Battery Testing Standards IS 15549 : 2005

The primary regulatory framework is IS 15549:2005 (Stationary Valve Regulated Lead Acid Batteries — Specification). This standard, reaffirmed in 2020, incorporates critical amendments (including Amendment 3) to address modern safety requirements and material durability for high-integrity energy storage.

This standard is not universal to all lead-acid types; it specifically targets high-performance stationary cells:

• Telecom Batteries: For 4G/5G base stations and exchanges.
• UPS Systems: Industrial-grade backup for data centers.
• Power Plants: Control and instrumentation backup.
• Solar/Renewable Storage: Deep-cycle VRLA units used in stationary grids.

Testing is exhaustive to simulate years of field use in weeks:

• Electrochemical Analysis: Ah and Wh efficiency checks.
• Material Endurance: High-temperature aging and cycle-life testing.
• Integrity Checks: Container pressure tests and flame arrestor verification.
• Environmental Stability: Charge retention and thermal runaway resistance.

For reports to be legally and commercially valid, testing must be conducted in a NABL-accredited laboratory (ISO/IEC 17025). Furthermore, if the goal is BIS certification, the lab must be recognized under the Bureau of Indian Standards (BIS) Laboratory Recognition Scheme.

The lead time is primarily dictated by the physical nature of battery discharge cycles:

• Standard Testing: 4 to 6 weeks for basic type tests.
• Endurance Testing: Can extend to 3–4 months if full cycle-life verification is required.
• Documentation & Review: 1 additional week for final reporting.

To ensure a statistically significant result, a minimum of 3 to 6 units of the same model/rating are typically required. These must be shipped in "factory-charged" condition with appropriate safety packaging to prevent terminal short-circuiting during transit.

The cost varies based on battery capacity (Ah rating):

• Standard Type Testing: Approximately ₹45,000 – ₹75,000 per model.
• Additional Charges: Logistics, custom fixtures for large cells, and endurance testing premiums.

Note: Official BIS filing fees are separate from laboratory testing fees.

To initiate the process, manufacturers must provide:

• Technical Data Sheets: Detailed specifications and $C_{10}$ ratings.
• BOM (Bill of Materials): Details on container material (PPCP/ABS) and separators (AGM).
• Internal Test Reports: Pre-check data from the factory.
• Circuit/Assembly Diagrams: Showing internal cell connection and valve placement.