Hylio AgroDrone AG-122 User manual

AgroDrone Spray System
AG-122
Maintenance Manual V2.2

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 2
Contents
Component Identification 3
Overview 3
Description 4
Daily Maintenance Checklist 6
Maintenance Schedule 7
Inspection Schedule 7
Inspection Criteria 8
Safety 10
Safe Maintenance Guidelines 10
Warning Signs 10
Ground Testing 11
When to Ground Test 11
Ground Test Steps and Checks 11
Flight Testing 12
When to Flight Test 12
Flight Test Steps and Checks 12

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 3
Component Identification
Overview
There are 19 components on the AG-122 which must be identified, excluding the two plastic 3
Gallon Tanks and carbon fiber tubes/aluminum that constitute the UAS frame.

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©2020 Hylio Inc. All Rights Reserved 4
Description
#
Part
Description
Fasteners
Torque (N*m)
1
Clockwise
Propeller
30x90 inch dual blade
2
4 mm hex
3.0
4
2.5 mm hex
2.0
2
Counter-
Clockwise
Propeller
30x90 inch dual blade
2
4 mm hex
3.0
4
2.5 mm hex
2.0
3
GPS 1
Here2 GNSS,
STM32F302
microprocessor with
IMU and barometer
3
2.5 mm hex
0.65
4
Arm Elbow
Joint
Foldable arm joints,
one elbow for each 2
arms
8
3 mm hex
2.0
1
5 mm hex & 10 mm
hex bolt
8.0
5
Motor/ESC
Assembly
100kv motor with
40mm circular mount
4
3 mm hex
5.0
6
Threaded
Arm Clamp
Threads on to Arm
elbow Joint to secure
arm during setup
n/a
n/a
n/a
7
Nozzle
Body
Dual Nozzle body
assembly
5
2.5 mm hex
1.2
8
Battery 1
16k mah battery with
AS150 U connector
n/a
n/a
n/a
9
Battery 2
16k mah battery with
AS150 U connector
n/a
n/a
n/a
10
Antenna
Ground Station Link
Radio Interchangeable
Antenna
3
2.5 mm hex
0.65
11
Micro USB
Connector
Flight controller data
transfer connection
3
2.5 mm hex
0.65
12
GPS 2
Here2 GNSS,
STM32F302
microprocessor with
IMU and barometer
3
2.5 mm hex
0.65
13
Motor LED
Configurable to any
RGB color
2
2 mm hex
1.0
14
Plastic
guard
Plastic guard for
aesthetics on front and
rear of drone
6
2.5 mm hex
1.0
15
Pump 1
0 –75 PSI rating,
flowrate dependent on
nozzle tip
4
2.5 mm hex
2.0
16
Altitude
Detection
Radar
IP67 millimeter wave
radar (one on front and
rear)
4
2.5 mm hex &
locknut
1.5

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 5
17
Flowmeter
6mm OD press fit tube
inlet, 0.3 L/min –6
L/min flowrate range
n/a
n/a
n/a
18
Pump 2
0 –75 PSI rating,
flowrate dependent on
nozzle tip
4
2.5 mm hex
2.0
19
Flowmeter
Filter
Removable/reusable
80 mesh screen filter
in front of flowmeter
n/a
n/a
n/a
Center
Plastic
Cover
Small plastic shell
covering the flight
controller between the
two tanks
6
2.5 mm hex
0.75
Top Plastic
Cover
Screws in the top
plastic cover to front
and rear of drone
2.5 mm hex
2.0
All
unnamed
fasteners
All fasteners unnamed
in this list
2.5 mm hex
2.0
3 mm hex
2.0
*Obstacle Avoidance radars, FPV cameras, and second flowmeter/filter are not shown in this
diagram

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 6
Daily Maintenance Checklist
Follow these steps for all UAS at the end of each day of spray operation. All cleaning MUST be
completed same day to ensure hardware longevity.
STEP 1: CLEANING
1
Clean chemical residue from the inside of the tanks and pumps system:
Pump 2 gal clean water through the system 3 times (1 gal in each tank)
Use a degreaser if necessary
2
Clean chemical waste and dirt off drone exterior with a wet rag
(a degreaser is recommended to be used)
A. Tanks
B. Frame
C. Motors
D. Radar
E. Propellers
F. Flowmeter/filter, and nozzles/nozzle bodies
3
Remove nozzle tips and nozzle filters from nozzle bodies, soak in water and clean
STEP 2: HARDWARE MAINTENANCE
5
Remove RFD antenna
6
Check for leaks in spray system
7
Inspect GPS bases, Radar mount, motors, drone base, flowmeter/filter mount. If you
cannot resolve a problem on your own, contact the Hylio team immediately.
9
Verify that the propellers are secured tightly and undamaged
10
Verify that all hardware is tightly secured and clean
STEP 3: AGROSOL
11
Connect the drone to AgroSol and go to the maintenance tab
12
Download logs
13
Upload logs
14
Clear logs
15
Perform the compass calibration (Every 3 months, if drone begins to fly poorly, if drone
is moved more than 50 miles, or drone is near an area of significant magnetic
interference). Do not calibrate near large metal objects: buildings, vehicles, power lines
STEP 4: TOOL-KIT
16
Check spray team’s Tool-Kit for any broken or missing parts

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 7
Maintenance Schedule
Inspection Schedule
Parts are identified in Hylio AG-122 Operations Manual>UAS Hardware. Regularly inspect each
part based on flight hours. Flight hours are automatically tracked internally on each UAS and
can be viewed in the AgroSol Maintenance Tab. In the event of a crash, perform an inspection
of all parts before resuming operation.
Part
# Flight Hours
Propeller (CCW/CW)
5
Rotor (CCW/CW)
10
Ground Station Link Radio Antenna
5
GPS
5
GPS Mast
5
Altitude Detection Radar
10
Flowmeter Unit
10
Flowmeter Accuracy
5
Pumps
10
Pneumatic Spray System Tubing
5
Nozzle Body
5
Two 3 Gallon Tanks
5
40 mm Carbon Fiber Tubes (Arms)
10
Arm Elbow Joint
5
Aluminum Landing Gear and Mounts
10
Plastic Guard
10
Internal Components
10
Battery Trays
10
Batteries
10
Threaded Arm Clamp
5
Micro USB Connector
5
Flowmeter Filter
10
Top/Bottom CF Plates
10
All unnamed fasteners
10

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©2020 Hylio Inc. All Rights Reserved 8
Inspection Criteria
If the part does NOT pass the listed criteria upon inspection, replace/repair part immediately. As
a part of the inspection for each part, check for tightness of all fasteners listed for that part in the
component identification description. Check for tightness to the listed torque.
Part
Inspection Criteria
Propeller (CCW/CW)
- No cracks or chips larger than 0.1-inch radius
- Propeller blade level with arm
- M3x12 mount screws tight and rust free
- 10 mm lug bolts tight and rust free
Rotor (CCW/CW)
- No rattling or scratching noise when spun by hand
- No large dents or cracks in rotor housing
- LED mount screws tight
- Rotor guard mount screws tight
Ground Station Link
Radio Antenna
- Antenna casing structurally intact
- Antenna screwed in tight to antenna mount
(comes loose often)
- Antenna mount screws tight and rust free
GPS
- Correct LED indicator colors when powered on
- GPS secured straight and tight to mast (Double sided tape OK)
- GPS housing and wire not damaged
(check closely at mount points and where wire enters frame)
- Acceptable GPS accuracy performance
- GPS does not frequently give errors in AgroSol
GPS Mast
- No cracks in material
- All screws tight and rust free
Altitude Detection
Radar
- Radar housing intact
- Radar wire not damaged
(check closely at mount points and where wire enters frame)
- Unit does not heat up when powered on
- Acceptable altitude readouts in AgroSol
Flowmeter Units
- Flowmeter housing intact
- Acceptable flowrate readouts in AgroSol
- Flowmeter wire not damaged
(check closely at mount points and where wire enters frame)
Flowmeter Accuracy
- Flowrate performance during flight (gal/ac output) should be
within 2%, or 5% in the worst case
- Set a constant test flowrate and measure output over 1 minute
using a graduated cylinder, actual flowrate should match desired
- If flowrate is not to desired accuracy, perform the flowmeter
calibration as described in the software manual
Pumps
- Pump housing intact
- Acceptable maximum pump pressure performance
(maximum pressure output will decline over time)

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©2020 Hylio Inc. All Rights Reserved 9
- Pump wire not damaged
(check closely at mount points and where wire enters frame)
Pneumatic Spray
System Tubing
- No leaks in tubing when spraying at max pressure
- Tubing clean of chemical residue
Nozzle Body
- No leaks when spraying at max pressure
- No cracks in plastic nozzle body
- Internal filter clean and undamaged
Two 3 Gallon Tanks
- No leaks when tank is full (check tank outlet nipple and bottom
cap)
- No cracks or damage to plastic
40 mm Carbon Fiber
Tubes (Arms)
- No visible cracks in carbon fiber tubes
- All screws tight and rust free
Arm Elbow Joint
- 5 mm pin bolt EXTREMELY tight (check torque)
- No cracks in composite housing
- All screws tight and rust free
Aluminum Landing
Gear and Mounts
- No visible cracks or incorrect bends in aluminum legs frame.
Drone does not wobble when sitting on landing gear
- All screws tight and rust free
Plastic Guard
- Guard fastener screws tight and rust free
- No large cracks or visible damage
Internal Components
- Take off plastic shell top: inspect inside center frame for damage
- All connectors plugged in tight
- No loose dangling wires
- No signs of damaged components or electrical shorts
Battery Trays
- All screws on inside and outside of trays tight and rust free
- Battery connector on drone side clean on inside and all screws
tight and rust free
Batteries
- Battery case does not have dents, connector wires do not show
wear or fray
Threaded Arm Clamp
- No cracks in plastic
- Threads still hold tight
Micro USB Connector
- Clean and free of debris inside connector
- Not loose in housing
- Rubber cap in place
Flowmeter Filters
- No cracks in plastic housing
- No leaks from filter
- Filter mesh clean
Top Plastic Covers
- No cracks or other visible damage on plates
- All screws tightened to listed torque
All unnamed fasteners
- All tightened to listed torque

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 10
Safety
Safe Maintenance Guidelines
1
Never perform maintenance cleaning procedures with the batteries inside the drone,
even if the batteries are disconnected.
2
Always wear appropriate personal protective equipment when cleaning with chemicals.
4
Always communicate with the spray team about potential safety or maintenance
concerns before beginning maintenance procedures.
6
Always be aware of the GPS LED indicator lights and buzzer sounds. They will indicate
the safety status of the drone.
7
Always follow safe battery charging and storage procedures.
Warning Signs
Look out for the following signs/symptoms. They are indicators of a potential problem.
1
Smell or appearance of electrical smoke from center frame or motors.
This occurs when there is an electrical short in the system.
2
Visual wear on any wire housing. Can cause electrical short if left to degrade over time.
3
Any components or wires getting hot when powered on, aside from motors after flight.
This occurs when there is an electrical short in the system.
4
Permanent discoloration of aluminum parts and spray tubing, or excessive rust. This
occurs when the UAS is not cleaned properly after spraying corrosive compounds.
5
Frame “wobble” when placed on flat ground. Occurs when frame screws are loose.
6
Arm “wobble” at the elbow joint. Occurs when M5 Elbow pin is loose. Can cause
dangerous vibrations during flight.
7
Inconsistent flowmeter readings. Occurs when dirt gets inside the flowmeter housing, or
when flowmeter cables are loose.

Hylio Agrodrone (AG-122) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 11
Ground Testing
When to Ground Test
Follow ground testing checklist after any of the following events:
- Crash
- Unknown issue stops user from flying
- At every 5-hour and every 10-hour routine maintenance check
Ground Test Steps and Checks
1) Place drone outside in a location 15 feet from any obstacle, where it can spray and spin
its motors without issue
2) Put exactly 1 gallon of fluid in each tank. Check for any leaks
3) Take a pair of batteries, measure the voltage, and connect to drone
4) Open AgroSol and connect to the drone over RFD. Verify RFD connection works
5) Spray out gallon at 0.5 gallon per minute, time how long it takes for tank to empty. It
should take 4 minutes. If time is off by over 5%, recalibrate flowmeter
6) While spraying, check for any leaks in the spray system
7) Check battery voltage on AgroSol, if off by over 0.2V recalibrate voltage
8) Check for correct radar altimeter reading. Pick up drone and move it around to confirm
the altimeter reading changes as expected
9) Turn on TX. Flip flight mode switch. Check that flight mode changes in AgroSol as
expected
10)Upload a mission. Check mission uploads on first try without issue
11)Check that GPS gets a lock
12)Arm motors. DO NOT TAKE OFF. Check that all motors spool up and rotate in the
correct CW/CCW direction. Check for errors on arming
13)Disconnect batteries
14)Connect drone to laptop using direct USB connection. Check that connection works and
logs can be downloaded

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©2020 Hylio Inc. All Rights Reserved 12
Flight Testing
When to Flight Test
Follow ground testing checklist after any of the following events:
- Crash
- Unknown issue stops user from flying
- At every 10-hour routine maintenance check
Flight Test Steps and Checks
1) Take drone outside to a safe and open testing field
2) Perform compass calibration
3) Upload a safe standard testing mission. This mission should be verified safe and low
altitude by flights on another drone that is confirmed to fly well. This mission should be
no more than an acre. Ensure the RTL altitude and spray altitude are separated by at
least 10 ft. Upload mission with 0 pump power. Check that the mission uploads on the
first try. Check that the mission appears in the operations tab as uploaded
4) STRICTLY FOLLOW PREFLIGHT CHECKLIST
5) Arm motors. Check that all motors spin up in the right CW/CCW direction
6) Take off. Check that drone takes off to correct RTL altitude. Check the motors are not
making any unusual noises. Check the drone appears to fly stable
7) As the drone descends to the mission area, check that it yaws to face the mission line
direction within acceptable error, (recalibrate compass if not)
8) Check that the drone flies stable during the spray section of the mission, check the
drone reaches speeds as set on the spray mission.
9) Pause drone. Check that pause and click to fly work. Resume mission. Check that
resume mission works. RTL mission. Check that RTL works
10)When the drone returns to descend for land, check that the land looks stable and
controlled.
11)Fill the tanks with 1 gallon of fluid each. Upload a mission using dynamic flowrate that
will spray 1.5 gallons over the entire mission. Follow steps 4-7 again.
12)Let the drone finish the mission, and measure the remaining volume in the tank.
Recalibrate flowmeter if off by more than 5%
13)Perform one final flight with a full tank. Adjust the mission dynamic flowrate to spray the
full tank over the mission area AND RUN EMPTY. Turn on empty tank RTL. Use the
Toolbox calculator to ensure a slow enough speed is selected. Follow steps 4-7 again.
14)Verify the drone RTL when the tank is empty. Verify the total volume sprayed in AgroSol
matches what was sprayed.