Circulation of draft Guidelines for series approval of Storage Batteries for conducting testing in test Labs for implementation of Solar Systems, Devices and Component Goods Order 2025 – EQ

Summary:

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## **Context & Objective**

* Issued by: **Ministry of New & Renewable Energy (MNRE), Standards & Quality Control Division**.
* Purpose: To guide **manufacturers and test labs** in the **series approval process** of storage batteries (Lead Acid, Lithium-ion, Nickel-based) for testing and registration with **BIS**, as per **Solar Systems, Devices and Component Goods Order 2025**.
* Standard Reference: **IS 16270:2023 – Secondary Cells & Batteries for Solar PV Applications** (General Requirements and Methods of Test).

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## **1. Product Family Definition**

* A **product family** is defined by the maximum configuration of components/subassemblies.
* Models in a family must have **common design, construction, and critical parts** to ensure conformity.

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## **2. Material & Construction Requirements**

* **Lead-Acid Batteries**:

* Containers: hard rubber, transparent SAN, FRP, polypropylene.
* Sealed types: polypropylene copolymer, ABS, SAN, or acid-resistant plastics.
* Electrolytes and separators must meet IS 16270 standards.

* **Nickel-Cadmium / Nickel-Metal Hydride Batteries**:

* Containers: alkali-resistant (nickel-plated steel, stainless steel, nonporous plastic).
* Electrolyte: KOH with LiOH additive.
* Separators must be alkali-resistant with insulating capacity.

* **Lithium-Ion Batteries**:

* Cell casing: depends on type (cylindrical, prismatic, pouch).
* Pack enclosures: flame-retardant, impact-resistant.
* Materials/components must meet national/international safety standards.

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## **3. Testing Procedures**

* Samples randomly picked by labs from production batches.
* Manufacturers must supply **material details, separator type, sealing method, dimensions, connectors, and electrolyte level indicators** (for vented types).
* **Charging procedure**: As per manufacturer; if not given, follow IS 16270 standards.
* Environmental conditions (temperature, humidity) to be as per manufacturer’s specs, else standard defaults apply.

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## **4. Sampling & Sequence of Tests**

* Each chemistry has **specific sampling rules**:

* **Lead Acid (Vented & VRLA)** → IS 13369, IS 1651, IS 15549 compliance; must be marked with source, Ah capacity, year, origin.
* **Nickel-Cadmium (vented & prismatic gas recombination)** → IS 10893/10918/15767 compliance; must be permanently marked.
* **Nickel-Metal Hydride & Portable Ni-Cd** → IS 16048 (Part 1 & 2); must have durable markings.
* **Lithium-Ion (Portable & Industrial)** → IS 16047 (Part 3) & IS 16822; must provide details like chemistry, separator material, dimensions, rated capacity.

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## **5. Requirement (Pass/Fail Criteria)**

* Tests must strictly meet **Clauses 8 & 9 of IS 16270 (2023)**.
* Failures in short-term tests (e.g., capacity) require resubmission of that rating for testing.

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## **6. Selection of Representative Models**

* Short-term tests → All ratings in a series.
* Endurance/type tests → Only **highest rated model** in the series.
* If passed, approval extends to the entire product series.
* Manufacturer must provide **undertaking of consistency** in alloy composition, electrode materials, grid purity, thickness, and production quality systems.

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## **7. Series Grouping for Type Testing**

* **Lead-Acid (2V Flooded & VRLA, 12V Flooded & VRLA)** grouped into **capacity bands** (e.g., ≤400 Ah, 400–700 Ah, >1000 Ah).
* **Nickel-Cadmium & Nickel-Metal Hydride** grouped into **≤45 Ah, 90–500 Ah, 500–1000 Ah, >1000 Ah**.
* **Li-ion (Cylindrical/Prismatic/Pouch)** grouped into **≤20 Ah, 20–100 Ah, 100–500 Ah, 500–1000 Ah, >1000 Ah**.
* For each group, the **highest rated model** is tested as representative.

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## **8. Safety & Installation Guidelines**

* Batteries are hazardous (fire, explosion, chemical, electrical). Safe installation and handling required.
* Key safety requirements:

* Use lifting devices; monitor temperature; maintain terminals.
* Ensure expansion capability info; mark shock hazards.
* Install per safety data sheets; insulate exposed components.
* Parallel connections → each system must have isolator.
* Safe handling gear: acid/alkali-resistant aprons, gloves, goggles, neutralizers (bicarbonate, boric acid).
* Manufacturer must provide a **safety brochure** covering:

* Electrical characteristics (voltage range, load pattern).
* Charging conditions (rapid/trickle charge).
* Size, weight, terminal type, lifecycle, storage period.
* Disposal/recycling procedures.
* Storage guidelines:

* Keep on wooden/plastic planks, not damp areas.
* Avoid combustible materials/heat sources.
* Ensure ventilation and restricted access.

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