wide range of climatic
conditions.
(e) Capability to accept charge from existing service chargers with minimum technical
supervision.
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Specification No. CQAL/637 :2006
5.2 The following information shall be legibly and indelibly marked on each battery by
punching/moulding screen printing, If specified:
(a) Srl No. of battery.(To be engraved)
(b) Defence Cat No. .(To be engraved)
(c) Month and Year of Manufacture.(To be engraved)
(d) Supplier‟s Name and type
(e) Country of Manufacture
(f) Nomenclature, Rated Voltage & Rated Ampere Hour Capacity.
(g) For charged batteries, the date of expiry of charged battery condition together with
instructions thereafter shall be indicated.
(j) Best before dates to be clearly indicated on the bty.
(k) Government Mark i.e. broad Arrow ( ) in a suitable size as given in the relevant drawing
of the battery depending upon the battery container as per Drg No. EL 13401(metric). The Arrow
shall be filled with bright acid resistant yellow paint.
(l) Batteries supplied in white container of Poly propylene (PP) screen printing shall be done
or a sticker or good quality which does not peel off during normal use may also be used for
indicating nomenclature of Battery. However, sticker shall not be used for making
Government mark i.e.( )
m) In case of dry charged battery, the date of expiry of dry charged battery condition together
with instructions thereafter shall be indicated.
n) Labels: In addition to the foregoing detailed instructions regarding climate
classification, vent plugs, cleaning, specific gravity of the electrolyte for initial filling, initial
charging and maintenance of the battery shall be printed on a label and fixed. The label will also
indicate best before dates i.e. 42 months from date of manufacture and the user is entitled free
replacement. Embossed marking indicating free replace of battery will be provided if the bty does
not perform as best before dates. The label shall be durable, acid resistant and the instruction shall
be legible during use of the battery and till completion of all the specified tests.
Note: The standard layout of the label and the instruction to be printed thereon can be
obtained from the Inspection Authority
6. DIMENSIONS AND TOLERANCE
6.1 The overall dimensions of the battery and tolerance shall be as specified in the relevant drawing.
Capacities, overall dimensions and mass (with electrolyte of 1.280 + .01 specific gravity at 27°C) shall
conform to Table VI. In case tolerances are not specified in the drawing then they shall conform to
tolerances as per IS 2102.
6.2 The mass of the dry battery shall be as per specified value mentioned in Table VI.
6.3 Tolerance for temperature where not specified shall be +2°C.
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Specification No. CQAL/637 :2006
6.4 SO will categorically highlight the drawing as to conformance to OES to OEM drawings or
otherwise.
7. WORKMANSHIP AND FINISH
7.1 All parts shall be manufactured and assembled in accordance with the latest engineering
techniques and with excellent workmanship.
7.2 The hardware items like terminals, studs, inter cell connectors, fasteners, etc. shall be protected
against corrosion.
7.3 The battery container shall be of plastic material and shall be acid resistant/self extinguishing type
conforming to IS 14257.
7.4 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.
8. PACKING THE INDIVIDUAL BATTERY
8.1 The individual battery shall be packed and sealed in polythene cover and then put in
corrugated/cardboard carton before being packed in packing case lined with rubberized
coir/thermocol. All associated items accompanying the battery shall be packed and put in the
same carton case along with the battery.
8.2 The design of packing case shall be such that it is sturdy and easy to handle. These shall be of
reusable type.
8.3 The nomenclature and DS Cat No. Of store, make, date of manufacture, quantity and Srl No. of
batteries inside and handling instructions shall be marked on the packing case in addition to
consignee and consignors address.
8.4 Marking
8.4.1 Polarity of cell terminals shall be punched legibly and indelibly.
8.4.2 Supplier‟s Instruction giving details regarding climatic classification, charging rate of ( I5 )
current/Voltage and maintenance shall be supplied with each battery.
9.0 PRE-INSPECTION OF SUPPLIES BY SUPPLIER
9.1 Supplier shall satisfy themselves that the stores manufactured are in accordance with the contract
and fully conform 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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Specification No. CQAL/637 :2006
9.2 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 test reports.
9.3 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
conforming 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.
9.4 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.
10.0 QUALITY ASSURANCE
10.1 . The onus of building Quality into the product will rest with the supplier since he is the first
party quality assurer. The sample picked up from the production lot should be able to demonstrate the
stated performance as per the specifications. Control sample testing will be done from samples picked up
from production lots.
10.1.1 Control samples will be picked up from the bulk cleared and I-note issued
10.1.2 The Supplier shall demonstrate by virtue of having being assessed as complying with the
requirements of JSG 015 and being currently registered on the Defence Contractor‟s list / OES supplier as
recommended by OEM that the control exercised in his works over materials, components, manufacturing
process, manufacturing location and product testing is such that batteries in bulk production will comply
in all respects with the requirements of the specification.
10.2 Quality Assurance Procedure
The Supplier shall ensure that quality is built into the product in conformance to the specified
requirements by the following methods:-
(i)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 of the above materials are being kept.
(ii) Inspection of batteries and representative samples (control sample) for the tests as specified in the
relevant supplement to this specification.
(iii)Supplier has to carry out all the electrical tests as per pclause12.1.9. Relevant test records, test results
for the tests should be available with the supplier for audit by QA agencies.
11.0 SAMPLING PROCEDURE
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Specification No. CQAL/637 :2006
11.1. Lot : All the batteries of the same type, design and ratings manufactured by the same plant during
the same period using same process and materials and offered for inspection at a time, shall constitute a
lot. The number of batteries to be selected from the lot shall be in accordance with column 2 & 3 of the
Table shown below:-
Table showing lot size, sample size & criteria for conformity
SAMPLING PROCEDURE
(Ref Para 11)
Lot Size Sample Size Criteria for Acceptance
(No. of samples selected) (No. of Defective Samples)
Ist Stage IInd C1 C2
Total C3
n Stage n
2n
(1) (2) (3) (4) (5) (6) (7)
Up to 50 2 ---- 2 0 1 0
3 ---- 3 0 1 0
51-300
301-500 5 5 10 0 2 2
501-1000 8 8 16 0 2 2
1001 & above 13 13 26 0 3 4
11.2 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.
11.3 If the number of defective samples is zero C1(at col.5) the lot shall be considered as conforming to
the specified requirements and shall be accepted.
11.4 If the number of defective sample is equal to or greater than C2(col.6) the entire lot shall be
rejected.
11.5 If the number of defective sample is greater than zero C1(at col.5) but less than C2 (col.6)
a further sampling of the same size (col. 3) is done and these 2nd stage samples are
subjected to all the class „B‟ tests as done before.
11.6 If the number of defectives in 1st and 2nd stages combined is less than C3 (col.7) the lot shall be
accepted. Otherwise the entire lot shall be rejected.
11.7 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
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Specification No. CQAL/637 :2006
will be carried out. The audit of records and test results will be carried out by QA agencies as per
table given below based on size of the lot
Total No. of Batteries Percentage of Decision on acceptance
Batteries to be
tested
First 50 100% Acceptance of only those samples,
which are conforming to spec.
50 to 200 10% Acceptance of lot if no defect is
noticed. If defects are noticed on
one or more samples, carry out
double sampling plan of 8 nos. each
and acceptance limit as per table
given above. (The 10% sample test
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 the tested samples exceed
16, double sampling plan with 13
samples for each stage may be
carried out).
12.0 PRODUCT SPECIFICATION
12.1. Acceptance Tests : Tests conducted on bulk supplies. These tests comprises Class “A” Tests
(on 100% of the lot) and class “B” Tests (on 10% of the lot). These tests are listed at Table II.
12.1.1. The supplier shall provide the Regional Quality Assurance Establishment, free of cost, all test
facilities for satisfying himself that the stores are being manufactured in accordance with this
specification and for this purpose the Regional Quality Assurance Establishment must have
free access to the Supplier/sub-contractor premises at all reasonable times during the run of the contract.
12.1.2. On receipt of supply order, the Supplier shall prepare production schedule and QA plan and submit
to Regional Quality Assurance Establishment.
12.1.3. The Supplier shall submit bill of material, which should contain details of the components (bought
out and fabricated in-house), specification, drawing and source of supply. In case of any
unavoidable change of source/grade/specification for any component, the Supplier shall intimate
QA authority with detailed justification for the change and the prior approval of the QA authority
shall be obtained. However, such changes w.r.t. the approved bill of materials shall be restricted
to barest minimum.
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Specification No. CQAL/637 :2006
12.1.4. 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.
12.1.5. 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. These quality records
shall be maintained and produced to QA agency during quality audit.
12.1.6. 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.
12.1.7. Regional Quality Assurance Establishment shall verify conformance to 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.
12.1.8. The Supplier shall intimate Regional Quality Assurance Establishment detailed production
schedule well in advance so that they can plan and carry out process audit.
12.1.9. The Supplier shall carry out in-house tests as indicated in the tableIII 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.
Details of tests to be carried out by the Supplier: The following test will be carried out by the
supplier in addition to other test being carried out for each supply order and results will be
submitted to the QA agency along with the call letter.
TABLE III
Srl Classification of Tests Title of Tests Test Para.
No.
(a) on 12 samples (Group1)
(i) General (a) Visual& 15.1
Physical 15.2
Examination
(b)Dimensions and
layout 15.3
(c)Marking 15.4
(d) Air Pressure 15.9
(ii) Electrical Charge acceptance 15.8
5Hrs Capacity 15.5
(b) on 02 samples (Group 2)
High rate discharge 15.6.3
at room temp
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Specification No. CQAL/637 :2006
HRD at -15º C 15.6.1
Overcharge 15.12
Endurance
16.2
Cold Cranking
15.10
Life Cycle test*
(c) on 02 samples (Group 3)
Cold Cranking 16.2
Water Consumption 16.3
Reliability of
soldered area 17. 7
Retention of Charge 15. 17
Electrolyte retention 15.18
(d) on 02 samples (Group4)
Vibration 15.11
Robustness of 15.7
handles
Robustness to 15.14
fastening
High Voltage 15.16
(e) on 02 samples (Group 5)
Test for dry charged 15.15
battery
Dry storage test 1 17.8
One Sample year
(g) on 02 samples (Group 6)
Resistance against 15.16
deep discharge
Reserve capacity 16.1
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Specification No. CQAL/637 :2006
Drop test 17.9
* Life cycle test:- The Efficacy of the test needs to be established by the supplier to satisfy himself.
However this test may not be applicable for every lot offered. To ensure consistency of Quality in their
production QA agency may ask for the record of LCT as part of their Quality Audit.
13.0 CLASSIFICATION OF TESTS
13.1 Acceptance Tests Details
13.1.1 Acceptance Tests for Btys.
The following shall constitute the acceptance tests:-
(a) Physical examination.
(b) Dimensions and layout.
(c) Marking
(d) 5-h capacity test.
(e) High rate discharge test at room temperature
(f) High voltage test.
(g) Torsion strength of terminals.
(h) Robustness of handle.
The test will be tested as given in Table IV below.
TABLE IV
ACCEPTANCE TEST FOR MT BTYS
(Ref Para 13.1.1)
Srl Classification of Test Title of Test Test Clause No.
No.
(a) Class „A‟ Test
(i) General Visual&Physical 15.1&15.2
Examination
Dimensions & 15.3
Weight
Marking 15.4
(ii) Electrical Test for dry charged 15.15
batteries
(b) Class „B‟ test
(i) General Visual&Physical 15.1&15.2
Examination
Dimensions & 15.3
Mass
Marking 15.4
Strength of 15.13
17
Specification No. CQAL/637 :2006
Terminals
Electrical 5Hr Capacity 15.5
(ii) HRD at -15ºC. 15.6.1
HRD at Room temp 15.6.3
Water Consumption 16.3
Test
High Voltage Test 15.16
13.2 Control Sample Tests: These tests are listed at Table V. Number of tests to be conducted on
control samples will be prerogative of government QA agency. QA authority may decide to carry
out all the tests or selectively important test only. Criteria for selection of tests will depend upon
past performance of control samples and confidence level of QA authority to ensure the quality of
the stores.
13.2.1 The responsibility of building in Quality into the product will rest with the Supplier and assurance
of same will be checked by the QA agencies. Control sample testing will be done from samples picked
up from production lots. Number of samples to be drawn for test shall be decided based on the lot size
offered for bulk Quality check.
13.2.2 The control samples drawn from the lot will be treated as a true representative of the particular
lot and the results of the test on these samples will be applicable to the entire quantity comprising the lot.
13.2.3 Government QA agency may check the process capability of firm any time during production.
Firm should be able to demonstrate the quality of the product any time during its manufacture.
13.2.4 Clearance of bulk supply will not wait for completion of control sample testing .However in
case of failure of control sample in functional / electrical test , entire lot represented by control
samples will be replaced by the supplier on his own risk and cost .
13.3 Sampling Scheme and Criteria for Acceptance : A recommended sampling scheme and criteria
for the acceptance of lots for various lot sizes is given in Para 11 and table thereto.
TABLE V
Control Sample Test
(Ref Para 13.2)
Srl Classification of Test Title of Test Test Clause. No.
No.
(i) General Visual&Physical 15.1&15.2
Examination
Dimensions & 15.3
Layout
18
Specification No. CQAL/637 :2006
Marking 15.4
Strength of 15.13
Terminals
Vibration 15.11
Rasistance
(ii) Electrical 5Hr Capacity 15.5
Reserve Capacity 16.1
Test for dry charged 15.15
bty
High Voltage Test 15.16
Resistance against 15.16
deep discharge
Life cycle 15.10
Water Consumption 16.3
Test
HRD at -15ºC 15.6.1
HRD Test at Room 15.6.3
Temp
Cold Cranking 16.2
Charge acceptance 15.8
Reliability of 17.7
soldered area
Retention of charge 15.17
Electrolyte retention 15.18
Test
Over charge 15.12
endurance
14.0 EQUIPMENT
14.1 Voltmeter and Ammeter
The voltmeter and ammeter used shall be of an accuracy class not inferior to 0.5 in accordance
with IS 1248 (Part 2) : 1983.
14.2 Thermometer
A thermometer with an appropriate scale shall be used for measuring temperature and one division
of graduated scale shall represent at the most 1 deg C. The accuracy of the calibration shall be not
less than 0.5 deg C.
14.3 Hydrometer
The specific gravity of the electrolyte shall be measured by a hydrometer provided with a
graduated scale, one division of which shall represent at the most 0.005 unit of specific gravity.
The accuracy of calibration shall be not less than 0.005 unit of specific gravity.
14.4 Instrument for Measuring Length
For measuring overall dimensions, a caliper or metal ruler shall be used of accuracy not inferior to
0.5 mm.
19
Specification No. CQAL/637 :2006
15.0 METHODS OF TEST AND REQUIREMENTS
15.1 Visual Examination.
The surface of the battery shall be clean. There should not be any runs of lead, bubbles, pits and
cracks on the body of the battery. Conformance of the components to the relevant drawings shall
be ensured during the assembly stage.
15.2 Physical Examination
For acceptance tests the batteries shall be checked for conformance to 13.1 only.
15.3 Dimensions and Layout : The dimensions and layout shall be checked for Conformance to Table
VI.
15.4 Marking The batteries shall be checked by visual inspection for conformity with clause 8.4
& 5.2.
20
Specification No. CQAL/637 :2006
Table VI
Capacities, Overall Dimensions and Mass
Battery Type Capacity Maximum overall Battery Mass Referenc DS Cat Number
at 5 Hr Dimensions (mm) Height with e 20 hr LV6/MT4/6140
Rate electrol Rate -
in AH Length Width yte capacity
Height
12 V Type to 7
Battery 20 AH Discharge 5 Drg CIL30 Sec Duration -- Of 18 Over 20
16 SK 667, 2303 No. Charge 000094
12 V 32 AH Current
25.6 Sec
197 Voltage
129 Min
203 Endurance11 charge32 Acceptance
227 000439
12 V 60 AH A 48 Voltage
260 V
173 204 cycles 18endurance
225 60 000012
12 V 70 AH 56 V
306 173 204 225 22.5 units 70 000424
12 20 AH
12 VV 88 AH 60
70.4 8.4
410 --
176 2.0
213 233165 32.5 4 88 3 000489
12 32 AH
12 VV 92 AH 150
73.6 8.9
410 --
176 2.5
213 233275 31 3 100 3 000013
12 V 100 AH 80 410 176 213 233(165) 31 100 000128
12 V 60 AH
12V 110 AH 30088 7.8
410 --
176 1.9
213 233315 32.5 7 110 6 000441
12 V 120 AH 96 505 182 213 257(190) 36.5 120 ---
12 V 70 AH
12V 140 AH 300
112 -- CIL 8.2 2476 D
Drg SK 2.8 315 55 9 140 7 000095
12 V 177 AH 141.6 521 278 220 270(190) 61.5 177 000139
12 V 88 AH
12 V 180 AH 500
144 --
521 8.2
278 2.6
220 270485 61.5 7 180 11 000098
12 V 200 AH 160 521 278 220 270(290) 64 200 ---
V 12 AH
12 6V92 AH 300
9.6 -- 8.8 SK 980 C
Drg CIL 4.0 415 3.5 5 12 10 000004
6 V 90 AH 72 Drg CIL SK 997 A (250) 19 90 000005
V 120 AH
12 6V100 AH 30096 -- 8.8CIL SK 4.0
Drg 991 415 23 5 120 10 000016
6 V 150 AH 120 Drg CIL 981 C (210) 28 150 0000007
110 AH
12VV 150 AH
6 500
120 -- 8.2 SK 3965
Drg CIL 2.6 485 28 7 150 11 000163
2A (290)
12 V 120 AH
NOTES 500 -- 8.2 2.6 485 7 12
(290)
1.All acceptance tests shall be carried out on the basis of discharge at the 5-h rate only. The 20h
capacity AH 420 9.0
12 V 140 is indicated only to establish an equivalence with other test specification.
-- 3.5 290 4 13.5
12 V 177 the Supplier can have--their own nomenclature, the specific designation should
2.While AH 500 8.9 4.8 700 11 18 conform to
one of the types as listed above. (420)
500 -- 8.9 4.8 700
12 V 180 AHelectrolyte has been indicated for the purpose of reference only.11
3.Mass with 18
(420)
4. Drgs mentioned here are only for ref & for dimensional purposes only.
12 V 200 AH 500 -- 9.0 5.6 785 13 20
15.5 Capacity (5-h rate) (470)
6V 12 AH 36 4.5 -- 3.5 165 4 2.5
AH 270 -- 3.5
6V 90 The 5-h capacity shall 4.5determined by discharging of 165 charged 4
be fully 2.5
battery at a constant current
AH 360
6V 120of I = 0.2C5 amperes4.5 a final--
to 3.5 4 2.5
165 V/5.25V for 12V/6V bty under the
terminal voltage of 10.50
AH 450
6V 150following conditions: 4.5 -- 3.5 165 4 2.5
6V 150 AH 450 4.5 -- 3.5 165 4 2.5
2A(a) Time to commence discharge after fully charged battery has stood an
21
Specification No. CQAL/637 :2006
Open circuit for 2 to 12h
(b) Electrolyte level between +1 mm to –5 mm from upper
Level marked on battery.
(c) Electrolyte temperature during 20 to 35 deg C
discharge
(d) Intervals of recording current, Every 30 min
Voltage and temperature readings
(e) Intervals of noting electrolyte Before start and on completion of
Specific gravity discharge.
15.5.1 Temperature correction
The capacity obtained by multiplying the discharge current in amperes by the discharge duration in
hours shall be corrected to the standard reference temperature 27 deg C as follows:-
C27 = Ct
1 + 0.01 (t-27)
Where
C27 = 5-h capacity at an average electrolyte temperature of 27 deg C.
Ct = 5-h capacity at an average electrolyte temperature t, and
t = mean of initial and final electrolyte temperature in degrees Celsius.
15.5.2 Requirement
Batteries tested shall reach the rated 5-h capacity during the course of the first three cycles
after initial charge. Alternatively the battery will be deemed to have passed the capacity test
if it meets 95% of the rated 5-h capacity in the first discharge.
15.6 High Rate Discharge
15.6.1 High Rate Discharge at -15 deg C
The high rate discharge is tested at -15 deg C under the following conditions:
(a) Before a high rate discharge test, the bty shall be subjected to a 5-h capacity test.
(b) The batteries under test shall comply with the conditions given in Table VII.
(c) The battery shall be discharged at the current specified against its type in Table IX down to
a terminal voltage of 6.00 V. The terminal voltage shall be taken at 5 To 7 s and at 30 s
intervals thereafter.
22
Specification No. CQAL/637 :2006
Table VII
Test Conditions
(clause 15.6.1)
______________________________________________________________________
Condition Requirement
Minimum period the fully charged battery shall 16 h
Stand for stabilization
Temperature of electrolyte at start of discharge -15 + 2 C
___________________________________________________________________
15.6.2Requirement
The battery shall meet the minimum terminal voltage specified after 5 to 7 s or 30 s respectively
and the minimum duration to 6.00 V in Table IX.
Note : If the battery fails to reach the values specified in Table IX, two more tests may be carried
out up to a total of three high rate discharges.
15.6.3 High Rate Discharge at Normal Temp
After the 20 hr (or equivalent 10 hr) rate of discharge after initial filling the battery shall be tested at
the high rate of discharge at normal temperature.
The high rate of discharge capacity at normal temperature is determined by a discharge at a constant
current of 1=3 C(20) A, the discharge being stopped when battery terminal voltage has fallen to
4.00 V in the case of 6 V battery or 10.5V in the case of 12 V battery. The initial temperature of
the electrolyte measured in the central cell(s) shall be 27+ or -2 deg C. During discharge, the
terminal voltage shall be taken at 5 to 7 seconds after the start and at 30 seconds intervals thereafter.
Requirement : The battery tested shall meet the minimum requirements specified at (a) in for 20
hr rated batteries and at (b) in table given below for special batteries for the high rate discharge at a
normal temperature.
REQUIREMENTS FOR HIGH RATE DISCHARGE AT NORMAL TEMPERATURE
Initial temp Discharge Minimum Battery Terminal Voltage Final
of the Current Discharge at 5-7 Sec
Electrolyte Time
Deg C A Minutes Sec 6V 12V 6V 12V
a. 27+ or -2 3c20 5 5.00 10.00 4.00 8.00
30
b. 27+ or -2 3c20 5 4.50 9.00 4.00 8.00
00
23
Specification No. CQAL/637 :2006
15.7 Robustness of Handles.
A load equal to twice the weight of the battery is lifted with electrolyte is attached to one handle of
the battery and the other handle is lifted with the held of a lifting device the battery is lifted to a
height of one meter with a speed of 0.2m/sec followed by smooth lowering. The process shall be
repeated 5 times. After the test, no traces of loosening of the hinge from the walls of the housing,
no cracking of the walls, no bending of the hinges or breaking away of the handle shall be
observed.
15.8 Charge Acceptance
The charge acceptance is tested on a new battery not subjected to any test under the following
conditions, and the current value measured after an interval of 10 min from commencement of
charging.
(a) State of battery before test the battery is charged in accordance with
charging procedure (Para 3.5).
It is then discharged at the 5-h discharge rate for 2.5 h
at an electrolyte temperature of 20 to 35 deg C. It is
then allowed to stand at an ambient temperature of 0
+ 2 deg C for not less than 12 h.
(b) Temperature of electrolyte at 0 + 2C
commencement of charging
(c) Charging voltage at battery 14.4 + 0.1V
terminals
15.8.1 Requirement
The battery shall meet the minimum requirement in Table IX.
15.9. Air Pressure test : The seal of each cell of the battery shall be checked by compressed air as a
pressure equal to 70cm of water. The volume of the tubes and auxiliary parts in connection with
the cell under pressure shall not exceed 0.5 liter. Air pressure in the cell shall be noted 15 seconds
after the supply has been disconnected . At the end of 15 seconds the level of water in the
manometer connected to the cell shall not fall below 67 cm. The air pressure test shall be carried
out in dry uncharged condition.
15.10 Life Cycle Test
15.10.1 The life cycle test is carried out on a battery, which has passed the test of 15.5 and 15.6.1
(a) Throughout the test and during the checking discharges, the battery shall be
kept at an ambient temperature (in a water bath or environmental test chamber) of 40 – 45
deg C.
24
Specification No. CQAL/637 :2006
(b) The battery shall be subjected to a series of discharges and charges as in Table VIII
(c) During the test, at the 25th, 50th, 75th and every 25 the cycle thereafter, a continuous
discharge shall be made at the current in Table VIII. Srl No. (i) until the terminal voltage
drops down to 10.20 V and 5.1V for 6V and the duration measured.
(d) The test is terminated when the capacity obtained as the product of discharge
time (at 40 to 45 deg C ambient) and the discharge current falls to 50 percent or less of the
5-h capacity in Table VI and does not increase again.
(e) After every checking discharge (c) the battery shall be recharged at the
appropriate current in Table VIII, Srl No. (ii) until the specific gravity (corrected to 27 deg
C) and terminal voltage is constant for 3 consecutive 30 min readings.
(f) Throughout the test, the level of electrolyte shall be maintained at the specified
level by topping up with pure water/distilled water. Topping up should be down during
the charging portion of cycles. The battery shall not be topped up immediately before the
checking discharges (c).
The number of tests at 5-h rate (15.5) and high rate discharge (15.6.1) shall be added to the number
of life cycles obtained graphically above.
Requirement : The battery shall meet the minimum requirements given in Table IX.
Table VIII
Life Cycle Test
(Clause 15.9)
Srl No. Requirement Battery Type
High Current Medium Low Current
Current
12 V 88 AH 12 V 60 AH 12 V 32 AH
12 V 92 AH 12 V 70 AH 12 V 20 AH
12 V 100 AH 6V 90 AH 6 V 12 AH
12 V 110AH
12 V 120 AH
12 V 140 AH
12 V 177 AH
12 V 180 AH
12 V 200 AH
6 V 120 AH
6V 150 AH
6 V 150 AH 2A
(1) (2) (3) (4) (5)
(i) Discharge at 1 h at 40A 20A 10A
current
(ii) Charge for 5 h at current 10A 5A 2.5A
25
Specification No. CQAL/637 :2006
Note : Each discharge and charge make one cycle
Table IX
Electrical Performances
(Clauses 15.6.1, 15.6.3, 15.8.1 , 15.10 and 15.12)
Battery Type Capacity Maximum overall Battery Mass Referenc DS Cat Number
at 5 Hr Dimensions (mm) Height with e 20 hr LV6/MT4/6140
Rate electrol Rate - 15.11
in AH Length Width yte capacity
Battery Type Capacity Height
Maximum overall Battery Mass Vibra
Referenc DS Cat Number
Battery Type Discharge
at 5 Hr 5 to 7 30 Sec Duration
Dimensions (mm) Height Of
No. with Over hr Charge
e 20 LV6/MT4/6140 tion
Current
Rate Sec Voltage Min Endurance Rate Acceptance Resist
electrol charge -
A
in AH Voltage Width
Length V cyclesyte endurance
capacity ance
V
Height units
Battery Type Discharge 58.47
12 V 20 AH 60 to 30-- 2.0
Sec Duration 165
No. Of 4
Over 3
Charge 15.11.
12 V 32 AH 150
Current 8.9
Sec --
Voltage 2.5
Min 275
Endurance 3
charge 3
Acceptance 1 The
A Voltage V (165)
cycles endurance resista
12 V 60 AH 300 7.8
V -- 1.9 315 7
units 6 nce to
(190) vibrati
12 V 20 AH 60 8.4 -- 2.0 165 4 3
on is
12 V 70 AH
32 300
150 --
8.9 8.2
-- 2.8
2.5 315
275 9
3 7
3
condu
(190)
(165)
cted
12 V 88 AH
60 500
300 --
7.8 8.2
-- 2.6
1.9 485
315 7 11
6
on a
(290)
(190)
fully
12 V 92 AH
70 300 -- 8.8
8.2 4.0
2.8 415
315 5
9 10
7 charg
(250)
(190) ed
12 V 88 AH
12 V 100AH 300
500 -- 8.8
8.2 4.0
2.6 415
485 5
7 10
11 batter
(210)
(290) y after
12 V 92 AH
12V 110 AH 500
300 -- 8.2
8.8 2.6
4.0 485
415 7
5 11
10 it has
(290)
(250) passe
12 V 120 AH
100 500
300 -- 8.2
8.8 2.6
4.0 485
415 7
5 12
10 da
(290)
(210)
12V 140 AH
12 V 110 AH 420
500 9.0
-- --
8.2 3.5
2.6 290
485 4
7 13.5
11 capaci
12 V 177 AH 500 -- 8.9 4.8 700
(290) 11 18 ty test
12 V 120 AH 500 -- 8.2 2.6 (420)
485 7 12 (
12 V 180 AH 500 -- 8.9 4.8 700
(290) 11 18 15.5).
12 V 140 AH 420 9.0 -- 3.5 (420)
290 4 13.5 The
12 V 200 AH
177 500 -- 9.0
8.9 5.6
4.8 785
700 13
11 20
18 batter
(470)
(420) y is
6V 180 AH
12 V 12 AH 36
500 4.5
-- --
8.9 3.5
4.8 165
700 4
11 2.5
18 tested
6V 90 AH 270 4.5 -- 3.5 165
(420) 4 2.5 under
6V 200 AH
theV120 AH conditions:-
12 following 360
500 4.5
-- --
9.0 3.5
5.6 165
785 4
13 2.5
20
6V 150 AH 450 4.5 -- 3.5 (470)
165 4 2.5
6V 12(a) 36
6V 150AH Discharge current during vibration =3.5 C5 amperes.
AH 450 4.5 -- 0.2 165 4 2.5
6V 2AAH Direction of vibration = vertical simple harmonic motion.
90(b) 270 4.5 -- 3.5 165 4 2.5
6V 120 AH 360 4.5 -- 3.5 165 4 2.5
6V 150 AH 450 4.5 -- 3.5 165 4 2.5 26
6V 150 AH 450 4.5 -- 3.5 165 4 2.5
2A
Specification No. CQAL/637 :2006
(c) Peak to peak amplitude = 2.3to 2.5mm.
(d) Acceleration = 3G(29.4 m/s2)
(e) Duration of vibration = 2h.
OR
15.11.2. The test shall be performed in accordance with IS 9000(Part 8) : 1981. The samples
shall be first tested for capacity test at 20-h rate before putting into vibration test. The
test consists of vibrating the batteries at a frequency of 16 Hz with a total displacement
of 5 mm for a period of 2 h. During vibration the batteries shall be discharged at the 20-
h rate.
15.11.3 Requirement
There shall be no abnormality or sudden drop in voltage or spillage of electrolyte exhibited
by the battery during the test.
15.12 Overcharge Endurance
15.12.1 The overcharge endurance test is conducted on a battery, which has passed the test of 15.8
and 15.5 and has been fully charged.
(a) Throughout the test the battery shall be kept at an ambient temperature (in a water bath or
environmental test chamber of 40 to 45 deg C).
(b) The battery shall be charged at the appropriate current given in Table X for a period of 110
h.
(c) The battery is then allowed to stand for 68 hrs on open circuit after (b).
(d) At the end of the open circuit stand (c) the battery is discharged at the appropriate current
in Table X, Srl No. (ii) for 30 seconds.
(e) The procedure (b), (c) and (d) constitute one overcharge endurance cycle. Immediately
after (d), the battery shall be subjected to the next cycle of overcharge without recharging.
(f) When the terminal voltage of the battery reaches down to 7.20 V before 30 s in the test (d),
the overcharge endurance test is terminated and the battery is deemed to have reached the
end of its overcharge endurance.
(g) During the test the battery shall be periodically topped up with pure water to maintain the
correct electrolyte level.
Table X
Overcharge Endurance Test
(Clause 15.12)
Srl No. Requirement Battery Type
27
Specification No. CQAL/637 :2006
High Current Medium Low Current
Current
12 V 88 AH 12 V 60 AH 12 V 32 AH
12 V 92 AH 12 V 70 AH 12 V 20 AH
12 V 100 AH 6 V 90 AH 6 V 12 AH
12 V 110 AH
12 V 120 AH
12 V 140 AH
12 V 177 AH
12 V 180 AH
12 V 200 AH
6 V 120 AH
6 V 150 AH
6 V 150 AH 2A
(1) (2) (3) (4) (5)
(i) Charging current (110 h) 9A 4.5A 2.25A
(ii) Discharge test current to 250A 150A 755A
7.20 V
15.12.1.1Requirement
The battery shall meet the number of overcharge endurance cycles specified in Table IX, the
number excluding the last cycle in which the discharge duration was less than 30 seconds.
15.13 Strength of Terminal.
15.13.1 Fitting suitable adapters to the positive and negative terminals and applying a torque to the
adopter by means of a torque wrench in the direction of rotation test the strength of terminal .
The torque applied shall be as follows:-
(a) 11.8 Nm for small terminals
(b) 14.7 Nm for standard terminals.
15.13.2 Requirement
The battery terminals shall withstand the torque applied without breaking off or exhibiting any
abnormality.
(Note – This test is optional and shall be carried out only if specifically asked for by the
purchaser.)
15.14 Robustness to Fastening.
15.14.1 The robustness to fastening is tested under the following conditions:
(a) Fastening is made at ambient temperature,
28
Specification No. CQAL/637 :2006
(b) During the test the temperature shall be kept between 60 to 65 deg C, and
(c) The duration of test is 5 h after fastening. During this period and after test the state of the
battery is examined.
The battery is fastened vertically, diagonally or horizontally in accordance with the method given
in Table XI.
Table XI
Fastening Condition
(Clause 15.14)
Battery Type Fastening Method Fastening Load per One Bolt
12 V 32 AH, 12 V 60 AH Vertical or Horizontal 980 N
12 V 70 AH
12 V 88 AH, 12 V 92 AH Diagonal or Horizontal 1960 N
12 V 100AH, 12 V 110 AH
12 V 120 AH,12 V 177 AH,
12 V 180 AH,12V 200 AH
15.14.2 Requirement
There shall be no visual deformation in the battery during the test.
15.15 Test for Dry-Charged Battery
15.15.1 The battery shall be tested within 60 days of manufacture.
15.15.2 The battery shall be maintained at a temperature of 27 + 2 deg C for 24 h prior to
test.
15.15.3 The battery shall then be filled with electrolyte of specific gravity 1.280 + 0.01,
the temperature of the electrolyte before filling shall be 27 + 2 deg C.
15.15.4 20 min after the completion of filling, the battery shall be discharged at a constant
current I = 0.2C5 until the terminal voltage has filed in 10.5 V. Readings during
the discharge and the calculation of capacity shall be noted as 15.5
15.15.5 Requirement
The battery shall give not less than 80 per cent of its rated 5 h capacity.
Note – This test is applicable to those batteries, which have been declared as „dry-charged‟ by the
Supplier.
15.16 High Voltage Test
15.16.1 An AC Voltage of 8KVapplied between one terminal of the battery and the outer
container of the battery.
15.16.2 There shall be no breakdown or flashover.
29
Specification No. CQAL/637 :2006
15.17 Retention of charge test : The battery shall be fully charged at normal rate specified by the
Supplier, and the level and specific gravity of the electrolyte in each cell shall then be adjusted, if
necessary. The battery shall then be subjected to two consecutive capacity tests, the initial capacity
C being calculated as the mean of the two results obtained .
After a complete recharge and cleaning of electrolyte form its surface, the batteries are stored for a
period of 28 days without disturbance at a temperature of 200 C to 300 C. The terminal voltage,
specific gravity and the temperature of electrolyte in the cells to be checked once a day during this
period and recorded.
15.17.1 After 28 days storage the batteries must be subjected to capacity test. The value of the capacity
measured after storage is denoted by C1. The loss of capacity „S‟ expressed as percentage is
calculated from the following formula
C-C1
S = ----------- X 100 percent
C
The loss of capacity shall not exceed 20 %
15.18 Electrolyte retention Test : Test for electrolyte retention will be made under the following
condition. The electrolyte will be adjusted to the level stated in the instruction card attached to the battery
at the end of a discharge at 20h or 5h rate as relevant. The vent plugs will be firmly placed on the vent
holes. The battery will then be charged at the normal rate recommended by the Supplier.
15.18.1 The escape of electrolyte shall not occur during the following tests
When the battery is tilted through 450 in a plane normal to its major length and so held for 20
seconds
When the battery is tilted through 450 in a plane normal to its minor length and so held for 30
seconds
16.0 SPECIAL TESTS
The following special tests may be conducted.
(1) Reserve Capacity (16.1)
(2) Cold cranking performance (CCA)(16.2)
(3) Water Consumption Test (16.3)
16.1 Reserve Capacity
The reserve capacity is the period of time indicated by the Supplier in minutes for which a fully
charged battery can maintain a discharge current of 25A to a cut-off voltage of 10.5 V at a
temperature of 25 + 2 deg C.
Reserve capacity test may be conducted on a battery, which has passed the tests under 15.5 and
15.6.1 The test conditions to be maintained are those given under the clause 15.5 (a), (b), (d) and
(e).
30
Specification No. CQAL/637 :2006
16.2 Cold Cranking Performance
The cold cranking performance is the discharge current in amperes, to be declared by the Supplier,
which a battery can deliver at –18 deg C depending upon any one of the criteria define below:
(i) For 60 s to a cut-off voltage of 8.4 V.
(ii) For 30 s to a cut-off voltage of 9.0 V.
The Supplier declare cold cranking amperes conforming to any one of the above criteria.
The cold cranking at –18 deg C may be conducted on a battery which has passed the requirements
under 15.5 and 15.6.1 The battery under test shall comply with the following conditions.
(a) The fully charged battery shall stand for stabilization for a minimum period of 20h
(b) Temperature of electrolyte at start of discharge shall be –18 + 1 deg C.
(c) The battery shall be discharged at the current specified by the Supplier against its type.
During discharge the terminal voltage shall be recorded after every 15 s.
16.3 Water Consumption Test. The battery after being charged shall be cleaned dried and weighed
to an accuracy of +0.05%.
The battery shall be placed in a water-bath maintained at a temperature of 40°C to +2°C.
The top of the battery case shall emerge not more than 25 mm above the level of the water. A
minimum space of 25 mm shall be maintained around each battery.
The battery shall be charged at a constant voltage of 14.4 V + 0.05 V (measured across the battery
terminals) for a period of 500h.
Immediately after this overcharge period, the battery shall be weighed as specified.
The loss in weight shall not exceed the value 6g/Ah Ct (or 4g/min Ct), or as specified in national
requirements.
Alternatively, the battery shall be submitted, without water addition, to a cold cranking
performance test to the end voltage Vt=7.2V.
17.0 ENVIRONMENTAL TESTS ( FOR SPECIAL BATTERY i,e. 12 V 20 AH)
17.1 Contamination Test.
17.1.1 The battery shall be charged as per laid down procedure.
17.1.2 The battery shall then be subjected to contamination test. After the test, the battery shall
be examined for any physical damage. The battery shall be allowed to remain under
normal atmospheric conditions for a period of 2 hours and then discharged and Ah value
shall be recorded. The Ah value shall comply with the requirements.
31
Specification No. CQAL/637 :2006
17.2 Dust Test.
The battery shall be charged as per laid down procedure. The vent plugs shall be in closed condition.
The battery shall then be subjected to dust test as per test No. 14 of JSS 55555:2000. After
completion of test, the battery shall be wiped off to remove external dust and shall be allowed to
remain under normal atmospheric conditions for one hour and then shall be subjected to discharge
test. The battery shall comply with the specified requirements.
17.3 Dry Heat Test.
The battery shall be charged as per laid down procedure. The battery shall then be kept in a
dry heat chamber the inside temp of which is maintained at 70°C + 2°C for 6 hours. While
still in the chamber at 70°C, the battery shall be discharged. The battery shall comply with
the specified requirements. The battery shall be taken out of Dry Heat Chamber and be
physically examined. There shall be no signs of any physical damage to the battery.
17.4 Impact Strength.
This test is conducted on the battery, which has passed the tests at Para 13.1. The battery is charged
as per the specified procedure. The checking of impact strength is carried out with an acceleration of
117.7m/sec2 (12g) for impulse duration of 10 to 15 m.sec with frequency of impact unto 100 per
minute for a total number of 2000 impacts. At the end of the test the surface of the battery is
examined. There shall be no damage to the parts. Presence of isolated drops of electrolyte on the
surface of the battery is permitted. The battery shall be allowed to remain for a period of 1 hour
under the normal atmospheric conditions. The battery shall then be subjected to starting discharge
operation test. The battery shall conform to the requirement mentioned at para 15.5
17.5 Damp Heat Test.
17.5.1 Damp Heat Test shall be carried out on the battery in dry state. Damp heat test shall be conducted
in accordance with test number 10 of JSS 55555: 2000 as follows:
Exposure for 1\6 hours at + 40 + 20°C and Rel. Humidity not less than 95%.
Exposure for 3 hours at Lab. Temp and humidity saturation.
The battery shall be taken out from the damp heat chamber and shall be allowed to remain under standard
recovery conditions for a period of 2 to 4 hours. The battery shall then be visually examined.
There shall be no damage or corrosion to the exposed parts of the battery.
17.6 Corrosion (Salt) Test.
This test shall be conducted on the battery in dry state. The test shall be conducted in accordance
with procedure No. 3 of Test No. 9 of JSS 55555: 2000; the duration of salt spray shall be for 1
hour. The battery shall then be taken out of salt spray chamber and wiped clean taking care not to
cause short circuit of the terminals. The battery shall then be stored at standard ambient
temperature for 2 to 4 hours. At the end of recovery period, the battery shall be visually examined.
There shall be no damage or corrosion to the exposed parts of the battery.
32
Specification No. CQAL/637 :2006
17.7 Reliability of soldered areas.
17.7.1 This test is conducted on the battery, which has passed the capacity test .The battery, shall be
charged as per specified procedure. An alternate cycle of discharge and break as given below shall
be carried out till the terminal voltage of the battery reaches 12V.
17.7.2 Discharge of 1280A for duration of 5 sec followed by break for duration of 10 sec.
17.7.3 There shall be no change in the shape and appearance of the soldered areas and current carrying
parts w.r.t. Before the discharge was conducted. The reliability of internal soldered areas and the
absence of internal damages to the parts are assessed by conducting discharge test. The battery
shall conform to the specified requirements mentioned at para 15.5.
17.8 Dry Storage Test (1 Year)
The dry charge test as above shall be repeated on the batteries stored for a period of one year
(without recharging). The battery shall be kept at a temp of 27ºC +2ºC for not less than 24 hours.
The battery shall then be filled with electrolyte having a temp of 27ºC +2ºC and specific gravity of
1.280 + 0.010 (at a temp of 27ºC). The electrolyte level shall be 10 to 12 mm above the above the
protective shield. The battery shall be kept in the filled condition for 20 minutes. After 20
minutes, the battery is discharged at 420 A to an end voltage of 6.0 V. During discharge, the
terminal voltage shall be taken at 5 to 7 seconds from the start and at intervals of 30 sec thereafter.
The duration to reach the end voltage shall not be less than 3 minutes.
17.9 Drop Test.
17.9.1 Drop test shall be carried out as per 12.1.1 clause 23.0 of JSS 55555. The batteries shall be dropped
on its base form a height of 8 mm and the number of drops shall be six.
17.9.2 The battery shall be examined for any physical damage and shall pass the air pressure test as per
clause 15.9 of this specification.
17.10 Tropical exposure Test
17.10.1 The battery shall be exposed to tropical conditions as laid down in clause 9.0 of JSS 55555. The
duration of the test shall be 14 days. After recovery the battery shall pass the air pressure test as per
clause 15.9 of this specification.
18.0 TRANSIT AND STORAGE.
18.1 The battery shall always be in a state of full charge before being packed for shipment.
18.2 The battery shall be placed with adequate packing on all sides and transported in upright
position only.
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Specification No. CQAL/637 :2006
18.3 The Supplier shall be responsible for the safe delivery of stores at the consignee‟s end and transit
damage if any shall be promptly attended to by him.
18.4 The battery shall be protected against rain, mist, dust, snow and direct sun while in transit and
storage as far as possible. It shall be stored in a cold dry atmosphere away from source of heat and
fumes.
18.5 While in storage the voltage of the battery shall be checked once in 3 months. If the voltage falls
below the specified voltage, the battery shall be charged. Necessary charging instructions shall be
provided by the Supplier along with the battery.
19.0 Receipt Inspection by the Consignee.
19.1 The receipt inspection shall be carried out through 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 under intimation to all concerned.
20.0 Stocking and Issue.
20.1 The stores shall be stocked for the barest minimum period (not exceeding six months)in the depots.
The battery shall always be stored in fully charged condition. The voltage of the battery should be
checked periodically. If the voltage falls below the specified value(10.5V for 12V bty and 4V for 6V
bty), the battery shall be trickle charged and this should be strictly ensured by all depots.
20.2 The battery shall be issued to the units as soon as possible on first-in first-out basis and it shall be
ensured that full benefits accruing from the warranty clause are made available to the user.
20.3 Batteries shall be issued to the user along with all associated items as originally supplied by the
Contractor.
20.4 Under no circumstances the batteries shall be stocked beyond the warranted shelf life .
21.0 Warranty
The Supplier will render the following warranty in respect of batteries:-
(a) That the batteries supplied will be free from manufacturing defects and this will be repaired
replaced in-situ, free of cost, if found defective within a period of 36 months of in use
life..
(b) Minimum six months shelf life when stored at any temperature in the range from –30 °C to
+70°C .
(c) Satisfactory functioning with the main equipment in the temperature range from
–30°C to + 55°C.
21.2 Control Sample
21.2.1 To ensure that batteries give specified/guaranteed number of life cycle, control samples are to be
drawn on the following scale:-
34
Specification No. CQAL/637 :2006
Total Qty on order No. of Control Samples to be drawn
(i) For upto and including 1000 Nos. 02 samples
(ii) For upto and including 2000 Nos. 02 samples for every 1000 Nos
(iii) Exceeding 2000 Nos. 04 samples for the first 2000 Nos.
and 1 sample for every 1000 Nos of the
balance Qty on order.
21.2.3 The contractor shall indicate in advance the schedule of production for the entire quantity
on order and will ensure that the same is continuous and consistent.
21.2.4 For orders for qtys upto 500 nos, the entire qty on order will be produced in one batch and
tendered in one lot.
21.2.5 For orders for qtys upto 2000 nos, production will be done in batches of 1000 nos.
21.2.6 For orders for qtys running into several thousands, the production will be done in
minimum of 1000 nos. (or multiple of 1000 nos.) and lot tendered will consist minimum of 1000 nos. each
time.
21.2.7 The month and year of manufacturing to be marked on the individual batteries will be that
conforming to the month and year of tendering the lot. Warranty period will be counted from the date of
tendering stores.
21.2.8 The control samples drawn from the lot will be treated as a true representative of the
particular lot and the results of the life cycle test on these samples will be applicable to the entire quantity
comprising the lot.
21.2.9 Selection of control sample as mentioned in Cl 21.2 will be at the discretion of QA agency.
The selection of control sample will be dependent on quality and consistency of supplies by the supplier.
(J
JANARDHAN)
Joint
Controller
Dated: Dec 2006 for Director General Quality
Assurance
35
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