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© 2016 XFLY LLC. All Rights Reserved.

PILOT OPERATING HANDBOOK

xFold Professional UAV

Author: XFLY LLC Revised:2/10/2016
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© 2016 XFLY LLC. All Rights Reserved.

PILOT OPERATION HANDBOOK

XFold Pro UAV

This book is offered in “PDF” format. xFold Customers can customize the checklists to their exact 

needs. Please print out this POH and keep in a notebook that stays with the copter for reference. 

Keep log books mentioned in section 4 with the UAV as well.

Print out and make readily available the checklists above and the error message legend of various 

flashing lights. 

Errors & Omissions should be sent to support@xfoldrig.com. We will promptly update the POH for 

everyone to have the latest updates available.

TABLE OF CONTENTS

● Section 1: General

● Section 2: Limitations

● Section 3: Emergency Procedures

● Section 4: Normal Procedures

● Section 5: Checklists

● Section 6: Weight and Balance/Equipment List

● Section 7: Air Vehicle and Systems Description

● Section 8: Handling, Service and Maintenance

● Section 9: Supplements
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 1

GENERAL

NOTE: In an effort to 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 important to 

periodically check for online upgrades to the COTS components, including hardware, firmware and 

software.

WARNING: Great care must be taken with the batteries. Much of this manual and supplemental 

information is devoted to the use and care of the batteries, especially the flight batteries. They are 

less volatile than gasoline, though they should be treated with the same respect. Become very 

familiar with proper techniques of their use.

● GENERAL CHARACTERISTICS

o Primarily for ISR, Aerial Photography Surveying, and Commercial applications.

o Economical due to extensive use of COTS products

o Low Visual Signature

o Low Aural Signature

o Quick Launch and Recovery

o Short Training Period

o Simple Operation

o Waypoint Navigation (if applicable)

o Back packable

o VTOL

o Quick Repairs

o Redundant Flight Systems

o Safety Return to Home during lost link or low battery

o High Degree of Mission Success

o GPS navigation aid

o Various sensors

o Operating Temp Range: -5°C to +60°C

o Flight Modes: Manual and GPS aided waypoint navigation
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© 2016 XFLY LLC. All Rights Reserved.

o Maximum Operating Altitude: 1000 meters

o Maximum Operation Wind Conditions: 10 m/s

o Propulsion System: LiPoly batteries

o Takeoff: Manual or Automatic

o Landing: Manual or Automatic

o Takeoff/Recovery Area: 5m square

xFold model and specifications
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© 2016 XFLY LLC. All Rights Reserved.

PROPELLERS

o Distributor: XFLYo Material: Carbon Fiber

o Number of propellers: 8

o Stock Propeller sizes: XFLY 8” 15”16,17,21” depending on model

o Number of blades: 2

ELECTRONIC SPEED CONTROLS

o Distributor: XFLYo Number of speed controls: 8-12

o Speed control model number: XFLY 20A-80A depending on model

o Signal Frequency: 30 - 450 Hz

o Drive PWM Frequency: 24 KHz

● AUTOPILOT

o Manufacturer: DJIo Autopilot Model Number: Naza v2 or 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 / Windows 7

o Hovering Accuracy: Vertical: ± 0.5m; Horizontal: ± 2m

● WIRELESS LINKS

o Distributor: XFLY

o Frequency: 2.4 Ghz, and or 5.8 Ghz

o Power Consumption: Typically, less than 1 watt

o Usable Range: Less than 5 km. 

● FUEL/FLIGHT BATTERY

o Manufacturers: Various COTS suppliers

o Battery chemistry recommended: Lithium Polymer

o Battery Maximum Rated Discharge Rate: 45C maximum

o Battery recommended Charge Rate: 1C which takes approximately 1 hour to charge
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© 2016 XFLY LLC. All Rights Reserved.

o Battery Rest Time between discharging and charging: 30 minutes’ minimum, 1 hour 

recommended. 

o Batteries used simultaneously: 2 minimum, 4 maximum

o Recommended Battery Discharge Amount: 80%

● WARNINGS

o Never power a video transmitter or receiver 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 proper 

precautions.

o Batteries fully charged must be handled with extreme care.

o Batteries must not be stored above 60% charged state.

o Store batteries between 40% - 60% charged state. Fully charge just before use.

o Fully charged batteries which are not to be used within 24 hours should be 

discharged to 40% - 60% charged state.

o Discharging LiPoly batteries in excess of 80% of their rated capacity can cause harm 

to the batteries.

o Using more than one battery at a time requires the proper wiring harness so that the 

voltage is no more than what the copter is rated at. Over voltage 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 Propellers must be balanced to avoid excessive vibration.

o GPS/Compass must be facing forward.

o Do not use GPS Mode without GPS lock.

o Use low strength thread locking compound on all screws.

o Wireless Video and Data ranges vary considerably on many factors including 

weather, equipment, and obstructions. Be prepared for com failures.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 2

LIMITATIONS

● AIRSPEED LIMITATIONS

o Vne – Velocity to Never Exceed: 15 m/s

o Va – Typical Maneuvering Speed – 5 m/s

● WEIGHT LIMITS

o Takeoff Weight see chart

▪ Must be checked prior to takeoff if any change in equipment is made

▪ Up to four batteries can be used and be less than max TO weight if the sensor 

weight is minimal.

● CENTER OF GRAVITY LIMITS

o 2mm from the center of any of the pairs of arms

▪ Must be checked before every flight to ensure batteries were installed in the 

proper location.

▪ Check all pairs of arms before flight

● MANEUVER LIMITS

o This aircraft is intended for non-aerobatic operations

o G-loading maximum: 2G

● TEMPERATURE LIMITS

o Operating Temp Range: -5°C to +60°C

o In cold temperatures

▪ Keep Batteries above 5°C 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 higher the temperature increase during use

▪ At temperatures above 45°C, use of 2 or more batteries is required to lower 

the load on any one battery pack to keep it cooler.

o WEATHER LIMITS
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© 2016 XFLY LLC. All Rights Reserved.

o Light dust and light rain require the use of a shield for the electronics in the 

center section. 

o Light dust and light rain are acceptable for the unshielded motor and ESC.

o RANGE LIMITS

o FUEL

§ Fuel capacity is a primary limiting factor.

§ Flying into the wind will use more battery power to 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 of a mission and downwind at 

the end to avoid depleting the battery before returning to base. Have 

alternative landing sites available in case of emergency landing.

o WIRELESS LINK

§ Wireless links will be stable in LOS (line of sight) in most conditions

§ Wireless links are always susceptible to shorter ranges due to

• Atmospheric conditions

• Other transmission devices in the area

• Jamming

• Antennas not aligned properly

• Improper voltage

• Antenna blockage from AV in certain positions

• Multipath – reflection off buildings or ground which cause 

multiple signals to arrive at different times and/or phase.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 3

EMERGENCY PROCEDURES

● MOTOR FAILURE

o Operation is possible with one motor/ESC/propeller failure

▪ The two adjacent motors/ESCs will be increased in thrust automatically by the 

flight controller to overcome the loss

▪ In cases where the airframe is loaded over recommended weight aircraft may 

become uncontrollable

▪ Operation should be terminated as soon as possible to reduce the possibility 

of damage to the remaining motors

● COMMUNICATION FAILURE

o Video link failure

▪ 5.8 Ghz being the shortest wavelength in general AV use has the least ability 

to penetrate. This link should be the first to be lost.

▪ It is best to lose video first! It is the least likely to cause a crash when it fails.

▪ 5.8 Ghz can lose link with little warning.

▪ Ensure that the GCS station antennas are perpendicular to the AV. Do not 

point the antenna at the AV.

▪ Yaw the AV to change the antenna position

▪ Other links should still be good. Return back to the GCS until link is restored.

▪ Transmitters produce heat when in operation. When overheated they may 

have thermal protection which interrupts use temporarily. Use of a heat sink or 

fan may be required especially with high ambient temperatures.

▪ 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

o RC link failure

▪ 2.4 Ghz antennas can lose link with little warning.
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© 2016 XFLY LLC. All Rights Reserved.

▪ Anything in between the two antennas can cause temporary signal loss 

especially a person. 

▪ Hold the transmitter up in the air and walk in the general direction of the AV 

(aerial vehicle).

▪ Ensure that the antenna is vertical. Do not point the antenna at the AV.

▪ The failsafe on the RC link should be set so that the AV returns to home. 

Should this require a heading change, the antenna may move into a more 

desirable position and link will be restored. 

▪ The onboard equipment may block the signal. Yaw the AV so that the 

antennas point towards the GCS.

▪ A LRS (long range system) can be used as a permanent solution. This is 

higher in wattage and usually on 433 Mhz.

o Data Link Failure

When drop outs are noticed to increase in frequency that is the limit of the 

range. 

▪ If using 2.4 MHz, this is on wifi frequency. If a wifi noise is nearby it can 

swamp the signal. 2.4 MHz may not be usable in that area. Change to a 

different freq. or remain closer to the AV

o LOW BATTERY POWER

▪ Fail-safes can be set such that in the event of low battery power, either due to 

a failure or too long of a flight, the warning light on the AV will constantly flash 

amber. This is the first level of warning.

▪ The second warning level is red flashing lights

▪ Auto landing will occur when battery power is low. It may land in a tree or a 

lake, so this is not desirable.

▪ Landing with 80% of battery depleted is best. Batteries should be drawn down 

equally when in use if they are both charged equally and both in relatively the 

same condition/age. 

▪ Do not mix partially charged batteries. Only use completely charged batteries.

▪ Over discharging a battery below or 3.3V a cell can permanently damage the 

battery.

o GCS FAILURE

▪ Takeover by the external pilot should happen ASAP using the RC link.

▪ Most often happens due to a low battery.
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© 2016 XFLY LLC. All Rights Reserved.

▪ Keep a spare 3-5 cell LiPoly battery with the appropriate plug to plug into the 

charge jack for emergency use. Most chargers are 19V output which is roughly 

equivalent to a 4-cell battery. 3-cell batteries may work.

o COMPASS CALIBRATION ERROR

▪ If the compass is out of calibration the warning light will flash red. This is the 

same signal as low voltage. If the voltage is correct, there is a calibration error.

▪ Recalibrate the compass following the instruction manual

o FIRE

▪ Fires can occur due to a short circuit or battery failure.

▪ Disconnect the battery ASAP unless there is danger in doing so if there is any 

electrical issue.

▪ It is not possible to put out a battery fire.

▪ Do not attempt to put out a battery fire with water. Use a fire extinguisher to 

put out fires surrounding the battery. A CO2 fire extinguisher is better than the 

powder or chemical type. CO2 does not leave a residue.

o FORCED LANDINGS

▪ If alternate emergency landing zones should be chosen ahead of time.

▪ Be sure that the LZ is clear of people to avoid any incidents.

▪ Land in the nearest LZ which is clear of people.

▪ Announce your intentions of landing as loud as necessary to alert people of 

the incoming AV. 
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 4

XFold UAV

CHECKLISTS

● BENCH SET UP & TESTS

o All screws/bolts are tight

o Timer alarm for flight time to not exceed 80% battery capacity set properly

o Full throttle operation allows slow ascent.

o Batteries are secure

o Antennas are secure

o Props balanced

o Props aligned

o Props not chipped

o Wiring tied down

o No excessive flexing of motors or booms

o Booms/motors will not twist

o CG

o Warning lights set for low battery

o Max power of motors will lift the weight of the copter not exceeding the maximum 

rated weight at safe speed. If weight changes, the max throttle setting must be 

checked.

o Batteries charged. Replace any battery which cycles below 80% of rated capacity

▪ iPad Tablet and Laptop Computer battery

▪ Flight Battery

▪ Handheld Rx Battery

▪ RC TX Battery

▪ Video Rx Battery

▪ Spare Laptop Battery

● INVENTORY CHECKLIST

o Load Flight plan

o xFold UAV

o Spare parts/tools

o Spare batteries
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© 2016 XFLY LLC. All Rights Reserved.

o RC TX

o Laptop

o Battery Charger

o Battery Charger Alligator Clips

o Battery Charger Leads for Flight Battery

o Battery Charger Leads for Spare Laptop Battery

o Battery Charger Leads for Video Rx Battery

o Bubble level

o Flight Controller Cable

o Ground Power Supply

o Ground Power Cable

o Laptop Charger

● TRANSMITTER SWITCH ASSIGNMENTS 

o Modify to your transmitters

o Print out and keep readily accessible

o Review as required before operation

o COMMAND AND CONTROL OF COPTER

▪ J1 T1: Left Right

▪ J2 T2: Forward Backwards

▪ J3 T3: Altitude 

▪ J4 T4: Yaw

▪ SA: Return to Home D-RTH Up-Off

▪ SB: NA

▪ SC: NA

▪ SD: NA

▪ SE: Flight Path – D-Manual C-Course Lock Up-Home Lock

▪ SF: Landing Gear D-Gear Down Up-Gear Up

▪ SG: Flight Mode – D-Manual C-Atti Up-GPS

▪ SH: NA

▪ RD: NA

▪ LD: NA

▪ RS: NA

▪ LS: NA
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© 2016 XFLY LLC. All Rights Reserved.

o COMMAND AND CONTROL OF GIMBAL

▪ J1 T1: Tilt

▪ J2 T2: Pan

▪ J3 T3

▪ J4 T4: Only T4 works for Roll adjustments

▪ SA: NA

▪ SB: Speed switch F-Slow C-Med B-Fast

▪ SC: NA

▪ SD: NA

▪ SE: Mode switch D-Lock C-Follow U-Off

▪ SF: NA

▪ SG: NA

▪ SH: NA

▪ RD: NA

▪ LD: NA

▪ RS: NA

▪ LS: NA

● PREFLIGHT CHECKLIST

o Confirm all communication radios are operational if used

o Have a manual flight plan avoiding obstacles

o Check wind direction

o Set a perimeter of 100 meters – area must be clear of people

o Check for overhead power lines and other obstacles to avoid

o Check blades, arms, etc. for cracks/damage

o All antennas installed and all pointing in correct directions

o Engage GCS

o Upload auto piloted flight plan

o Remove lens cap / Clean lens

o Ensure camera has SD card installed.

o Install batteries on copter

o Check CG

o IMU pointing forward

o GPS/Compass is stable and pointing forward

o Level copter with front pointing in correct direction for course lock – do not turn on

o Throttle on TX Down

o Return to Home Switch Off

o Adjust gain to correct position (if required)

o Flight Path Switch Off – Not Course or Home or POI
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© 2016 XFLY LLC. All Rights Reserved.

o Turn on Pilot TX

o Check Model Selection on TX

o Check TX battery voltage (above 7.5v)

o Calibrate GPS/Compass before the first flight each day or if receiving continuous red blinks 

or continuous white blinks.

o After calibration, reset the copter by cycling battery with copter pointed in the correct heading 

for course lock.

o Do not move or vibrate the sUAVs until 30 seconds after full GPS Lock. Initial 3 red blinks 

are normal meaning no GPS lock. Wait until no flashes. Continue with checklist.

o Mode switch lock (FPV On)

o Turn on Photography TX

o Check Model Selection on TX

o Check TX battery voltage (above 7.5v)

o Engage Attitude Mode – Must Achieve Double Amber Flash A2 and naza

o Engage GPS Mode – Must Achieve Double Purple Flash A2 green flashing naza

o Do not engage motors. Set throttle to center position. Must achieve single amber flash and 

single purple flash when in Attitude and GPS modes.

o Mode switch fallow (FPV Off)

o Verify camera operation (Drive Mode – Remote Cmdr must be “on”, manual focus, intelligent 

auto)

o Verify data link if installed – rolling copter manually should change gauges

o Verify altitude is about 0 via gauge on computer

o Alternate Emergency Landing Sites Established

● TAKEOFF CHECKLIST

o Confirm clear for takeoff with ATC

o Engage camera in photo or video mode

o Engage GPS mode – Double purple flash A2 green for naza

o Announce loudly: “CLEAR PROP”

o Position the sticks in the lower left hand corners, then immediately raise the throttle 2

clicks, and center the right stick.

o Advance throttle to 1⁄4 power for 5 seconds. Assure all motors are operating.

o Verify that left/right and forward/back stick movement engages the proper motors

o Verify data and video links are still operational

o Announce loudly: “TAKING OFF”

o Advance throttle to 3⁄4 position. Copter must jump off of the ground. 

o Ascend to 3 meters. Center throttle stick. Should be single green flash. Verify 

wireless link stability, GPS hold, camera operation, gauges, are working properly
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© 2016 XFLY LLC. All Rights Reserved.

o Verify copter stability. If unstable, land and reset gains, recalibrate, or retest as 

necessary.

o Proceed with manual mission (for autopilot operation see next step)

o For autopilot operation

▪ Ascend to 10 meters

▪ Command AVO to proceed with mission.

o Manual pilot/observer must monitor the informational LED and be ready to take over 

in manual mode when necessary.

o Manual pilot to request copter flight battery voltage readout from AVO periodically.

● QUICK PREFLIGHT CHECKLIST

o Level copter with correct heading – do not turn on

o AVO - Throttle Down

o AVO - Manual Flight Mode

o AVO - Flight Path Off

o SO – HDMI off

o SO - FPV

o Engage Both TX’s

o Engage Copter

o GPS Mode

o Course Lock

o Engage Sensor

o Takeoff

● ERROR MESSAGES

o White flashes

▪ IMU malfunction. Land and determine cause. Possibilities:

● GPS/Compass not pointing forward

● IMU not pointing forward

● Set up of X, Y, Z for location of IMU and Compass is incorrect

o Excessive rocking/instability possible causes:

▪ Weak motor

▪ Structure flexing from fatigue or cracks

● Motor mount

● Main frame
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© 2016 XFLY LLC. All Rights Reserved.

● Booms

▪ Loose Bolts causing flexing or misalignment 

● Props

● Mounts

▪ Props out of balance

▪ Props misaligned

▪ Excessive wind speeds or gusts

▪ Excessive Gains

▪ Excessive motor power. Max motor power 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 if 

loss sats for more than 30 seconds. Possible causes:

▪ Clouds

▪ Structures

▪ GPS mal-function

▪ GPS too close to electrical components

▪ GPS vibration

● LANDING CHECKLIST

o Landing area clear

o Sufficient battery capacity

o Note obstacles in flightpath

o Announce loudly: “LANDING”

o Turn off copter

o Turn power off to transmitter

o After landing contact ATC

o First cut power to the AV

o Note elapsed time of flight

o Adjust any parameters (camera servo speed, exponential, etc.)

o After landing then complete flight log

▪ Date and time of flight

▪ Batteries used

▪ Time of Flight
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 5

PERFORMANCE

● FLIGHT TIMES

o The AV is designed to hover at high efficiency. Hovering is much less efficient than 

flying on a wing, thus flight times are lower when compared to fixed wing aircraft.

o All the weight of the AV is supported by power from the batteries. As the batteries are 

used in a flight, the amount of power available decreases. Therefore, the power 

reserve 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 power 

to lift off initially on a full charge, the power reserve at partial charge may be too low 

to allow for maneuvering and will result in a crash.

o High lateral speeds will add lift to slightly improve efficiency. The rotors act similar to 

fixed wings at higher speeds. This increase in efficiency may be negated by the 

increased power consumption of forward flight.

o High winds or gusts decrease efficiency/flight time. The motors work harder to hold 

position.

o As weight increases flight times decrease.

● WIRELESS TRANSMISSION

o Refer to the specific manuals for performance ratings.

o Wireless communications utilized provide acceptable communication for LOS.

o In general:

▪ LOS is required

▪ The higher the GCS antennas, the better the range

▪ Any freq. at may have severe degradation due to location to other admitters 

such as cell towers

▪ RSSI (Received Signal Strength Indication) should be monitored for indication 

of communication drop out.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 6

WEIGHT AND BALANCE EQUIPMENT LIST

● CG

o CG is critical to the efficient operation of any 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 of the 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 change to the components or their placement.

o The CG should be tested by lifting the UV with fingers on the bottom of the arms. 

Check all 3 pairs of arms. The CG should be no more than 2mm off in any on the 3 

checks. The closer the CG is to the centerlines of the arms the more efficient and the 

more stable the AV will be.

● WEIGHT

o Weight is critical to the operation of any AV

o Weight is especially critical to a rotor wing aircraft. At full throttle the motors have a 

finite amount of thrust. 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 a4.2V. At 

20% remaining capacity they have about 3.7V. This is a loss of 80% of the power 

available which is significant.

o Do not overload the AV or there will not be sufficient reserve power to maneuver at 

low battery levels.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 7

AIR VEHICLE AND SYSTEMS DESCRIPTION

● FUEL/BATTERY REQUIRED

o Manufacturers: Various COTS suppliers.

o Refer to manufacturer data sheet.

o Battery chemistry required: Lithium Polymer 

o Battery Voltage: 3.3V minimum, 3.7V nominal, 4.2V maximum per cell

o Battery Minimum Rated Discharge Rate: 45C minimum

o Batteries used simultaneously: 2 typical

o Recommended Battery Discharge Amount: 80%

● WERELESS COMMUNICATIONS

o Refer to the specific manuals for performance ratings.

o Never power a video transmitter or receiver 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 longer range than high freqs

o Higher freqs can transfer more data than lower freqs

o Higher freqs use smaller/shorter antennas

o The higher the GCS antennas, the better the range and reception

o Any freq at may have severe degradation due to location to other admitters such as 

cell towers

o Range must be constantly monitored. 

o Alternate antenna types may be utilized to improve link/range. Patch, helical, omni, 

etc. can be substituted. They must be verified before use.

o Alternate freqs may be utilized to improve link/range.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 8

HANDLING, SERVICE AND MAINTENANCE

● PROPELLER CARE

o Propellers must be checked each flight for nicks or cracks

o Propellers are designed to last indefinitely if they do not impact dust, dirt or more.

● BATTERY CARE AND USE

o Refer to 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 proper 

precautions.

o Batteries fully charged must be handled with extreme care.

o Any battery 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% of its rated capacity should be discarded.

o Cycle test each battery after every 50 cycles or if a battery is suspected to have lost 

as significant amount of its capacity to determine the current capacity. 

o Properly dispose of batteries. First discharge the battery fully using a battery cycler. 

Bring to a recycler such as a home improvement store. 

o Always charge flight batteries under “balance” mode.

o Flight Battery Recommended Charge Rate: 1C which takes approximately 1 hour to 

charge

o Flight Battery Maximum Charge Rate: May exceed 1C. Charge rates higher than 1C 

will decrease life cycles. Maximum charge rating per the manufacturer will provide 

300+ cycles. Use the lowest charge rate which is practical.

o Battery Rest Time between discharging and charging: 30 minutes’ minimum, 1 hour 

is recommended. 

o Do not charge if the battery is more than 2°C warmer than ambient, especially if the 

temperature is above 20°C. The outer surface is cooler than the inner core after use. 

Damage will occur when charging a warm battery.

o Recommended Battery Discharge Amount: 80%. Using more of the capacity of the 

battery will decrease the life cycles
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© 2016 XFLY LLC. All Rights Reserved.

o As battery temperature approaches freezing the capacity of Lithium Polymer batteries 

decrease. Keep warmer than 10°C before installing into the UV (unmanned vehicle).

o Battery capacity decreases at higher discharge rates. Using more batteries 

decreases the discharge rate of each battery thereby extending individual battery 

capacity slightly.

o Lower discharge rates improve the life cycles.

o Batteries are rated at greater than 300 life cycles. 1,000+ life cycles are possible.

o Batteries must not be stored above 60% charged state for extended periods.

o Batteries should be stored below 25°C for extended periods

o Store batteries between 40% - 60% charged state. Fully charge just before use.

o Fully charged batteries which are not to be used within 24 hours should be 

discharged to 40% - 60% charged state using the battery discharger.

o Using more than one battery at a time requires the proper wiring harness so that the 

voltage is no more than what the copter is rated at. Over voltage will cause serious 

damage to electrical equipment.

● PREVENTATIVE MAINTENANCE

o ANNUAL INSPECTION (SUGGESTED)

▪ If the airframe has in excess of 300 hours in a one-year period, an annual 

inspection must be 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 latest revisions

• 150 HOUR PM (SUGGESTED)

• An approved technician 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 latest revisions.
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© 2016 XFLY LLC. All Rights Reserved.

SECTION 9

SUPPLEMENTS

COTS components have been utilized in the construction of this AV. All instruction manuals, 

operating handbooks, warning notices, and more are available as separate documents. 

Components which may have separate documentation available at (www.xfoldrig.com). Links to 

these documents are available on the website. 
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© 2016 XFLY LLC. All Rights Reserved.