Hylio AgroDrone AG-110 User manual

AgroDrone Spray System
AG-110
Maintenance Manual V2.1

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 2
Contents
Daily Maintenance Checklist 3
Maintenance Schedule 4
Inspection Schedule 4
Inspection Criteria 5
Safety
Safe Maintenance Guidelines
Warning Signs
Ground Testing
When to Ground Test
Ground Test Steps and Checks
Flight Testing
When to Flight Test
Flight Test Steps and Checks

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 3
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 tank and pump system:
Pump 1 Gal clean water through the system 3 times
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. Tank
B. Frame
C. Motors
D. Radars
E. Propellers
F. Pump, flowmeter, and spray bars
3
Remove nozzle tips and nozzle filters from spray bars, soak in water and clean
STEP 2: HARDWARE MAINTENANCE
4
Tighten screws on carbon fiber extension bar mounting plates
5
Inspect GPS bases, Radar mounts, motors, drone base, extension bar/base, and
propellers for damage, looseness, or missing screws. If you cannot resolve a problem
on your own, contact the Hylio team immediately for assistance
6
Check for leaks in spray system
7
Verify that the propellers are secured tightly and undamaged
8
Verify that all hardware is tightly secured and clean
STEP 3: AGROSOL
9
Connect the drone to AgroSol and go to the maintenance tab
10
Download logs
11
Upload logs
12
Clear logs
13
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
14
Check spray team’s Tool-Kit for any broken or missing parts

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 4
Maintenance Schedule
Inspection Schedule
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
Battery Connector (as150u)
10
GPS
5
GPS Mast
5
Obstacle Detection Radar
10
Altitude Detection Radar
10
Flowmeter Unit
10
Flowmeter Accuracy
5
Pump
10
Pneumatic Spray System Tubing
5
Nozzles
5
2.65 Gallon Tank
5
Spray Bar Mount
10
40 mm Carbon Fiber Tubes (Arms)
10
Arm Elbow Joint
5
20 mm Carbon Fiber Tubes (Legs)
10
20 mm Carbon Fiber Tube Mounts (Legs)
10
Plastic Shell
10
Internal Components
10
Frame Mounts
10

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 5
Inspection Criteria
If the part does NOT pass the listed criteria upon inspection, replace/repair part immediately.
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
- 4 mm hex 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 nut screwed in tight on plastic shell
Battery Connectors
- No signs of wear or distress on wires from connectors into frame
(inspect closely right where wires enter frame)
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
- Top of mast level to drone
- All screws tight and rust free
- Mast parts not cracked/damaged
Obstacle 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
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 Unit
- 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

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- If flowrate is not to desired accuracy, perform the flowmeter
calibration as described in the software manual
Pump
- Pump housing intact
- Acceptable maximum pump pressure performance
(maximum pressure output will decline over time)
- 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
Nozzles
- No leaks when spraying at max pressure
- No cracks in plastic nozzle body
- Internal filter clean and undamaged
2.65 Gallon Tank
- No leaks when tank is full (check tank outlet)
- No cracks or damage to plastic (check 4 mount points)
Spray Bar Mount
- No cracks or chips in carbon fiber plate or aluminum tube mount
- All screws tight and rust free
40 mm Carbon Fiber
Tubes (Arms)
- No visible cracks in carbon fiber tubes
- All screws tight and rust free
Arm Elbow Joint
- No cracks (can crack when CF mount screws overtightened)
- No left-right “wobble” (tighten clasp/hinge M4 screws to fix)
- All screws tight and rust free
20 mm Carbon Fiber
Tubes (Legs)
- No visible cracks in carbon fiber tubes
- All screws tight and rust free
20 mm Carbon Fiber
Tube Mounts
- No visible cracks or damage on any mount
(4 each of 4 mount types: frame mount, tank mount,
horizontal 20 mm tube mount, 20 mm foot tube mount)
- All screws tight and rust free
Plastic Shell
- Shell fastener screws tight and rust free
- Shell closes evenly on all sides (sides seal shut)
- 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
Frame Mounts
- Inspect all 4 of each tank mount, cross beam mount, chassis
mount, and foot mount
- Check for cracks in mount material
- Check for fastener tightness

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 7
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.
3
Always communicate with the spray team about potential safety or maintenance
concerns before beginning maintenance procedures.
4
Always be aware of the GPS LED indicator lights and buzzer sounds. They will indicate
the safety status of the drone.
5
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 M4 Elbow Joint Pivot screw 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-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 8
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 the 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.
Should take 2 minutes. If 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

Hylio Agrodrone (AG-110) Maintenance Manual
©2020 Hylio Inc. All Rights Reserved 9
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 accelerometer, compass and level calibrations. Check that all calibrations are
able to be completed
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 6 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 tank with 2 gallons of fluid. 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.