ASTM F3005-22

Standard Specification for Batteries for Use in Small Unmanned Aircraft Systems (sUAS)

ABSTRACT
This standard specifies the requirements for batteries used in small Unmanned Aircraft Systems (sUAS). It covers the standard terminology for sUAS as well as the requirements with respect to cells, mechanical design and assembly, electrical design, and maintenance of the pack and the recording of maintenance data.
SCOPE
1.1 This standard defines the requirements for batteries used in small Unmanned Aircraft Systems (sUAS).  
1.2 This standard does not define requirements for the systems in which sUAS battery packs may be utilized.  
1.3 This standard is subordinate to Specification F2910.  
1.4 If allowed by a nation’s GAA, certain sUAS may be exempt from this standard and may use commercial off-the-shelf (COTS) batteries in non-safety-critical payloads (lithium chemistries may not be exempted). Air transport regulations still shall be adhered to when air transport is used for COTS cells or batteries in bulk.  
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.  
1.6 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

General Information

• Status: Published
• Publication Date: 30-Sep-2022
• ICS: 49.050 - Aerospace engines and propulsion systems
• Technical Committee: F38 - Unmanned Aircraft Systems
• Drafting Committee: F38.01 - Airworthiness

Relations

• Refers: ASTM F3060-20 - Standard Terminology for Aircraft
• Effective Date: 01-Jan-2020
• Refers: ASTM F3060-16a - Standard Terminology for Aircraft
• Effective Date: 01-Nov-2016
• Refers: ASTM F3060-16 - Standard Terminology for Aircraft
• Effective Date: 01-Apr-2016
• Refers: ASTM F3060-15b - Standard Terminology for Aircraft
• Effective Date: 15-Sep-2015
• Refers: ASTM F3060-15a - Standard Terminology for Aircraft
• Effective Date: 01-May-2015
• Refers: ASTM F3060-15 - Standard Terminology for Aircraft
• Effective Date: 01-Mar-2015
• Refers: ASTM F3060-14 - Standard Terminology for Aircraft
• Effective Date: 01-Dec-2014

Overview

ASTM F3005-22: Standard Specification for Batteries for Use in Small Unmanned Aircraft Systems (sUAS) sets the requirements for batteries employed in small Unmanned Aircraft Systems. Created by ASTM International, this standard focuses on the quality, safety, and performance of battery cells and packs used in sUAS. It addresses key aspects such as terminology, mechanical and electrical design, manufacturing, maintenance, and data recording, promoting reliability and traceability throughout the battery lifecycle.

Applicable globally where small UAS operate under regulatory permission, ASTM F3005-22 supports safer airspace by minimizing risks related to battery failure, which can compromise flight safety.

Key Topics

• Battery Requirements for sUAS: Describes mandatory specifications for battery cells and packs, including process controls, quality assurance, traceability, and documentation.
• Mechanical Design & Assembly: Outlines best practices for assembling battery packs to withstand vibration, impact, and potential abuse during operation.
• Electrical Design: Covers expected chemistries (NiCd, NiMH, LiIon, LiFePO₄, LiPo, SLA), wiring, connectors, capacity labeling, and node access for safety monitoring.
• Testing & Inspection: Details processes for capacity testing, physical inspection of cells, voltage checks, and requirements for lot tracking and records retention.
• Maintenance Procedures: Specifies user responsibilities for battery maintenance, regular testing, damage evaluation, storage, and safe disposal.
• Safety & Compliance: Emphasizes the importance of clear labeling, safety warnings, recovery identification, and adherence to safety protocols.
• Terminology & Acronyms: Defines consistent language, including terms like C-rating, characteristic thermal threshold (CTT), depth of discharge (DOD), and differentiates requirements using "shall," "should," and "may" statements.

Applications

ASTM F3005-22 is essential for organizations involved in the design, production, operation, and maintenance of small UAS. Its applications include:

• sUAS Manufacturers: Helps ensure that battery packs are designed and tested to rigorous standards, reducing risk of in-flight failures and improving product reliability.
• Operators & Maintenance Personnel: Provides guidelines for battery inspection, charging, cycling, and end-of-service criteria, which contribute to safe and efficient drone operations.
• Regulatory Compliance: Supports compliance with other governing standards and national aviation authorities, particularly regarding safety-critical applications and transport of battery packs.
• Quality Assurance & Traceability: Ensures all battery cells and packs are traceable through records management, facilitating recalls or investigations if necessary.
• Safety in Airspace Operations: Reduces hazards related to battery malfunctions, such as inability to safely terminate flights or loss of control, which can have significant safety and airspace management implications.

Related Standards

The following documents complement the implementation of ASTM F3005-22:

• ASTM F2910: Design and Construction of Small Unmanned Aircraft System (sUAS)
• ASTM F3060: Terminology for Aircraft
• ASTM F3341/F3341M: Terminology for Unmanned Aircraft Systems
• ANSI/ASQ Z1.4-2008: Sampling Procedures and Tables for Inspection by Attributes
• UL 1642: Standard for Lithium Batteries

By following ASTM F3005-22 alongside these related standards, stakeholders ensure a comprehensive approach to battery safety, reliability, and regulatory conformity for small unmanned aircraft systems.

Keywords: sUAS battery standard, unmanned aircraft system battery, ASTM F3005-22, battery safety, drone battery requirements, battery maintenance, small UAS compliance

Standards Content (Sample)

This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F3005 −22
Standard Specification for
Batteries for Use in Small Unmanned Aircraft Systems
(sUAS)
This standard is issued under the fixed designation F3005; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 2.2 Other Standards:
ANSI/ASQ Z1.4-2008 Sampling Procedures and Tables for
1.1 Thisstandarddefinestherequirementsforbatteriesused
Inspection by Attributes
in small Unmanned Aircraft Systems (sUAS).
UL 1642 Standard for Lithium Batteries
1.2 This standard does not define requirements for the
systems in which sUAS battery packs may be utilized.
3. Terminology
1.3 This standard is subordinate to Specification F2910.
3.1 Unique and Common Terminology—Terminology used
1.4 If allowed by a nation’s GAA, certain sUAS may be
in multiple standards is defined in F3341/F3341M, UAS
exempt from this standard and may use commercial off-the-
Terminology Standard and F3060, Aircraft Terminology Stan-
shelf (COTS) batteries in non-safety-critical payloads (lithium
dard.Terminology that is unique to this specification is defined
chemistries may not be exempted). Air transport regulations
in this section.
still shall be adhered to when air transport is used for COTS
3.2 Definitions and Acronyms—The standard terminology
cells or batteries in bulk.
forsUASasdefinedinhigherlevelstandardsappliesingeneral
1.5 This standard does not purport to address all of the
to this standard except as noted below.
safety concerns, if any, associated with its use. It is the
3.3 Definitions of Terms Specific to This Standard:
responsibility of the user of this standard to establish appro-
3.3.1 C-rating, n—maximum steady-state current (amps) at
priate safety, health, and environmental practices and deter-
which the battery cell or pack may be discharged without
mine the applicability of regulatory limitations prior to use.
having pack temperature exceed the CTT of its constituent
1.6 This international standard was developed in accor-
cell(s) or result in a reduction in cell life. C-rating is expressed
dance with internationally recognized principles on standard-
as a multiple of the capacity. For example, a battery with a
ization established in the Decision on Principles for the
nominal capacity of 4Ah may have a C-rating of 5C, meaning
Development of International Standards, Guides and Recom-
that 20 A would be considered its maximum safe current.
mendations issued by the World Trade Organization Technical
Barriers to Trade (TBT) Committee.
3.3.2 characteristic thermal threshold, CTT, n—the tem-
perature beyond which a rechargeable battery cell of particular
2. Referenced Documents
chemistry and structure will exhibit permanent deterioration of
its critical performance parameters as evident upon subsequent
2.1 ASTM Standards:
charge/discharge cycles. Cell capacity and internal resistance
F2910 Specification for Design and Construction of a Small
are critical performance parameters. CTTis rated at both upper
Unmanned Aircraft System (sUAS)
and lower thresholds.
F3060 Terminology for Aircraft
F3341/F3341M Terminology for Unmanned Aircraft Sys-
3.3.3 depth of discharge, DOD, n—ratio of cell or pack
tems
capacity expended relative to its nominal capacity.
3.3.4 pack, n—a single cell or composition of battery cells
connected in series or in parallel or both plus monitoring
This specification is under the jurisdiction of ASTM Committee F38 on
electronics, structure, and connector(s).
UnmannedAircraftSystemsandisthedirectresponsibilityofSubcommitteeF38.01
on Airworthiness.
Current edition approved Oct. 1, 2022. Published December 2022. Originally
approved in 2014. Last previous edition approved in 2014 as F3005 – 14a. DOI:
10.1520/F3005-22. Available from American Society for Quality (ASQ), 600 N. Plankinton Ave.,
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Milwaukee, WI 53203, http://www.asq.org.
contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Applicable only to 5.1 on cell suppliers.
Standards volume information, refer to the standard’s Document Summary page on Available from Underwriters Laboratories (UL), 2600 N.W. Lake Rd., Camas,
the ASTM website. WA 98607-8542, http://www.ul.com.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3005 − 22
3.3.5 pack assembler, n—that supplier which performs the 3.4.10 MSDS—Material Safety Data Sheet
manufacturing processes that integrate the essential compo-
3.4.11 NiCd—Nickel Cadmium
nentsintoafunctionalpack.Intheeventthatmultiplesuppliers
3.4.12 NiMH—Nickel Metal Hydride
are involved in the assembly process, the pack assembler is the
3.4.13 PCM—Protective Circuit Module
supplier that performs the final electrical connection(s). One
supplier may weld solderable tabs to a batch of cells, a second 3.4.14 PVC—Polyvinyl Chloride
supplier may connect circuitry, wiring and a connector, and yet
3.4.15 SDS—Safety Data Sheet
a third may install the assembly in a plastic housing. In this
3.4.16 SLA—Sealed Lead Acid
example, the second supplier would be the pack assembler.
3.4.17 sUAS—Small Unmanned Aircraft System
3.3.6 shall versus should versus may, v—use of the word
3.4.18 UAS—Unmanned Aircraft System
“shall” implies that a procedure or statement is mandatory and
must be followed to comply with this standard, “should”
3.4.19 UN-GHS—United Nations Global Harmonization
implies recommended, and “may” implies optional at the System
discretion of the supplier, manufacturer, or operator. Since
“shall” statements are requirements, they include sufficient 4. Applicability
detail needed to define compliance (for example, threshold
4.1 This standard relates to and is referencedbyothersUAS
values, test methods, oversight, reference to other standards).
standards at the sUAS system level as listed in Section 2. This
“Should” statement are provided as guidance toward the
standard is mandatory at any point in the sUAS system in
overall goal of improving safety and could include only
which batteries are used, except for payload downlinks that
subjective statements. “Should” statements also represent pa-
have no effect on flight safety.
rametersthatcouldbeusedinsafetyevaluationsandcouldlead
4.2 This standard is written for all sUAS that are permitted
to development of future requirements. “May” statements are
to operate over a defined area and in airspace defined by a
provided to clarify acceptability of a specific item or practice
nation’s GAA. Unless otherwise specified by a nation’s GAA,
and offer options for satisfying requirements.
this standard applies only to UAthat have a maximum takeoff
3.3.7 small unmanned aircraft system, sUAS, n—composed
gross weight of 55 lb/25 kg.
ofthesmallunmannedaircraft(sUA)andallrequiredon-board
4.3 Criticality of this standard is derived from safety risk
subsystems, payload, control station, other required off-board
analysis. The following failures are critical and are listed
subsystems, any required launch and recovery equipment, and
hierarchically, the first being the most critical:
command and control (C2) links between the sUA and the
4.3.1 Loss of independent power for flight termination by
controlstation.Sinceanyoneoftheprecedingsubsystemsmay
any means requiring battery power, resulting in inability to
affect reliability and thus safety of the sUAS, batteries used in
terminate the flight safely;
thosesubsystemsshallcomplywiththisstandardunlessfailure
4.3.2 Failure of primary power for the FCS resulting in loss
of the battery will not compromise safety. For purposes of this
of control to permit safe flight or recovery;
standard sUAS is synonymous with small Remotely Piloted
4.3.3 Failure of ignition power (if a battery is utilized
Aircraft System (sRPAS), and SUA is synonymous with a
instead of a magneto, alternator, generator or the like for
small Remotely Piloted Aircraft (sRPA).
internal combustion) or primary power for electric propulsion,
3.3.8 supplier, n—any entity engaged in the design or
creating the inability to return the sUAS to base and creating a
production of a battery pack or any component of a pack
ground impact hazard.
intended for use in a sUAS. The cell supplier is the manufac-
turer of the fundamental cell(s) constituent in a battery core.
5. Cells
Various suppliers contribute to the production of a pack, and
5.1 Responsibility of Cell Suppliers—As a minimum, the
any differences between them are described both explicitly and
cell supplier shall possess and provide the following:
by context throughout the document.
5.1.1 Process Control Plan for the specific cell being
3.4 Acronyms:
provided,including Quality Control Proceduresand Recording
3.4.1 COTS—Commercial off the Shelf
Methods.
3.4.2 CTT—Characteristic Thermal Threshold
5.1.2 A Quality Assurance Plan for the specific cell being
provided,includingcompliancewithUL1642requirementsfor
3.4.3 DOD—Depth of Discharge
cells.
3.4.4 IC—Internal Combustion
5.1.3 MSDS, also known as SDS per the UN-GHS for
3.4.5 Li—Lithium
chemicals classification.
5.1.4 Technical Data Sheet shall be a formal document, not
3.4.6 LiFe—Lithium Ferrite (commonly used, abbreviated
reference to LiFePO ) preliminary or informal. The manufacturer’s datasheet shall
include specification of the upper CTT.
3.4.7 LiFePO —Lithium Iron Phosphate
5.1.5 Every cell shall be marked with its Lot Number and
3.4.8 LiIon—Lithium Ion
Supplier’s Name to aid failure analysis, facilitate traceability,
3.4.9 LiPo—Lithium Polymer (commonly used term for a and minimize the extent of a recall should such action become
package-specific variation of the Lithium Ion chemistry) necessary.
F3005 − 22
5.2 Responsibility of Pack Assembler: 5.2.3.2 The MSDS (also known as SDS per the UN-GHS for
chemicals classification) for the cell type used in the pack;
5.2.1 Lot Testing—A sample from each lot of cells shall be
5.2.3.3 The data items, by lot,listedunder5.1.3–5.1.5(that
subjected to capacity testing and physical inspections. The
is, the pack assembler is to carry forward the data provided by
capacity test and physical inspections may, but are not required
the cell supplier);
to be performed on the same cells. Sampling shall be in
5.2.3.4 Pack assembler’s specified shipping/storage
accordance with ANSI/ASQ Z1.4-2008. Any alternate plan
voltage—These data are not intended to be a record of
must be approved by the GAA.The sampling plan shall accept
measured voltage for each pack but to stipulate the voltage
on zero defects.
range that the procuring entity can expect to measure upon
5.2.1.1 Capacity Test—The sample shall undergo one com-
receipt of a pack for the particular chemistry;
plete charge-discharge cycle to verify the integrity of the lot.A
5.2.3.5 The lot number of constituent cells used in a pack
charge-discharge cycle is defined as a full charge followed by
traceable to the pack serial number;
a full discharge to the depth specified by the cell manufacturer
5.2.3.6 Date of manufacture of the pack—As defined in
or as typical for the subject chemistry.
Section 6, the date may be codified in the serial number.
5.2.1.2 Physical Inspection—Physical inspections shall be
5.2.4 Pack Assembly Requirements—Amulti-cell pack shall
performedonthesample.Asubjectcellistoberejectedforany
not contain cells from more than one lot.An exception may be
of the following conditions:
madeifthreeconditionsaremet: (1)thedateofmanufactureof
(1) Swelling;
the cells are within a six-month span; (2) all cells to be used in
(2) Electrolyte leakage;
the pack are tested for capacity and found to be within5%of
(3) Out-gassing;
each other; and (3) all of the cells were manufactured recently
(4) Odor,evenintheabsenceofvisibleelectrolyteleakage,
enoughtobeconsideredacceptableforuseinnewconstruction
an obvious odor shall be considered evidence of a deteriorated
for the particular chemistry.
cell;
5.2.5 Final Test—Asaminimum,eachcompletedpackshall
(5) Deformed or damaged casing;
be subjected to two charge-discharge cycles, following which
(6) Punctures;
the pack shall be charged to its appropriate, chemistry-specific
(7) Tab condition—Seals are to be undamaged, and welds
shipping/storage voltage. A charge-discharge cycle is defined
are to be unbroken and of satisfactory quality. If a cell is
as a full charge followed by a full discharge to the depth
supplied with a PCM connected, accessible solder connections
specified by the cell manufacturer or as typical for the subject
to the tabs shall also be inspected. If a solder connection is
chemistry. The pack shall demonstrate its rated capacity by
unacceptable, it may be reworked by the pack assembler.
means of this testing to be acceptable for delivery to the
5.2.2 Received-Voltage Test—The pack assembler shall
procuring entity.
measure this voltage on every cell in the lot. The measurement
shallbemadebeforeanyloadorchargehasbeenappliedtothe
6. Mechanical Design and Assembly
cell. The measurement is taken directly at the cell tab,
6.1 In-Process Quality—The assembly process shall be
bypassing any protection circuitry that may be connected. In
devised such that it is conducive to observation of the physical
the event that a cell’s received voltage is outside limits that are
conditions listed in 5.2.1.2.This requirement does not stipulate
normal or recoverable for the particular chemistry, the cell
inspection of cells beyond lot testing but rather is intended to
shall be rejected. The received voltage shall not vary signifi-
maximize exposure of the cells to visual scrutiny during
cantly from what is considered the typical chemistry-specific
assembly.
storage/shippingvoltageorthemeanmeasurementforthebulk
ofthelot.Thereceivedvoltageforalotwilltypicallyvarylittle
...

This document is not an ASTM standard and is intended only to provide the user of an ASTM standard an indication of what changes have been made to the previous version. Because
it may not be technically possible to adequately depict all changes accurately, ASTM recommends that users consult prior editions as appropriate. In all cases only the current version
of the standard as published by ASTM is to be considered the official document.
Designation: F3005 − 14a F3005 − 22
Standard Specification for
Batteries for Use in Small Unmanned Aircraft Systems
(sUAS)
This standard is issued under the fixed designation F3005; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope
1.1 This standard defines the requirements for batteries used in small Unmanned Aircraft Systems (sUAS).
1.2 This standard does not define requirements for the systems in which sUAS battery packs may be utilized.
1.3 This standard is subordinate to Specification F2910.
1.4 If allowed by a nation’s GAA, certain sUAS may be exempt from this standard and may use commercial off-the-shelf (COTS)
batteries in non-safety-critical payloads (lithium chemistries may not be exempted). Air transport regulations still shall be adhered
to when air transport is used for COTS cells or batteries in bulk.
1.5 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility
of the user of this standard to establish appropriate safety safety, health, and healthenvironmental practices and determine the
applicability of regulatory limitations prior to use.
1.6 This international standard was developed in accordance with internationally recognized principles on standardization
established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued
by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
2. Referenced Documents
2.1 ASTM Standards:
F2910 Specification for Design and Construction of a Small Unmanned Aircraft System (sUAS)
F3060 Terminology for Aircraft
F3341/F3341M Terminology for Unmanned Aircraft Systems
2.2 Other Standards:
ANSI/ASQ Z1.4-2008 Sampling Procedures and Tables for Inspection by Attributes
UL 1642 Standard for Lithium Batteries
This specification is under the jurisdiction of ASTM Committee F38 on Unmanned Aircraft Systems and is the direct responsibility of Subcommittee F38.01 on
Airworthiness.
Current edition approved June 1, 2014Oct. 1, 2022. Published July 2014December 2022. Originally approved in 2014. Last previous edition approved in 2014 as
F3005 – 14.F3005 – 14a. DOI: 10.1520/F3005-14A.10.1520/F3005-22.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM Customer Service at [e-mail]. For Annual Book of ASTM Standards
volume information, refer to the standard’sstandard’s Document Summary page on the ASTM website.
Available from American Society for Quality (ASQ), 600 N. Plankinton Ave., Milwaukee, WI 53203, http://www.asq.org.
Applicable only to 5.1 on cell suppliers.
Available from Underwriters Laboratories (UL), 2600 N.W. Lake Rd., Camas, WA 98607-8542, http://www.ul.com.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3005 − 22
3. Terminology
3.1 Unique and Common Terminology—Terminology used in multiple standards is defined in F3341/F3341M, UAS Terminology
Standard and F3060, Aircraft Terminology Standard. Terminology that is unique to this specification is defined in this section.
3.2 Definitions and Acronyms—The standard terminology for sUAS as defined in higher level standards applies in general to this
standard except as noted below.
3.3 Definitions of Terms Specific to This Standard:
3.3.1 C-rating, n—maximum steady-state current (amps) at which the battery cell or pack may be discharged without having pack
temperature exceed the CTT of its constituent cell(s) or result in a reduction in cell life. C-rating is expressed as a multiple of the
capacity. For example, a battery with a nominal capacity of 4 Ah may have a C-rating of 5C, meaning that 20 A would be
considered its maximum safe current.
3.3.2 characteristic thermal threshold, CTT, n—the temperature beyond which a rechargeable battery cell of particular chemistry
and structure will exhibit permanent deterioration of its critical performance parameters as evident upon subsequent charge/
discharge cycles. Cell capacity and internal resistance are critical performance parameters. CTT is rated at both upper and lower
thresholds.
3.3.3 depth of discharge, DOD, n—ratio of cell or pack capacity expended relative to its nominal capacity.
3.3.4 pack, n—a single cell or composition of battery cells connected in series or in parallel or both plus monitoring electronics,
structure, and connector(s).
3.3.5 pack assembler, n—that supplier which performs the manufacturing processes that integrate the essential components into
a functional pack. In the event that multiple suppliers are involved in the assembly process, the pack assembler is the supplier that
performs the final electrical connection(s). One supplier may weld solderable tabs to a batch of cells, a second supplier may
connect circuitry, wiring and a connector, and yet a third may install the assembly in a plastic housing. In this example, the second
supplier would be the pack assembler.
3.3.6 shall versus should versus may, v—use of the word “shall” implies that a procedure or statement is mandatory and must be
followed to comply with this standard, “should” implies recommended, and “may” implies optional at the discretion of the
supplier, manufacturer, or operator. Since “shall” statements are requirements, they include sufficient detail needed to define
compliance (for example, threshold values, test methods, oversight, reference to other standards). “Should” statement are provided
as guidance toward the overall goal of improving safety and could include only subjective statements. “Should” statements also
represent parameters that could be used in safety evaluations and could lead to development of future requirements. “May”
statements are provided to clarify acceptability of a specific item or practice and offer options for satisfying requirements.
3.3.7 small unmanned aircraft system, sUAS, n—composed of the small unmanned aircraft (sUA) and all required on-board
subsystems, payload, control station, other required off-board subsystems, any required launch and recovery equipment, and
command and control (C2) links between the sUA and the control station. Since any one of the preceding subsystems may affect
reliability and thus safety of the sUAS, batteries used in those subsystems shall comply with this standard unless failure of the
battery will not compromise safety. For purposes of this standard sUAS is synonymous with small Remotely Piloted Aircraft
System (sRPAS), and SUA is synonymous with a small Remotely Piloted Aircraft (sRPA).
3.3.8 supplier, n—any entity engaged in the design or production of a battery pack or any component of a pack intended for use
in a sUAS. The cell supplier is the manufacturer of the fundamental cell(s) constituent in a battery core. Various suppliers
contribute to the production of a pack, and any differences between them are described both explicitly and by context throughout
the document.
3.4 Acronyms:
3.4.1 COTS—Commercial off the Shelf
3.4.2 CTT—Characteristic Thermal Threshold
F3005 − 22
3.4.3 DOD—Depth of Discharge
3.4.4 IC—Internal Combustion
3.4.5 Li—Lithium
3.4.6 LiFe—Lithium Ferrite (commonly used, abbreviated reference to LiFePO )
3.4.7 LiFePO —Lithium Iron Phosphate
3.4.8 LiIon—Lithium Ion
3.4.9 LiPo—Lithium Polymer (commonly used term for a package-specific variation of the Lithium Ion chemistry)
3.4.10 MSDS—Material Safety Data Sheet
3.4.11 NiCd—Nickel Cadmium
3.4.12 NiMH—Nickel Metal Hydride
3.4.13 PCM—Protective Circuit Module
3.4.14 PVC—Polyvinyl Chloride
3.4.15 SDS—Safety Data Sheet
3.4.16 SLA—Sealed Lead Acid
3.4.17 sUAS—Small Unmanned Aircraft System
3.4.18 UAS—Unmanned Aircraft System
3.4.19 UN-GHS—United Nations Global Harmonization System
4. Applicability
4.1 This standard relates to and is referenced by other sUAS standards at the sUAS system level as listed in Section 2. This
standard is mandatory at any point in the sUAS system in which batteries are used, except for payload downlinks that have no effect
on flight safety.
4.2 This standard is written for all sUAS that are permitted to operate over a defined area and in airspace defined by a nation’s
GAA. Unless otherwise specified by a nation’s GAA, this standard applies only to UA that have a maximum takeoff gross weight
of 55 lb/25 kg.
4.3 Criticality of this standard is derived from safety risk analysis. The following failures are critical and are listed hierarchically,
the first being the most critical:
4.3.1 Loss of independent power for flight termination by any means requiring battery power, resulting in inability to terminate
the flight safely;
4.3.2 Failure of primary power for the FCS resulting in loss of control to permit safe flight or recovery;
F3005 − 22
4.3.3 Failure of ignition power (if a battery is utilized instead of a magneto, alternator, generator or the like for internal
combustion) or primary power for electric propulsion, creating the inability to return the sUAS to base and creating a ground
impact hazard.
5. Cells
5.1 Responsibility of Cell Suppliers—As a minimum, the cell supplier shall possess and provide the following:
5.1.1 Process Control Plan for the specific cell being provided, including Quality Control Procedures and Recording Methods.
5.1.2 A Quality Assurance Plan for the specific cell being provided, including compliance with UL 1642 requirements for cells.
5.1.3 MSDS, also known as SDS per the UN-GHS for chemicals classification.
5.1.4 Technical Data Sheet shall be a formal document, not preliminary or informal. The manufacturer’s datasheet shall include
specification of the upper CTT.
5.1.5 Every cell shall be marked with its Lot Number and Supplier’s Name to aid failure analysis, facilitate traceability, and
minimize the extent of a recall should such action become necessary.
5.2 Responsibility of Pack Assembler:
5.2.1 Lot Testing—A sample from each lot of cells shall be subjected to capacity testing and physical inspections. The capacity
test and physical inspections may, but are not required to be performed on the same cells. Sampling shall be in accordance with
ANSI/ASQ Z1.4-2008. Any alternate plan must be approved by the GAA. The sampling plan shall accept on zero defects.
5.2.1.1 Capacity Test—The sample shall undergo one complete charge-discharge cycle to verify the integrity of the lot. A
charge-discharge cycle is defined as a full charge followed by a full discharge to the depth specified by the cell manufacturer or
as typical for the subject chemistry.
5.2.1.2 Physical Inspection—Physical inspections shall be performed on the sample. A subject cell is to be rejected for any of the
following conditions:
(1) Swelling;
(2) Electrolyte leakage;
(3) Out-gassing;
(4) Odor, even in the absence of visible electrolyte leakage, an obvious odor shall be considered evidence of a deteriorated cell;
(5) Deformed or damaged casing;
(6) Punctures;
(7) Tab condition—Seals are to be undamaged, and welds are to be unbroken and of satisfactory quality. If a cell is supplied
with a PCM connected, accessible solder connections to the tabs shall also be inspected. If a solder connection is unacceptable,
it may be reworked by the pack assembler.
5.2.2 Received-Voltage Test—The pack assembler shall measure this voltage on every cell in the lot. The measurement shall be
made before any load or charge has been applied to the cell. The measurement is taken directly at the cell tab, bypassing any
protection circuitry that may be connected. In the event that a cell’s received voltage is outside limits that are normal or recoverable
for the particular chemistry, the cell shall be rejected. The received voltage shall not vary significantly from what is considered
the typical chemistry-specific storage/shipping voltage or the mean measurement for the bulk of the lot. The received voltage for
a lot will typically vary little from cell to cell and certainly should remain within a 10 % window. (For example, a LiPo will
normally be shipped in a half-charge state, holding at about 3.8 V). If the cell is outside the storage/shipping voltage, the cell shall
undergo the capacity test and physical inspections of 5.2.1 to ensure its integrity. The received-voltage test may be performed as
part of the assembly process rather than as an incoming test if the lot will be utilized for production before significant self-discharge
occurs.
5.2.3 Records and Certifications—The pack assembler shall obtain and make available to the GAA and the procuring entity
pertinent information regarding the pack assembly. These data shall be available so long as that pack model is marketed or sold
and for a minimum of three years thereafter. These data shall either be shipped with the pack(s), provided upon request or be
accessible by other means such as the pack assembler’s website:
F3005 − 22
5.2.3.1 The technical data sheet from the cell supplier for cells used in the pack;
5.2.3.2 The MSDS (also known as SDS per the UN-GHS for chemicals classification) for the cell type used in the pack;
5.2.3.3 The data items, by lot, listed under 5.1.3 – 5.1.5 (that is, the pack assembler is to carry forward the data provided by the
cell supplier);
5.2.3.4 Pack assembler’s specified shipping/storage voltage—These data are not intended to be a record of measured voltage for
each pack but to stipulate the voltage range that the procuring entity can expect to measure upon receipt of a pack for the particular
chemistry;
5.2.3.5 The lot number of constituent cells used in a pack traceable to the pack serial number;
5.2.3.6 Date of manufacture of the pack—As defined in Section 6, the date may be codified in the serial number.
5.2.4 Pack Assembly Requirements—A multi-cell pack shall not contain cells from more than one lot. An exception may be made
if three conditions are met: (1) the date of
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