Ministry of Defence

Defence Standard 61-21

Issue 3 Publication Date 20th March 2009

General Specification
For
Batteries

Reprinted
11th February 2011
Incorporating Amendment 1
 AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

1 11/02/11 Clause 18

REVISION NOTE

Issue 3 is a major revision following changes to the related documents and standards.

HISTORICAL RECORD

This standard supersedes the following:

Interim Defence Standard (Def Stan) 61-3 Issue 5 dated 30th November 1992.
Defence Standard (Def Stan) 61-9 (Part 1)/Issue 4 dated 18th June 1993.
Defence Standard (Def Stan) 61-21 Issue 2 dated 22nd August 2003.
 DEF STAN 61-21/3 AMENDMENT 1

CONTENT

Description Page

Content 1
Preface 2
Main Text 3

SECTION 1 GENERAL REQUIREMENTS

0 Introduction 3
1 Scope 3
2 Warning 3
3 Related Documents 4
4 Definitions 6
5 Abbreviations 8

SECTION 2 PRODUCT CONFORMITY CERTIFICATION

6 Applicability 9
7 Responsibilities 9
8 Certification Procedure 9
9 Product Conformity Certificate 10
10 Interim and Full Certification 10
11 Batch Certification 10
12 Modification of Certified Products 11
13 Performance Assessment Sheets 11
14 Certificate Duration 11
15 Disclosure of Non Compliance 11

SECTION 3 QUALITY REQUIREMENTS

16 Quality System Requirements 12

SECTION 4 TRANSPORTATION PACKAGING AND LABELLING

17 Transportation Requirements and Dangerous Goods Classifications 13

18 Packaging and Labelling 14
19 Military Air Transport Requirements 15

Table 1 List of UN Dangerous Goods Classifications 14

SECTION 6 DEFINITION OF COMMON BATTERY TERMS

Table 2 Definition of Common Battery Terms 16

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DEF STAN 61-21/3 AMENDMENT 1

PREFACE

Standards for Defence

Generic Specification

For

Batteries

a. This standard provides the generic requirements for batteries for Ministry of Defence
use.

b. This standard has been produced on behalf of the Defence Materiel Standardization
Committee (DMSC), by the Defence Battery Standardization Committee (DBSC), for use
where there is no suitable National or other standard which is acceptable to the Ministry of
Defence.

c. This standard 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 Acquirer 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 suppliers in the execution of contracts for the MOD. To the extent permitted by law,
the MOD hereby excludes all liability whatsoever and howsoever arising (including, but
without limitation, liability resulting from negligence) for any loss or damage however
caused when the standard is used for any other purpose.

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 DEF STAN 61-21/3 AMENDMENT 1

TEXT

Standards for Defence

Generic Specification

For

Batteries

SECTION 1 GENERAL REQUIREMENTS

0 INTRODUCTION

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

specifications whenever possible. This Defence Standard has been generated to address the
current requirements for batteries. This standard is applicable when invoked directly by an
MOD invitation to tender, contract, or when referred to by other MOD battery
specifications.

1 SCOPE

This standard specifies the MOD requirements for batteries. This generic document
combines with a series of supplements that contain the specific requirements relating to
individual battery types. The requirements of these individual battery supplements shall take
precedence over those of this standard where conflict arises. The procedure for the
generation of a new battery supplement is defined in Def Stan 61-17 (The Requirements for
the Selection of Batteries for Service Equipment).

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.

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SECTION 1 GENERAL REQUIREMENTS

3 RELATED DOCUMENTS

3.1 The publications shown below are referred to in the text of this standard and its
associated supplements. Publications are grouped and listed in alpha numeric order. These
documents are subject to frequent change and or amendments.

Designation
AOF
AQAP 2110 (series)
BS EN ISO/IEC 17050
BS EN 60068: (series)
BS EN 60086: (series)
BS EN 60095: (series)
BS EN 60622
BS EN 60896: (series)
BS EN 60952: (series)
BS EN 61056: (series)
BS 2G 239
Def Stan 00-00(Part 2)
Def Stan 61-17
Def Stan 81-41
JSP 335
2006/66/EC
Title
Acquisition Operating Framework
NATO Quality Assurance Requirements
Conformity Assessment - Supplier’s declaration of conformity
Environmental testing
Primary batteries
Lead-acid starter batteries
Sealed nickel cadmium prismatic single cells
Stationary lead-acid batteries
Aircraft batteries
Portable lead-acid cells and batteries
Primary active lithium batteries for use in aircraft
Presentation and Management of Defence Standards
Requirements for the Selection of Batteries for Service
Equipment
Packaging of Defence Materiel
Dangerous Air Cargo Regulations
EU Directive. Waste Battery Collection / Recycling Provisions

Other Government Departments:

Department for Transport www.dft.gov.uk

Dep. for Business Enterprise www.berr.gov.uk

& Regulatory Reform

Health & Safety Executive www.hse.gov.uk

Department for Environment www.defra.gov.uk

Food & Rural Affairs

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 DEF STAN 61-21/3 AMENDMENT 1

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 Def Stans.

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SECTION 1 GENERAL REQUIREMENTS

4 DEFINITIONS

Unless otherwise stated, ISO 9000 definitions apply.

For the purpose of this standard and its associated supplements the following additional
definitions apply:

4.1 Generic Standard

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

4.2 Supplement

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

4.3 Mandatory Clauses in Defence Standards

Defined as clauses that use the word “shall”. Optional or non-mandatory clauses use the
word “should”.

4.4 Acquirer

Governmental and/or NATO Organisations, who enter into a contractual relationship with a
supplier, defining the product and quality requirements.

4.5 Supplier

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

4.6 Standard Sponsor

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

4.7 Defence Battery Standardization Committee

The DBSC is made up of representatives from DStan, MoD user groups,

Acquirers/Provisioners, Subject matter experts, Technical and QAR support groups.

4.8 Quality Assurance Representatives

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

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4.9 Storage Life and Cell Age

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

The storage life of a battery is defined as the number of years of temperate storage at the
end of which a battery retains its ability to perform a specified service output (typically
discharge life or capacity).

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

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DEF STAN 61-21/3 AMENDMENT 1

SECTION 1 GENERAL REQUIREMENTS

5 ABBREVIATIONS

Designation Title

ADR European Agreement concerning the International Carriage of

Dangerous Goods by Road
ADN UN Regulations for the Carriage of Dangerous Goods by Inland
Waterways
AP Allied Publication (NATO)
AQAP Allied Quality Assurance Publication (NATO)
BS British Standard
BS EN European Standard
BSI British Standards Institute
Def Stan Defence Standard
DBSC Defence Battery Standardization Committee
DMSC Defence Material Standardization Committee
DStan UK Defence Standardization
IATA International Air Transport Association
ICAO International Civil Aeronautics Organisation
IEC International Electro-technical Commission
IMO IMDG International Maritime Organisation _ International Maritime
Dangerous Goods Code
ISO International Standards Organisation
JSP Joint Service Publication
MOD Ministry of Defence
PAS Performance Assessment Sheet
PCC Product Conformity Certification
PM/ESM Project Manager/Equipment Support Manager
RID European Agreement concerning the International Carriage of
Dangerous Goods by Rail.
UN United Nations

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SECTION 2 PRODUCT CONFORMITY CERTIFICATION

6 APPLICABILITY

6.1 Product Conformity Certification (PCC) provides confidence that specific products
will meet their contractual requirements. The process of PCC aligns with MOD risk
management practices and provides objective evidence that risks have been contained or
minimised. Objective evidence includes information and data from the suppliers
Declaration of Conformity, Quality Plan, Test report(s) and Build Standard documentation.

6.2 PCC should be applied where a risk assessment by the DBSC has identified a need for
additional assurance that the performance of a specific product has been, or is being,
achieved above that provided by the supplier’s quality management system.

6.3 The incorporation of PCC in a standard or supplement is in accordance with the

procedure defined in Def Stan 00-00(Part 2) and the Acquisition Operating Framework
(AOF). Further details of PCC and “Contracting for Quality” can be found at
WWW.AOF.MOD.UK

6.4 PCC can be excluded (or modified) by contract action if the risk assessment by the
acquirer identifies that there are alternative requirements.

6.5 Battery supplements broadly fit into two PCC categories:

Major (High Risk) - the certification requires extensive testing, including

performance, environmental and interface assessment.

Basic (Medium Risk) - the certification requirements may be limited to performance

testing and physical assessment only.

Note. Batteries assessed as Low Risk are commonly procured to Commercial or National
Standards.

7 RESPONSIBILITIES

When PCC is required by the contract, or identified as a requirement, the supplier is

responsible for providing the necessary PCC.

8 CERTIFICATION PROCEDURE

The procedures that shall be adopted for the PCC process are defined in BS EN ISO/IEC
17050 (Conformity Assessment – Suppliers Declaration of Conformity).

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DEF STAN 61-21/3 AMENDMENT 1

9 PRODUCT CONFORMITY CERTIFICATE

9.1 The Product Conformity Certificate issued by a supplier shall be in accordance with
BS EN ISO/IEC 17050 (clause 8). The supplier shall submit to the acquirer, objective
evidence to demonstrate compliance with the requirements of the Defence Standard
supplement.

9.2 The supplier shall include the following additional information on the PCC:

a. The contract reference.

b. The supplier’s accreditation certificate number.
c. Any deviations from the test procedures defined in the supplement.
d. Any instances of failure to meet the requirements defined in the supplement.
e. Interim or Full status (detailed in clause 10).
f. Reference to the conformance test report.
g. Reference to the names and addresses of the test laboratories involved.
h. Reference to the manufacturing data package (build standard) for materials,
piece parts and processes used in the battery construction.
i. Batch certification (detailed in clause 11) may be considered by the acquirer
in exceptional circumstances. (Where the build standard for materials, piece
parts and processes used in the battery construction cannot be controlled or
verified).

10 INTERIM AND FULL CERTIFICATION

Suppliers shall carry out PCC to “Full Certification” as this provides the greatest confidence
in the product.

However, due to the protracted timescale of certain battery storage tests, some battery
supplements allow interim certification. This may enable the supplier to commence product
delivery in advance of full certification. Under these circumstances, the supplement details
the minimum test regime necessary to provide sufficient product confidence until full
certification is provided.

11 BATCH CERTIFICATION

Under exceptional circumstances the acquirer may consider allowing a batch certification
process when the build standard cannot be controlled or verified. The acquirer may
consider allowing batch certification to provide a minimum level of confidence for the
Basic (Medium Risk) products.

The supplier shall propose a batch certification plan to provide confidence that all aspects of
the Interim PCC can be achieved.

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12 MODIFICATION OF CERTIFIED PRODUCTS

12.1 Changes to the product that have not been disclosed to the acquirer may invalidate
the PCC. This shall include, but not be limited to, changes in materials, component
specifications, manufacturing processes and sites of manufacture.

12.2 The supplier shall address the impact of the change against all aspects of the
specification and submit a report to the acquirer including the proposed level of retest. The
acquirer shall assess the significance of the change and may require additional tests detailed
in the supplement when considered necessary.

13 PERFORMANCE ASSESSMENT SHEETS

To assist the acquirer during the tender assessment stages, a PAS will be provided as an
annex in each supplement. The PAS augments the PCC and formal test report by
summarising the technical compliance data and displaying the data in a common format.

14 CERTIFICATION DURATION

The maximum duration of a PCC shall be the duration of the contract for which it was
provided. However, the supplier shall review all the supporting data if the PCC is more
than 2 years old and consider additional testing to ensure that the product continues to meet
the requirements of the supplement.

15 DISCLOSURE OF NON COMPLIANCE

15.1 PCC. Any failures during the certification process shall be reported on the PCC.
The acquirer may request a detailed failure investigation and may request further samples
are subjected to the test (or test sequence).

15.2 Periodic Validation. Any/All shortfall in performance against the specified

requirements shall be promptly reported to the acquirer (for the duration of the contract).

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DEF STAN 61-21/3 AMENDMENT 1

SECTION 3 QUALITY REQUIREMENTS

16 QUALITY SYSTEM REQUIREMENTS

The supplier’s quality system shall be in accordance with the AQAP 2110, 2120 or 2130
series.

16.1 Quality Planning

The supplier shall submit a Quality Plan (QP) which addresses the contractual requirements
to the acquirer prior to the start of the activities, unless otherwise directed.

The QP shall play two complimentary roles:

1. Describe and document the quality management system requirements “contract

specific” necessary to satisfy the contract requirements.

2. Describe and document the planning of the product realisation, in terms of quality
requirements for the product, needed resources, required control activities
(verification, validation, monitoring, inspection, testing), and acceptance criteria.

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SECTION 4 TRANSPORTATION, PACKAGING AND LABELLING

17 TRANSPORTATION REQUIREMENTS AND DANGEROUS GOODS

CLASSIFICATIONS

17.1 All deliveries of cells and batteries (and equipment packed together with or
containing batteries) shall be supplied appropriately certified, packaged labelled and
documented to permit their forward consignment from the UK by all modes of civil
transport. This necessitates that all deliveries are compliant with the requirements of the
latest extant editions of the following regulations:

ADR European Agreement concerning the International Carriage of Dangerous

Goods by Road.

RID European Agreement concerning the International Carriage of Dangerous

Goods by Rail.

IMO IMDG International Maritime Organisation - International Maritime

Dangerous Goods Code

ADN UN Regulations for the Carriage of Dangerous Goods by Inland

Waterways

ICAO Technical Instructions for the Safe Carriage of Dangerous Goods by Air

IATA Dangerous Goods Regulations.

Note: Where certain battery types are prohibited from transport on joint passenger and cargo
aircraft, or where the maximum net mass of the package prevents its carriage (i.e. where the
weight of the contracted Primary Packaging Quantity exceeds the maximum limit) items
shall be packaged for carriage on cargo only aircraft.

17.2 All types of batteries need to be considered for Dangerous goods Classification.
Definitions of Dangerous Goods and the list of articles and substances together with their
Proper Shipping Names, Classification and UN Numbers are detailed in the UN
Recommendations on the Transport of Dangerous Goods, additional definitions and
clarifications are detailed in some of the transport mode specific regulations. The current list
of Dangerous Goods Classifications applicable to cells and batteries within the current
edition of the UN model regulations are detailed in Table 1.

17.3 The Dangerous Goods regulations and their interrelationship are complex. In
addition to stipulating packaging and labelling requirements constructional and test criteria
are often invoked.

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DEF STAN 61-21/3 AMENDMENT 1

Table 1

List of UN Dangerous Goods Classification Applicable to Cells and Batteries

UN Class
Name & Description Number

BATTERIES, CONTAINING SODIUM, Or CELLS, UN 3292 4.3

CONTAINING SODIUM
BATTERIES, DRY, CONTAINING POTASSIUM UN 3028 8
HYDROXIDE SOLID, electric storage
BATTERIES, WET, FILLED WITH ACID, electric UN 2794 8
storage
BATTERIES, WET, FILLED WITH ALKALI, UN 2795 8
electric storage
BATTERIES, WET, NON-SPILLABLE, electric UN 2800 8
storage
BATTERY-POWERED VEHICLE or BATTERY- UN 3171 9
POWERED EQUIPMENT
LITHIUM METAL BATTERIES (including lithium UN 3090 9
alloy batteries)
LITHIUM METAL BATTERIES CONTAINED IN UN 3091 9
EQUIPMENT or LITHIUM METAL BATTERIES
PACKED WITH EQUIPMENT (including lithium
alloy batteries)
LITHIUM ION BATTERIES (including lithium ion UN 3480 9
polymer batteries)
LITHIUM ION BATTERIES CONTAINED IN UN 3481 9
EQUIPMENT or LITHIUM ION BATTERIES
PACKED WITH EQUIPMENT (including lithium
ion polymer batteries)

18 PACKAGING AND LABELLING

All deliveries of cells and batteries (and equipment packed together with or containing
batteries) shall be packaged and labelled in accordance with the detailed transport regulations.
Additional requirements (such as PPQ) may be detailed in the individual product supplement
or contract.

Note: Primary Package Quantity (PPQ) is defined in Def Stan 81-41 Part 1, Annex B as:
The quantity of an item of material selected as being the most suitable for packaging for issue
to the ultimate user.

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19 MILITARY AIR TRANSPORT REQUIREMENTS

If clearance for military air transport is required in accordance with JSP 335, then this shall
be specified in the relevant supplement or contract.

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DEF STAN 61-21/3 AMENDMENT 1

SECTION 6 DEFINITION OF COMMON BATTERY TERMS

Table 2 Definition of Common Battery Terms

Term Definition
Cell Basic electrochemical unit to provide electrical energy by the conversion of
chemical energy.
Battery One or more electrochemical cells interconnected to provide the required voltage
and current characteristics.
Battery–Primary A battery which is not intended to be recharged and should be discarded when it
has delivered its electrical energy.
Battery- A battery which after discharge may be recovered to a serviceable state by
Secondary charging.
End point The on-load voltage at which discharge is normally terminated. End-point voltage
voltage may vary according to the rate of discharge.
Capacity The quantity of electrical charge that a battery can deliver (at a specific rate) to a
specific end point. Capacity is normally expressed in Ampere Hours (Ah).
Discharge rate The specified rate at which the battery is discharged. (Note: The achieved
capacity will vary depending on the rate of discharge.)
Charge Rate The rate at which a battery is charged for a specific time. After which the battery
should be restored to optimum capacity.
Shelf / Storage The Shelf / Storage life of a battery is defined as the maximum time from the date
life of manufacture for which the battery can be stored (under specific conditions of
temperature and humidity) and still provide the assured minimum performance.
Self Discharge The rate at which a battery will discharge without any external current or load
being applied.
Electrolyte The conducting medium between the plates of a battery.
Battery-Dry Technically, sealed, non vented systems that do not contain liquid electrolytes. In
practice, however, most small cylindrical cells (even those with liquid
electrolytes) are classified as dry.
Battery-Wet Batteries whose plates are immersed in a fluid electrolyte (either acid or alkali).
In some instances, the electrolyte is incorporated in a thixotropic gel.
Note: Some wet batteries are supplied without electrolyte, (which is added during
commissioning).
Maintenance A secondary battery, which does not require periodic ‘topping up’ to maintain
Free electrolyte volume.
Recombination A secondary battery, where evolved gasses are subsequently recombined within
the battery
Vented A normal sealed battery that allows the controlled escape of gasses to relieve
excess pressure.
Nickel Metal A secondary battery system, that uses nickel for its positive electrolyte and
Hydride hydrogen absorbed in metallic alloy for the negative electrode.
Lithium Ion A secondary battery system that utilises lithium containing compounds but does
not contain metallic lithium.

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 ©Crown Copyright 2011

Copying Only as Agreed with DStan

Defence Standards are Published by and Obtainable from:

Defence Equipment & Support

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Internet e-mail enquiries@dstan.mod.uk

File Reference

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

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 should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk,
updated weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to
notify UK Defence Standardization (DStan) without delay in order that the matter may be investigated
and appropriate action taken.