The Ministry of New and Renewable Energy has released comprehensive guidelines for testing and approval of storage batteries under the Solar Systems Devices and Component Goods Order 2025. The guidelines cover lead acid lithium acid 

The guidelines cover lead acid lithium ion and nickel based batteries and aim to guarantee stable performance and safety in solar photovoltaic applications. Manufacturers and laboratories are need to adhere with these rules for BIS registration which ensures that all solar systems use trustworthy and high quality batteries.

The guidelines also define a product family to simplify testing and approvals. This permits a representative battery model to be tested for all performance and safety requirements, minimizing repetitive testing while guaranteeing that all models within the same family fulfill the required standards. Manufacturers must submit full technical details and comply with recommended procedures to maintain compliance with IS 16270.

Importance of MNRE Guidelines

The MNRE guidelines are important, as they ensure the safety, performance, and reliability of batteries used in solar systems. They offer a clear framework for both manufacturers and testing laboratories, promoting standardized practices.

• Manufacturer Guidance: MNRE guidelines help manufacturers understand the complete process of submitting batteries for testing, ensuring timely sample selection, appropriate material compliance, complete documentation, and BIS registration, mitigating any delays and enhancing overall quality guarantee.
• Laboratory Standardization: Testing laboratories profit from clearly defined sequences and performance benchmarks, allowing uniform evaluations, precise measurement of battery capabilities, and generation of reliable test reports for lead-acid, lithium-ion, and nickel-based batteries.
• Product Family Definition: By outlining product families, the guidelines minimize repetitive testing, letting representative models to go through full assessment while other models with similar design and materials can be approved on the basis of same performance norms.
• Safety Assurance: Safety protocols defined in the guidelines ensure correct battery installation, handling, and storage. These measures minimize risks of fire, chemical exposure, electrical hazards, and physical injuries during operation, transportation, or routine maintenance.
• Performance and Reliability: The guidelines promote long-term battery performance by helping manufacturers maintain quality across all batches. They support laboratories in verifying durability, capacity, and efficiency, confirming that solar systems function safely and effectively over time.
• Collaboration and Transparency: By encouraging constant practices and clear documentation, the guidelines promotes collaboration between manufacturers and laboratories. This boosts safer installations, reduces operational failures, and fortifies the renewable energy infrastructure in India.

Defining a Product Family

A product family is a group of battery models that are built from the same optimal configuration of components and subassemblies. All models share a common design construction and key parts. This categorization ensures compliance with performance requirements while minimizing repeated testing.

Testing a representative model from a product family allows approval of other models in the same series, provided there are no changes in materials, manufacturing methods, or component specifications. Manufacturers are required to submit a declaration ensuring that all models comply with same quality system and production process to be considered in the same family.

Key Battery Types and Material Requirements

The MNRE guidelines cover three main battery types. Each type has specific requirements to ensure safety and performance.

• Lead Acid Batteries: Lead acid batteries must be manufactured using high quality materials that are free from defects. Vented batteries should have containers made from hard rubber fibre reinforced plastic or polypropylene. Sealed batteries should use acid resistant plastics. Sulphuric acid water and separators must adhere to IS 16270 requirements. Appropriate labeling and durable markings including source of manufacture capacity and year of manufacture are mandatory for all batteries.
• Nickel Cadmium and Nickel Metal Hydride Batteries: Nickel based batteries should use high strength alkali resistant containers made from stainless steel nickel plated steel or non-porous plastics. Electrolytes are prepared using potassium hydroxide distilled water and lithium hydroxide additives to achieve particular concentrations. Separators must be alkali resistant and electrically insulating. All cells must be consistently manufactured and marked with manufacturer information nominal voltage rated capacity and production date as per applicable IS standards.
• Lithium Ion Batteries: Lithium ion batteries must be made with high quality raw materials free from faults. Cell casing must suit the cell type cylindrical prismatic or pouch. Battery pack inclusions must be flame retardant impact resistant and follow the national and international safety rules. Manufacturers must give details of container type chemistry separator materials dimensions weight voltage and rated capacity. Proper markings on cells are required and should be permanent and no deteriorating.

Procedure for Submitting Batteries for Testing

Testing laboratories will pick batteries at random from production batches. Manufacturers must provide:

• Material and type of container.
• Type of separator and sealing.
• Overall dimensions and weight.
• Recommended charging procedures.

For lead-acid batteries, manufacturers must provide:

• Level indicators for opaque containers.
• Minimum and maximum markings for transparent containers.
• Appropriate connectors for all cells.

Charging Guidelines

• Labs must follow manufacturer instructions for charging.
• If no instructions are given, IS 16270 standard methods will be applied.
• Temperature and humidity must be maintained as recommended.

Sampling and Sequence of Tests

Testing requirements differ by battery type. Samples are designated from production batches and must have the same voltage rated capacity electrolyte composition and dimensions. Proper markings on each cell or battery are required including manufacturer information country of origin and year of manufacture.

• Stationary Lead Acid Batteries: For vented stationary lead acid batteries the number of samples must follow IS 16270. All cells submitted must have the same minimal voltage capacity electrolyte composition and overall dimensions. Testing sequence consist of capacity discharge performance and endurance tests.
• Valve Regulated Lead Acid and Tubular Gel Batteries: Valve regulated and tubular gel batteries must follow IS 15549. Samples must meet specifications for voltage capacity and composition. Proper permanent markings are required. Testing includes type tests and endurance evaluations.
• Nickel Cadmium Batteries: Vented nickel cadmium batteries must meet IS 10893 and IS 10918. Cells must have uniform voltage capacity and electrolyte composition. Markings must be durable and include manufacturer information nominal voltage and production date.
• Nickel Cadmium Prismatic Rechargeable Cells: Prismatic rechargeable cells must meet IS 15767. Positive terminals must be marked and samples must follow the same manufacturing standards. Tests include short term capacity tests and endurance evaluations.
• Portable Nickel Cadmium and Nickel Metal Hydride Batteries: Portable batteries must follow IS 16048 standards. All cells must have the same nominal voltage rated capacity and dimensions. Markings must include manufacturer's name, polarity date of manufacture and capacity. Testing follows IS 16270 sequences.
• Lithium Ion Batteries: Lithium-ion batteries for portable and industrial use must meet IS 16047 and IS 16822. Samples must have the same chemistry container type and dimensions. Proper connectors and manufacturer-recommended charging procedures must be provided. Cells must be permanently marked with voltage and capacity information.

Representative Model Selection

A representative model is selected to minimize repetitive testing. The highest rated sample undergoes full type tests including endurance tests. If a short term test fails the particular rating must be retested. Manufacturers must ensure that all models are produced with the same materials processes and quality standards.

The following table defines the series of secondary lead-acid cells and batteries:

Safety and Maintenance Guidelines

Batteries can be dangerous if mishandled. They can cause fire explosion chemical hazards or electrical shocks. Proper installation storage and handling is critical. Manufacturers must give detailed safety instructions and recommendations.

1. Lifting and handling heavy batteries safely.
2. Monitoring temperature and maintaining proper connections.
3. Specifying whether battery bank capacity can be expanded.
4. Providing information about electrical hazards.
5. Following the safety data sheet for each battery type.
6. Restricting access to unauthorized personnel.
7. Ensuring proper ventilation and insulation of exposed parts.
8. Installing isolators for parallel-connected systems.
9. Using protective gear such as gloves, goggles, aprons.
10. Providing detailed instruction brochures including voltage, charging, size, weight, and lifespan.
11. Storing batteries according to manufacturer’s instructions and avoiding damp areas.
12. Specifying procedures for disposal and recycling of batteries.

Conclusion

The MNRE guidelines for storage battery testing under the Solar Systems Order 2025are essential for India’s renewable energy sector. They provide clear instructions on testing performance and safety standards for lead acid lithium ion and nickel based batteries. Compliance with IS 16270 ensures reliable efficient and safe solar installations. These guidelines increase confidence in solar systems by making manufacturers laboratories and end users adhere to uniform high quality standards.