# PILOT OPERATING HANDBOOK
DJI S-900/Zenmuse

Author: Gene Payson Revised: 9/02/2014 http://www.troybuiltmodels.com


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# PILOT OPERATION HANDBOOK DJI S-900/Zenmuse

This bookis offered in a format so thatpilots can customize the checklists to their exact needs. Please print outthis handbook, make notes while watching the video regarding the checklist, then change the wording and orderto suityour needs. Then printoutthe revised form and laminate it in plastic. Use it everytime you operate your aircraft. Keep the log books regarding the following: 1) Pilotflight time 2) Aircraft flight time 3) Aircraftmaintenance and updates 4) Batteryusage, date put into service, voltage, mah vs time Print out and make readily available the error message legend ofvarious flashing lights. Know whatto do withouthesitation should you observe warnings. Insurance is a must! Notonly will itbe expensive to repair your aircraft in the event ofan incident, ifyou injure bystanders or damage otherpeople's property you are liable for damages which could run into the millions ofdollars. One insurance company which currently writes policies on sUAS is www.Transportrisk.com Errors & Omissions should be sentto customerservice@troybuiltmodels.com. We will promptly update the POH for everyone to have the latest updates available.



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## 2 © 2014 Troy Built Models, Inc. All Rights Reserved.

# DJI S900 KEY PARAMETERS

MaxTakeoffWeight: 18 lbs. Approved Cameras: SonyNex5/7, Panasonic GH3/4, Blackmagic Cinema 

### ---No Gimbal 13.5lbs

### = S900 NO Gimbal and TBM 21000 12.3lbs

### = S900 NO Gimbal and TBM 15000

--- Nex-7 Gimbal 17.2lbs

## = S900 withNex-7 and TBM 21000 16lbs = S900withNex-7 and TBM 15000

--- GH3/GH4 Gimbal 17.68lbs = S900 with GH3/GH4 and TBM 21000 16.48lbs = S900 with GH3/GH4 and TBM 15000

--- BMPCC Gimbal 17.3lbs

### = S900 and TBM21000 16.1lbs = S900 and TBM 15000

--- SD Gimbal 22.5lbs

## = S900 and TBM21000- OVERWEIGHT! 21.3lbs 

### = S900 and TBM 15000- OVERWEIGHT!

FlightTimes using 90% ofbattery: 15,000 mah battery with gimbal and camera: 15+min 21,000 mah battery with gimbal and camera: 20+ min These times are averages in ourtests. Individual flight times may differbased on weight and flying style.



## 3 © 2014 Troy Built Models, Inc. All Rights Reserved.

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# DJI S-900/Zenmuse CHECKLISTS

• DJI S-900 BENCH SET UP & 

### TESTS o All screws/bolts are tight 11) 

### o Timer alarm for flight timeto not exceed 80%battery capacity set properly 

### o Batteries are secure 

### o Antennas are secure 

### o Props balanced 

### o Props aligned 

### o Props not chipped o Checkblades, arms, etc. for cracks/damage 

### o Wiring Tight 

### o No excessive flexing ofmotors or booms 

### o Booms/motors will not twist o Center ofgravity is correct 

### o Warning lights set for lowbattery ifused 

### o Batteries charged. Replace any battery which cycles below 80% ofrated capacity • Laptop Battery • Flight Battery • Handheld Rx Battery • RC TxBattery • Video Rx Battery • Spare Laptop Battery



### • DJI S-900 INVENTORY CHECKLIST ,U o LoadFlightplan 

### o Aircraft 

### o Camerawith SD card 

### o Spare parts/tools 

### o Spare batteries 

### o Two RC transmitters 

### o Laptop 

### o Battery Charger 

### o Flight Controller Cable 

### o Video monitor, stand, battery, antennas o Goggles 

### o Datalink & cable 

### o Battery Y-harness



## 4 © 2014 Troy Built Models, Inc. All Rights Reserved.• DJI S-900 PREFLIGHT CHECKLIST o Position: GCS, S900 o Emergency LZ o Wind o Area secure o Antennas o GCS o Lens cap o CameraOn o SD card o Flight battery: voltage- install

- CO o C2 Tx: Switches- On- Model Selection- 5.4V+ o Photo Tx- Switches- On- Model Selection- 5.4V+ o Copter On o Calibrate?

- Cycle o Copter Voltage on GCS o GPS Mode- Double Purple/Single Purple o Course Lock Mode

- Green o Camera/Gimbal tests o Upload mission o Zero altitude

• TAKEOFF CHECKLIST 

### o Timer o GPS mode (Course lock?) o Motor startup/checks o Takeoff o Landing Gear

• LANDING CHECKLIST 

### o LZ clear o Landing Gear o Land o Flight Time o Copter/CameraPower down o AdjustParams o Power Down batteries o Motor Temps o Logbooks



## 5 © 2014 Troy Built Models, Inc. All Rights Reserved.-------------------------------------------------------------------------------------------------

• ERROR

### MESSAGES o White flashes • IMU malfunction. Land and determine cause. Possibilities: • GPS/Compass notpointing forward • IMU notpointing forward • Set up ofX, Y, Z for location ofiMU and Compass is incorrect o Excessive rocking/instability possible causes: • Weak motor • Structure flexing from fatigue or cracks • Motor mount • Main frame • Booms • Loose Bolts causing flexing ormisalignment • Props • Mounts • Props out ofbalance • Props misaligned • Excessive wind speeds or gusts • Excessive Gains • Excessive motorpower. Max motorpower must a little more than typical ascent power. o Red Flashes (1, 2 or 3 flashes with pauses)- GPS loss (3 is more serious). Land ifloss lasts for more than 30 seconds. Possible causes: • Clouds • Structures • GPS mal-function • GPS too close to electrical components • GPS vibration



# 6 © 2014 Troy Built Models, Inc. All Rights Reserved.

### TABLE OF CONTENTS

• Section 1: General • Section 2: Limitations • Section 3: Emergency Procedures • Section 4: Normal Procedures • Section 5: Performance • Section 6: Weight and Balance/EquipmentList • Section 7: AirVehicle and Systems Description • Section 8: Handling, Service and Maintenance • Section 9: Supplements



# 7 © 2014 Troy Built Models, Inc. All Rights Reserved.---------------------------------------------------------------------------------------------



### SECTION 1 GENERAL NOTE: In an effortto minimize costs and maximize spare parts availability, many COTS (commercial off the shelf) components have been utilized. Some may have slight modifications to better suit this application. Most COTS products have separate data sheets, assembly manuals and instruction manuals. They are reference in this document, with key factors being emphasized. As with all high technology products utilizing constantly evolving software, it is importantto periodically check for online upgrades to the COTS components, including hardware, firmware and software. WARNING: Great care must be taken withthe batteries. Much ofthismanual and supplemental information is devoted to the use and care ofthe batteries, especiallythe flight batteries. They are less volatile than gasoline, though they should be treated with the same respect. Become very familiar with propertechniques oftheir use.

• GENERAL CHARACTERISTICS o Primarily for ISR (Intelligence, Surveillance, and Reconnaissance) o Economical due to extensive use ofCOTS products o LowVisual Signature o LowAural Signature 1

.. o Quick Launch and Recovery o ShortTraining Period o Simple Operation o WaypointNavigation o Backpackable o VTOL o Quick Repairs o Redundant Flight Systems o Safety Return to Home during lost link or lowbattery o High Degree ofMission Success o GPS navigation aid o Various sensors o 18 lb maxtakeoffweight o Operating Temp Range: -5°C to +60°C o FlightModes: Manual and GPS aided waypoint navigation o Maximum Operating Altitude: 1000 meters o Maximum Operation Wind Conditions: 

## l0

**~Is** o Propulsion System: LiPoly batteries o Takeoff: Manual orAutomatic o Landing: Manual orAutomatic o Takeoff/Recovery Area: 5m square



## 8 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • IMPORTANT DIMENSIONS o Distance rotor to rotor across the center: 35" o Height with GPS/Compass folded down: 21" o Heightwith GPS/Compass up: 25" o Length oflanding gear skids: 17" o Distance between landing gear skids: 18" o Collapsed size: 22" x 19"

• IMPORTANT WEIGHTS

i ·' 

### o ---No Gimbal o 13.5lbs

### = S900 NO Gimbal and TBM 21000 o 12.3lbs 

### = S900 NO Gimbal and TBM 15000 o --- Nex-7 Gimbal o 17.2lbs

## =S900 with Nex-7 and TBM 21000 o 16lbs = 

### S900 with Nex-7 and TBM 15000 o --- GH3/GH4 Gimbal o 17.68lbs = 

### S900 with GH3/GH4 and TBM 21000 o 16.48lbs = 

### S900 with GH3/GH4 and TBM 15000 o --- BMPCC Gimbal o 17.3lbs 

### = S900 and TBM 21000 o 16.1lbs 

### = S900 and TBM 15000 o --- 5D Gimbal o 22.5lbs 

### = S900 and TBM 21000- OVERWEIGHT! o 21.3lbs 

## =S900 and TBM 15000- OVERWEIGHT!

• MOTORS o Manufacturer: DJI-Innovations o Number ofmotors: 8 o Motor type: 41mm x 14mm o Motor Model Number: 41.14-11 o Motor KV /RPM: 400 o Motor max@25.2V: 10,000 rpm o Motor Max Power: 500 Watts o Power rating: 3000 Watts maximum power consumption for all6motors o Current Max: 100 amps o Amp Draw Typical Average: 55 amps
• PROPELLERS o Manufacturer: DJI-Innovations o Material: Composite o Number ofpropellers: 6 o Propeller model number: Dn 15 x 5.2 o Number ofblades: 2- folding o Propeller Diameter: 15" o Propeller Pitch (fixed): 5.2" o Max rpm: 10,000 rpm 

## 9 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • ELECTRONIC SPEED CONTROLS o Manufacturer: DJI-Innovations o Number ofspeed controls: 6 o Speed control model number: DJI 40A Opto o Rating in amps: 40 Amps continuous o Signal Frequency: 30

- 450 Hz o Drive PWMFrequency: 8KHz

• AUTOPILOT o Manufacturer: DJI-Innovations o Autopilot Model Number: DJI A2 o Components: GPS/Compass, IMU, Master Controller, Power Distribution System, LED Indicator Lighting System, Data Transceiver, GCS Software o Power Consumption: 5W o Operating Temp Range: -5°C to +60°C o Software Compatible: Windows XP sp3 

### IWindows 7 o HoveringAccuracy: Vertical:± 0.5m; Horizontal:± 2m

• ANALOG WIRELESS LINKS o Distributor: DJI-Innovations o Frequencies: • 2.4 Ghz datalink with WiFi • 2.4 Ghz Command & 

### Control • 5.8 Ghz Video o Power Consumption: <1 watt o Usable Range: <2 km.

• DIGITAL WIRELESS LINKS (Lightbridge) o Distributor: DJI-Innovations o Frequencies: • 2.4 Ghz (C2 & 

### Video) o Power Consumption: <1 watt o Usable Range: <2 km.

• FLIGHT BATTERY o Manufacturers: Various COTS suppliers o Battery chemistry recommended: Lithium Polymer o Battery Capacity: up to 21,000 mah or greater depending on max gross weight o Battery cell countrequired: 6S (6 cells in series) o Battery Voltage: 21V minimum during hover, 22.2V nominal, 25.2V maximum o Battery Minimum Rated Discharge Rate: 20C minimum o Battery Minimum Charge Rate: lC (3C preferable) o Battery Rest Time between discharging and charging: 0-30 minutes o Batteries used simultaneously: typically 1 o Recommended Battery Discharge Amount: 80-90%



# 10 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • FLIGHT PARAMETERS o Flight Time: 20+ minutes typical o Payload Max: 9.5 lbs for battery, sensor and gimbal



### • WARNINGS o Neverpower a video transmitter orreceiver without an antenna connected or overload failure will occur. o Read all information regarding batteries contained in this manual and supplements. o Batteries are highly flammable and can explode, especially when fully charged. Improper charging, vibration, impact, high discharge, etc. can lead to explosion and fire. Batteries must be charged under constant supervision and using properprecautions. o Batteries fully charged must be handled with extreme care. o Batteries must not be stored above 60% charged state. o Store batteries between 20%

- 60% charged state. Fully chargejustbefore use. o Fully charged batteries which are not'to be used within 24 hours should be discharged to 20% -50%charged state. o Discharging LiPoly batteries in excess of80% oftheir rated capacity can cause harm to the batteries. o Using more than one battery at a time requires the properwiring harness so thatthe voltage is no more than 25.2V. Overvoltage will cause serious damage to electrical equipment. o Using more than one battery at a time requires weight and balance checks. Proper CG is critical to performance. Airframe must not be overloaded. o GPS/Compass mustbe facing forward. o Do notuse GPS Mode without GPS lock. o Use low strength thread locking compound on all screws. o Wireless Video and Dataranges vary considerably on many factors including weather, equipment, and obstructions. Be prepared for com failures

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## ll © 2014 Troy Built Models, Inc. All Rights Reserved.

### • AIRSPEED LIMITATIONS 

### SECTION2 LIMITATIONS

o Vne- Velocity to NeverExceed: 15 m/s o Va- Typical Maneuvering Speed- 5 m/s

• POWER&POWERPLANTLIMITATIONS o 40 Amps max per motor o 40 Amps max per speed control o 320 Amps max total o Do notexceed 80-90% discharge ofrated battery capacity o Do not charge batteries which are warmerthan air temperature o Allow batteries to cool after use before charging o Leave an air gap between batteries when multiple batteries are used simultaneously

• WEIGHT LIMITS o TakeoffWeightMax: 18 lbs • Must be checked priorto takeoffifany change in equipment is made

• CENTER OF GRAVITY LIMITS o 3mm from the center ofany ofthe three pairs ofarms • Must be checked before every flight to ensure batteries were installed in the proper location. • Check all 4 pairs ofarms before flight

• MANEUVERLIMITS o This aircraft is intended for non-aerobatic operations o G-loading maximum: 20

• TEMPERATURE LIMITS o Operating Temp Range: -10°C to +40°C o In cold temperatures • Keep IMU atroom temperature ifpossible before the flight • Keep Batteries above 

## soc before flight • Do not fly with any frost or ice on the propellers o In warm temperatures • Batteries heat up when discharged • The higher the discharge rate the higherthe temperature increase during use • Attemperatures above 45°C, use of2 or more batteries is required to lowerthe load on any one battery pack to keep it cooler.

• WEATHERLIMITS o Light dust and lightrain require the use ofa shield for the electronics in the center section. o Light dust and light rain are acceptable for the unshielded motor and ESC.



## 12 © 2014 Troy Built Models, Inc. All Rights Reserved.• RANGE LIMITS o FUEL • Fuel capacity is aprimary limiting factor. • Flying into the wind will use more battery powerto travel the same ground distance. Higher air speeds will be required to penetrate the wind which used more battery power. Take this into account when flying a mission. • Where possible, fly upwind at the start ofa mission and downwind at the endto avoid depleting the battery before returning to base. Have alternative landing sites available in case ofemergency landing.

o WIRELESS LINK • Wireless links will be stable in LOS (line ofsight) in most conditions • Wireless links are always susceptible to shorter ranges due to • Atmospheric conditions • Othertransmission devices in the area • Jamming • Antennas not aligned properly • Impropervoltage • Antennablockage from AV in certain positions • Multipath- reflection offbuildings or ground which cause multiple signals to arrive at different times and/orphase.



# 13 © 2014 Troy Built Models, Inc. All Rights Reserved.

## SECTION3 EMERGENCY PROCEDURES

• MOTORFAlLURE o Operation is possible with one motor/ESC/propeller failure • The two adjacentmotors/ESCs will be increased in thrust automatically by the flight controllerto overcome the loss • In cases where the airframe is highly loaded the maximum rating of40 amps may be exceeded bythese two motors/ESCs • Operation shouldbe terminated as soon as possible to reduce the possibility ofdamage to the remaining motors

• COMMUNICATIONFAILURE o Video link failure • 5.8 Ghz being the shortestwavelength in general AV use has the least ability to penetrate. This link should be the first to be lost. • Itis bestto lose video first! Itis the least likely to cause a crash when it fails. • 5.8 Ghz can lose link with little warning. • Ensure thatthe GCS station antennas are perpendicularto the AV. Do notpointthe antenna at the AV. • Yawthe AV to change the antennaposition • Other links should still be good. Return backto the GCS until link is restored. • Transmitters produce heatwhenin operation. When overheated they may have thermal protection which interrupts use temporarily. Use ofa heat sink orfan may be required especially with high ambienttemperatures. • Higher gain antennas may be used, but do so with caution. High gain antennas are directional. • Multiple antennas using "diversity" can be used. Diversity is a device which determines the best signal, and uses that. • 5.8 Ghz even at high wattages theoretically has less range than lower frequencies. Changingto 1.3 Ghz is an option, though there are other issues to be considered. o RC link failure • 2.4 Ghz antennas can lose linkwith little warning. • Anything in between the two antennas can cause temporary signal loss especially a person. , • Hold the transmitter up in**th~** air and walk in the general direction oftheAV (aerial vehicle).

. • Ensure thatthe antenna is vertical. Do notpointthe antenna at the AV. • The failsafes on the RC link should be set so thatthe AV returns to home. Shouldthis require a heading change, the antenna may move into a more desirable position and linkwill be restored. 

## • The onboard equipmentmay blockthe signal. Yawthe AV so that the antennas point towardsthe GCS. • A LRS (long range system) can be used as a permanent solution. This is higher in wattage and usually on 433 Mhz. o DataLink Failure • 900 Mhz do not lose link without some warning. When drop outs are noticed to increase in frequency that is the limit ofthe range. 

## 141 © 2014 Troy Built Models, Inc. All Rights Reserved.--------------------------------------------------------------------------------------------

• Ifusing 900 Mhz, this is on cell phone frequency. Ifa cell tower is nearby it can swamp the signal. 900 Mhz may not be usable in that area. Change to a different freq. orremain closerto the AV

o LOWBATTERY POWER • Fail-safes can be set such that in the. event oflow battery power, either due to a failure ortoo long ofa flight, the warning light on the AV will constantly flash amber. This is the first level ofwarning. • The second warning level is red flashing lights • Auto landing will occurwhen battery power is low. Itmay land in a tree or a lake, so this is not desirable. • Landingwith 80-90% ofbattery depleted is best. Therefore landing with 17,000 mah used and 3,000 mah remaining ofa 20,000 mah battery is desirable. Batteries should be drawn down equally when in use ifthey are both charged equally and both in relatively the same condition/age. · • Do notmix partially chargedbatteries. Only use completely chargedbatteries. • Over discharging a battery below 19.8V can permanently damage the battery.
o GCS FAILURE • Takeoverbythe external pilot should happen ASAP using the RC link. • Most often happens due to a low battery. • Keep a spare 3 cell LiPoly battery with the appropriate plug to plug into the charge jackfor emergency use. Most chargers are 19V output which is roughly equivalentto a 4-cell battery. 3-cell batteries may work.



### o COMPASS CALIBRATIQNERROR 1 .:· • Ifthe compass is out ofcalibration the warning light wiii flash red. This is the same signal as low voltage. Ifthe voltage is correct, there is a calibration error. • Recalibrate the con:pass follo,wing the instruction manual



### o FIRE 

## • 

## •
• 

## • Fires can occur due to a short circuit orbattery failure

. Disconnectthe battery ASAP unless there is danger in doing so ifthere is any electrical issue. Itis notpossible to putout a battery fire

. Do not attemptto putout a battery fire. Use a fire extinguisherto put outfires surroundingthe battery. A C02 fire extinguisher is betterthan the powder or chemical type. C02 does not leave a residue. Water can be used though it may cause other electrical component failures.

o FORCED LANDINGS • Ifalternate emergency landing zones should be chosen ahead oftime. • Be sure thatthe LZ is clear ofpeople to avoid any incidents. • Land in the nearestLZwhich is clear ofpeople. • Announce your intentions oflanding as loud as necessary to alertpeople ofthe incoming AV.



# 15 © 2014 Troy Built Models, Inc. All Rights Reserved.

### SECTION 4 SET UP SUGGESTIONS

• ELECTRONICS BURNIN o We recommendthatyouputweights onto the landing skids to keep the copter onthe ground andrun the copter at about70%throttle for about 2 hours to bum in the electronics. Most electronic failures occur in the first 2 hours ofoperation. • GPS/COMPASS MASTLENGTH o We found thatthe higherthe mast, the betterthe GPS reception • Nex5Nvs. Nex7 vs. Panasonic GH3 o These cameras are excellent for stills, and very good for video. The bestfor video is the Panasonic GH4 with 4kcapabilities. o We found thatthe Nex 5Ntakes exceptional quality stills and video, though most professionals use theNex 7, o Usethe Panasonic GH4 ifyouprimarily shoot video • RADIO SETUP o Followthe instructions in the manual ,, o Wepreferthe switch assignment as shown in the checklists above though feel free to modify to your liking • COPTERCOMMAND AND CONTROL o We recommend the use ofa dual rate switch for main copter operation. • High rate- used to initializethe motors. The flight controller will not engage unless it sees full down throttle, full left rudder, full left cyclic and full back cyclic. However, these may be too high for normal flying. Onhigh rate it is helpful to utilize fairly high exponential to make the stick feel soft around center. Adjustto yourpreference. • Lowrate- used for typical flying. Setthe endpoint adjustments such thatfull stick deflection offers the maximum speed required in normal flying. Ifconditions require higherflight speeds, switch to high rate. On low rate it is also helpful to utilize a small amount ofexponential to make the stickfeel soft around center. Adjust to your preference. • ZENMUSE COMMAND AND CONTROL o We recommendthe use ofa dual rate switch for gimbal operation.

• TIMERS • High rate- used to initialize the gimbal. The gimbal may not engage unless it sees full motion. However, these may be too high for shooting video smoothly. This is bestfor still photography so as to putthe camera on target quickly. On high rate it is helpful to utilize fairly high exponential to make the stickfeel soft around center. Adjust to your preference. • Lowrate- used for videographyl Set.the end point adjustments such thatfull stick deflection offers the maximum speed required for videography. Ifconditionsrequire highergimbal speeds, switch to highrate. On low rate 

### itis also helpful to utilize a small amount ofexponential<to make the stickfeel soft around center. Adjustto your preference. ·


### o Use ofthe countdown timer is a good backup method to ensure landing with battery power. • Setthe timer for 20 minutes (orwhatyou deem appropriate) and have 

### it startwhen the throttle is over K Then adjustthe timerupwards until the amount ofbattery used is about 80-90% ofthe total available. Ifusing 20,000 mah batteries, atotal of 17,000 mah would be the target. Setthe timer suchthatyouhave a minute or so to land after 

## 161 © 2014 Troy Built Models, Inc. All Rights Reserved.• BATTERIES**---------~-----------------------------**

the alarm sounds so thatyou have adequate time to returnto base. Adjustto your preference.


### o Replace the transmitter standard battery with aLipoly battery to extend use times to 8hours. Supplied batteries often last about 2 hours.

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## 171 © 2014 Troy Built Models, Inc. All Rights Reserved.

## NORMAL PROCEDURES

• PREFLIGHTCHECKLIST o Confirm all communication radios are operational • Radio with ATC • Radios with others in the group o Set a perimeter of 100 meters • Area mustbe clear ofpeople to avoid collision o Check for overhead power lines and other obstacles to avoid o Check structural integrity • In event ofprior crash, inspect all booms, props and motor mounts for excessive flex indicating structural fatigue/failure o Have a manual flight plan avoiding obstacles. o Load auto flight plan ifusing one • Be surethatthe total flight time is under 10 minutes to avoid low battery o Clean lens • Remove lens cap o Ensure camerahas SD card installed • Many flights have been wasted due to this! o Install batteries • Ensure thatthe straps are tight and;the Velcro keeps the batteries from moving which will avoid a shift in the CG (CenterofGravity- orthat itbalances evenly) o . Check CG (Center ofGravity) ' · • Liftthe copter on each ofthe 3 pairs,ofarms. The copter shouldbalanceproperly. If not, do not fly. Rearrange the equipment such thatthe CG is o IMUpointingforward , • The Inertial MeasurementUnit is set so that it must face forward o GPS/Compass installed, limited free play, pointing forward • This device mustbe installed with a screwto hold it in place. Itcannot vibrate easily. Ifit does notpointforward, the corrections in ATTl and GPS mode will be incorrect and it will crash. The FC will provide a warning with constant flashing white lights. o Level copterusing a bubble level with front pointing in correct direction for course lock- do nottum on • Keep in mind the best angle for pointing the landing gear in the directionthatwill keep the landing gear outofthe shotwhen flying. o Tum on PilotTx o Ifusingthe rate gyro, set it atthe correctposition. This is usually a slider switch. Gains should have the range set from 200-350. Use the highest gain possible which does not cause oscillation. o CheckModel Selection on Txto be S900 o Throttle on TxDown o Return to Home switch Off 1'. •' '; o Adjust gain to correctposition (ifrequired) o Manual FlightMode Switchto manual (not,ATTI or GPS mode) o FlightPath Switch Off- Not Course orHqme or POI o CheckTxbattery voltage (above 7.5v) • These settings above are reqtiired to initialize the copterproperly. Ifthe switches are in the incorrect position, it will not initialize properly which may cause some ofthe functions like course lock or GPS mode to not operate properly. 

# 18 © 2014 Troy Built Models, Inc. All Rights Reserved.• Ifthe copter does not function properly aftertakeoff, land immediately and disconnect the copterpower. Thenput all the switches in the properposition for initialization and turn the powerbackon to the copter. o Count down timer should be set correctly depending on battery capacity. This can be adjusted to yourflying style. The timer should engage at 

### Y4 throttle and trigger an alarm atthe proper time. This is a backup alarm in case the indicator lights on the copter are notvisible. o Turn onPhotography Tx 

### o CheckModel Selection on Tx

- shouldread Zenmuse 

### o Check Txbattery voltage (above 5.4v for Futaba 14ch) 

### o HDMI switch Off 

### o Freestyle switch Off(FPV On) • These settings above are required to initialize the Zenmuse properly. Ifthe switches are in the incorrectposition, it will not initialize properly which may cause some of the functions like live video or gimbal operation to not operate properly. • Ifthe camera or gimbal do not function properly, disconnectthe copterpower. Then put all the switches in the proper-position for initialization and turn the powerback on to the copter. o Engagepowerto copter • Plug in the 2 batterypacks. Typically the battery packs use red T-style connectors in a parallel wire harness. This Y-harness has a yellow connector. Itis preferableto connectthe batteries to theY-harness first, then plug in the yellow connector. This reduces (but does not eliminate) electrical arcing. • 6 quick chirps should be heard confirming 6S LiPoly batteries are recognized by the ESCs. • Hearing less than 6 chirps indicates fewer cell battery packs are being recognized which is incorrect,. Checkfor improper or damaged batteries. 

### o Do notmove orvibrate the Squadcopteruntil 30 seconds after full GPS Lock • Initial 

### 3 red blinks is normal meaning no GPS lock. No red flashes indicates full GPS lock. • Continue with checklist as you are waiting for full GPS lock, but do notmove the copter. • Ifthe GPS takes more than 5 minutes to lock, there is aproblem with the area. It is not receiving the proper signals from the satellites. GPS signals are weak, so trees, people, buildings, terrain, weather, have an effect. Move the copter into a more open area where it can more easily see the satePites. o Check CopterVoltage from both

**Tx'~, (tran~mitters)**  • The transmitters receive a signal from the corresponding receivers. The voltages are regulated to about 5v. Ifthe voltagtdsbelow 4.4v or above 6v do not fly. There may be powerregulation issues. l;':Q.e receivers cannotwork outside this voltage consistently. Also there is some issue ifthe voltage is outside thatrange which should be resolved before flying. o EngageAttitude Mode- Must achieve double amber flash o Engage GPS Mode- Must achieve double purple flash o Engage course cock mode- Must achieve double green flash o Disengage course lock mode. Must achieve double purple flash. Stay in this mode untiljust priorto takeoff, aftertakeoffat any time, ordo not use. o Do notengage motors. Setthrottle to centerposition. Must achieve single purple flash when in GPS mode. • To verify thatthe sticks are all centeredproperly: 

# 19 © 2014 Troy Built Models, Inc. All Rights Reserved.

l I j• With throttle in the centerposition, use the trim buttons on the transmitter to check thatthe sticks are centered. Trimthe roll (the sticklocated on the right side ofthe transmitterwhen moved to the right and left) to the right, counting the number of clicks until a double flash occurs. Then centerthe trim. Then move the trim to the left, countingthe number ofclicks until a double flash occurs. An equal number ofclicks should be counted each side ofcenter. • Do this check for the 3 stick movements otherthan throttle. • Centerthe trim such that when the stick is in the neutral position thatthere are equal numbers ofclicks in each direction

.. 1 This ensures thatwhen the sticks are neutralized thatthe flight controllerwill recognize this signal and engage GPS mode. o Calibrate GPS/Compass before the first flight each day or ifreceiving continuous red blinks orcontinuous white blinks. • Flipthe GPS mode switch 7times very quickly from manual to GPS. End with the switch in the manual position. The indicator light will be blue. Rotate the copter about 1.5 turns in a horizontal position. A green flashing light indicates thatthis is complete. Then hold the coptervertically and rotate about 1.5 turns. A white flashing light indicates that this is complete. Repeat ifnecessary until this is completed. o After calibration, resetthe copterby cycling battery with copterpointed in the correctheading for course lock. o Engage Camera o HDMI switch On • This will stop video from playing on the back ofthe camera and will send the video signal to the video transmitterviathe HDMI connection. o Freestyle switch On (FPV Off) • This allows the camerato be operated freely through the transmitter o Verify cameraoperation • Operatethe shutter • Setthe focus to auto or manual. Mcipual setting is usually set to infinity to stop constantfocusing ofthe camera. 'q o Verify data link ifinstalled • Roll the copter about45

**deg~ees** .on its side by lifting one side ofthe copter and resting one side ofthe

**lan~ing** gear on the ground • A correspondingroll should be seen onthe gauge. • Ifthe copter is rolled to the right, it will appear on the gauge thatthe horizon rolls to the left- notthe right because the view from inside the copter is thatthe horizon rolls the opposite direction ofthe copter. o Verify altitude is about 0 via gauge on computer • Ifit is not about 0, the altitude settings for the waypoints will be offby this amount. This could cause the copterto fly at 10 meters or 30 meters ifthe waypoint is setfor 20 meters andthe altitude is offby 10 meters one way or another. Ifthe copterthinks it is at 10 meters when it is onthe ground, then it will only rise 10 meters above the groundto achieve what itbelieves itto be 20 meters above the ground. • The altitude canbe reset using the ground control softwareby going to altitude offset. o Alternate Emergency Landing Sites Established

• NORMAL TAKEOFF o Confirm clearfor takeoffwith ATC :'i • Necessary ifwithin5 miles ofan airport 

## 20 © 2014 Troy Built Models, Inc. All Rights Reserved.• ATC clearance is required days.or w;eeks before flying. o Engage GPS mode- Double purple flash when the throttle is down. o Switch to Course Lock flight mode ifrequired. Purple flashes are replaced with green flashes. Flying in course lock is notrequired;buthelpful in many instances. o Announce loudly: "CLEARPROP" o Move both ofthe sticks to the bottom left corners to engage the motors. Within 1 second move the throttle up 1/8- 1/4. The copter should not lift offuntil about 

### Yz stick is reached. o Verify data and video links before lifting off. Ifanything is not working properly, move the throttle stickto lowto disengage the motors and determine a solution. o Ifall flight checks are passed, announce loudly: "TAKING OFF" o Advance throttle to about 3/4. Coptermustjump offofthe ground to avoid one skid coming up before the other skid, and the skid on the ground getting caught and flipping the copter over sideways. o Ascend to 3 meters. Then decrease throttle to 

### Yz to engage the GPS hold. o Verify links, GPS, Attitude, etc. Should be single purple flash. o Verify thatthe copter is holdingposition within .5m in all directions. o Verify camera operation o Verify course lock is operational by rotating 90 degrees and pushing forward on stick. o Verify copter stability. Ifunstable, land and reset gains, recalibrate, orretest as necessary. o Proceed with manual mission or o For autopilot operation n! • Ascendto 10meters • Command AVO to proceed with mission. • Pilot shoulq say "It'syours" • Response from AVO "I have it" o Manual pilot/observer must monitorthe informational LED and be ready to take over in manual mode when necessary. • White flashes indicates flight controller issue • Amber flashes indicates low battery • Red flashes indicate loss ofGPS or severe battery condition • Quick decisions are required when red flashes are indicated • 10 seconds or moreofloss ofGPS signal will stop waypoint guidance and any GPS hold andput into manual mode. • Red indicator light battery warning requires immediate landing o Manual pilotto request copter flight battery voltage readout from AVO periodically. • Resetthe first and second indicator lights as required for your setup. • When recharging the batteries, the goal is to put4,000 mah into a 5,000 mah battery pack. Adjust the voltage warnings to your style offlying.
1 • Also use the countdown timer on the transmitter. This gives a good indication of battery level becausethe current

**us~d** is fairly constant from flight to flight.

• POSTLANDING o Note flight time from transmitter. Write this down in the log book. o Note battery powerused during the flight. Write this down in the log book. o ALWAYS disconnect the main powerto the AV first, then turn offthe transmitter. 

## 21 © 2014 Troy Built Models, Inc. All Rights Reserved.o Check motortemperatures by touching them with your fingers. Any motors which are excessively hot should be further inspected and possibly replaced. o Check battery temperatures by touching them with your fingers. Battery temperatures should not be hotto the touch. Battery temperatures should be slightly above ambient. o Inspect all components especially the propellers for wear. o Note in logbook which batteries were used to calculate life cycle.

• AIRCRAFT FLIGHTLOG BOOK (Can be purchased inexpensively) o Keep a log ofall flights. • Date • Time ofDay • Time in Operation (in hours) • Battery serial numbers • Mah used in flight

. • Location • Pilot, Observer, Sensor OperatorNhmes • Flight Objective • Remarks

• AIRCRAFTMAINTENANCE LOG BOOK (Can be purchased inexpensively) o Keep a log ofsignificant inspections, tests, repairs, alterations, equipment changes. • Date maintenance is performed • Accumulated hours ofoperation • Remarks

• PILOTLOG BOOK (Can be purchased inexpensively) o Keep a log ofall flights. Include the following: • Aircraftflown • Aircraft serial number • Date • Time ofDay • Time in Operation (in hours) • Location • Flight Objective • Remarks



# 221 © 2014 Troy Built Models, Inc. All Rights Reserved.• FLIGHTTIMES 

### SECTIONS PERFORMANCE --------------

o The AVis designed to hover at high efficiency. Hovering is much less efficient than flying on a wing, thus flight times are low compared to fixed wing aircraft. o All the weight ofthe A V is supported by powerfrom the batteries. As the batteries are used in a flight, the amount ofpower available decreases. Therefore the powerreserve is constantly decreasing as the battery is being used. Thus loading a rotorcraft above its limit is not recommended. While the AV may have enough powerto lift offinitially on a full charge, the powerreserve atpartial charge may be too lowto allow for maneuvering and will result in a crash. o High lateral speeds will add lift to slightly improve efficiency. The rotors act similarto fixed wings at higher speeds. This increase in efficiency may be negated by the increased power consumption offorward flight. o High winds or gusts decrease efficiency/flighttime. The motors work harderto hold position. o As weight increases flight times decrease.

• WIRELESS TRANSMISSION o Referto the specific manuals for performance ratings. o Wireless communications utilizedprovide acceptable communication for LOS. o In general: • LOS is required • Thehigherthe GCS antennas, the

**q~tter** therange • Any freq. at may have severe degra(\l,ation due to locationto other admitters such as cell towers • RSSI (Received Signal Strength Indication) should be monitored for indication of communication drop out.



## 23 © 2014 Troy Built Models, Inc. All Rights Reserved.• CG 

### SECTION 6 WEIGHT AND BALANCE EQUIPMENT LIST

o CO is critical to the efficient operation ofany AV o When components are shifted, the CG will be altered. o The main components which are moved on a regular basis are the sensors and the batteries. o The sensors are typically in the front ofthe AV, and the batteries are located in the correct position to offset all the components on the AV. o The CG must be tested after any changeto the components or theirplacement. o The CG should be tested by lifting the UV with fingers onthe bottom ofthe arms. Check all 3 pairs ofarms. The CG should be no more than 2mm offin any onthe 3 checks. The closerthe CG is to the centerlines ofthe arms the more efficient and the more stable the AV will be. • WEIGHT o Weight is critical to the operation ofany aircraft o Weight is especially critical to a rotor wing aircraft. Atfull throttle the motors have a finite amount ofthrust. All the weight is lifted by the battery power, there is no wing to assist in providing lift. ' o As the batteries are operated, they lose power. At full charge they have about 25v. At 20% remaining capacity they have about 21v. This is a loss of8% ofthe power avai!able which is significant. " o Do not overload the aircraft orthereiwill no't be sufficientreserve powerto maneuver at low battery levels.



## 24 © 2014 Troy Built Models, Inc. All Rights Reserved.

### SECTION7 AIR VEHICLE AND SYSTEMS DESCRIPTION

• FLIGHTBATTERY REQUIRED o Manufacturers: Various COTS suppliers o Battery chemistry recommended: Lithium Polymer o Battery Capacity: up to 21,000 mah or greater depending on max gross weight o Battery cell countrequired: 6S (6 cells in series) o Battery Voltage: 21V minimum during hover, 22.2V nominal, 25.2V maximum o BatteryMinimum Rated Discharge Rate: 20C minimum o Battery Minimum Charge Rate: I

### C (3C preferable) o Battery RestTime between discharging and charging: 0-30 minutes o Batteries used simultaneously: typically 1 o Recommended BatteryDischarge Amount: 80-90%

• WERELESS COMMUNICATIONS o Referto the specific manuals for performance ratings. o Neverpower a video transmitter orreceiver without an antenna connected or overload failure will occur. o Wireless communications utilized provide acceptable communication for LOS. o In general: o LOS is required. o Lower frequencies penetrate objects such as trees better than higher freqs. o Lower freqs have longerrange than high freqs o Higher freqs cantransfer more data than lower freqs o Higher freqs use smaller/shorter antennas o The higherthe GCS antennas, the betterthe range and reception o Any freq at may have severe degradation d.ue to location to other admitters such as cell towers o Range must be constantly monitored. , , :. o Alternate antenna types may be utilized to,jmprove link/range. Patch, helical, omni, etc. can be substituted. They must be verified

**befor:~** 

### use. o Alternate freqs may be utilized to improve link/range.



## 25 © 2014 Troy Built Models, Inc. All

**Right~ ~eserved.** 

### SECTIONS HANDLING, SERVICEAND MAINTENANCE

• PROPELLER CARE o Propellers mustbe checked each flight for nicks or cracks o Propellers are designed to last indefinitely ifthey do not impact dust, dirt or more.
• BATTERY CARE AND USE o Referto instruction sheet included from the battery manufacturer. Typical information follows. o Batteries are highly flammable and can explode, especially when fully charged. Improper charging, vibration, impact, high discharge, etc. can lead to explosion and fire. Batteries must be charged under constant supervision and using properprecautions. o Batteries fully charged mustbe handled with extreme care. o Anybattery which puffs up is considered damaged and must not be used. It is in a dangerous state. Never charge a puffed up battery. o Any battery which holds less than 80% ofits rated capacity should be discarded. o Cycle test each battery after every 50 cycles or ifa battery is suspected to have lost as significant amount ofits capacity to determine the current capacity. o Properly dispose ofbatteries. First discharge the battery fully using a battery cycler. Bringto a recycler such as a home improvement

**stor~.·.** o Always charge flight batteries under "balal):€,e"mode. o FlightBatteryRecommended Charge RaieYicwhich takes approximately 1hourto charge o FlightBatteryMaximum Charge Rate: May exceed 5C. Charge rates higherthan 1 C will decrease life cycles. Maximum charge rating perthe manufacturerwill provide 300+ cycles. Use the lowest charge rate which is practical. o Battery Rest Time between discharging and charging: 30 minutes minimum, 1hour maximum. o Do not charge ifthebattery is more than 2°C warmerthan ambient, especially ifthe temperature is above 20°C. The outer surface is coolerthan the inner core after use. Damage will occurwhen charging a warm battery. o Recommended Battery Discharge Amount: 80%. Using more ofthe capacity ofthe battery will decrease the life cycles o As battery temperature approaches freezing the capacity ofLithium Polymerbatteries decrease. Keep warmerthan 5°C before installing into the UV (unmanned vehicle). o Battery capacity decreases at higher discharge rates. Using more batteries decreases the discharge rate ofeach battery thereby extending individual battery capacity slightly. o Lower discharge rates improve the life cycles. o Batteries are rated at greaterthan 300 life cycles. 1,000+ life cycles are possible. o Batteries mustnot be stored above 60% charged state for extendedperiods. o Batteries should be stored below 25°C for extendedperiods o Store batteriesbetween 40%

- 60% charged1state. Fully chargejustbefore use. o Fully chargedbatteries which are nottQ be;tised within 24 hours should be discharged to 40%

- 60% charged state using the battery dischlitrger. o Using more than one battery at atime requires the proper wiring harness so thatthe voltage is no more than 25.2V. Overvoltage wiU caus,e serious damage to electrical equipment.
!


## 26 © 2014 Troy Built Models, Inc. All Rights Reserved.--------------------------------

• PREVENTATIVEMAINTENANCE o ANNUAL INSPECTION (SUGGESTED) • Ifthe airframe has in excess of300 hours in a one year period, an annual inspection mustbe completed by an approved technician. • An approved technician should disassemble the AV and inspect all components for wear and replace any components as required. • Test all batteries for capacity. • Upgrade firmware and software to latestrevisions

o 500 HOURPM (SUGGESTED) • An approvedtechnician should disassemble the AV and inspect all components for wear and replace any components as required. • Replace all motors. • Test all batteries for capacity. • Upgrade firmware and software to**;l~test** revisions.



# 271 © 2014 Troy Built Models, Inc. All Rights Reserved.

### SECTION9 SUPPLEMENTS COTS components have been utilized in the construction ofthis AV. All instruction manuals, operating handbooks, warning notices, and more are available as separate documents. Components which may have separate documentation follow. Links to these documentsare available on the website. Print outthe significant documents and keep in a notebook with the copter at all times. AIRFRAME AUTOPILOT SYSTEM BATTERIES BATTERYCHARGER CAMERA MANUAL CAMERAGCS DATA WIRELESS LINK GIMBAL CAMERA MOUNT GIMBAL CAMERA MOUNT SERVOS LAPTOP COMPUTER MOTORS ONBOARD REGULATOR PROPELLERS RC/MANUAL COMMAND & CONTROL SYSTEM SPEED CONTROLS (ESCs) VIDEO CAPTURE HARDWARE VIDEO CAPTURE SOFTWARE VIDEO WIRELESS LINK



## 28 © 2014 Troy Built Models, Inc. All Rights Reserved.