JSS 6130-16 : 2016

(Second Revision)
Capt (IN) P Digitally signed by Capt (IN)
P Kishore JD Tech Coord
Kishore JD Tech Date: 2020.09.22 10:01:45
Coord +05'30'

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GOVERNMENT OF INDIA
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MINISTRY OF DEFENCE

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JOINT SERVICES SPECIFICATION

ON

CHARGERS BATTERY ELECTRONIC

FOR BATTERIES, SECONDARY, PORTABLE,
NICKEL CADMIUM
(DS CAT No. X2/6130-000 504)

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DIRECTORATE OF STANDARDISATION
DEPARTMENT OF DEFENCE PRODUCTION
MINISTRY OF DEFENCE
‘H’ BLOCK, NIRMAN BHAWAN PO
NEW DELHI–110011
 JSS 6130-16 : 2016
(Second Revision)

LIST OF MEMBERS ASSOCIATED WITH FORMULATION OF THIS STANDARD

1. The second revision of this Joint Services Specification 6130-16 has been approved
by Cmde C Raghuram, PDEE, Chairman, Electrical Standardisation Sub-committee by
circulation.

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

S. Name & Designation Organisation

No.
1. Shri Rahul Gupta, Jt Dir/E & I DGAQA
2. Lt. Col Sanjay Mishra Dy Controller CQA (L)/DGQA, Bangalore
3. Cdr Deepak Nair JDEE
4. Cdr Maneesh Singh, JDLS DLS/NHQ
5. Shri M K Roy, Sc „D‟ R & DE (Engrs), Pune
6. Shri G S Kondhre, SSO-I CQA (EE), Pune
7. Shri H R Meena, Dy Dir Eqpt Management (STD), MGO Branch,
New Delhi
8. Gp Capt A Bhattacharyya, Dir ES DES, Air HQ, New Delhi
9. Maj Naveen Siddhu, TSO-I HQ TG EME, New Delhi
10. Dr Ram Varma, ACE Director of Utility, E-in-C‟s Branch, New
offg Jt DGW (U) Delhi
11. Col Vivek Matta, Dir OS (L & E) DGOS (OS-17B)
12. Shri V Ravi Chandran, Addl GM BEL, Bangalore
13. Shri DAV Satyanarayan, NSO Service STD Cell (Navy)
14. Wg Cdr R Muralidhar, JD TETTRA Service STD Cell (IAF)
15. Col Patwal, OIC DSC, Badarpur
16. Lt Col A Shahu DSC, Pune
17. Lt. Col Tushar Mukherjee DSC, Bangalore
18. Shri Deendayal Singh, AE (QA) CQA (R)
19. Shri Rajeev Bhardwaj, Staff Captain Directorate of Standardisation

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 JSS 6130-16 : 2016
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RECORD OF AMENDMENTS

Amendment Amendment pertains Authority Amended by Signature

No. Date to S. No./Para No./ Name & &
Column No. Appointment Date
(In block letters)

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TABLE OF CONTENTS

S. No. Topic Page No.

0. FOREWORD 1

1. SCOPE 3

2. RELATED SPECIFICATIONS AND DOCUMENTS 3

3. STANDARD PATTERN 4

4. TERMINOLOGY 4

5. MATERIAL 8

6. MANUFACTURE/CONSTRUCTION 9

7. WORKMANSHIP AND FINISH 10

8. MARKING 11

9. SAFETY 11

10. PRE-INSPECTION OF STORES/CONSIGNMENT 11

11. QUALITY ASSURANCE 12

12. STORAGE AND TRANSIT 19

13. TECHNICAL DOCUMENTS 19

14. WARRANTY 19

15. PACKAGING 20

16. DEFENCE STORES CATALOGUE NUMBER/NATO STOCK 20

NUMBER

17. SUGGESTIONS FOR IMPROVEMENT 20

18. SUPPLEMENT 21

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0. FOREWORD

0.1 This Joint Services specification 6130-16 has been prepared by the Electrical
Standardisation Sub-committee on the Authority of Standardisation Committee, Ministry of
Defence by circulation.

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

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

0.4 This JSS 6130-16 : 2016 (Second Revision):

a) was prepared in the year 2002.

b) was revised in the year 2010.

c) is revision of JSS 6130-16 : 2010 (First Revision) and supersedes the same.

0.5 Quality Assurance Authorities for the items covered by this specification are the
Controller, Controllerate of Quality Assurance (Electronics), Bangalore-560006,
e-mail id-cqalbang-dgqa@nic.in. Enquiries regarding this specification relating to any
contractual condition shall be addressed to the Quality Assurance Authority named in the
tender or contract. Other enquiries shall be referred to Secy ESSC by email at
essc.defstand@gov.in or by post to:

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

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

a) Copies of IS from:

Bureau of Indian Standards,

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

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

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

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

Directorate of Standardisation Website:

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

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

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

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

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1. SCOPE

1.1 This specification covers the general requirements of design, manufacture, test
procedure, the Quality Assurance and Inspection of Charger Battery Electronic for Batteries,
secondary, portable, Nickel Cadmium for use in Defence to charge the Ni-Cd batteries used
with used on Radio Set. Characteristics of individual charger batteries are listed in the
supplements to this specification.

1.2 The Chargers battery are required to meet the following basic requirements:
a) Temperature of operation - &30ºC to +55ºC.

b) Storage - &40ºC to +70ºC.

c) Relative Humidity - Up to 100%.

2. RELATED SPECIFICATIONS AND DOCUMENTS

Table 1 Related Specifications and Documents

S. Specification No. Nomenclature

No. & Year
a) IS 1422 : 1983 Specification for Cotton Duck
(Third Revision)
Amd 4
Reaffirmed 2014
b) IS 1720 : 1978 Specification for Cotton Sewing Threads
(First Revision)
Reaffirmed 2017
c) IS 2074 : 1992 Ready Mixed Paint, Air Drying, Red Oxide Zinc
(Second Revision) Chrome, Priming-Specification
Amd 2
Reaffirmed 2014
d) IS 3618 : 1966 Specification for Phosphate Treatment of Iron and
Reaffirmed 2016 Steel for Protection Against Corrosion
e) IS 4353 : 1995 Submerged Arc Welding of Mild Steel and Low Alloy
(First Revision) Steels-Recommendations
Reaffirmed 2016
f) IS 5905 : 1989 Sprayed Aluminium and Zinc Coatings on Iron and
(First Revision) Steel-Specification
Reaffirmed 2016
g) IS 6127 : 1971 Specification for Varnish, Spar and Fungicidal
Reaffirmed 2015
h) IS 6488 : 1999 Textiles-Cotton Webbing for Personal Web
(Third Revision) Equipment-Specification
Reaffirmed 2016

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Related Specifications and Documents (Concluded)

S. Specification No. Nomenclature

No. & Year
j) IS 8982 : 2019 Ready Mixed Paint, Finishing, Air-drying for War
(Second Revision) Equipment-Specification
k) IS 8983 : 1978 Specification for Ready Mixed Paint, Finishing,
Reaffirmed 2014 Stoving for War Equipment
m) IND/SL/3623A Varnish, Special Fungicide-H1 (a)/8010-000274
n) JSS 0251-01 : 2015 Procedure for Preparation and Production of
(Second Revision) Technical Publications for Electronic & Electrical
Equipment
p) JSS 50003 : 2015 Drawing Procedure for Electronic and Electrical
(Second Revision) Stores
q) JSS 5999-10 : 2015 Procedure for the Qualification Approval and
(Second Revision) Acceptance of Standard Electronics Components
r) JSS 51034 : 1992 Detailed Specification for Wire Electrical, High
Reaffirmed 2012 Temperature Fluoropolymer Insulated
Amd 1
s) JSS 55555 : 2012 Environmental Test Methods for Electronic and
(Third Revision) Electrical Equipment
Amd 1
t) JSS 8010-59 : 2016 Paint RFU, Finishing, Petrol Resistant Interior
(Third Revision) Chocolate Red Oxide
w) JSG 50102 : 2013 List of Approved Electronic Components
(Fifth Revision)
Amd 1 & 2
y) DEF 5000 General Requirements for Service
Telecommunication Equipments
z) BSG 177 Uninyvin Cables
aa) DTD 904C Cadmium Plating
ab) CQA(L)/497 Detailed Specification for Battery Charger 48 V, 10 A
ac) CQA(L) 4382 Drawing for Battery Charger 48 V, 10 A
(PROV)

3. STANDARD PATTERN

A Standard Pattern if available with Purchasing Authority or the Quality Assurance Authority
may be obtained and shall constitute the standard as regards to any particulars or properties
not noted/defined in the specification. The store shall otherwise conform to this specification.

4. TERMINOLOGY

4.1 ac Mains

4.1.1 ac Mains of 230 V ±10% , 50 Hz, ac, Single Phase which is fed as one of the input
sources of charger‟s battery.

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4.1.2 The Technology used should be Switch Mode Power Supply (SMPS) to reduce mass
and size. Arrangement to be made for automatic cut off input mains in case voltage falls
below 180 V or increased beyond 260 V.

4.2 Secondary Battery Input Source

Shall mean Battery Secondary lead acid of suitable voltage and Ah capacity used as one of
the input source to the Charger‟s battery.

4.3 Charging Set

Shall mean Generator Set battery charging complete with Spares & Accessories capable of
providing a suitable output voltage to be used as one of the input sources to the charger‟s
battery.

4.4 Battery

Shall mean Ni-Cd sintered plate or cylindrical Ni-Cd batteries used as power sources for the
Radio Sets. These batteries are charged using chargers battery covered by this specification.

4.5 Charger

Shall mean Charger Battery working on Constant Current system used for charging/
discharging/functional test of the Ni-Cd batteries and lead acid batteries.

4.6 In case of Charger Battery, Solar used for powering Radio Sets AN/PRC, RS HB &
STARS „V‟ the charging process depends entirely on the incident (insolation) sunlight
available. The charging process is not controllable. The Charging current generated by the
Solar cells is directly proportional to the intensity of the incident sunlight (insolation)
whereas generated voltage is practically independent of insolation.

4.7 Charging Voltage/Output Voltage

It is the dc voltage available at the output terminals of the chargers to charge the respective
battery meant for a particular radio set.

4.8 Charging Time

It is the duration of charge required for charging the Ni-Cd batteries to the full capacity meant
for a specific radio set as per the requirement of the governing specification.

4.9 Colour Bands

In case of Analogue meters are used where SMPS are not used. It is the marking on the meter
dial of the chargers in different colours by which the state of charge of the battery can be
known.

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4.10 Current Regulation

The variation in (output) constant charging currents of the chargers that can be permitted due
to variations of input voltages (ac or dc) as well as output voltages.

4.11 Continuous Working

The duration in hours up to which the chargers can be continuously utilised without any
adverse effect on the chargers. The duration of charge will depend upon type of battery.

4.12 Discharge Current/Rate

The current that is obtained from the battery when it is connected across the discharge
terminals/socket through the dummy resistive loads provided in the chargers.

4.13 Discharge Voltage

The battery ON LOAD Voltage that will be existing across the discharge terminals/sockets of
the charger when the battery is connected to the dummy resistive load.

4.14 Discharge Resistance

4.14.1 The discharge circuit consists of fixed resistance as loads when the switch meant for
discharge is switched „ON‟ by connecting the battery to be discharged the discharge resistors
come in the circuit and the battery starts getting discharged. These are dummy resistive loads.

4.14.2 The discharge circuit shall get disconnected when battery voltage reaches to fully
discharged condition to the respective battery ratings.

4.15 Initial Charging Current/Rate

This type of charging is given at the time of commissioning the battery for the first time. This
is also termed as “Low Rate” charging. The current during this method of charging will be
less than the normal rate of charging, but the charging time is more than the normal charging
time.

4.16 Normal Charging Current/Rate

This charge is given during the course of actual use or during the laboratory test. The
charging is done for a fixed number of hours as per the battery specification.

4.17 Fast Charge

This is a fast mode of charging adopted when the battery is required to be brought into use
within a short time. The current will be double the normal charging current. This facility shall
be used in case of emergency. This charge is also termed as Accelerated charge.

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4.18 Functional Test (FT)

This facility is provided in the chargers to check the state of charge of a battery to know
whether the battery is the in fully charged/partly charged or fully discharged condition and to
find out the number of hours of charge required to bring the battery into fully charged
condition and built in discharge functional test required wherever sealed cylindrical Ni-Cd
batteries are likely to be used.

4.19 Over Voltage

This is the excessive voltage by 10% of the maximum operating voltage (ac or dc) that could
be applied to the charger without causing damage. If over voltage is applied to the chargers as
per specification limit, the fuse provided for the purpose shall blow off immediately.

4.20 Over Heating/Temperature Rise Test

The rise in temperature, if the charger is heated due to continuous use, over the ambient
temperature by 15ºC no adverse effect should occur to the charger.

4.21 Reverse Polarity at Input Side

This facility should be provided, incase the wrong connections are made at input side of the
charger.

4.22 Reverse Polarity at Output Terminals

This facility should be provided if the dc output terminals are connected to the battery with
reverse connections.

4.23 Reverse Current

This is the current that flow from the battery under charge, in the event of failure of ac mains
to the charger. This should not exceed by maximum 10 mA.

4.24 Short Circuit

This protection is provided at the output terminals/sockets in case of accidental short circuit
occurs.

4.25 State of Charge

It is to check the status of the Battery i.e. to indicate whether the battery is fully charged,
partially charged or fully-discharged. If the digital meter is used in the panel, the No. of hours
of charge required shall also be furnished.

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4.26 Resistive Loads

These are dummy resistive loads across functional terminals of the chargers. These resistors
will be in Ω for the purpose of carrying out discharge of the battery and simultaneously to
check the functional test.

5. MATERIAL

5.1 All materials and components used for manufacturing of the stores shall be of highest
grade and conform to the latest IS/BS/DEF/MIL/JSS specifications so as to withstand
extremes of climatic conditions given in relevant clause of this specification. As far as
possible only LCSO Qualification approved components shall be used and where such
approved components are not available, the manufacturer shall provide a list of the required
number of each of non-approved components for getting departmental approval status.

5.2 Welding

All metal welding in mild steel shall conform to IS 4353.

5.3 Finish

All steel and iron parts will be perfectly cleaned and shall be zinc plated to conform to
IS 5905.

5.3.1 The equipment shall be given a priming coat of paint, RFU, priming, red oxide of
iron, zinc chrome, priming to IS 2074.

5.3.2 Brushing/spraying with paint RFU finishing, air drying, brushing/spraying, olive
green scamic 314 to IS 8982.

5.2.3 Lamination of the transformer used shall be antirust treated, the transformer shall be
vacuum impregnated with thermostat varnish to IND/SL/3263 A and then given a coating
of varnish special fungicidal to IS 6127 followed by a finish coat of electro enamel post
office red to IS 8983.

5.3.4 Non-ferrous parts shall be given a primary coating of red-oxide of iron, zinc or
chromate to IS 2074 and then a finishing coat of paint.

5.4 All exposed parts which are energised electrically shall be insulated, fully enclosed or
properly guarded and earthed. The equipment shall incorporate high quality glass epoxy
printed circuit board.

5.5 All components used shall be preferably indigenised and type approved.

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6. MANUFACTURE/CONSTRUCTION

6.1 General

The charger is intended for field use and hence shall be rugged enough and it shall meet the
relevant test for category L2/L3 of JSS 55555. The front panel shall be suitably protected to
avoid damage during transit or use. Metallic cover for safeguarding the front panel
components shall provide a suitable front panel cover.

6.2 Chassis

This shall be of either Aluminium alloy or of mild steel and shall be rugged. The design shall
be of drip proof construction. The mass shall be as low as possible.

6.3 Heat Sinks

Standard Heat Sinks/cooling fans shall be provided for dissipation of heat.

6.4 Front Panel

All controls/switches, connectors, meters, fuses etc, shall be available on the front panel with
suitable markings. Due consideration shall be given to the human engineering point of view.
ac Mains socket/plug shall be of recessed type.

6.5 The following shall be provided.

6.5.1 Suitable leather handle for lifting the charger.

6.5.2 Rubber grommets/anti-vibration mounting at the bottom.

6.6 Side, top and back cover shall be of removable type for ease of maintenance and
repair.

6.7 Printed Circuit Board used shall be of plug-in type with PCB Connectors. Provision
may also be made for test points.

6.8 The operating and storage conditions of the charger are as under:
a) Temperature - 1) Operation - &30ºC to +55ºC

2) Storage - &40ºC to +70ºC

b) Relative Humidity - up to 100%.

c) Altitude - From mean sea level (MSL) to 5500 m.

6.9 The equipment shall be capable of working satisfactorily under salt and dust laden
atmosphere.

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6.10 It shall be possible to select any one type of battery with a selector switch.

6.11 It shall be possible to select any one type of input sources with an input selector
switch.

6.12 It shall be possible to select any mode of charging by means of a selector switch viz
Initial, Normal and Fast.

6.13 Discharge/F.T. Switch shall be provided with F.T. position of non-locking type.

6.14 A suitable dc analogue meter/digital meter to indicate input dc voltage, output

voltage, output current, discharge voltage, discharge current, state of charge of battery in-
terms of colour bands for analogue meter and No. of hours required in case of digital meter
shall be provided. If the analogue meter is used it shall be hermetically sealed if the digital
panel meter is used the change of scale should be automatic. The selection of the above
parameters shall be done with the help of rotary/push-button switch.

6.15 Input terminals/socket, Output terminals/sockets, Discharge/F.T. terminals/sockets

shall be provided separately.

6.16 A red LED to show that Input is „ON‟ shall be provided.

6.17 Suitable fuse with cartridge fuse link to protect the unit against excessive input
current be provided. Extractor type of fuse holder shall be used for holding the fuse.

6.18 The controls and indicators shall be marked with their functions to facilitate ease of
operation, maintenance and repair. The circuit reference of these controls can be marked on
the back of the front panel or at a suitable location near to them. A circuit diagram can also be
fitted by etching/engraving on an aluminum sheet.

7. WORKMANSHIP AND FINISH

7.1 The manufacturer before undertaking fabrication/assembly of the equipment shall

forward to the Quality Assurance Authority a list of materials/components to be used by him
along with relevant specification and source of supply.

7.2 Once the list of components and materials has been finalised no change or deviation
shall be made by the manufacturer without the written permission of the Quality Assurance
Authority.

7.3 All fasteners shall be rust proofed and chromium plated. Spring washers and lock
nuts shall be provided wherever required.

7.4 The electrical wiring shall be given a coat of anti-fungus varnish conforming to
IS 6127.

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8. MARKING

8.1 Etched/engraved anodised aluminium name plate containing the following

information shall be provided at a suitable location on the front panel:
a) Manufacturer‟s Name/Monogram.

b) Complete description of item.

c) Type/Model No./Serial No.

d) DS Cat No./NSN No.

e) Governing Specification.

f) Batch/Year of Manufacture.
g) Inspection Mark.

8.2 Operating Instructions plate with block diagram shall also be provided on an anodized
aluminum plate by etching/engraving, at a suitable place on the charger.

8.3 All wiring and layout of components shall be as per standard engineering practice so
as to facilitate ease of maintenance and repair. The wiring shall be suitably marked with
Identification ferrules and all loose wiring shall be properly bunched/cleated. Colour coding
of wires shall be maintained which shall conform to JSS 51034 style WH2F.

8.4 Bag Canvas (olive green colour) for carrying the equipment if it is manpack or to
cover the equipment when not in use with a separate pouch for keeping UHB and carried
spares/accessories with suitable straps for carrying and shall be treated with anti fungus
material shall be provided as per IS 1422 and the designation of the respective equipment
shall be printed on the Bag Canvas. (As per Para 8.1).

8.5 DS Catalogue Number/NSN shall also be marked on all accessories.

9. SAFETY

The equipment shall be incorporated with safety features required to safeguard personnel and
equipment during operation, maintenance, repair and calibration. Suitable information in this
regard shall be provided in the User Hand Books.

10. PRE-INSPECTION OF STORES/CONSIGNMENT

10.1 Manufacturers/contractors must satisfy themselves that the stores manufactured are in
accordance with the terms of the contract and fully conform to the required specification by
carrying out thorough pre-inspection of each lot before actually tendering the same for
inspection to the Quality Assurance Officer nominated under the terms of the supply order/
contract. A declaration by the contractor that necessary pre-inspection has been carried out on
the stores tendered will be submitted along with the challan. The declaration will also include

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the method followed in carrying out the pre-inspection showing the features checked/tested
and will have the test certificate/test reports attached to the challan/declaration.

10.2 If the Quality Assurance Officer finds that pre-inspection of the consignment as
required above has not been carried out, the consignment is liable for rejection.

11. QUALITY ASSURANCE

11.1 Unless otherwise specified in the contract or supply order the supplier is responsible
for the performance of all quality assurance requirements as specified herein except as
otherwise specified in the contract/supply order/Indent. The supplier may use his own or any
other facilities for the performance of the quality assurance requirements specified herein,
unless disapproved by the Quality Assurance Authority. The Quality Assurance Authority
reserves the right to perform any of the Quality Assurance Checks set forth in the
specification and also any other additional tests.

11.2 As per policy quality assurance checks of sub-contracted items will invariably be
done by the main contractor i.e. Prime Production Agency under their own arrangements.
Senior Quality Assurance Establishments will carryout quality assurance checks at the
premises of Prime Production agency which may also include inwards goods quality
assurance checks of sub-contracted items.

11.3 Evaluation of the samples taken from any portion of the consignment or during
Surveillance inspection shall conform to the requirement when tested in accordance with the
methods mentioned against each in this specification.

11.4 Bulk samples shall be forwarded to AHSP concerned from bulk supplies to check/
monitor the quality wherever required.

11.5 Product Specification

11.5.1 Details of the respective chargers have been furnished in the Supplements.

11.5.2 Conditions of Use

Refer Supplements for details.

11.6 Quality Evaluation and Assurance Approval

11.6.1 General

11.6.1.1 Unless otherwise specified in the contract/indent or purchase order the

supplier is responsible for the performance of all inspection requirements specified herein.

11.6.1.2 The manufacturer shall purchase the components, sub-assemblies only from
the approved sources. Proper check of incoming raw material, components and
sub-assemblies should be done and suitable documents maintained to ensure that only
acceptable materials are used in manufacture/supply.

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11.6.1.3 The manufacturer should submit the list of all the stages of Quality control
audit immediately after placement of the supply order.

11.6.1.4 The manufacturer is expected to thoroughly test end product before the same
is offered for inspection. Quality Assurance Officer may, therefore, check whether such a
testing has been done by the manufacturer before tendering the stores for inspection. The
record of such testing should be made available to the Quality Assurance Officer.

11.6.1.5 Unless otherwise specified in the detailed tests herein or in the detailed
specification, the quality assurance shall be performed under the conditions of (a) to (d) for
equipment having a specified warm up or stabilisation period after switching on. Formal
measurements and observations shall be made only after the specified interval.
a) Temperature - 15ºC to 35ºC.

b) Relative Humidity - 45% to 75%.

c) Air Pressure - 86 kPa to 106 kPa.

d) Input power - ac 230 V ±10%, 50 ±3 Hz (115 V/230 V, 60 Hz for

Naval equipments, & 400 Hz for Airborne eqpts wherever specified).

e) dc Input - As applicable.

11.7 Acceptance Tests

11.7.1 On receipt of Bulk Production Clearance from the competent authority against a
contract, the manufacturer shall give advance intimation to the Quality Assurance Officer
mentioned in the contract about the production programme for the stores ordered. The
manufacturer shall make available to the Quality Assurance Officer all facilities to oversee
the in-house quality control checks. The stores shall be tendered in convenient lots to the
Quality Assurance Officer for his acceptance inspection, as specified in the subsequent
paragraphs.

11.7.2 Class ‘A’ Tests on 100% of the Bulk:

a) Visual examination for constructional details, markings and general conditions
of the stores and its associated items in conformity with detailed drawings and
specimen sample as approved by Quality Assurance Authority.

b) Dimensional checks and mass.

c) Fitment with the Main Equipment where Relevant.

d) Input Voltage Variation & Output Voltage Variation.

e) Prepack Checks.

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11.7.3 Class ‘B’ Tests on 10% of the Bulk

a) Only equipments conforming to the requirements will be accepted. The bulk
will be released only on satisfactory completion of Class „B‟ tests detailed in clause
11.7.3 (b).

b) To be carried out on 10% of the total number of equipments on order

(tendered lot) uniformly spread out and picked up at random which have met the
Class „A‟ requirements.

c) Class ‘C’ tests - To be carried out on about 1% or less of the total number of
equipments against the order which have met the requirements of Class „A‟ & „B‟
tests.

11.7.4 Climatic and Durability

The charger shall be classified under category L-2 & L-3 Appx „A‟ & „A-1‟ given in
JSS 55555 as specified by purchaser. (Table of environment test is given as Appendices „A‟
& „B‟ respectively). Whenever performance checks are to be carried out during/after various
tests listed in Appx „A‟ the charger shall be loaded for a period shown in the tests. Before
each performance check the insulation resistance of the charger shall be measured and it shall
not be less than 1 MΩ.

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11.8 Test Details

Table 2 Test Details

Test Test Class of Test Equipment Description Requirements

No. test required
a) General Examination A1 The condition & workmanship and finish Same as column 5.
shall be satisfactory. The markings shall be
made legible and indelible and shall be as
specified in clause 8 of this specification.

1) Visual The charger shall be visually examined for Same as column 5.

examination any defects in construction, It shall be free
from moisture, rust etc, corrosion of metal
parts or any kind of deterioration.

2) Dimensions A2 i) Graduated scale The dimensions shall be checked for Same as column 5.
(Overall) -1m compliance as specified in different
supplements given.
ii) Vernier calipers

3) Mass A3 Weighing Machine The charger with and without carried spares Shall meet the relevant
and accessories shall be weighed. specification requirement.

4) Front panel A4 - Check for the layout of front panel Suitable front panel cover
layout components shall be provided to protect
the front panel components.

5) Construction & A5 - Constructional details as per clause 6 of this Shall meet the
general features specification. requirements.

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Table 2 Test Details (Continued)

Test Test Class of Test Equipment Description Requirements

No. test required
6) Input Current A6 i) Rheostats The charger shall be connected with resistive The variation shall be ±5%
regulation and loads and multimeters at both I/P & O/P or 50 mA in output current
Output currents ii) ac Mains terminals to check the variation in the I/P whichever is higher for all
Supply voltage from 180 V-260 V by Dimmerstat I/P 3 modes of charging.
terminals & the output voltage is dependent
iii) 12 V Secondary on the type of battery to be charged. Details as per Supplements.
Battery

iv) Dual Regulated

Power Supply dc
0 V-60 V and 0 A-
10 A

v) Multimeters

vi) Dimmerstat

7) Input Current A7 Test equipments as Measure the input current consumed across The Input current will vary
Consumption per clause 11.9 a) 6) the input terminals by connecting an in accordance the Input
Ammeter in series with the Input, by keeping voltage to the charger Viz
the O/P maximum. ac/dc.

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Table 2 Test Details (Continued)

Test Test Class of Test Equipment Description Requirements

No. test required
8) Battery B1 Test equipments as Connect the respective Ni-Cd The charger shall be capable of
Charging per clause 11.9 a) 6) batteries to the charger and adjust charging the batteries at various
the control for the desired mode of modes specified for respective
charging. batteries. The tolerance for charging
current for the charger shall be ±5%
or 50 mA whichever is higher.

9) Continuous B2 Test equipments as Connect the respective Ni-Cd The charger shall be capable of
working per clause 11.9 a) 6) batteries to the charger and adjust working continuously for 4 hours in
the control for the desired mode of the FAST mode without undue
charging. heating to the components or body
of the charger.

10) Over voltage B3 - Apply 120% of specified voltage The charger shall withstand
and short circuit whether dc or ac at the input satisfactorily at both the tests
protection terminals. For Short Circuit test without causing any damage to the
apply the specified input voltage charger.
then short the output terminals of the
charger.

11) Reverse polarity B4 - Reverse the polarity of the input No damage should occur. The
protection voltage and switch ON the charger. charger shall function normally
when the correct polarity restored.

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Table 2 Test Details (Concluded)

Test Test Class of Test Equipment Description Requirements

No. test required
12) Reverse current B5 - One Ni-Cd battery be connected to the The battery under charge
protection charger. The mains supply may be switched shall not send a reverse
OFF when the battery is fully charged. current of more than
10 mA.

13) Discharge/ B6 Multimeters Connect the fully charged battery across the The voltages to the colour
Functional test “Discharge terminals” The battery should be bands shall be as specified
discharged, connect an Ammeter to indicate for the respective battery
the discharge current flowing from the charger.
charger. In case analogue meter is used
respective colour bands should be provided
with specified voltage limits.

14) Calibration of B7 Multimeters Resistive The panel meter provided on the charger shall The difference between the
meters Loads be checked using external meters both for panel and external meter
current and voltage for accuracy of the panel shall not exceed
meter. The readings should be noted down. ±2%.
The accuracy shall be within ±0.5%.

15) Environmental C1 - Details are given at respective Supplements. The charger should
tests withstand the respective
tests as specified.

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11.9 Award of Qualification Approval

11.9.1 Qualification Approval Authority for the items of stores covered by this JSS will be:

The Controller,
Controllerate of Quality Assurance (Electronics),
JC Nagar PO,
Bangalore-560006.

11.9.2 The manufacturers have to submit at least three prototype samples of the equipment.
Out of these, two samples will be submitted for AHSP Evaluation, and one sample for user‟s
trials and maintenance evaluation. However, the No. of prototypes to be submitted may also
be specified, in the supply order/contract.

12. STORAGE AND TRANSIT

The equipment shall be stored in dry room temperature or as specified by the manufacturer.
The equipment shall be placed and suitably packed in packing case/transit case during transit.

13. TECHNICAL DOCUMENTS

13.1 The drawings for the equipment and accessories/sub-assemblies shall be forwarded by
the manufacturer with the prototype sample while submitting for Evaluation, along with
relevant catalogues wherever possible as per the relevant terms and conditions of the supply
order.

13.2 The Technical Documents Viz User Hand Book, Design Specification, Technical
Manual with Illustrated Spares Part List (ISPL) as Part IV of Technical Manual (TM), List of
components, List of maintenance spares, ie MRLS (Manufacturers Recommended List of
spares), and Procurement drawings, that are to be supplied by the manufacturer shall be
prepared in accordance with JSS 0251-01 (Guide to documentation) for preparation of
drawings, procedure laid down in JSS 50003 may be followed. 3 sets of Drawings, one set on
RTF/Cloth negative and 2 sets of Blue Prints) shall be forwarded to the AHSP.

14. WARRANTY

14.1 The stores supplied against the relevant specification shall be deemed to bear the
warranty of the contractor against defective design, material, workmanship and performance
for a period of 15 months or as per relevant clauses of contract/supply order from the date of
receipt at consignee‟s, end.

14.2 If during the period under which the equipment is under warranty the stores supplied
are found to be defective, the same shall be replaced/rectified with serviceable store by the
contractor at site free of any charges or as may be decided by the purchasing officer on the
recommendation of consignee/Quality Assurance Authority.

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15. PACKAGING

15.1 The store shall be securely packed to avoid damage in the transit so as to reach the
consignee in perfect serviceable and ready to use condition. The packaging shall be marked
clearly with consignee‟s address and other necessary details for easy identification by the
consignee. The packaging shall, however be done to the entire satisfaction of the Quality
Assurance Authority.

15.2 Additional requirements, if any, shall be specified in contract by the indenting

Authority.

15.3 A Wide Arrow mark in RED indicating the Top of the package to be marked on all
the packages to indicate the direction in which they are to be stored, transported, opened etc.

16. DEFENCE STORES CATALOGUE NUMBER/NATO STOCK NUMBER

16.1 The DS Cat No./Nato Stock Number allotted to the items covered by this specification
have been indicated in the respective supplement sheets. The action for allotment of
Cat No./NSN for other Charger batteries will be taken up by the AHSP during grant of bulk
production clearance and the same will be intimated to the manufacturer and other agencies
concerned.

16.2 The DS Cat No./NSN will be mentioned on the equipment at a suitable location and
also in the documents pertaining to the equipment.

17. SUGGESTIONS FOR IMPROVEMENT

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

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

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SUPPLEMENT

DETAILED SPECIFICATION FOR CHARGER

BATTERY FOR RS LUP 322

1. GENERAL FEATURES

The battery charger I/P 230 V ±5 V ac, 50 Hz or 36 V dc, Out Put 31.8 ±2 V dc, 1 A
(Cat No. X2/6130-000 442 used on Radio Set LUP 322. The Battery Charger is designed for
charging 24 V, 4 Ah Nickel Cadmium batteries Packs which are used with Radio Set
LUP 322. Two battery packs can be charged simultaneously and independently with this
rechargeable battery system.

2. USED ON DATA

The main equipment of these chargers is TRANSMITTER RECEIVER RADION RS LUP

322 (Z1/5820-003940)

3. TECHNICAL DATA
a) Nominal Voltage - 24 V.

b) Rated Capacity of Battery - 24 V, 4 Ah.

c) Construction & Layout - As per Manufacturer‟s drawing approved by CQA(L)

Bangalore.

d) Environmental Specification - JSS 55555 (L-2A).

e) Overall Dimensions and Mass:

1) Dimensions

i) Height - 400 mm (maximum).

ii) Width - 325 mm (maximum).

iii) Mass - 30 kg (maximum).

2) Weight - 9.5 kg Max

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4. PARAMETRIC REQUIREMENTS

Table 3 Parametric Requirements

Class of JSS 6130-16 Test/Parameter Specified Performance

Test Clause No.
A1 11.8 (a) General Examination The charger shall be visually
examined for any defects in
construction, It shall be free from
moisture, rust etc, corrosion of metal
parts or any kind of deterioration.
11.8 (a) (1) Visual Examination The condition and workmanship and
finish shall be satisfactory. The
markings shall be made legible and
indelible and shall be as specified in
clause 8 of this specification.
A2 11.8 (a) (2) Dimensions (over all) Depth - 340 mm
Width - 265 mm
Height - 105 mm
A3 11.8 (a) (3) Mass Mass - 9.5 kg (Max)
A6 11.8 (a) (6) Input Current Input Voltage
Regulation and i) 36 V to 44 V dc
Output Current ii) 205 V-255 V, 50 Hz, ac
B3 11.8 (a) (7) Output Voltage
A7 Charging Current 1A 24.5-32.3 V ac
(Max)
B1 11.8 (a) (8) Battery Charging Two batteries of rating 24 V, 4 AH
can be charged simultaneously and
over charging is protected by timer
circuit. Trip-off time of Battery
charger is 7 h ±15 min.
B2 11.8 (a) (9) Continuous working The batteries of RS LUP 322 shall be
charged continuously for a period of
7 h ±15 min in constant current mode
using this charger.
B3 11.8 (a) (10) Over voltage & short The specified under and over Voltage
circuit protection. for the charger is 36 and 44 V dc and
205 and 255 V ac at the input. A
tripping circuit will protect the battery
charger from variation in input voltage
and no damage shall be occurred.
Short circuit protection provided by
means of glass fuses. Any short circuit
in output, fuse will blow and circuits
will be protected.
B4 11.8 (a) (11) Reverse Polarity The charger shall withstand any
Protection (dc) accidental reverse polarity connection
at Input terminals (dc).

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Table 3 Parametric Requirements (Concluded)

Class of JSS 6130-16 Test/Parameter Specified Performance

Test Clause No.
B5 11.8 (a) (12) Reverse current The reverse current protection should
protection be less than 0.1 mA.
B6 11.8 (a) (15) Environmental tests: JSS 55555 Category L2A.
except for the
following testes

5. ACCESSORIES AND CARRIED SPARES

Accessories

S. No. Nomenclature Qty. Cat No./Details

a) Battery Charging Cable 02 No. Z1/5995-002 139
b) Mains Power Cable 01 No. Z1/5995-000 639
c) Battery Cable 01 No. Z1/5995-000 638
d) Bag Cloth Canvas for keeping the charger 01 No. X2/8105-000 190
e) Fuses 01 No. 4A (For dc i/p)
01 No. 0.8 A (For ac i/p)
02 No. 1A (For O/P)
f) User Hand Book 01 No. -

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PERFORMANCE REQUIREMENT-ENVIRONMENTAL TESTS

(GOVERNING SPECIFICATION-JSS-55555, CATEGORY L-2A)

S. Test Name Test No. Test Details Specified Performance

No.
a) Vibration 28/3.4.2(c) Endurance by sinusoidal Visual examination & PC
Table with Frequency 5 Hz to to be carried out and
4.28.2.3 (a) 350 Hz ±6 mm const disp should be satisfactory
or 2g acc. Whichever is
lesser, 2 h in each axis,
Eqpt OFF condition.
b) High 17/3.2.6 Operation at Temperature - PC to be carried out
Temperature Test 55ºC ±3ºC during last 30 min and
Operation Test condition Duration - 16 h. Eqpt in ON should be satisfactory
„K‟ Condition in Last 30 min
c) High Temp 17/3.2.6 Storage at +70ºC ±3ºC PC to be carried out after
Storage Test Duration 16 h recovery at RT and
Recover period 2 h to 4 h should be satisfactory
Duration: 16 h Eqpt OFF
condition
d) Damp Heat 10/3.2 Temperature - 40ºC ±2ºC 1. PC to be carried out
Test Relative Humidity - 95% during last 30 min and
Duration - 16 h should be satisfactory
Recovery - 2 h to 4 h
2. PC to be carried out
after recovery and should
be satisfactory
e) Low 20/3.2.4 Temperature - &20ºC ±3ºC 1. PC to be carried out
Temperature Procedure 4 Duration - 16 h during last 30 min and
Test Condition J Recovery - 2 h to 4 h. Eqpt should be satisfactory
Operational in ON Condition during
last 30 min 2. PC to be carried out
after recovery and should
be satisfactory
f) Altitude test 3, Procedure Temp: &20ºC ±3ºC 1. PC to be carried out
1, Test Altitude: 3000 m 70 kPa during last 30 min and
Condition Duration: 16 h should be satisfactory
L1, Recovery 2 h to 4 h
Table 4.3-1, 2. PC to be carried out
Test after recovery and should
Condition be satisfactory
A-1
g) Sealing Test 23/3.1.1 Eqpt to be pressurized to At the end of 30 min, the
Procedure 1 air pressure of 25 kPa air pressure reading
Test Duration: 30 min should not fall more than
Condition A 10 kPa, should be
satisfactory

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PERFORMANCE REQUIREMENT-ENVIRONMENTAL TESTS

(GOVERNING SPECIFICATION-JSS-55555, CATEGORY L-2A) (CONCLUDED)

S. Test Name Test No. Test Details Specified Performance

No.
h) Immersion 19/3.3.4, Depth of water 1 meter No ingress of 30 min, the
test Test (excess pressure 9.8 kPa at air pressure reading
condition C +25ºC) During immersion should not fall more than
Table 02 h the equipment is to be 10 kPa, should be
4.19-1 thoroughly dried by satisfactory
wiping. Recovery period:
2 h to 4 h
j) Dust Test 14/Clause Temperature 40ºC ±3ºC, No ingress of dust to be
3.2 RH 50%, Dust observed. PC after test to
Concentration 25 g +5 g. be found satisfactory
Duration 01 h. Recovery
2 h to 4 h.
k) Tropical 27/3.2.7 Temperature 20ºC ±2ºC 1. PC carried out during
Exposure Test RH 95% and 35ºC ±2ºC the first two h of the
Test Condition B RH 95% No. of Cycles – 35ºC period of the 7
14 cycle

2. PC to be carried out
after recovery 14 cycles
and should be found
satisfactory
m) Drop Test 13/3.2.3 Drop height: 250 mm No. Visual examination and
Test of drop one drop each side PC to be carried out and
Condition D should be found
satisfactory
n) Toppling 26/3.2 4 topple each on all the Visual examination and
Test faces PC to be carried out and
should be found
satisfactory
p) Bump Test Test Peak acceleration of 1. Equipment should
condition 5 400 m/s2. not Deteriorate and
Table No. Pulse duration : 6 m/s, should be satisfactory
4.5-2 No. of bumps 1000 ±10,
(Clause 1-3 bumps/s 2. PC to be carried out
3.3.2) and should be
satisfactory

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