# PILOT OPERATING HANDBOOK

DJI S-1000/Zenmuse

Author: Gene Payson Revised: 6/05/2014 http://www.troybuiltmodels.com



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## PILOT OPERATIONHANDBOOK DJI S-1000/Zenmuse This book is offered in a format so thatpilots can customize the checklists to their exactneeds. Please print outthis handbook, make notes while watchingthe video regarding the checklist, then change the wording and order to suit yourneeds. Thenprint outthe revised form and laminate it in plastic. Carry it you're your aircraft. Then use it every time you operate your aircraft. Keep the log books regarding the following: 1) Pilot flight time 2) Aircraft flight time 3) Aircraftmaintenance and updates 4) Battery usage, 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 it be expensive to repair your aircraft in the event ofan incident, ifyou injure bystanders or damage otherpeople'sproperty 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 latestupdates available.

KEYPARAMETERS Max TakeoffWeight: 24 lbs Weight with Zenmuse and all other equipment

- no camera, no battery: 13.4 lbs Weight ofNex5/6/7 camera: lib Weight ofCanon 5D camera: 1.75lbs MaxBattery Weightwith Zenmuse/Nex Camera: 9.5 lbs MaxBattery Weightwith Zenmuse/Canon 5D: 9lbs Flight Times using 90% ofbattery: 16,000 mah batteryNex 7: 17 min 20,000 mah batteryNex 7: 20 min 32,000 mah batteryNex 7: 22 min Flighttimes using the Canon 5D or other cameras similar in weight will reduce the flight times by about 1 minute. These times are averages in ourtests. You may get longer or shorter flight times based onweight and flying style, thoughthese numbers shouldbe fairly accurate.



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

# DJI S-1000/Zenmuse CHECKLISTS

• DJI S-1000 BENCH SET UP & TESTS 

### o All screws/bolts are tight o Timer alarm for flight time to not exceed 80% battery capacity setproperly 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 RxBattery • RC Tx Battery • Video Rx Battery • Spare Laptop Battery

• DJI S-1000 INVENTORY CHECKLIST 

### o Load Flightplan o Aircraft o Camera with 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



## 3 © 

### 2014 Troy Built Models, Inc. All Rights Reserved.• DJI S-1000 PREFLIGHT CHECKLIST o Check areato fly on Google maps o Confirm walkie talkie and ATC corns operation o Inform ATC ofyour flight plan ifrequired o Determine emergency flight plan and alternate landing zones avoiding power lines and obstacles o Check wind direction o Set aperimeter of50-100 meters -areamust be clear ofpeople o All antennas (9?) installed and all pointing in correct directions o Engage GCS, monitor, laptop, goggles, etc. (bring up flight plan) o Remove lens cap I Clean lens o CameraOn o Ensure camerahas SD card installed. o Checkbattery voltage o Install battery on copter. o Check CG o Level copter with front pointing in correct direction for course lock- do not tum on o On Copter TX

- Set switches

- Throttle Down, Return to Home switch Off, Manual FlightMode Switch On, Flight Path Switch Off- Not Course or Home Lock o Copter Transmitter On o CheckModel Selection on Tx o Check Txbattery voltage (above 7.4v) o On Photo Tx- set switches

- HDMI switch Off, Freestyle switch On o Photography Transmitter On o CheckModel Selection on Tx o CheckTxbattery voltage (above 7.4v) o Plug inbattery black lead first. o Calibrate GPS/Compass ifnecessary o Ifcalibrated, cycle battery with correct heading for course lock. o Do nottouchthe Copteruntil 30 seconds after full GPS Lock. Initial3 red blinks is normal meaning no GPS lock. Waituntil no flashes. Continue with checklist. o Check Copter Voltage from GCS o Engage Attitude Mode -MustAchieve Double AmberFlash o Engage GPS Mode- MustAchieve Double Purple Flash o While in GPS mode engage "Course Lock" mode. Must achieve green Flash o Do not engage motors. Setthrottle to centerposition. Must achieve single amber flash inAttitude Mode and single purple flash in GPS mode o HDMI switch On (video on camera itselfshould go off) o Freestyle switch On (FPV Off) o VerifY camera operation (Ifproblems, checkDrive Mode- Remote Cmdr must be "on", manual focus, intelligent auto) o Verizy data link ifinstalled

- rolling copter manually should change gauges o Upload flight plan o VerifY altitude is about 0viagauge on computer/GCS/video monitor/goggles o Timers setproperly



## 4 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • TAKEOFF CHECKLIST o Declare intentions for takeoffwith ATC o Engage GPS mode -Doublepurple flash o Engage Course Lock mode (double green flash) o Announce loudly: "CLEARPROP" o Position the sticks in the lower left hand comers, then immediately raise the throttle 2 clicks, and centerthe right stick. o Advance throttle to 

### Y4 power for 5 seconds. Assure all motors are operating. o Verify that left/right and forward/back stickmovement engages the proper motors o Verify data and video links are still operational o Announce loudly: "TAKING OFF" o Advance throttle to full. Coptermustjump offofthe ground. o Ascend to 3 meters. Centerthrottle stick. Should be single green flash. Verify wireless link, GPS hold, camera operation, gauges, etc. are workingproperly. 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, or retest as necessary. o Raise landing gear o Proceedwith manual mission o For autopilot operation • Ascend to 1 0meters manually • Engage autopilot o Manual pilot/observer must monitorthe informational LED and be ready to take over in manual mode when necessary. o Manual pilotto request copter flight battery voltage readout from camera operator periodically.

• QUICKPREFLIGHT CHECKLIST o Landing zone clear o Level copter with correctheading o Battery 4.1+ full, 3.8 depleted o Camera on. SD card in. o Both TX

- all switches down o Both TX on o Copter on o Check GPS and Course lock checks o Video check o Photo check o Timers ready o Takeoff o Raise Landing Gear o Unplug 6batteries upon landing



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

### • ERRORMESSAGES o White flashes • IMU malfunction. Land and determine cause. Possibilities: • GPS/Compass notpointing forward • IMU not pointing forward • Setup 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 motor power. Max motorpowermust 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 

### • LANDING CHECKLIST o Landing area clear o Lower landing gear o Note obstacles in flightpath o Announce loudly: "LANDING" o First cut powerto the aircraft o Note elapsed time offlight o Adjust any parameters (camera servo speed, exponential, etc) o Tumpower offto transmitters, camera, goggles, monitors, Rxs, etc. o Touch motors to verify temperatures are similar o Complete flight log • Date and time offlight • Batteries used • Time ofFlight o ContactATC



## 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 andMaintenance • 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 slightmodifications to better suitthis application. Most COTS products have separate data sheets, assembly manuals and instruction manuals. They are reference in this document, withkey 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 with the batteries. Much ofthis manual and supplemental information is devoted to the use and care ofthe batteries, especially the 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 Low Visual Signature o LowAural Signature o QuickLaunch and Recovery o ShortTraining Period o Simple Operation o WaypointNavigation o Backpackable o VTOL o QuickRepairs o Redundant Flight Systems o Safety Return to Home during lost link or low battery o High Degree ofMission Success o GPS navigation aid o Various sensors o 24lb maxtakeoffweight o Operating Temp Range: -5°C to +60°C o FlightModes: Manual and GPS aided waypoint navigation o Maximum OperatingAltitude: 1000 meters o Maximum Operation Wind Conditions: 10 m/s o Propulsion System: LiPoly batteries o Takeoff: Manual orAutomatic o Landing: Manual orAutomatic o Takeoff/Recovery Area: 5m square

• IMPORTANT DIMENSIONS o Distance rotor to rotor across the center: 41" o Height with GPS/Compass folded down: 21" o Heightwith GPS/Compass up: 25" o Length oflanding gear skids: 18" o Distance between landing gear skids: 21" 

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

### • IMPORTANT WEIGHTS o Weight including Nex 7 camera, Zenmuse gimbal, A2 autopilot system, landing gear, data transceiver, RC transceiver, video transmitter, regulators and all wiring- everything except battery: 13.4 lbs o Maximum TakeoffWeight: 24 lbs o Battery Weight: up to 9.5 lbs withNex camera and Zenmuse Gimbal

• MOTORS o Manufacturer: DJI-Innovations o Number ofmotors: 8 o Motortype: 41mm x 14mm o Motor Model Number: 4114-11 o Motor KV /RPM: 400 o Motor max@ 25.2V: 10,000 rpm o Motor Max Power: 500 Watts o Powerrating: 4000 Watts maximum power consumption for all 8motors o CurrentMax: 100 amps o Amp Draw Typical Average: 65 amps

• PROPELLERS o Manufacturer: DJI-Innovations o Material: Composite o Number ofpropellers: 8 o Propellermodel number: DJI 15 x 5.2 o Number ofblades: 2- folding o Propeller Diameter: 15" o PropellerPitch (fixed): 5.2" o Max rpm: 10,000 rpm

• ELECTRONIC SPEED CONTROLS o Manufacturer: DJI-Innovations o Number ofspeed controls: 8 o Speed control model number: DJI 40A Opto o Rating in amps: 40 Amps continuous o Signal Frequency: 30 -450Hz o Drive PWM Frequency: 8KHz

• AUTOPILOT o Manufacturer: DJI-Innovations o Autopilot Model Number: DJI A2 o Components: GPS/Compass, IMU, Master Controller, Power Distribution System, LED IndicatorLighting 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 Hovering Accuracy: Vertical:± 0.5m; Horizontal:± 2m



## 9 © 2014 Troy Built Models, Inc. All Rights Reserved.• 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: 1watt o Usable Range: Less than 2 km.

• FUEL/FLIGHT BATTERY o Manufacturers: Various COTS suppliers o Battery chemistry recommended: Lithium Polymer o Battery Capacity: 16,000

- 42,000 mah 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: 1 C (3C preferable) o Battery Rest Time between discharging and charging: 0-30 minutes o Batteries used simultaneously: 1-4 o Recommended Battery Discharge Amount: 80-90%

• FLIGHTPARAMETERS o Flight Time: up to 30 minutes o Payload Max: 11 lbs o Power Consumption in a Hover at 21lbtakeoffweight: 1500 Watts, 65 amps



### • WARNINGS o Neverpower 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 usingproperprecautions. o Batteries fully chargedmustbe handled with extreme care. o Batteries must not be stored above 50% charged state. o Store batteries between 20%

- 50% charged state. Fully chargejustbefore use. o Fully charged batteries which are notto be used within 24 hours should be dischargedto 20%

- 50% charged state. o DischargingLiPoly batteries in excess of80% oftheir rated capacity can cause harmto 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 andbalance checks. Proper CG is critical to performance. Airframe mustnotbe overloaded. o Propellers mustbe balanced to avoid excessive vibration. o GPS/Compass mustbe facing forward. o Do notuse GPS Mode without GPS lock. o Use low strength thread locking compound on all screws. 

# 10

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

### o Wireless Video and Dataranges vary considerably on many factors including weather, equipment, and obstructions. Beprepared for com failures.



# ttl©2014 Troy Built Models, Inc. All Rights Reserved.• AIRSPEED LIMITATIONS 

### SECTION2 LIMITATIONS

o Vne-VelocitytoNeverExceed: 15m/s o Va- Typical Maneuvering Speed- 5m/s

• POWER & POWERPLANTLIMITATIONS o 40 Amps maxpermotor o 40 Amps maxper speed control o 320 Amps maxtotal o Do not exceed 80-90% discharge ofrated battery capacity o Do not charge batteries which are warmer than 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 TakeoffWeight Max: 24 lbs • Mustbe checkedpriorto takeoffifany change in equipment is made

• CENTER OF ORAVITY LIMITS o 3mm from the center ofany ofthe three pairs ofarms • Mustbe checkedbefore 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 0-loadingmaximum: 20

• TEMPERATURELIMITS o Operating Temp Range: -1

## ooc to +40°C o In coldtemperatures • Keep IMU atroom temperature ifpossible before the flight • Keep Batteries above 5°C before flight • Do notfly with any frost or ice on the propellers o In warm temperatures • Batteries heat up when discharged • The higherthe discharge rate the higher the temperature increase during use • Attemperatures above 45°C, use of2 or more batteries is required to lowerthe load on any one battery packto keep it cooler.

• WEATHERLIMITS o Light dust and light rain 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.

• RANGE LIMITS o FUEL 

## 12 © 2014 Troy Built Models, Inc. All Rights Reserved.• Fuel capacity is aprimary limiting factor. • Flying into the wind will use more batterypowerto travel the same ground distance. Higher air speeds will be required to penetrate the wind which used more battery power. Takethis into account when flying a mission. • Where possible, fly upwind atthe start ofa mission and downwind atthe end to avoid depleting the battery before returningto 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 shorterranges due to • Atmospheric conditions • Othertransmission devices in the area • Jamming • Antennas not alignedproperly • Impropervoltage • Antenna blockage from AV in certainpositions • Multipath

- reflection offbuildings or ground which cause multiple signals to arrive at differenttimes and/orphase.



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

## SECTION3 EMERGENCY PROCEDURES

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

• COMMUNICATION FAILURE o Video link failure • 5.8 Ghz beingthe shortest wavelength in general AVuse 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 atthe AV. • Yawthe AV to change the antennaposition • Other links should still be good. Return backto the GCS until link is restored. • Transmitters produce heat when in operation. When overheatedthey may have thermal protectionwhich interrupts use temporarily. Use ofaheat 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" canbe 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, thoughthere are other issues to be considered. o RC link failure • 2.4 Ghz antennas can lose link with little warning. • 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 ofthe AV (aerial vehicle). • Ensure thatthe antenna is vertical. Do notpointthe antenna atthe AV. • The failsafes on the RC link should be set so thatthe AV returns to home. Should this 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 thatthe antennas point towards the GCS. • A LRS (longrange system) can be used as apermanent solution. This is higher in wattage and usually on 433 Mhz. o DataLinkFailure • 900 Mhz do not lose link without some warning. When drop outs are noticed to increase in frequency that is the limit ofthe range. 

## 14 © 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 LOWBATTERYPOWER • Fail-safes can be set suchthat in the event oflowbattery 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. • Landing with 80-90% ofbattery depleted is best. Therefore landing with 17,000 mah used and 3,000 mahremaining 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 not mix partially charged batteries. Only use completely charged batteries. • Over discharging a battery below 19.8V canpermanently 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. • Keep a spare 3 cell LiPoly battery withthe appropriate plugto plug into the charge jackfor emergency use. Most chargers are 19V outputwhich is roughly equivalentto a 4-cell battery. 3-cell batteries may work.

o COMPASS CALIBRATION ERROR • Ifthe compass is out ofcalibrationthe warning lightwill flash red. This is the same signal as lowvoltage. Ifthe 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. • 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 put out a battery fire. Use a fire extinguisherto put out fires surroundingthe battery. A C02 fire extinguisher is betterthan the powder or chemical type. C02 does not leave a residue. Water can be usedthough it may cause other electrical componentfailures.

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 nearest LZwhich 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 on the ground and run the copter at about 70% throttle for about 2 hours to bum in the electronics. Most electronic failures occur in the first 2 hours ofoperation. • GPS/COMPASS MAST LENGTH o We found thatthe higherthe mast, the betterthe GPS reception • Nex5N vs. Nex7 vs. Canon 5D vs. Panasonic GH3 o These cameras are excellent for stills, and very good for video. The best for video is the Panasonic GH4 with 4kcapabilities. o We found thatthe Nex 5Ntakes exceptional quality stills and video, though most professionals use the Nex 7. The Canon 5D is betterthan the Nex7 due to its larger sensor. o Use the Panasonic GH4 ifyou primarily shootvideo • RADIO SET UP o Followthe instructions inthe manual o We preferthe switch assignment as shown in the checklists above though feel free to modify to your liking • COPTER COMMAND AND CONTROL o We recommendthe use ofa dual rate switch for main copter operation. • High rate- used to initialize the motors. The flight controllerwill not engage unless it sees full down throttle, full leftrudder, full left cyclic and full back cyclic. However, these may be too high for normal flying. On high rate it is helpful to utilize fairly high exponential to make the stickfeel soft around center. Adjustto yourpreference. • Lowrate- used for typical flying. Setthe endpoint adjustments such that full stick deflection offers the maximum speedrequired in normal flying. Ifconditions require higher flight speeds, switchto high rate. On low rate it is also helpful to utilize a small amount ofexponential to make the stickfeel soft around center. Adjustto your preference. • ZENMUSE COMMAND AND CONTROL o We recommendthe use ofa dual rate switch for gimbal operation.

• TIMERS • Highrate

- 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 stick feel soft around center. Adjustto your preference. • Lowrate- used for videography. Setthe endpoint adjustments suchthat full stick deflection offers the maximum speed required for videography. Ifconditions require higher gimbal speeds, switch to high rate. On low rate it is also helpful to utilize a small amount ofexponential to make the stick feel 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 (or whatyou deem appropriate) and have it startwhen the throttle is over Y4. 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 suchthat youhave a minute or so to land after 

## 16 © 2014 Troy Built Models, Inc. All Rights Reserved.• BATTERIES the alarm sounds so that you have adequate time to return to base. Adjustto your preference.

o Replace the transmitter standard battery with a Lipoly battery to extenduse times to 8hours. Suppliedbatteries often last about 2 hours.



# 17 © 2014 Troy Built Models, Inc. All Rights Reserved.

### NORMAL PROCEDURES

• PREFLIGHT CHECKLIST o Confirm all communication radios are operational • Radio with ATC • Radios with others in the group o Set a perimeter of 1 00 meters • Area must be clear ofpeople to avoid collision o Check for overheadpower lines and other obstacles to avoid o Check structural integrity • In eventofprior 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 sure thatthe total flight time is under 1 0 minutes to avoid low battery o Clean lens • Remove lens cap o Ensure camera has SD card installed • Many flights have been wasted due to this! o Install batteries • Ensure that the straps are tight and the Velcro keeps the batteries from moving which will avoid a shift in the CG (Center ofGravity- orthat itbalances evenly) o Check CG (Center ofGravity) • Liftthe copter on each ofthe 3pairs ofarms. The copter should balance properly. If not, do not fly. Rearrange the equipment suchthat the CG is o IMU pointing forward • 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 screw to hold it in place. It

### cannot vibrate easily. Ifit does notpoint forward, 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 copter using a bubble level with front pointing in correct direction for course lock- do not turn on • Keep in mind the best angle for pointing the landing gear in the direction thatwill keep the landing gear out ofthe shot when flying. o Turn on Pilot Tx o Ifusing the rate gyro, set it at the 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 S800 o Throttle on Tx Down o Return to Home switch Off o Adjust gain to correctposition (ifrequired) o Manual FlightMode Switch to manual (not ATTl or GPS mode) o Flight Path Switch Off- Not Course or Home or POI o Check Txbattery voltage (above 7.5v) • These settings above are required to initializethe copterproperly. Ifthe switches are in the incorrectposition, 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 tumthe powerback on to the copter. o Count down timer should be setto 20 minutes. This can be adjusted to your flying style. The timer should engage at 114 throttle andtrigger an alarm at the propertime. This is a backup alarm in case the indicator lights onthe copter are not visible. o Tum on Photography Tx o CheckModel Selection onTx- should read Zenmuse o Check Txbattery voltage (above 7.5v) 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, itwill not initialize properlywhich may cause some of the functions like live video or gimbal operationto not operate properly. • Ifthe camera or gimbal do notfunction properly, disconnectthe copterpower. Then put all the switches in the properposition for initialization and tumthe powerback on to the copter. o Engage powerto copter • Plug in the 2 batterypacks. Typically the batterypacks use red T-style connectors in a parallel wire harness. This Y-hamess has a yellow connector. Itis preferable to connectthe batteries to the Y-hamess first, thenplug 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 or vibrate the Squadcopteruntil 30 seconds after full GPS Lock • Initial3 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 not move the copter. • Ifthe GPS takes more than 5 minutes to lock, there is a problem withthe area. Itis 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 satellites. o Check Copter Voltage from both Tx's (transmitters) • The transmitters receive a signal from the corresponding receivers. The voltages are regulated to about 5v. Ifthe voltage is below 4.4v or above 6v do not fly. There may be powerregulation issues. The receivers cannotwork outsidethis voltage consistently. Also there is some issue ifthe voltage is outside thatrange which should be resolved before flying. o Engage Attitude Mode- Must achieve double amber flash o Engage GPS Mode

- Must achieve double purple flash o Engage course cockmode

- Must achieve double green flash o Disengage course lockmode. Must achieve double purple flash. Stay in this mode untiljust priorto takeoff, after takeoffat any time, or do not use. o Do not engage 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.• Withthrottle in the centerposition, use the trim buttons on the transmitterto check thatthe sticks are centered. Trim the roll (the stick located on the right side ofthe transmitterwhen movedto the right and left) to the right, countingthe number of clicks until a double flash occurs. Then centerthe trim. Then move the trimto 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 stickmovements otherthan throttle. • Centerthe trim such thatwhen the stick is in the neutral positionthatthere are equal numbers ofclicks in each direction. This ensures thatwhenthe sticks are neutralized thatthe flight controllerwill recognize this signal and engage GPS mode. o Calibrate GPS/Compass before the first flight each day orifreceiving continuous red blinks or continuous white blinks. • Flip the GPS mode switch 7 times very quickly from manual to GPS. Endwith the switch in the manual position. The indicator lightwill be blue. Rotate the copter about 1.5 turns in a horizontal position. A green flashing light indicates thatthis is complete. Then holdthe copter vertically and rotate about 1.5 turns. A white flashing light indicates thatthis is complete. Repeat ifnecessary until this is completed. o After calibration, reset the 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 sendthe video signal to the video transmitter viathe HDMI connection. o Freestyle switch On (FPV Off) • This allows the camerato be operated freely through the transmitter o Verify camera operation • Operate the shutter • Setthe focus to auto or manual. Manual setting is usually setto infinity to stop constant focusing ofthe camera. o Verify data link ifinstalled • Roll the copter about 45 degrees on its side by lifting one side ofthe copter and resting one side ofthe landing gear onthe ground • A corresponding roll should be seen on the gauge. • Ifthe copter is rolledto 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 offbythis amount. This could cause the copterto fly at 10 meters or 30 meters ifthe waypoint is set for 20 meters and the altitude is offby 10 meters one way or another. Ifthe copterthinks it is at 10 meters when it is on the ground, then it will only rise 10 meters above the ground to achieve what itbelieves itto be 20 meters above the ground. • The altitude can be resetusing the ground control software by goingto altitude offset. o Alternate Emergency Landing Sites Established

• NORMAL TAKEOFF o Confirm clear for takeoffwith ATC • Necessary ifwithin 5 miles ofan airport 

## 20 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • ATC clearance is required days or weeks before flying. o Engage GPS mode

- Double purple flash whenthe 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 comers 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 low to disengage the motors and determine a solution. o Ifall flight checks are passed, announce loudly: "TAKING OFF" o Advance throttle to about 3/4. Copter mustjump 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 holding position 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, or retest as necessary. o Proceedwith manual mission or o For autopilot operation • Ascendto 1 0meters • CommandAVO to proceed with mission. • Pilot should say "It'syours" • Response from AVO "Ihave it" o Manual pilot/observermust monitor the informational LED and be ready to take over in manual mode when necessary. • White flashes indicates flight controller issue • Amberflashes indicates low battery • Red flashes indicate loss ofGPS or severe battery condition • Quick decisions are required when red flashes are indicated • 10 seconds or more ofloss ofGPS signal will stop waypoint guidance and any GPS hold and put into manual mode. • Red indicator light battery warning requires immediate landing o Manual pilotto request copter flight battery voltage readout from AVO periodically. • Reset the 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. Adjustthe voltage warnings to your style offlying. • Also use the countdown timer on the transmitter. This gives a good indication of battery level becausethe currentused is fairly constant from flight to flight.

• POST LANDING o Note flight time from transmitter. Write this down in the log book. o Note battery power used during the flight. Write this down in the log book. o ALWAYS disconnectthe main powerto the AV first, then tum offthe transmitter. 

# 21 © 2014 Troy Built Models, Inc. All Rights Reserved.

### o Checkmotortemperatures 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. Batterytemperatures shouldbe slightly above ambient. o Inspect all components especially the propellers for wear. o Note in logbookwhich 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 OperatorNames • Flight Objective • Remarks

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

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



## 22 © 2014 Troy Built Models, Inc. All Rights Reserved.

### • FLIGHT TIMES 

### SECTIONS PERFORMANCE

o The AVis designed to hover at high efficiency. Hovering is much less efficientthan flying on a wing, thus flight times are low comparedto fixed wing aircraft. o All the weight ofthe AVis supported by power from 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 arotorcraft above its limit is not recommended. While the AV may have enoughpowerto 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 liftto slightly improve efficiency. The rotors act similarto fixed wings athigher speeds. This increase in efficiency may be negated by the increasedpower consumption offorward flight. o High winds or gusts decrease efficiency/flighttime. The motors workharder to 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 • The higherthe GCS antennas, the betterthe 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.



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

### • CG 

### SECTION6 WEIGHT AND BALANCE EQUIPMENT LIST

o CG 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 change to the components or theirplacement. o The CG should be tested by lifting the UV with fingers on the 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. At full 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. Atfull charge they have about 25v. At20% remaining capacity they have about 21v. This is a loss of8% ofthe power available which is significant. o Do not overloadthe aircraft orthere will not be sufficientreserve powerto maneuver at low battery levels.



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

### SECTION7 AIRVEHICLE AND SYSTEMS DESCRIPTION

• FUEL/BATTERYREQUIRED o Manufacturers: Various COTS suppliers. o Refer to manufacturer data sheet. o Battery chemistry required: Lithium Polymer o Battery Capacity: 16,000 mah (minimum) o Battery cell countrequired: 6S (6 cells in series) o Battery Voltage: 21V minimum at hover, 22.2V nominal, 25.2V maximum o Battery Minimum Rated Discharge Rate: 20C minimum o Batteries used simultaneously: 1-4 

### typical o Recommended Battery Discharge Amount: 80-90%

• WERELESS COMMUNICATIONS o Referto the specific manuals for performance ratings. o Neverpower a video transmitter or receiver without an antenna connected or overload failure will occur. o Wireless communications utilizedprovide acceptable communication for LOS. o In general: o LOS is required. o Lower frequencies penetrate objects such as trees betterthan higher freqs. o Lower freqs have longer range than high freqs o Higher freqs can transfer more datathan 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 due to locationto other admitters such as cell towers o Range mustbe constantly monitored. o Alternate antenna types may be utilized to improve link/range. Patch, helical, omni, etc. can be substituted. They mustbe verified before use. o Alternate freqs may be utilized to improve link/range.



# 25 © 

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

### SECTION 8 HANDLING, SERVICE AND 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 CAREAND 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 usingproperprecautions. o Batteries fully charged must be handled with extreme care. o Any battery whichpuffs up is considered damaged and must not be used. It

### is in a dangerous state. Never charge apuffed 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 suspectedto 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 store. o Always charge flight batteries under "balance" mode. o Flight Battery Recommended Charge Rate: 1 C which takes approximately 1hour to charge o Flight BatteryMaximum Charge Rate: May exceed 5C. Charge rates higherthan 1 C will decrease life cycles. Maximum charge rating perthe manufacturer will 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 ifthe battery 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 warmbattery. 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 Polymer batteries decrease. Keep warmer than 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 greater than 300 life cycles. 1,000+ life cycles are possible. o Batteries must notbe stored above 60% charged state for extendedperiods. o Batteries should be stored below 25°C for extendedperiods o Store batteries between 40%

- 60% charged state. Fully chargejustbefore use. o Fully chargedbatteries which are notto 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 properwiring harness so thatthe voltage is no more than 25.2V. Over voltage will cause 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 yearperiod, 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 approved technician should disassemble the AV and inspect all components for wear and replace any components as required. • Replace all 8 motors. • Test all batteries for capacity. • Upgrade firmware and software to latestrevisions.



## 27 © 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. Linksto these documents are available onthe website. Print outthe significant documents and keep in a notebook with the copter at all times. AIRFRAME AUTOPILOT SYSTEM BATTERIES BATTERY CHARGER CAMERA MANUAL CAMERAGCS DATA WIRELESS LINK GIMBAL CAMERA MOUNT GIMBAL CAMERA MOUNT SERVOS LAPTOP COMPUTER MOTORS ONBOARD REGULATOR PROPELLERS RCIMANUAL COMMAND & CONTROL SYSTEM SPEED CONTROLS (ESCs) VIDEO CAPTURE HARDWARE VIDEO CAPTURE SOFTWARE VIDEO WIRELESS LINK



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