pilot’s operating hand ook alpha 800 · ahrs attitude and heading reference system ads altitude...

PILOT’S OPERATING HANDBOOK ALPHA 800

Alpha Unmanned Systems S.L. Av. Fuente Nueva, 14

28703, San Sebastián de los Reyes, Madrid. SPAIN CIF B86928009

www.alphaunmannedsystems.com All rights reserved.

Note: All UAV Maintenance and operation documentation is designed to supplement the training given on Alpha Unmanned Systems' comprehensive UAV Operator Course. UAV Maintenance must only be carried out by persons qualified on that Course; failure to comply may invalidate the UAV warranty and may lead to accidents. For further information and the latest updates contact [email protected].

Accomplished Revised Approved

Cosme Arin Alejandro Madrid Álvaro Escarpenter

Signature Signature Signature

Date: Date: Date: 31/03/2020 31/03/2020 31/03/2020

http://www.alphaunmannedsystems.com/

mailto:[email protected]

COMMERCIAL IN CONFIDENCE OPS-M-POH A800 V2.1 Pilot Operating Handbook

www.AlphaUnmannedSystems.com

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Version Record

Version Date Description

1.0 09/01/2015 Initial Version

1.1 20/04/2015 Manual updating and rebuild

1.2 10/04/2017 ALPHA 800 and fiscal address update

1.3 31/05/2017 Fixed mistake in rotor diameter

1.4 04/12/2018 General Update with new software capabilities

1.5 24/05/2019 Manual flight limitations and disclaimer

1.6 02/08/2019 General Manual update & new GCASE included

1.7 14/10/2019 Included release to service procedure after maintenance or storage & Annexes. Minor changes.

2.0 06/11/2019 General update with V8 software capabilities

2.1 27/03/2020 Single operator proccedure update



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TABLE OF CONTENTS SECTION 0: SYMBOLS, ABBREVIATIONS AND TERMINOLOGY ........................................................... 5 SECTION 1: GENERAL ........................................................................................................................ 7 SECTION 2: LIMITATIONS ................................................................................................................ 13 SECTION 3: EMERGENCY PROCEDURES ........................................................................................... 17 SECTION 4: NORMAL PROCEDURES ................................................................................................ 35 SECTION 5: PERFORMANCE............................................................................................................. 52 SECTION 6: WEIGHT AND BALANCE ................................................................................................ 57 SECTION 7: SYSTEMS DESCRIPTION ................................................................................................ 59 SECTION 8: SERVICE & MAINTENANCE............................................................................................ 73 SECTION 9: SUPLEMENTS ................................................................................................................ 97 ANNEX 1: PREFLIGHT CHECKLIST ..................................................................................................... 99 ANNEX 2: SINGLE OPERATOR PREFLIGHT CHECKLIST .................................................................... 101 ANNEX 3: RELEASE TO SERVICE PROCEDURE ................................................................................ 103



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SECTION 0: SYMBOLS, ABBREVIATIONS AND TERMINOLOGY

AHRS Attitude and Heading Reference System

ADS Altitude Determination Sensors

AGL Avobe Ground Level

AP Autopilot

BWRD Backward

BLOS Beyond Line Of Sight

BVLOS Beyond Visual Line Of Sight

CG Center of Gravity

CCW Counter Clockwise

CFRP Carbon Fiber Reinforced Polymer

CHT Cylinder Heat Temperature

CPU Central Processing Unit

CW Clockwise

EGT Exit Gust Temperature

FOV Field Of View

FWD Forward

GCS Ground Control Station

GDT Ground Data Terminal

GNSS Global Navigation Satellite System

GRP Glass reinforced Plastic

HC Helicopter

IAS Indicated Air Speed

IPC Illustrated Parts Catalog

KIAS Indicated Air Speed in Knots

LiPo Lithium Polymer battery

LiFe Lithium Iron phosphate battery

LOS Line Of Sight

LUT Look Up Tables

MTOW Maximum Take-off Weight

MMEL Master Minimum Equipment List

NSEW Nort, South, East & West

PCM Power & Communications Module

PEP Peak Envelope Power

PFD Primary Flight Display

PLL Phase Locked Loop

PTU Pan Tilt Unit

PWM Pulse Width Modulation

PY Payload

RMS Root Mean Square

RX Receiver

SN Serial Number

SW Software

TX Transmitter



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TO Take Off

UAV Unmanned Aerial Vehicle

VTOL Vertical Take-off and Landing

WP Waypoint

FP Flight Plan



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SECTION 1: GENERAL TABLE OF CONTENTS

1.1 Introduction ....................................................................................................................... 8 1.2 The ALPHA 800 UAV ........................................................................................................... 8

1.2.1 Alpha 800 dimensions ................................................................................................ 9 1.2.2 Engine ........................................................................................................................ 9 1.2.3 Rotors ...................................................................................................................... 10

Main Rotor ........................................................................................................... 10

Tail Rotor .............................................................................................................. 10

1.2.4 Fuel and Oil .............................................................................................................. 10 1.2.5 Weights .................................................................................................................... 10 1.2.6 The VECTOR ............................................................................................................. 10 1.2.7 The GCS .................................................................................................................... 11



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1.1 Introduction

This handbook contains 8 sections and gives the operator a general overall description of the Alpha 800 UAV.

1.2 The ALPHA 800 UAV The Alpha 800 is a rotary wing unmanned aircraft that operates as a helicopter with the possibility of vertical take-off and landing, hovering and navigating in automatic flight according to a previously-loaded flight plan. The operation is monitored by a Ground Control Station (GCS) and communications between the UAV and the GCS are in real time, allowing the ground operator to observe the images captured by the video camera installed on-board or the data from any other client-specified payload, as well as to have full manual UAV control by means of a joystick. The ALPHA 800 can be used for a wide range of applications where an onboard operator’s presence is not necessary. Avoiding risk to humans, unmanned aerial vehicles can be used for military or civilian applications, such as aerial surveillance and reconnaissance, fire detection, monitoring of law enforcement, etc. The ALPHA 800 is a tactical, automatic VTOL UAV. It is suitable for day or night, non-military or “Intelligence, Surveillance, Target Acquisition and Reconnaissance” (ISTAR) missions. The ALPHA 800 can provide, depending on the configuration, from 2 to 3 hour endurance missions with multiple payload capabilities. Avoiding the need for highly qualified personnel, ALPHA 800 can complete its entire mission automatically, from take-off to landing by means of a compact, redundant flight control system.



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1.2.1 Alpha 800 dimensions

Figure 1-1 - ALPHA 800 dimensions

1.2.2 Engine

Number of Engines 1

Number of Cylinders 1

Cylinder material Aluminum

Piston displacement 29 cc

Fuel Metering Carburetor

Engine Type Two-stroke gasoline engine

Power Rating 2 KW @ 13000 rpm

Table 1-2 - Engine features



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1.2.3 Rotors

Main Rotor

Blades material GRP, reflex

Number of blades 2

Aerodynamic profile Asymmetric

Diameter 1800mm

Table 1-3 - Main rotor features

Tail Rotor

Blades material CFRP

Number of blades 2

Aerodynamic profile Symmetric

Diameter 260mm

Table 1-4 - Tail rotor features

1.2.4 Fuel and Oil

Total Capacity 3.6l

Total Usable 3.4l

Table 1-5 - ALPHA 800 fuel capacity

Approved Fuel Grades:

- Mix of 95 octane non-leaded gasoline with 2.5% synthetic lubricant oil. Whenever possible use 98 octane fuel.

1.2.5 Weights

Maximum Takeoff Weight 14kg

Maximum Landing Weight 14kg

Standard Empty Weight 8.5kg

Maximum Useful Load 3kg

Table 1-6 - ALPHA 800 weight

1.2.6 The VECTOR

The VECTOR is a fully integrated autopilot with manual override and payload control capabilities. It includes sensors (accelerometers, gyroscopes, magnetometer and static and dynamic pressure gauges), a GPS, single processor, an interface to control servos and payloads.



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The VECTOR makes the ALPHA 800 capable of fully automatic take off and landing, as well as flight plans following. A manual override mechanism allows the ground operator to have full manual UAV control by means of a joystick, similar to the ones used for R/C airplanes or helicopters, requiring no extra training or adaptation. In terms of safety, the VECTOR Auto Pilot is an exceptionally robust and dependable system. It uses advanced estimation algorithms that greatly enhance the navigation accuracy and make the VECTOR capable of surviving several sensor failures. Upon radio-link loss, the VECTOR returns home and lands automatically. Automatic autorotation feature allows autonomous landing in the event of an engine or tail rotor failure. The VECTOR provides redundant servo outputs and prevents exceeding the UAV’s flight envelope. Aside from providing flight control, the VECTOR can perform payload control functions, such as a gyro stabilized camera for observation UAVs. NOTE: For more information please refer to the VECTOR User Manual.

1.2.7 The GCS

A complete two-screen Ground Control Station is housed in a compact and robust Pelicase. It includes the communication systems, a rugged PC for GCS software, several communication interfaces and the joystick for calibration and manual flight. NOTE: For more information please refer to the GCase User Manual. (DEV-M-GCSUM GCase User Manual V1.2)



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SECTION 2: LIMITATIONS

TABLE OF CONTENTS

2.1 Airspeed limitations ......................................................................................................... 14 2.2 Power plant limitations .................................................................................................... 14 2.3 Maximum weight ............................................................................................................. 14 2.4 Maneuver Limits .............................................................................................................. 14 2.5 Flight Load Factor Limits ................................................................................................... 14 2.6 Minimum Flight Crew ....................................................................................................... 15 2.7 Icing ................................................................................................................................. 15 2.8 Runway surface ................................................................................................................ 15 2.9 Altitude Limits .................................................................................................................. 15 2.10 Environmental Conditions ................................................................................................ 15 2.11 Manual Flight Limitations ................................................................................................. 15 2.12 Carburetor Icing ............................................................................................................... 16



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2.1 Airspeed limitations

Speed IAS Remarks

VNE 90 km/h Never Exceed Speed is the speed limit that must not be exceeded at any time.

VNO 65 km/h Maximum Structural Cruising Speed is the speed that should not be exceeded except in smooth air, and then only with caution.

Vcruise 45 km/h Maneuvering Speed is the maximum speed at which full control travel may be used. Is equivalent to Cruise Speed.

Table 2-1 - Airspeed limitations

Warning: VNE above Hover Ceiling (reference POH 5.7) is reduced to Vcruise (45km/h IAS) while horizontal or ascending flight and reduced to VNO (65km/h IAS) while in descending flight.

2.2 Power plant limitations

Engine Type Two stroke gasoline piston engine Power Rating 2KW @ 13000 rpm Maximum Rotor RPM 1500rpm Approved Oils 2T Synthetic oil Fuel Grade 95 Octane gasoline

Table 2-2 - Power plant limitations

2.3 Maximum weight

Maximum Takeoff Weight 14Kg

Maximum Landing Weight 14Kg

Standard Empty Weight (no payload-no fuel) 8.5Kg

Maximum Useful Load 3Kg

Table 2-3 - Maximum weight limitations

2.4 Maneuver Limits Aerobatic maneuvers, including spins, are prohibited.

2.5 Flight Load Factor Limits

+3g / -3g



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2.6 Minimum Flight Crew

The minimum flight crew is one Operator for the UAV and one operator for the payload. If the payload does not require any type of control the UAV can be flown with only one operator.

2.7 Icing

Flight into known icing conditions is prohibited.

2.8 Runway surface

This UAV may be operated on any clear solid surface.

Recommended minimum size of the take-off area: 10x10 m

2.9 Altitude Limits

Maximum Takeoff Altitude ASL 7.220ft (2200 m) Maximum Operating Altitude ASL 10.000ft (3048 m)

Table 2-4 - Altitude limits (ISA)

2.10 Environmental Conditions

Temperature range -10 ºC to +50 ºC (14º F to 122ª F)

Table 2-5 - Environmental conditions

2.11 Manual Flight Limitations

Maximum horizontal speed IAS 90 Km/h Maximum Vertical ascend speed

3m/s if horizontal speed is between 0 and 55 km/h IAS 1.5m/s if horizontal speed is between 55 and 90 km/h IAS

Maximum Vertical descend speed

4.5 m/s

Maximum Pitch and Roll. 30º

Table 2-6 – Manual flight limitations

WARNING: When on MANUAL MODE (MANUAL HOT) the external pilot has full control over the UAV, there is no limitation in terms of speed, maximum angles or any logic from the autopilot to maintain the UAV within the flight envelope. Therefore, when flying in manual mode, the EP is completely responsible for the flight. The AP will only stabilize the aircraft and



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will switch to SAFE in case of communication loss. Governor, RPMs protection and Autorotation logics are also deactivated on while on MANUAL FLIGHT.

2.12 Carburetor Icing

Under mild temperatures and high air humidity, water vapor can freeze on the surfaces of the carburetor throat, causing the engine to reduce output power or even stop it completely.

Carburetor icing can be identified by the internal pilot by periodically checking the rotor RPMs and the throttle percentage applied by the Autopilot. During icing formation, rotor RPMs will start to decrease and throttle percentage will start to increase from normal levels. If any of these phenomena are observed, please land the aircraft immediately.

Table 2-7 – Carburetor icing probability



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SECTION 3: EMERGENCY PROCEDURES TABLE OF CONTENTS

3.1 MASTER MINIMUM EQUIPMENT LIST............................................................................... 18 3.2 Emergency Procedures ..................................................................................................... 21

3.2.1 Emergency Flight Modes: ......................................................................................... 22 3.2.2 Warning ................................................................................................................... 24

Alarms .................................................................................................................. 24

Gauges ................................................................................................................. 28

3.2.3 Caution..................................................................................................................... 28 Alarms .................................................................................................................. 29

Gauges ................................................................................................................. 32

3.2.4 Advisory ................................................................................................................... 33



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3.1 MASTER MINIMUM EQUIPMENT LIST ➢ IMU (Inertial measurement unit failure)

1. CHECK condition of shock-absorbing mounts 2. REPLACE shock-absorbing mounts if necessary 3. CHECK ALPHA 800 airframe, blade tracking, or AP wires

IMU Alarm OFF GO ………………………… IMU Alarm still ON NO GO

➢ INT (Internal autopilot failure. Autopilot has detected one/ multiple failures)

1. CHECK all connections

2. CHECK power supply

INT Alarm OFF GO ………………………… INT Alarm still ON NO GO

➢ GPS (No accurate GPS fix. GPS not used for navigation)

1. CHECK GPS antenna connection

2. CHECK GPS antenna has clear view of sky 3. WAIT up to 15 minutes for GPS to acquire fix

GPS Alarm OFF GO ………………………… GPS Alarm still ON NO GO

➢ UAV VOLT CRITICAL (System voltage critical)

1. If RPMS are low this alarm will be triggered 2. Back up battery reading must be between 14-16.5 V

V1 Alarm OFF when RPMS are at flying level GO ………………………… V1 Alarm ON when RPMS are at flying level NO GO (ABORT TAKE OFF)

➢ LAPTOP FAILURE (NOT AN ALARM. Laptop or Visionair failure)

1. RESTART LAPTOP

2. LAUNCH Visionair

LAPTOP and VISIONAIR functioning GO

…………………….

LAPTOP and VISIONAIR not functioning NO GO



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➢ LUL (Long Uplink Loss)

1. CHECK UAV / GTRACK antenna connections

2. CHECK UAV / GTRACK power supply 3. CHECK GTRACK antenna correct aiming direction 4. Check Total Bandwidth used (lower video quality if needed)

LUL Alarm OFF GO ………………………… LUL Alarm still ON NO GO

➢ RPM NOT USED (Engine RPM below threshold)

When rotor is launched this alarm must disappear and RPM gauge must show a coherent reading. It starts reading from 300 RPM. In case of sensor redundancy, both sensors must fail for this alarm to be triggered.

1. INSPECT the RPM sensor or sensors in case of redundancy

RPM Sensor failure NO GO

………………….

Engine running rough NO GO

➢ UAV VOLT LOW (System voltage low)

1. CHECK batteries voltage manually 2. REPLACE batteries if needed 3. CHECK for Alternator transition when T/O rpms are reached by the rotor.

V1 Alarm is OFF GO ………………………… V1 Alarm still ON NO GO

➢ SUL (Short Uplink Loss)

1. CHECK UAV / GTRACK antenna connections

2. CHECK UAV / GTRACK power supply

SUL Alarm OFF GO ………………………… SUL Alarm still ON NO GO



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➢ ACCELEROMETERS (Accelerometers out of range)

1. CHECK condition of shock-absorbing mounts 2. REPLACE shock-absorbing mounts if necessary 3. CHECK ALPHA 800 airframe


➢ GYROSCOPES (Rate gyros out of range)

1. CHECK condition of shock-absorbing mounts 2. REPLACE shock-absorbing mounts if necessary 3. CHECK ALPHA 800 airframe


➢ TEMPERATURE OUT OF RANGE (Autopilot temperature out of range / temperature

sensor failure)

Ambient TEMP (< -45oC) OR (> 70oC) NO GO

………………………

Ambient TEMP (> -45oC) AND (< 70oC) Sensor failure NO GO

➢ PS (Static pressure (airspeed and altitude) sensor out of range)

1. CHECK Static tube for obstructions

PS Alarm OFF GO ………………………… PS Alarm still ON NO GO

➢ QD (Dynamic pressure (airspeed) sensor out of range)

1. CHECK Pitot tube for obstructions

QD Alarm OFF GO ………………………… QD Alarm still ON NO GO

➢ MAGNETOMETER (Magnetometer not functioning)

1. Engine must be running



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2. VERIFY no ferromagnetic materials near Autopilot

3. WAIT for the autopilot to initialize the magnetometer 4. RECALIBRATE magnetometer if alarm persists 5. Check NSEW indications and error

MAG Alarm OFF and indications coherent GO ………………………… MAG Alarm is ON NO GO

➢ PYO/PY1 (Autopilot <-> payload communications failure)

PYO: Refers to Engine Monitor

PY1: Refers to the camera

1. CHECK payload connections (Port 0 or Port 1)

PYO/PY1 Alarm ON GO

Not critical. Consider not going depending on importance of payload for the mission.

➢ ON GROUND

This alarm must be on while aircraft is on ground, but not when it is flying. Don´t take care of it while on ground or preflight checking.

3.2 Emergency Procedures This section contains the recommended procedures for managing various types of emergencies, malfunctions and critical situations. WARNING: AFTER AN ACTUAL EMERGENCY OR MALFUNCTION MAKE AN ENTRY IN THE UAV LOGBOOK. MAINTENANCE ACTION MAY BE REQUIRED AND NECESSARY BEFORE NEXT FLIGHT.

For definitions of terms, abbreviations and symbols used in this Section, refer to Section 0. These procedures deal with common emergencies. Although the procedures contained in this section are considered the best available, the pilot’s sound judgment is of paramount importance when confronted with an emergency. The pilot may deviate from these procedures if judged necessary under the given circumstances (specific failure condition, outside factors, and type of terrain overflown). To assist the pilot during an inflight emergency, three basic rules have been established:



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1. Maintain aircraft control 2. Analyze the situation 3. Take proper action

NOTE: It is impossible to establish a predetermined set of instructions which would provide a ready-made decision applicable to all situations.

3.2.1 Emergency Flight Modes:

EMG MODE: EMERGENCY mode may not be commanded directly by the operator and is the result of a failure in magnetometer and/or GPS while flying in any other operation mode. EMERGENCY mode will only be triggered with the mentioned failures if IAS Speed Control is disabled. Autopilot will maintain pitch and roll angles at 0o, altitude will be maintained by means of the barometer, although drifting due to the wind may occur. Attitude and heading can be commanded in EMERGENCY mode using the Joystick (MANUAL switch from JY02 should be in DOWN position (MANUAL)). The external pilot will be able to manually approach the aircraft to the landing area in EMERGENCY mode if regular flight conditions are not recovered after several seconds. Altitude will be automatically maintained at the last valid altitude before entering EMERGENCY mode. Once the aircraft is in Line Of Sight (LOS) it can be switched to MANUAL mode and manually landed. Once in EMERGENCY mode if the sensor causing the autopilot (AP) to enter in EMERGENCY mode is recovered, the AP will switch to HOVER mode. If there is a Long Uplink Loss (LUL) while in EMERGENCY mode, the AP will command to start descending gently and try to land. GPS DENIED NAVIGATION DESCRIPTION: This emergency mode is the result of a GPS alarm triggering. The Autopilot logics allow the UAV to keep on flying with degraded navigation capabilities. Below are described different scenarios that might arise. If UAV on ground, TAKE-OFF commands will not be accepted with GPS alarm on. If UAV flying, depending on the current configuration and mode, the autopilot will automatically react in different ways.

• IAS speed control enabled: - The platform will never fly below 12m/s. (42,3 km/h)



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- In HOVER mode: the autopilot will perform a loiter around the position the

platform had when the GPS alarm was triggered.

- In NAV- TO: will never end in a hover, ending in a loiter around the

corresponding position instead.

- In LAND mode: the autopilot will command a return to the Landing Site,

loitering then around the cross-shaped closest entrance point.

- In LAND mode, if a LUL Communications Failure happens, it starts loitering

around the Landing Site.

- In AUTO mode: the aircraft should follow one of the defined flight plans

previously configured for Auto mode.

• IAS speed control disabled: the autopilot will instantly switch to EMERGENCY mode. MAGNETOMER FAIL NAVIGATION DESCRIPTION: This emergency mode is engaged when a MAG alarm is triggered. Thanks to the Autopilot capabilities the UAV is able to fly with some degraded performances. Different situations are described below. IF UAV is on ground, TAKE-OFF commands will not be accepted with MAGNETOMETER alarm on. If UAV is flying, depending on the current configuration and mode, the autopilot will automatically react in different ways.

• IAS speed control enabled: - The platform will never fly below 12m/s (42,3 km/h).

- In HOVER mode: the autopilot will perform a loiter around the position it

had when the MAGNETOMETER alarm was triggered.

- In NAV-TO: these modes will never end in a hover, ending in a loiter around

the corresponding position instead.

- In LAND mode: the autopilot will command a return to the Landing Site

- In AUTO mode: the aircraft should follow one of the defined flight plans

previously configured for Auto mode.

• IAS speed control disabled: after 30 seconds with MAGNETOMETER alarm declared, the autopilot will switch to EMERGENCY mode. AUTOROTATION: If a complete engine fail happens, ENGINE alarm will be declared and the UAV will descend to maintain RPMs. If the collective pitch falls into negative values, AUTOROTATION alarm will



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pop up. From that moment, the UAV will perform an autonomous autorotation in which the Internal Pilot can only command a HOVER TO or a NAV TO in order to guide the UAV towards a safe area. If the UAV has a laser altimeter installed it will automatically perform a flare close to the ground to reduce speed, otherwise it will continue gliding until the ground is reached. TAIL FAILURE alarm also makes the autopilot reduce Engine to IDLE and perform an autonomous autorotation.

3.2.2 Warning

Below there is an overview of the Autopilot Waring alarms and their description or meaning. Warnings always refer to severe danger situations in which operator must take immediate action to avoid the progress into an accident. Instructions are also given on what actions should operators take.

Alarms

➢ ENGINE (Engine saturation or Engine failure alarm)

1. If alarm is engaged during a long ascent this alarm may be normal if intermittent. If

alarm is engaged during hover or normal flight conditions this is an advisory of a

complete engine failure.

2. Command NAV TO or HOVER TO aiming for a safe landing area.

3. Command altitude that AGL = 0.

………..

UAV in operator’s LOS:

1. Autonomous autorotation

UAV beyond operator’s LOS:


➢ IMU (Inertial Measurement Unit failure)


1. Engage Manual mode

2. Land UAV manually

3. Shut down engine


1. Engage Land mode or fly to towards home. 2. Wait until UAV in visual range 3. UAV not returning Emergency Landing



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➢ INT (Internal autopilot failure)

UAV in operator’s LOS



3. Shut down engine


1. Engage Land Mode

2. Wait until UAV in visual range

3. UAV not returning Emergency landing

➢ UAV VOLT CRITICAL (System voltage Critical)

If voltage >13V but <22V generator failed and LIFE is the backup, about 20 minutes of flight are

remining. Switch off payloads and follow LOS or BLOS procedure.

If voltage < 13V if LOS Land Immediately if BLOS Emergency Landing.




3. Shut down engine


1. Engage Land mode 2. Wait until UAV in visual range 3. UAV not returning Emergency landing

➢ MASTER GNSS (GPS failure)

Note: GPS Fixed minimum 6 satellites and Dilution of precision (HDOP, VDOP & TDOP) values must be < 1.5




3. Shut down engine


1. Engage Land mode towards home. 2. Wait until UAV in visual range 3. UAV not returning Emergency landing



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➢ LAPTOP FAILURE

WARNING: When the built-in computer has a failure, it is possible to force a return to

home of the UAV shutting down communications. Powering off GTRACK GDT will cause

communications failure. The autopilot can be configured to ignore communications

failure. If so, UAV will continue mission and will not land automatically. BE EXTREMELY

CAREFUL! See autopilot User Manual for more information



2. UNPLUG the GTRACK GDT - laptop connector

3. RESTART the laptop

4. LAUNCH Visionair software

5. PLUG the GTRACK GDT - laptop connector

6. CHECK telemetry data

………………..

Telemetry data GOOD Continue mission

Telemetry data FAILURE Follow landing procedure


1. POWER OFF the GTRACK GDT

2. RESTART the laptop

3. LAUNCH Visionair software

4. POWER UP the GTRACK GDT

5. CHECK telemetry data

………………..

Telemetry data GOOD Continue mission

Telemetry data FAILURE Follow landing procedure

➢ MAGNETOMETER (Magnetometer failure)




3. Shut down engine


1. Engage Land mode (If high wind increase speed to 65 km/h) 2. Wait until UAV in visual range 3. UAV not returning Emergency landing



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➢ BINGO TIME REACHED (BNG) Automatic switch to SAFE mode and landing.

WARNING: Vector can be configured to ignore Bingo time alarm. If so, UAV will continue

mission and will not land automatically. BE EXTREMELY CAREFUL! See Vector User

Manual for more information.

Landing is desired:

1. FOLLOW landing procedures ……………………

Landing is not desired:

1. ENGAGE desired flight mode 2. Reset Mission time

➢ CPU RESET

“Failsafe” should be active in configtool. Otherwise, the autopilot will restart in manual

mode. If “Safe Mode after Failsafe” is selected, the autopilot will switch to Safe mode after

a RESET event, otherwise it will maintain the flight mode.

When the On ground alarm is on and is not in takeoff mode and parachute has not been

deployed, the fail safe functionality is disabled and the alarm FAILSAFE DISARMED will

appear.

If the user has not configured the Failsafe functionality, the alarm FAILSAFE OFF will

appear.

➢ TAIL FAILURE

When the helicopter tail fails, the main rotor torque can’t be compensated and the

helicopter will spin at very fast angular rates. In this situation, the autopilot reduces the

engine to IDLE. That means ENGINE alarm will be declared and the helicopter will perform

an autonomous autorotation. AUTOROTATION alarm will be declared too.

1. Command NAV TO or HOVER TO aiming for a safe landing area.

………..





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➢ Long Comm Lost (LUL) Automatic switch to SAFE mode and landing.

WARNING: Vector can be configured to ignore the LUL alarm. In this case, UAV will

continue its mission and will not land automatically. BE EXTREMELY CAREFUL! See

Vector User Manual for more information.

1. CHECK GCS connections 2. CHECK GTRACK alignment 3. CHECK GTRACK GDT power supply

4. CONNECT external power supply (if required)

5. LUL alarm OFF Continue mission

6. LUL alarm ON FOLLOW landing procedures

Gauges

➢ CHT over 130 ºC (Engine overheat)




3. Shut down engine



3.2.3 Caution

Here are listed the lower risk level alarms of the autopilot. These alarms indicate potentially hazard situations in which the UAV performances are degraded and some corrective actions by the operators may be needed. Special care must be taken if operator actions aim to keep the UAV flying the mission.



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Alarms

➢ Short Comm Loss (SUL) Automatic switch to SAFE mode and landing.

IMPORTANT: Vector can be configured to ignore SUL alarm. If so, the UAV will continue

its mission and will not land automatically. BE EXTREMELY CAREFUL! See Vector User

Manual for more information.

1. CHECK ALL GCS connections 2. CHECK GTRACK GDT power supply 3. CONNECT external power supply (if required) 4. SUL alarm OFF Continue mission 5. SUL alarm ON FOLLOW landing procedures

➢ STATIC PRESSURE (PS) (Static pressure sensor out of range, and data is considered as not valid) Only

GPS altitude. In the situation where GPS alarm is happening at the same time, altitude estimation is

no longer reliable. Switch to LAND mode and be prepared to manual land once the UAV is in LOS.

1. CONTINUE mission

2. Land manually

➢ DYNAMIC PRESSURE (QD) (Dynamic pressure out of range, and data is considered as not valid) Should

be active before fly ( e.g. No Airspeed), should deactivate once appropriate IAS is reached. If happens

in flight, IP should decide whether to continue with the mission or return to base and land.

1. CONTINUE mission

2. Land manually

➢ PAYLOAD (0-3) (Vector <-> payload communications failure, camera (PY1) or Engine

Monitor (PY0) may not work properly)

1. Consider continuing mission

➢ ACCELEROMETERS (Accelerometers out of range, +/-8G in any axis)(Can be triggered due to excessive vibration)



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3. Shut down engine



➢ GYROSCOPES (Angular rate sensors out of range, >400º/sec)




3. Shut down engine



➢ TEMPERATURE OUT OF RANGE (Autopilot Internal temperature is out of range (-40ºc to +85ºc), or

there is a failure with the temp sensor) Autopilot not reliable




3. Shut down engine





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➢ UAV VOLT LOW (AP voltage critical)




3. Shut down engine



➢ RPM 2 (Engine RPM below threshold.)(RPM 2 BACKUP may appear in case of redundant RPM

sensor) (Starts reading from 300 RPM)

Check ENGINE (Engine failure alarm) alarm:

ENG alarm is on Follow ENG Check list

……………………

ENG alarm is off

The UAV in the operator’s LOS:



3. Shut down engine

The UAV beyond the operator’s LOS:


➢ RPM NOT USED (The data from all available Rotor RPM sensors is considered as not valid)

In case of having redundant RPM sensors, both sensors must fail for this alarm to be triggered (RPM 2 & RPM 2 BACKUP). With one or both sensors failing internal pilot must return to base and land. Caution, functions depending on Rotor RPM such Rotor RPM Protection/Autorotation and Governor will be disabled if this alarm is triggered.

➢ JOYSTICK EXTERNAL (Triggered if manual packets are not received)



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Check first if the Joystick is correctly connected and change Joystick cable if possible. If alarm persist, the pilot must command LAND using only automatic modes. Caution, several procedures as MAGNETOMETER or GPS failures include Manual Landing in them, these cannot be accomplished with JOYSTICK EXTERNAL alarm triggered.

Gauges

➢ FUEL LEVEL

If its < 0 ALPHA 800 has approximately 30 minutes of fuel remaining. Internal Pilot should consider

landing.


1. Engage LAND mode 2. Land UAV

3. Shut down engine


1. Engage LAND mode 2. Wait until UAV in visual range 3. Land UAV

4. Shut down engine

➢ RPM 2 (Also RPM 2 BACKUP in case of redundancy)

Rotor RPM reading starts from 300 RPM in normal behavior

Nominal RPM in main rotor is about 1200 – 1250 RPM.

The RPM sensors can be single or redundant depending on configuration.

In case of having two, under normal conditions, the less noisy measurement will be read

and if one fails the other one acts as backup. In case of a continued failure of one of the

RPM sensors land immediately.

It is normal for the RPM reading to be up or down the nominal RPMs because of the wind,

but if the RPMs are too deviated due to an excessive noise, land immediately following

LOS or BLOS procedures.


1. Engage LAND mode

2. Land UAV



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3. Shut down engine


1. Engage LAND mode


3. Land UAV

4. Shut down engine

If the chosen rpm sensor reading is higher than {1.4 · Nominal rpm}, it will be discarded and RPM 2 alarm will be active. (or RPM 2 Backup in case of redundancy)

➢ CHT over 120 ºC (Engine overheat)

Check engine for abnormal behavior, if ambient temperature is below 45º C, and after 5

minutes the temperature has not reduced, follow CHT over 130ºC procedure.




3. Shut down engine


1. Engage Land mode


3. UAV not returning Emergency landing

3.2.4 Advisory

System status information.

➢ ON GROUND Alarm

It is based on collective pitch level, GNSS speed and Altimeter feedback. This alarm must

be on while on ground but not once the aircraft is flying.

Caution, while on flight in case of communication loss, UAV will shut down the engine.

Increase speed to make the alarm disappear. If persist return immediately and land.

➢ OVER COMMAND Alarm

Active when external pilot inserts a joystick input during an automatic operation.



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SECTION 4: NORMAL PROCEDURES TABLE OF CONTENTS

4.1 Autopilot flight modes and logics ..................................................................................... 36 4.1.1 Autopilot flight modes description:........................................................................... 36 4.1.2 Flight Plans and Waypoints functionality. ................................................................. 36

LAND mode .......................................................................................................... 36

AUTO mode .......................................................................................................... 37

WAYPOINTS .......................................................................................................... 40

4.1.3 Automatic Transition Between modes ...................................................................... 41 Override capabilities on each flight mode. ............................................................ 41

4.1.4 Governor .................................................................................................................. 42 4.1.5 AP Protection logics .................................................................................................. 42

4.2 ALPHA 800 preflight checks .............................................................................................. 42 4.2.1 Two pilots operation ................................................................................................ 42 4.2.2 Single Operator ........................................................................................................ 46

4.3 ALPHA 800 Normal Operation Checklist ........................................................................... 50 4.3.1 TAKE OFF .................................................................................................................. 50 4.3.2 CLIMB ....................................................................................................................... 50 4.3.3 CRUISE ..................................................................................................................... 50 4.3.4 PRE-DESCENT ........................................................................................................... 51 4.3.5 APPROACH ............................................................................................................... 51 4.3.6 LANDING .................................................................................................................. 51



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4.1 Autopilot flight modes and logics

4.1.1 Autopilot flight modes description:

MODE DESCRIPTION

MANUAL/MANUAL HOT The stick position is used to generate a commanded pitch, roll, yaw rate and collective. Inner loop is active and will stabilize the platform to match the commanded attitude (the autopilot continues to provide pitch, roll and yaw stabilization)

TAKE-OFF The autopilot will execute the take off maneuver to make the platform go from the ground to flying in the air.

AUTO AUTO mode executes one of the the programmed Flight Plans (FP) based on waypoints.

NAV-TO or HOVER-TO The helicopter flies towards the desired WP and either stops (HOVER-TO) or loiters (NAV-TO) around the point.

HOVER The autopilot will maintain position, heading and altitude once HOVER mode is engaged and the platform is stopped.

SAFE The autopilot will command the aircraft to fly to a previously set Safety Altitude. Once achieved, it will automatically switch to LAND mode.

LAND The autopilot will command the aircraft to fly to a previously designated Flight Plan and performs the approximation in a calculated way optimizing the glide path to the cross - shaped landing flight plan. Default landing plan is selected during peflight checks.

4.1.2 Flight Plans and Waypoints functionality.

LAND mode

There are two types of landing flight plans: -Relative: When the coordinates of the waypoints change or depend on a GNSS source that might be moving. The reference source might be lost in some cases due to communication link problems or GNSS fixation, so this landing is not considered to be safe in emergency situations. - Absolute: The absolute landing flight plan is when all the coordinates of the waypoints do not change and are globally referenced.

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-manualmanual-hot-mode

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-take-mode

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-auto-mode

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-fly-mode

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-hover-mode

http://www.uavnavigation.com/support/kb/autopilot-software/rotary-wing-software/rotary-wing-safe-mode



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Since the relative references are considered not robust nor safe enough due to potential problems unrelated to the AP, it is really important to, at least, load one absolute landing flight plan to the AP. If this is not possible, the AP will trigger an alarm advising that there is no absolute landing flight plan available. The Landing Flight Plan is automatically generated by GCS software (Visionair) once the

operator places the target waypoint on the map by using the Flight Plan Editor. Once creating

a landing plan the user can set the final WP as absolute or referenced in order to set the

desired landing.

This cross-shaped flight plan can be extended by adding new waypoints to the flight plan.

Visionair will link automatically the first newer point to the closer WP of the cross, although

it can be manually modified.

By default, once the AP is in land mode, it will fly to the closest WP, but never to WPs 3, 2 or

1.

When the aircraft perform the standard landing, it will fly towards the closest WP, unless the

operator commands manually go to a certain WP.

Landing plans can be created similar to Auto mode plans explained in 4.1.2.2, using the Flight

plan editor.

AUTO mode

When Auto mode is commanded the aircraft should follow the defined flight plan, previously configured with the flight plan editor. The user can configure several Auto flight plans and Landing flight plans.

Figure 4.1 - Landing Cross in FP Editor



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Figure 4.2 Flight Plan Editor The options “V. speed” and “Loiter on last WP” are configured in this panel. When “V. speed” is selected, the autopilot will command the speed configured in the Flight Plan Editor. If the user manually change the commanded speed, this change will apply until a new WP is reached. If “Loiter on last WP” is selected, the AP will start loitering once it reaches the last WP. If not selected, once it reaches the last WP, it will switch to the first WP of the FP, restarting the complete FP. The definition of the flight plan is done either introducing the coordinates manually or by double clicking on the desired position in the map. The default commanded altitude and speed can be modified here:

Figure 4.3 Altitude and Speed for a FP

This information is obtained from the “Autopilot Mission Settings”. When modifying the speed or altitude, this change is applied on the leg formed by the modified WP and the previous WP. For example, in a 4 WP FP, if the WP1 speed is modified to 30 km/h, the helicopter will fly at 30 km/h when flying the leg that goes from WP4 to WP1. The altitude of a WP can also be changed by click & dragging the WP in the following altitude profile. The user can also use it to check the altitude over the ground level based on the digital elevation model (DEM).



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Figure 4.4 Flight plan Altitude profile

Visionair will evaluate if the flight plan profile is compatible with the flight plan settings configured in the “Autopilot Mission Settings”. If not, it will show a warning panel when the operator uploads the flight plan. When the flight plan is created but not uploaded to the autopilot, the flight plan will be blue. Once it is uploaded to the autopilot it will change its color to yellow.

Figure 4.5 Flight Plan Uploading

Until the AP FPs are downloaded for the first time in the session they are also yellow. WP can be deleted from the FP by either double left clicking over the WP, or by selecting the WP on the Flight plan editor and pressing Supr. The WPs can be moved by left clicking over the WP and drag to the desired position. WPs position can also be modified by left clicking over the coordinates shown in the flight plan editor. The whole flight plan can be moved by pressing ALT + clicking over any leg and dragging to the desired position. In order to upload FP´s, arrows pointing up indicate uploading action. The user can upload an individual flight plan or all flight plans by pressing the up arrow with “All”.



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Figure 4.6 Uploading Flight Plans Flight Plans can also be saved or loaded from files. Individually or collectively. Flight plans can be removed from Visionair or from the autopilot

WAYPOINTS

The user can choose between configuring the autopilot to stop on each WP or change

between WP without changing speed.

The flight plan editor allows the user to configure each WP by pressing the Config button.

Figure 4.8 Config button

The following panel should appear:

Figure 4.9 WP window

If the user selects the “Overfly waypoint” checkbox, the autopilot will stop on the WP.

In “Activate functionality” its possible to do conditional jumps if decided alarms are

triggered, Absolute jumps to other WP in other to go to an other Flight Plan, and even Loiter

if desired, being possible to define radius and sense of it.

Figure 4.7 Saving FP



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4.1.3 Automatic Transition Between modes

The AP will also enter into safe mode:

• If while in manual hot mode and CPU reset alarm and fail safe is not enabled.

• If there is a CPU reset and “change to safe after fail safe” is configured.

• If in landing or auto mode the next FP WP is not available.

• If the autopilot loses reference information and it is configured to enter into safe mode

when that happens.

Override capabilities on each flight mode.

Mode Altitude Heading Position

MANUAL Yes Yes Yes

TAKE-OFF min. Throttle Yes Yes

AUTO - - -

NAV-TO - - -

DIRECTED - - -

HOVER Yes (Gamepad only) Yes Yes

SAFE - - -

LAND min. Throttle Yes Yes

EMERGENCY - Yes Yes

Figure 4.10 Flight modes transition



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4.1.4 Governor

Governor is used in rotary wing platforms to keep engine/rotor rpm constant at a targeted rotor speed. The Governor manages the engine to provide always the necessary power for every flight condition. Once it is accordingly configured, Governor function will be enabled excepting for the following cases:

• MANUAL mode. (Configurable)

• UAV ON GROUND alarm while on LAND, HOVER or EMERGENCY mode.

• RPM NOT USED alarm.

By default, in manual mode, the governor is disabled. But if the operator requires the governor to be active, it can be activated by a user switch once it has been configured as so. The throttle and collective are controlled with one of the sticks. The stick value is mapped to a collective curve which is configured by the LUT tab in the config tools. Then, the collective output from the collective curve is mapped to a throttle curve. For each collective position, a throttle output is generated. The throttle curve can be configured as well in Config Tools/Lookup Tables.

4.1.5 AP Protection logics

• RPMs protection: Max collective is reduced if target RPMs of the governor are not

reached.

• Engine saturation: If engine >95% max collective is reduced. Only available when

governor function is configured.

• Collective saturation: If collective is saturated pitch and roll movements are reduced

to avoid collapse of flight.

• IAS navigation: The helicopter flies regarding the air speed not the GPS speed

whenever the speed is higher the predefined threshold

• AGL/Speed protection feature: Maximum GS is equal to AGL to avoid very high speeds

near the terrain. In order to increase the safety of the operation, the user can activate

an altitude and speed protection. This is done by setting “Min AGL” gain with a value

different from 0.

4.2 ALPHA 800 preflight checks

4.2.1 Two pilots operation

This procedure is provided as a check list in Annex 1 and it can be printed to keep it in hand during the preflight procedure.



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In this procedure, the tasks are divided between the internal pilot and the external pilot.

Internal Pilot External Pilot

GTRACK general condition………….……………..Check (Check no other GCS is switched on) GCASE ……………………….…Assemble and switch on GTRACK…………………….… Assemble and switch on GCase Duo battery …..…….………………..……....Check (14 to 16v)

Airframe general condition………….……………………….Check AP, servos and ignition switches ……………………………...Off Rotorhead…………………………………….………………………Check (Check links, bolts, shaft play and servos) Blades………………………..……..………………………………….Check (Condition and grip tension) Rotor dumpers……………………………………………………...Check (Check for strength and limited play) Jesus bolt……………………………….…………………………….Check Lubricate pitch control mechanisms (If necessary) One way bearing correct actuation………………………Check Tail rotor………………..………………….…………………………Check (Condition, links, bolts, blade grip tension, servos and control link) Transmission………………………….…………………………….Check (Belt tension, condition, gear teeth, clutch condition, drive belt and correct rotation) Antennas………………………………..……….……..……………Check AP connectors…………………………..………………………….Check Rubber dampers…………………………………………………..Check (Loose fittings or damage) Battery packs……………………………..…….………………….Check Wiring harness………………………………………………………Check Power distribution board……………….......……………….Check Engine exhaust ……………………………..........................Check RPM sensor………………………………………………….……….Check Fuel tanks……………………………….…………….Check sufficient Fuel lines………………………………….…………….…….Check clear Camera gimbal…………………………….……..…….………….Check Center of gravity…………………………………..…….………..Check

Call “Power on SwitchBox”

Main switch …………………………….………….…………………..On Response “ UAV power on” (Use Ext power to charge Main Battery)

LAUNCH VISIONAIR Dongle………………………………………………...……………Check Software Map calibration and DEM……………………………….Check Camera modes …………………………………………………Check Call “Camera mode………” Camera……………………………………………………………..Move

(Check correct camera movement) Response” Camera mode…….….gimbal correct”



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Check alarms, only ON GROUND and QD SENSOR FAIL must appear. Check speaker volume for audible alarms. Call “AHRS check: Pitch , roll and yaw and check servo corrections” (Check correct attitude indication in AHRS and proper correction in AHRS control surfaces) Call “ Pitch up, correcting downwards” Joystick……………………………………….…….Switch manual Call ”Manual mode. Check UAV control surface” Joystick…………………………………….………….Move controls Response ”Correct, roll right….” Call “Check Swashplate is leveled” No external imputs given GPS altitude and position…………………….Check stable (Check you have good signal from the satellites and look for 1 min that everything is stable) Call “Fuel up UAV” Check fuel quantity sensor actuation. Set Flight Plan(s) Using Visionairs Flight Plan Editor Call “ Move UAV to Take off location”

Move UAV…………………………………………Pitch, roll and yaw (Check servo correction) Response ”Roger, pitch up and correcting downwards” Response “Roger, checking control surfaces” ( Check control surface moves in right direction) Call ”Roll right, roll left, pitch up…….” Call “Swashplate leveled” Response “UAV Fuel full” Move UAV to take off location, heading facing wind Response “ UAV on take off location”

The preflight checklist will be done for the first flight of the day. Check A.

Record……………………………………………………….…………..Start Station Location……………………………………………………....Set T.O site……………………………………………………………………..Set

(External Pilot must assist the Internal Pilot as required and be alert to possible issues)



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(Caution: Insure heading entered is the one intended for TO) Landing FP…………………………………………………………...…Set Safety altitude………………………………………………………….Set Bingo time………………………………………………………………..Set Setting Menu checks………….………………………..As required Default Flight plan……………………..……………………….Loaded

Before starting the engine the briefing has to be complete. (Personnel/Costumers/Mission/Emergency)

Set to MANUAL mode Call “Ready for engine start” Joystick throttle……………….…….………………………..….Idle (Trim one third up) (Check Th% applied) Call “Throttle down, trim one third” Call “ Magnetometer check: N (E, S, W)” (Check magnetometer alarm off, check AHRS heading maximum error 7o) Call “N (E, S, W) Ok” (Perform Hard iron calibration if necessary) Check alarms, only ON GROUND & QD SENSOR FAIL & must appear. Check Landing plans & the rest of flight plans are uploaded Ensure GCS location is correct (via GPS) If not, enter manually in Visionair. Check voltages and all alarms clear (except QD, ON GND & CRITICAL VOLTAGE) Alarms must set to be audible Check altitude, position, velocity indications and communication Statistics. Command TO and check generator voltage and RPMs reading are correct.

Response “Roger, ready for engine start” Check Carburetor Arm Response “Roger, Throttle down, trim one third” Primer……………………………..………………….….Press Twice Call “Starting engine” (Step on skid while holding rotor with one hand) Recoil Starter…………….……………………….........Actuate Move UAV………………………………………….…… N, S ,E , W Response “ (N, S ,E , W)” Remove Ext. Power Check that trims are centered on the joystick and user switches are off.



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Fuel(Bingo time)…………………………………..……………….Set AHRS indications……………………………………………....Check Engine controls……………………………………………..….Check Flight plan……………………………………………………….Loaded Landing plan…………….……………………………………..Loaded Mission time……………………………………………………..Reset Camera……………………………………………………….……..Stow Recording data…………………………………………….…….Start Recording video………………………………………………....Start Alarms……………………………………………………….……….Clear Clearance…………………………………………………..…….Obtain Take-off brief……………………………………….……..Complete

NOTE: This checklist will be performed by the internal pilot. Once the UAV is beyond LOS, the external pilot’s task will be to help the internal pilot.

4.2.2 Single Operator

This procedure is provided as a check list in Annex 2 and it can be printed to keep it in hand during the preflight procedure. In this procedure, the tasks must be twice checked by the operator.

Single Operator

Airframe general condition………….……………………….Check AP, servos and ignition switches ……………………………...Off Rotorhead…………………………………….………………………Check (Check links, bolts, shaft play and servos) Blades………………………..……..………………………………….Check (Condition and grip tension) Rotor dumpers……………………………………………………...Check (Check for strength and limited play) Jesus bolt……………………………….…………………………….Check Lubricate pitch control mechanisms (If necessary) One way bearing correct actuation………………………Check Tail rotor………………..………………….…………………………Check (Condition, links, bolts, blade grip tension, servos and control link) Transmission………………………….…………………………….Check (Belt tension, condition, gear teeth, clutch condition, drive belt and correct rotation) Antennas………………………………..……….……..……………Check AP connectors…………………………..………………………….Check Rubber dampers…………………………………………………..Check (Loose fittings or damage) Battery packs……………………………..…….………………….Check Wiring harness………………………………………………………Check Power distribution board……………….......……………….Check Engine exhaust ……………………………..........................Check



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RPM sensor………………………………………………….……….Check Fuel tanks……………………………….…………….Check sufficient Fuel lines………………………………….…………….…….Check clear Camera gimbal…………………………….……..…….………….Check Center of gravity…………………………………..…….………..Check GTRACK general condition………….……………..Check (Check no other GCS is switched on) GCASE ……………………….…Assemble and switch on GTRACK…………………….… Assemble and switch on GCase Duo battery …..…….………………..……....Check (14 to 16v)

Power on SwitchBox Main switch …………………………….………….…………………..On UAV power on (Use Ext power to charge Main Battery)

LAUNCH VISIONAIR Dongle………………………………………………...……………Check Software Map calibration and DEM………………………………...Check Camera modes …………………………………………………Check Camera……………………………………………………………..Move (Check correct camera movement) Camera mode…….….gimbal correct Check alarms, only ON GROUND and QD SENSOR FAIL must appear. Check speaker volume for audible alarms. Operator must be placed in order to be able to check Visionair display while performing the UAV movements. AHRS check: Pitch , roll and yaw and check servo corrections (Check correct attitude indication in AHRS and proper correction in AHRS control surfaces) Move UAV……………………………………Pitch, roll and yaw (Check servo correction) Pitch up, correcting downwards Joystick……………………………………….…….Switch manual Manual mode. Check UAV control surface Joystick…………………………………….………….Move controls Checking control surfaces, Correct, roll right….



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(Check control surface moves in right direction) Check Swashplate is leveled No external imputs given GPS altitude and position…………………….Check stable (Check you have good signal from the satellites and look for 1 min that everything is stable) Fuel up UAV Check fuel quantity sensor actuation. Be careful. UAV can be Fuel full but as long as Take off weight never exceeds 14 kg (MTOW). Set Flight Plan(s) Using Visionairs Flight Plan Editor Move UAV to Take off location (Heading facing wind) UAV on take off location

The preflight checklist will be done for the first flight of the day. Check A.

Record……………………………………………………….…………..Start Station Location……………………………………………………....Set T.O site……………………………………………………………………..Set (Caution: Insure heading entered is the one intended for TO) Landing FP…………………………………………………………...…Set Safety altitude………………………………………………………….Set Bingo time………………………………………………………………..Set Setting Menu checks………….………………………..As required Default Flight plan……………………..……………………….Loaded

(The checklist and all the steps must be checked twice in order to avoid any issue)

Before starting the engine the briefing has to be complete. (Personnel/Costumers/Mission/Emergency)

Set to MANUAL mode Once Ready for engine start Check Carburetor Arm Joystick throttle……………….…….………………………..….Idle (Trim one third up) (Check Th% applied) Throttle down, trim one third Primer……………………………..………………….….Press Twice Starting engine (Step on skid while holding rotor with one hand)



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Recoil Starter…………….……………………….........Actuate Operator must place the helicopter facing the wind and check the magnetometer reading in visionair. (Check magnetometer alarm off, check AHRS heading maximum error 7o) (Perform Hard iron calibration if necessary) Refer to Section 8.1.12 Check alarms, only ON GROUND & QD SENSOR FAIL & must appear. Check Landing plans & the rest of flight plans are uploaded Ensure GCS location is correct (via GPS) If not, enter manually in Visionair. Remove Ext. Power Check voltages and all alarms clear (except QD, ON GND & CRITICAL VOLTAGE) Alarms must set to be audible Check altitude, position, velocity indications and communication Statistics. Check that trims are centered on the joystick and user switches are off. Command TO and check generator voltage and RPMs reading are correct. Fuel(Bingo time)…………………………………..……………….Set AHRS indications……………………………………………....Check Engine controls……………………………………………..….Check Flight plan……………………………………………………….Loaded Landing plan…………………………………………………..Loaded Mission time……………………………………………………..Reset Camera……………………………………………………….……..Stow Recording data…………………………………………….…….Start Recording video………………………………………………....Start Alarms……………………………………………………….……….Clear Clearance…………………………………………………..…….Obtain Take-off brief……………………………………….……..Complete



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4.3 ALPHA 800 Normal Operation Checklist

4.3.1 TAKE OFF

Fuel contents (Bingo time)…………………………………Check (Time)

Confirm fuel contents are sufficient for the flight (Add 10% of contingency fuel)

Confirm Bingo time is sufficient to reach the landing field and at least perform one missed approach.

Camera……………………………………………………………...Stow

Engine controls………………………………………………….Check

Make sure all the engine control monitors are working correctly.

AHRS………………………………………………………………….Check

Flight plan………………………………………………….…….Loaded

Make sure you’ve selected the correct flight plan, with the correct altitudes and speeds.

Take-off and landing fligh plan …………………………..…….Loaded

Make sure you’ve selected the correct T.O and landing site with the correct headings

Alarms……………………………………..……………….Check Clear

Clearance…………………………………………………………Obtain

Take-off brief…………………………….…….…………..Complete

Review T.O. and departure and mission profile including tracks, altitudes, MSA, etc.

Brief emergency actions following engine failure or fire.

4.3.2 CLIMB

Power……………………………………….………...60-80% Throttle

The speed might change depending on the weather.

Engine controls………………………….……Check (All green)

During the climb we have to monitor engine instruments and correct RPM’s.

Alarms…………………………………………………….………..Clear

20 m before top of climb, monitor correct level off.

4.3.3 CRUISE

Fuel (Bingo time)…………………………………………..Check

Make sure you have sufficient fuel to complete the mission and land safely.

Engine instruments………………………Check (All green)

Ammeter (Battery and Alternator)………..……..Check

Make sure the alternator is working and check for the correct voltages.

Altimeter (Safety altitude)…………………………….Check

Make sure your altimeter is working properly (GPS and Static vents alarms clear) and you are not going below your safety altitude.



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Alarms……………………………………………………………Clear

Location…………………………………..……………………Check

Make sure you are not flying over a danger area, not flying in busy airspace without clearance, clear of other traffic.

The cruise checks should be done every 5 to 10 minutes during the cruise.

4.3.4 PRE-DESCENT

Clearance……………………………………..…………..Obtain

Safety altitude……………………………………………Check

Before you descend you must double check your safety altitude.

4.3.5 APPROACH

Aircraft configuration…………………………………..Set

In the case you need to slow down the aircraft or set the camera for a better view on the approach.

Landing site…………………………..………………Loaded

Make sure you’ve selected the correct landing site with the correct heading.

Clearance……………………………………………….Obtain

If you are going to land on a controlled aerodrome you must ask for clearance.

Alarms…………………………..…………………………Clear

Fuel………………………………………………….……..Check

Check you have sufficient fuel to perform at least one miss approach.

Approach brief…….…………………………….Complete

Review the type of approach, landing and missed approach.

4.3.6 LANDING

Camera……………………………………………..Stowed

Final………………………..…………………………..Stable

If you don’t comply with the two procedures you must go around

NOTE: For more information, please refer to the ALPHA 800 SOP’s



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SECTION 5: PERFORMANCE TABLE OF CONTENTS

5.1 Take-off performance ...................................................................................................... 54 5.2 Landing performance ....................................................................................................... 54 5.3 Climb performance .......................................................................................................... 54 5.4 Cruise performance .......................................................................................................... 54 5.5 Range GCS/Video ............................................................................................................. 54 5.6 Range / endurance ........................................................................................................... 54 5.7 Hovering Performance ..................................................................................................... 55 5.8 Wind components ............................................................................................................ 56



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Conditions: Weight……………………………………………………………….MTOW (14kg) Atmosphere……………………………………………………….ISA

Winds…………………………………………………………………Zero Altitude………………………………………………………………Sea Level

5.1 Take-off performance

Take-off distance VTOL

Max. Take Off Altitude ASL 7220ft (2200 m)

Table 5-1 - Take off performance (ISA)

5.2 Landing performance

Landing distance VTOL

Max. Landing Altitude ASL 7220ft (2200 m)

Table 5-2 - Landing performance (ISA)

5.3 Climb performance

Vertical Speed (no Ground Speed)

1.5 m/s (5.4 km/h)

Vertical Speed (Cruise Speed)

3 m/s (10.8 km/h)

Throttle 65-75%

Fuel flow 1.65-1.80l/h

Table 5-3 - Climb performance (ISA)

5.4 Cruise performance

Cruise speed 45km/h

Throttle 45-65%

Fuel flow 1.5l/h

Table 5-4 - Cruise performance (ISA)

5.5 Range GCS/Video

Telemetry transmission range

25km radius (Depending on the antenna)

Video transmission range 25km radius (Depending on the antenna)

Table 5-5 - Range performance

5.6 Range / endurance

Maximum Range 112km

Maximum Endurance 2.5h

Table 5-6 – Endurance (ISA)



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Illustration 5-7 - Endurance chart (ISA)

5.7 Hovering Performance

Maximum in Ground Effect 7.700ft (2346m)

Maximum Out of Ground Effect 7.500ft (2286m) Table 5-8 – Hovering Performance (ISA)

Illustration 5-9 - Hovering Ceiling chart



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5.8 Wind components

The maximum allowable wind in flight is 45 km/h The maximum allowable Takeoff wind is 35 km/h The maximum allowable cross wind is 20 km/h (Takeoff or landing) For wind component calculations the following chart can be used:

Table 5-10 – Wind components chart



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SECTION 6: WEIGHT AND BALANCE TABLE OF CONTENTS

6.1 Center of Gravity Limits .................................................................................................... 58



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6.1 Center of Gravity Limits

Reference Datum Main rotor head

Forward 40mm forward of the datum

Aft 40mm aft of the datum

Table 6-1 - Center of gravity limits

To check the correct position of the center of gravity lift the UAV from the main rotor blades holders and ensure that the tail boom is strictly horizontal.



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SECTION 7: SYSTEMS DESCRIPTION TABLE OF CONTENTS

7.1 Illustrated parts catalog.................................................................................................... 60

7.1.1 ALPHA 800................................................................................................................ 60 7.1.2 GROUND CONTROL STATION .................................................................................... 61

7.2 Systems description ......................................................................................................... 61 7.2.1 Airframe ................................................................................................................... 61 7.2.2 Flight control ............................................................................................................ 61 7.2.3 Landing gear ............................................................................................................. 61 7.2.4 Engine ...................................................................................................................... 62 7.2.5 Transmission system ................................................................................................ 62 7.2.6 Fuel system .............................................................................................................. 62 7.2.7 VECTOR .................................................................................................................... 63 7.2.8 Electrical system ....................................................................................................... 63 7.2.9 PCM ......................................................................................................................... 65 7.2.10 Data link ................................................................................................................... 65

Diversity Antenna ............................................................................................. 66

7.2.11 Payload .................................................................................................................... 66 7.2.12 GCS .......................................................................................................................... 67

INTEGRATED COMPUTER .................................................................................. 69

Gamepad .......................................................................................................... 69

JOYSTICK ........................................................................................................... 70

7.2.13 Transport ................................................................................................................. 72 7.2.14 Optional equipment ................................................................................................. 72



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7.1 Illustrated parts catalog

7.1.1 ALPHA 800

Item Description Part Number Manufacturer

1 Airframe 010153000 Alpha Unmanned Systems 2 Fairing 010153201 Alpha Unmanned Systems 3 Engine 010172341 Alpha Unmanned Systems 4 Fuel tanks 010128001 Alpha Unmanned Systems 5 PCM 010139111 Alpha Unmanned Systems 6 Vector Autopilot 010139269 UAV Navigation 7 Onboard generator 010124311 Alpha Unmanned Systems 8 Main rotor blades 010162200 Alpha Unmanned Systems 9 Tail rotor blades 010164240 Alpha Unmanned Systems 10 GPS antenna 010134785 Alpha Unmanned Systems 11 Data link antennas 010134377 Alpha Unmanned Systems 12 Switch box/Power board 010124110 Alpha Unmanned Systems

Table 7-1 - IPC ALPHA 800



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7.1.2 GROUND CONTROL STATION

Item Description Part Number Manufacturer

1 GTRACK 15/30 0202002/003 Alpha Unmanned Systems 2 GPS antenna 32-2400-0 Tallysman 3 GCASE DUO 0201000 Alpha Unmanned Systems 4 Visionair software VISIONAIR UAV Navigation 5 Dongle - UAV Navigation 6 Gamepad F310 Logitec 7 Joystick JY02 UAV Navigation 8 GCASE-GTRACK Cable. TBD Alpha Unmanned Systems

Table 7-2 - IPC GCS

7.2 Systems description

7.2.1 Airframe

The ALPHA 800 is a UAV helicopter with a composite and aluminum material structure. The structure can support a MTOW up to 14 kg.

7.2.2 Flight control

The ALPHA 800 uses conventional helicopter flight controls.

For pitch and roll, the angle of attack of the main rotor blades is altered cyclically during rotation, creating different amounts of lift at different points of the cycle.

For ascents and descents, the angle of attack of the blades is collectively altered by equal amount at the same time resulting in increasing or decreasing overall lift.

For yawing, the pitch of the tail rotor blades, increases or reduces the thrust produced by the tail rotor. The tail rotor blade is powered by means of a belt.

7.2.3 Landing gear

Fixed helicopter legs.

6

7

3

4

1

5

2

8

https://es.farnell.com/tallysman-wireless/32-2400-0/ant-gps-l1-glonass-l1-sma-tw2400/dp/2056655



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7.2.4 Engine

The ALPHA 800 is powered by a two-stroke gasoline piston engine with a horsepower rating of 2,7 HP @ 1300 rpm

Engine system components:

• Oil system

• Engine cooling

• Engine fuel injection

• Engine fuel ignition

• Engine exhaust

• Engine controls

7.2.5 Transmission system

The ALPHA 800 main, tail rotor and generator are driven by industrial T5 transmission belts.

The transmission systems has two stages:

Stage 1 (Engine – Drive Shaft): 22/40

Stage 2 (Drive shaft – Main rotor shaft): 18/90

Tail rotor and generator are driven by the drive shaft with a relationship of 1/1 for the tail and

1/3 for the generator regarding the drive shaft.

Nominal rotor RPM : 1200 rpm

Nominal tail RPM: 7200 rpm

7.2.6 Fuel system

The fuel system is composed of two interconnected tanks, one on each side of the fuselage, that provide fuel for engine operation. Combined, both tanks have a capacity of 3.6 l. The fuel feeding schema makes the engine run on the right tank fuel first, and when it is over in this tank, makes the engine run on left tank fuel.

A fuel line delivers the fuel directly to the engine through the throttle metering valve. The left tank has two more lines; one is use for refueling and the other one for connecting to the right tank. This last tank has yet another line for ventilation.

Figure 7-3 - Fuel system



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7.2.7 VECTOR

The VECTOR is the main system of the aircraft. It’s not just an autopilot, it is used as a flight management system and all the systems of the ALPHA 800 are connected to it.

NOTE: For more information, please refer to the VECTOR User manual

7.2.8 Electrical system

The ALPHA 800 UAV electrical system consists of a generator that feeds electrical power to a switch box/distribution board which distributes the power to all the systems at the required voltage. The switch box has a backup battery that, in case of generator failure, is used as the main power source. The backup battery is a 5 cell LiFe which provides 16.4V and 40 minutes of electrical power. There is a second back up battery in the switch box consisting in a 3 cell Li-Po which provides 12V and 30 min extra of electrical power for emergency return home/landing.

The switch box powers up the PCM unit through two redundant lines. This unit manages all the inputs and outputs of the system. The Autopilot, the servos, the UAV sensors and the communication antennas all are connected to the PCM. Its internal CPU delivers specific data and power to the components of the system on demand. More about PCM in 7.2.9

Figure 7-4 - Electrical system



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7.2.9 PCM

PCM is a sealed box that acts as interface module between the autopilot and the rest of the

systems of the UAV. The PCM includes an Engine Monitor (EM) that reads sensors data and

outputs it converted using sensor calibration tables. Furthermore, the engine monitor can

exchange data with an autopilot and control up to two loads using this information.

PCMs have the following sensors:

• Radio Signal: Indicates the strength of the radio signal. (Must be > 70%)

• Fuel quantity 1: Shows the fuel levels at the first sensor in liters (ml).

• Internal temperature: Shows the temperature at the PCM in Celsius (Cº).

• External temperature: Shows the temperature in EGT when configured as External temperature in Celsius (Cº).

• Engine time: Indicates the time that the system has been working.

• CHT : Shows the temperature read on the cylinder heads in Celsius (Cº).

• Electrical Consumption: Shows Voltage (V) and Current (A)

The EM can handle up to three channels named GPIOs (General Purpose Inputs / Outputs)

which can be used to send or receive data from Autopilot or external switches and to two

Load Switches (LS)

LS have following configurable protections:

Temperature Maximum (ºC): LS will be off if the Internal Temperature exceeds 65º C.

Payload power consumption (W): LS will be off if the PY consumption exceeds 70 W.

Voltage Minimum/Maximum (V): LS will be off if the Voltage fall behind/exceeds 16 V.

7.2.10 Data link

The data link is a 2.4GHz radio. Its extremely high bandwidth (20 Mb/sec) means that it can

be used to pass both data and video between the RPAS/UAV and the Ground Control Station

with high ranges.

Modulations COFDM Channel Width 2, 4, 8 MHz Throughput 20 Mbps (8 MHz channel) Antennas (main/diversity) SMA Frequency range 2312 - 2502 MHz Output power 33dBm/1W Temperature range -40 to +85ºC Power Consumption Average: 5.2W Aircraft range Up to 15 km or 30 depending on GTrack configuration

Table 7-5 - Data link



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Diversity Antenna

The Data Link uses two antennas to improve the quality and reliability of the link. The second antenna acts only as RX. For systems delivered starting 2019 the radiolink is MIMO (Multiple Input and Multiple output).

7.2.11 Payload

The ALPHA 800 has a maximum payload capacity of 3 Kg. Thanks to this great payload capacity, several payload options can be installed. Below we’re listing a few of pre-integrated payloads:

UAV VISION CM100 Low weight compact double sensors with superior x30 zoom

CONTROP D/U-STAMP

Simple, compact and battle proved

OCTOPUS EPSILON 140 With both day and night sensors and onboard video processing.

DST OTUS-U135 Swedish made, with hundreds of hours and dual sensor option

FLIR SC655 The option for agricultural or wildlife research

VARIOCAM HD The highest resolution in IR

TETRACAM Multispectral option fully configurable

SCOUT LIDAR The lightest and most powerful LIDAR for unmanned vehicle



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7.2.12 GCS

The GCS is the control center that provides a complete control of the UAV, its sensors and its payloads.

The GCS acts as a bi-directional communication relay between the UAV and the GCase Duo software using its integrated radio link. It performs low-level message integrity verification, guaranteeing that no unnecessary communication will clog the link. Its integrated radio link allows data communication ranges in of up to 15 or 30 km depending on the GTRACK antenna used. With its integrated GPS, the GCS can track UAVs and aim antennas with great precision, even when the GCS is in transit. Using Serial communication, high gain directional antennas can be steered in pan and tilt to reach longer distances of video transmission.

The GCS incorporates communications through an Ethernet port, allowing the autopilot telemetry to be distributed over a computer network.

The GCS of the ALPHA 800 UAV consists of the following components:

• 1 GTRACK GDT (15km & 30km)

• 1 Joystick to control the ALPHA 800 UAV in manual mode

• 1 Gamepad to control the camera and the UAV.

• 1 GCase (Rugged pelicase)



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Figure 7 - 6 - GCS scheme

MANUAL CONTROL

Control rate 50 Hz Resolution 1 mrad Number of channels 4

COMMUNICATIONS

Baud rate 20 Mbps UDP (20 MHz channel) Range 25 km

Frequency 2.4 GHz Method CODFM Simultaneous UAVs NO

MECHANICAL/ENVIRONMENTAL

Deployed size GCS03 (mm, HxWxL) 30x103x123 Weight 196 g System connector Ethernet/DB-9 female Joystick connector DB-15 female Gamepad connector USB Power connector 2,5 mm barrel jack female

GTRACK connector MS3112E-16-26P

Temperature range -40º to +85ºC

Table 7-7 - GCS technical specifications



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INTEGRATED COMPUTER

The GCase Duo integrates a PC running UAV Navigation’s standard software:

• Visionair (for RPAS/UAV mission planning and execution)

• User Tools (for RPAS/UAV setup and calibration)

• Lynx (for post-mission analysis)

Processor Intel® Core™ i7-5550U Processor RAM 16GB Hard Drive 60 GB Chipset Intel® HD Graphics 620

Table 7-8 - PC technical specifications

Gamepad

The gamepad is used to:

• Control the ALPHA 800 gimbal and consequently the EO/IR camera

• Select Auto/Take-off/Hover/Land Mode

• Control ALPHA 800’s altitude and heading while being in Hover Mode

All the buttons are user configurable through Visionair (see Visionair Operator’s Manual for more information). In Figure 7- there is a typical configuration for the gamepad.

Figure 7-9 - Gamepad predefined functions

http://www.uavnavigation.org/products/visionair-ground-control-station-software

http://www.uavnavigation.org/products/user-tools

http://www.uavnavigation.org/products/lynx



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JOYSTICK

The RC style joystick is used to control the ALPHA 800 in Manual Mode.

Figure 7-10 - Joystick predefined functions



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Figure 7-11 - Joystick basic stick operations

Throttle stick

Roll stick

Pitch stick

Yaw stick



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7.2.13 Transport

The ALPHA 800 system is designed to be used in hard conditions. To achieve this, all the system is contained in rugged military specs flight cases.

• Airframe rugged transport case:

Figure 7 – 12 A800 Transport case

Dimensions (with wheels)……………………………………..1890x570x830 mm

Weight (empty/full)………………………………………………….……………28/39 kg

• GTRACK GDT transport case:

Figure 7 – 13 Gtrack GDT transport case

Dimensions (mm, LxWxH)…………………………….. 1570x1060x570 mm

Full Weight………………………………………………….150 kg



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SECTION 8: SERVICE & MAINTENANCE TABLE OF CONTENTS

8.1 Service Standard Procedures ............................................................................................ 74 8.1.1 Normal service procedure before going to fight field ................................................ 74 8.1.2 Charge/balance batteries ......................................................................................... 74 8.1.3 Check for autopilot software updates ....................................................................... 75 8.1.4 Autopilot configuration check ................................................................................... 77 8.1.5 Lubrication ............................................................................................................... 78 8.1.6 Fuel .......................................................................................................................... 78 8.1.7 Mission equipment preparation ............................................................................... 78 8.1.8 ALPHA 800 Airframe check ....................................................................................... 80 8.1.9 GCS Check ................................................................................................................ 80 8.1.10 ALPHA 800 wiring ..................................................................................................... 80 8.1.11 Magnetometer check ............................................................................................... 80 8.1.12 Magnetometer calibration ........................................................................................ 81 8.1.13 Servo movement check ............................................................................................ 83 8.1.14 Telemetry range test ................................................................................................ 83 8.1.15 Start the engine ........................................................................................................ 84

8.2 Maintenance .................................................................................................................... 85 8.2.1 UAV storage. ............................................................................................................ 85

Storage procedure. ............................................................................................... 85

Back to service procedure ..................................................................................... 86

8.2.2 Release to service procedure. ................................................................................... 86 Instructions: ......................................................................................................... 86

Structure of the procedure: .................................................................................. 87

Deviations or malfunctions reporting procedure: .................................................. 87

8.2.3 Batteries ................................................................................................................... 87 General notes ....................................................................................................... 87

Storage ................................................................................................................. 88

Useful life ............................................................................................................. 88

Memory effect, cell capacity ................................................................................. 88

Checking and charging the Batteries of the ALPHA 800 ......................................... 88

8.2.4 Airframe ................................................................................................................... 91 Cleaning the air filter ............................................................................................ 91

Cleaning the ALPHA 800........................................................................................ 91

Inspecting the pushrod ......................................................................................... 91

Inspect blade tracking ........................................................................................... 93

Blade tracking ....................................................................................................... 93

Inspecting camera mount and autopilot rubber dampers...................................... 94

Inspecting fuel filter .............................................................................................. 94

Inspecting fuel line................................................................................................ 95



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8.1 Service Standard Procedures

This section provides a description of the servicing procedures to follow in order to prepare the ALPHA 800 UAV for a mission in normal conditions.

8.1.1 Normal service procedure before going to fight field

Preparations to do before going to the flight site:

1) Batteries → CHARGE/BALANCE

2) Airframe → GENERAL INSPECTION

3) Wires and connectors → CHECK

4) Fuel → CARRY

8.1.2 Charge/balance batteries

Lithium batteries must be charged using the constant voltage method. The battery voltage rises steadily to 4.2 V/cell in the first phase of charging, and during this period the charger maintains a constant charge current at set value. If a discharged battery is charged at the 1 C1 rate, this initial phase lasts 50 to 60 minutes, during which around 80 – 90 % of the battery full capacity charged into it. When the battery reaches the final charge voltage of 4.2 Volts/cell, the charger will keep the voltage constant while the charge current declines; this occurs because the voltage difference between charger and battery is steadily growing smaller during this period. A further 35-40 minutes are then required to charge in the remaining capacity. A 3600 mAh LiPo LiFe cell must be charged at 3600 mAh maximum charge rate.

• ALPHA 800 UAV batteries charging process:

1) Select either 5S (LiFe) and 1 Amps or 3S (LiPo) 0.3 Amps power output at menu.

2) Connect the balancer’s connector to the balance port

3) Press start button

1 Charge current: 1C (charge rate) equals capacity value of battery



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Figure 8-1 - LiPo battery charger

• GCase DUO batteries charging process:

1) Connect adapter cable to the lateral power input connector at GCase DUO.

2) Both internal batteries are being recharged when the power supply is connected to the GCase Duo.

Look up 8.2.3to learn about batteries maintenance and storage.

8.1.3 Check for autopilot software updates

Login into support.uavnavigation.com and check for new Vector and Visionair software versions. To install the new Visionair version, just execute the downloaded file and follow the instructions on the screen. To upgrade the new Vector software the operator will need the last version of the User Tools (which can be downloaded also from the support website). Complete the following instructions to upgrade the Vector software:

1) Power up the GCS and the Vector

2) Open the Software Update tab in Maintenance Tool window, inside of Tools tab.

3) Select the port where the GCS is connected to the computer. The following window will appear:

http://www.uavnavigation.com/



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Figure 8-2 - Software Update

4) Click on the CHOOSE button and select the software file (.esp) downloaded from the support website.

5) Click on START

6) The progress bar indicates the remaining time until the software is loaded. When it is at 100%, Reset Vector will be highlighted in the Tasks window. Reset the Vector power.

7) The new software has been uploaded into the Vector.

IN CASE THERE IS ANY PROBLEM WHILE UPLOADING THE SOFTWARE, PLEASE CONTACT WITH UAV NAVIGATION.

To check the software version that the Vector is running:


2) Open the Visionair program / Tools / Configuration tools

3) The following window will appear:



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Figure 8-3 - Software Configuration tool

4) The software version is in the second item shown in the Product Information window / SW Details. In this case v8.4.17

8.1.4 Autopilot configuration check

To check the configuration that the Vector is running:




Figure 8-4 - Aircraft Configuration tool



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8.1.5 Lubrication

• Lubricate with just a drop the main rotor pitch slider with normal machine lubricant.

• Lubricate with just a drop the tail rotor pitch slider with normal machine lubricant.

• DO NOT LUBRICATE ANY OTHER PARTS OF THE ALPHA 800!

• THE GEAR WHEELS AND THE BELT DRIVES DO NOT USE LUBRICANT!

8.1.6 Fuel

The ALPHA 800 UAV engine works with a MIX OF 98 OCTANE NON-LEADED GASOLINE WITH 2,5%

SYNTHETIC LUBRICANT OIL. Use of 95 octane non-leaded gasoline is also permitted. The deposit of the ALPHA 800 UAV can carry a maximum of 3.6 liters of fuel. Take it into account when planning the mission.

8.1.7 Mission equipment preparation

Checklist to verify before going off on a mission with the ALPHA 800:

Documentation Alpha 800 Logbook of each helicopter

Preflight checklist forms, pen and folder

HC insurance

POH Pilots flight log

Pilots license

Pilots medical certificate

USB pendrive with insurance info

General equipment Helicopter

Antenna (check if the configuration is suitable for the helicopter's radio (900 MHz / 2.4 GHz)

Antenna Tripod

Tables (Helicopter & GCS) + chairs

Tent and anchors

GCS

Laptop computer with proper Visionair SW version

Generator + extension cable + multi-socket extension

Tools box

GCS accessories box

Measurement & chargers box

Batteries box (LIPO 4S/LIPO 6S/LIPO 3S)

Spare parts box Walkie talkies (check battery levels)

Paper roll

Gasoline can

Gasoline filler

Fuel funnel with filter



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General equipment 2 stroke oil

Oil measuring cap

Measurement & charger box

Switchbox charging cables Switchbox voltage test cables

Laptop charger

Batteries charger (LIPO, LIFE, etc.)

LIPO tester

GCS charging cable

Wattmeter

Sound level meter

IR thermometer

Weight scale

Anemometer

Binoculars

Compass

Caliper (Links bolt)

Blade pitch angle tool

Swashplate gauge

Measuring tape

GCS accessories box

Visionair Dongle

TPU cable Joystick cable

Joystick

2 x ethernet cable

GPS antenna

Mouse

Gamepad

900 MHz antenna (if needed)

USB pendrive

Tool box Pliers (Normal / Cutting / Bent nose / Needle nose / Circlip / Ball joint extractor)

Screwdrivers (Small flat blade for AP/Normal Flat blade/Slot head/M2.5/M3/M4/M5)

Allen wrenches

Open wrenches

Adjustable wrench

Rachet screwdriver set

Threadlocker

Cutter Clutch extraction tool

Scissors

Hammer



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Spare parts box Cable ties

Rubber dampers

Gears

Belts 3M Velcro

Gas filters

Main rotor blades (check for proper length)

Tail rotor blades

Fuel lines

Fuel tank cap and rubber gasket

Fuel valve

Note: For more information see Preflight check list and MMEL, Normal and Emergency procedures

8.1.8 ALPHA 800 Airframe check

A visual inspection is necessary to check that the system was not damaged during transportation. Check screws, cabling installation, camera support, telemetry antenna, GPS antenna, Vector and video batteries fixings. All must be well fixed to avoid the possibility of losing any part of the ALPHA 800 during the flight. Ensure that the weight and balance requirements have been met based on the ALPHA 800 configuration. If the CG is not aligned with the main rotor shaft, ballast should be added in the nose or tail. FOLLOW THE MAINTENANCE CHECKLIST BEFORE EVERY FLIGHT.

8.1.9 GCS Check

1) GTRACK GDT → FASTEN TO THE TRIPOD

2) GCS CONNECTIONS → CHECK

3) GTRACK DATA LINK ANTENNA → CHECK

4) JOYSTICK → CHECK CALIBRATION

8.1.10 ALPHA 800 wiring

Check that the ALPHA 800 wiring is OK and verify that each item is well connected.

8.1.11 Magnetometer check

To verify the correct calibration of the magnetometer:

• Check that the magnetometer alarm in Visionair is green



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• Put the ALPHA 800 on the ground pointing towards North with the help of a compass. Open the Visionair Primary Flight Display. Check that the heading is 0 degrees.

Figure 8-5 - Visionair PFD. The heading is inside the red rectangle (Here, 359).

• Check north, south, east and west positions doing the same process if the crew is composed by 2 operators. The error must not be more than 6-7 degrees.

If any of the listed checks fails, repeat the magnetometer calibration as explained in Section 8.1.12

8.1.12 Magnetometer calibration

This procedure must be carried out in any of the following instances:

• The configuration of the ALPHA 800 is modified

• The magnetometer check described in Section 8.1.11 has failed

• When the location of the flight has changed significantlly

Complete the following instructions to calibrate the magnetometer:

1) The engine must be running

2) Power up the GCS and the Vector autopilot


4) Go to Magnetometer Calibration tab. The following window will appear:



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Figure 8-6 - Magnetometer calibration tab

1) Click on the START button.

2) Stand with the helicopter facing the north.

3) First maneuver is to rotate the ALPHA 800 from nose up vertical position to nose down (pitch). This movement must be done slowly (no more than 90 degrees per second). Then, it is necessary to rotate the ALPHA 800 from left to right (roll), putting left side of the ALPHA 800 looking down and up.

Figure 8-7 - First step of the magnetometer calibration

4) This process must be repeated in the remaining 3 axes too. Taking care to not exceed the process maximum time defined by the status bar showed in Figure 8-6



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Figure 8-8 – Steps 2,3 & 4 of the magnetometer calibration

8.1.13 Servo corrections check

To confirm the correct performance of the servos, hold the ALPHA 800 from the landing legs. Rotate the ALPHA 800 nose down/up (pitch). The swash plate must move to the opposite position to compensate. Rotate the ALPHA 800 left/right (roll). The swash plate must move to the opposite position to compensate. Rotate the ALPHA 800 clockwise/counterclockwise (yaw). The tail rotor must move to the opposite position to compensate.

8.1.14 Telemetry range test

It is necessary to do a range test to assure that the telemetry system will have enough range of control. This procedure must be carried out if:

• The configuration of the ALPHA 800 is modified



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To check this, it is necessary to separate the ALPHA 800 UAV 200 meters from the GTRACK GDT tripod. In this situation we must have a total control over the ALPHA 800 which means that:

1) ALPHA 800 servos must move according to joystick deflections

2) Visionair must refresh the AHRS information in real time

3) The load of the downstream bandwidth shouldn’t be greater than 40%

4) The load of the downstream bandwidth shouldn’t oscillate more than ±5%

5) The ratio of RX pkt (bad) should be less than 1% of the RX pkt (good)

To look at the variables above described:

1) Open MORE WINDOWS, Statistics.

2) Select the port where the GCS is connected to the computer.


Figure 8-9 - Telemetry tab

In case one or more of the points to check above is not accomplished, check all the connections and installation procedures.

8.1.15 Start the engine

To start the engine, complete the following list.

1) Fuel line air bleed (Figure 8-10)



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2) Set joystick throttle stick to lowest position

3) Trim throttle to 1/3 from bottom

4) Pull engine recoil starter until engine starts

If the engine does not start, try moving the throttle trim 1 or 2 points higher from idle.

Figure 8-10 - Fuel line air bleed

8.2 Maintenance

The ALPHA 800 UAV is a low maintenance system; even so, there are some basic maintenance procedures described in this section that must be done periodically to assure a good and safe performance.

8.2.1 UAV storage.

Storage procedure.

For storage or periods longer than 2 weeks without performing any flight the user must follow the following procedure:

1) Disconnect the two power supply cables from the Switch Box. 2) Check that batteries inside the Switch Box are charged and balanced. 3) Check that batteries inside the GCase DUO are charged. Open the GCase

DUO Payload Bay and remove the internal batteries. 4) Install the blade holder. 5) Ensure that there is no fuel in the tanks or fuel lines, if present, flush it. 6) Empty the carburetor by priming the carburetor rubber bubble (Figure 8-

13). 7) Store the UAV in its transport box.



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Figure 8-11 – Emptying the Carburetor

WARNING: Batteries must be checked every month and charged if lower than 40% capacity. Check for balance also.

Back to service procedure

Follow release to service procedure in 8.2.2.

8.2.2 Release to service procedure.

After the maintenance of each Alpha 800 or after storage periods, it is recommended to

perform a thorough inspection of the whole system and some functional tests. The document

called “Release to service procedure” in Annex 3, describes the Return to Service Procedure,

and the checklists that must be followed to complete such procedure are included. Lists must

be printed, filled in and stored in the applicable documentation folder in conjunction with the

Maintenance Logs of the system.

Instructions:

Every time a system has gone through maintenance tasks or is back to service after storage

periods, it is required to print and to check one by one all the steps mentioned in the following

tables and complete the information on the S/N of the product, date, etc. Fill in the check

fields with OK or WRONG or the discrete value if applicable.

When one section is completed, the Pilot, Operator or UAV Technician must write down its

name, signature and date of the inspection.

Once all sections are completed the document must be digitalized and stored on the

applicable folder and the original copy kept in the physical Alpha800 system maintenance

records.



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Structure of the procedure:

The procedure is divided into 4 main sections which are:

• Section 1 - Alpha 800 Post Maintenance/Storage Checklist and AP configuration.

• Section 2 - Alpha 800 On ground Functional Test. (Preformed by a technician)

• Section 3 - Alpha 800 On flight Functional Test. (Preformed by the pilots)

• Section 4 - Alpha 800 Release to Service closing report and deviations.

This sections are included in ANNEX 3: RELEASE TO SERVICE PROCEDURE.

Deviations or malfunctions reporting procedure:

If any of the checked items would show an atypical deviation from the expected value or

shows a malfunction, a report describing the situation, as detailed as possible, must be

created. This report will be sent to the engineering department who will define the corrective

action or if the deviation is accepted after consensus with Alpha Unmanned Systems staff.

If the issue is considered a deviation or malfunction it must be reflected on the 4.2of the

Annex 3. A corrective action to get parameters back to tolerances should be defined and

applied. The concerned section of the Return to Service Procedure must be repeated to test

the effectiveness of the actions. To keep track of the accomplished tasks, an entry in the

Aircraft Maintenance Logbook will be made with a brief description of the jobs and detail of

the spare parts used.

8.2.3 Batteries

The batteries installed in the ALPHA 800 UAV and in the GTRACK GDT are based on last rechargeable Lithium technologies. These kinds of batteries must be charged with special LiPo chargers. Mishandling may lead to premature wear out and defects.

General notes

LiPo batteries must not:

• Be subjected to excessive heat or cold.

• Receive direct sunshine for extended periods of time.

• Be subjected to mechanical pressure or shock.

• Be left without supervision during the charge.

• Be short-circuited.

• Contact water or any other fluid.

• Be charged with reverse polarity.

• Be modified or opened.



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• Never place the charger and battery connected over a flammable or electrically conductive surface.

• If a multi-cell battery pack is used, it must consist exclusively of cells of the same capacity.

• Do not charge a warm battery. Let the battery cool until it reaches ambient temperature first.

• Do not charge batteries to more than 4.2 Volts per series-wired cell.

• Do not discharge batteries to less than 3 Volts per series-wired cell.

• Do not allow the fluid electrolyte to contact the eyes. If it does, rinse it off immediately with plenty of clean water and seek medical assistance as soon as possible.

• If the pack exceeds the final voltage, or falls below the final discharge voltage, the cells will be damaged; the damage takes the form of permanent loss.

Storage

Before a prolonged period of storage, spare batteries should be charged up to about 50%. After about five months the packs should be topped up again. LiPo cells feature an extremely low rate of self-discharge (approx. 0.2% per day), and can therefore be stored for long periods without problem. If the voltage falls to 3.2 V/cell, it is essential to recharge the pack.

Useful life

Change the batteries every 500 charge/discharge cycles or every year, whichever comes first.

Memory effect, cell capacity

Since LiPo cells do not suffer from memory effect, the discharge/charge process required with NiCd and NiMh batteries (cycling) is not necessary. In fact, you should avoid discharging a battery before recharging. Every time you charge a LiPo battery, its capacity is reduced slightly, so cycling would lead to unnecessary loss of cell capacity.

Note: for more information see 024 section of DEV-M-MM A800 Maintenance Manual V1.7

Checking and charging the Batteries of the ALPHA 800

The ALPHA 800 Switch box contains two batteries, one LIFE 5S and one LIPO 3S. These batteries are to be checked and charged by using the specific cable provided by ALPHA.



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The LIFE battery is charged and balanced each time that external power is connected or while the UAV is flying. It must however be checked in the same way as the LIPO to verify that it is operating correctly.

Figure 8-12 – Checking LIFE battery.



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Figure 8-13 – Checking LIPO battery.

Figure 8-14 – Charging LIPO battery.



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8.2.4 Airframe

In this section the airframe maintenance procedures for the ALPHA 800 are explained. In the following section there is a checklist with all the maintenance procedures and the frequency they have to be done.

Cleaning the air filter

• Ease off the metal clamp

• Loosen the Air filter by turning it counterclockwise.

Figure 8-15 - Air filter with metal clamp

• Once the Air filter is disconnected from the engine, clean the dust by blowing from

the inside with the help of an air compressor,

• Screw the Air filter by turning it clockwise. Tighten the cable tie.

Cleaning the ALPHA 800

• Clean with a soft and dry cloth the dust and dirt putting special attention to the moving

parts of the ALPHA 800 such as gears and axis.

• Spray WD-40 or similar cleaning agent to the moving parts.

• Clean with a soft and dry cloth the remainder product in order to avoid dust sticking

to the cleaned parts.

Inspecting the pushrod

• Hold the rod end and the swash plate where the ball joint is attached to firmly.



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• While holding the rod end and the swash plate, try to move the pushrod

Figure 8-16 - Ball joints at the extremes of a pushrod attached to a servo and the swash plate

Figure 8-17 - Ball joints at the extremes of a pushrod attached to the swash plate

• Check all the rods for looseness in the plastic extremes attached to the ball joints.

• If the rod end is fixed, it is OK. If the rod can move in any direction, replace it.

Ball Joint



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Inspect blade tracking

• Take two different colors of tape and put a small strip of one color on the leading edge

of one blade, and a small strip of the other color on the leading edge of the other

blade.

• Fix the ALPHA 800 in a safe place, start the engine and wait until the rotor reaches its

nominal speed.

• Keeping the pitch at 0 degrees and FROM A SAFE DISTANCE AWAY, bend over and get

your eyes at the same level of the spinning rotor blades.

• If the blades are tracking properly, then both rotors will spin in the same plane and

the colored tape will be a mix of both colors.

• If they are not tracking properly, then one rotor will look like it’s on top of the other

and the colored tape will be clearly visible.

Figure 8-18 - Blade tracking inspection. Blades are not tracking properly.

Blade tracking

• Blade tracking can be adjusted by lengthening or shortening the pitch control

pushrods (see Figure 8-21. It is necessary to check both rotor blades to have the same

pitch.

• Once these parts have been adjusted, repeat the inspection as explained in Section

8.2.4.4 until the blades are tracking in the same plane.



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Figure 8-19 - Pitch control pushrods to adjust the blade tracking

Inspecting camera mount and autopilot rubber dampers

• Check visually that the four rubber dampers are OK. The camera and autopilot have

to “float” when assembled with the rubber damper.

• Make sure the screws are securely fastened.

Figure 8-20 - Camera and AP rubber dampers

Inspecting fuel filter

• With time, the fuel filter may get blocked with tiny particles.

• Check visually that the filter is not obstructed. If the filter is dirty, replace it.



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8.21 – Fuel filter

Inspecting fuel line

• With time, the fuel lines may become rigid and cracks may appear.

• Check both visually and manually the flexibility of the fuel lines. If the transparency of

the tube disappears, replace it.

Figure 8.22 - Fuel line inspection.

Note: for more information about the maintenance tasks see DEV-M-MM A800 Maintenance Manual V1.7 (Visionair 8)



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SECTION 9: SUPLEMENTS

Reference manuals

• Visionair Operator’s Manual (UAV navigation)

• Vector User Manual (UAV navigation)

• DEV-M-MM A800 Maintenance Manual V1.7 (Visionair 8)

• OPS-R-VCL Van Checklist V1.0

• DEV-M-WEM A800 Wiring and Electronics Manual V1.0 Preflight checklist “Annex 1”

• Preflight checklist “Annex 2”

• Release to Service Procedure “Annex 3”



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ANNEX 1: PREFLIGHT CHECKLIST

GENERAL DATA ALPHA 800 serial number Engine serial number Log file number (Project/Flight nº/SN/date) Flight time Aircraft Take Off Weight

PRIOR TO DAY OF FLIGHT (AT BASE)

AIRFRAME CHECK (EXTERNAL PILOT)

Rotor head (links, bolts, shaft play).

Main blades & blade grip tension.

Rotor dumpers (Check for strength and limited play).

Jesus bolt.

Lubricate pitch control mechanisms (if necessary).

Check one way bearing correct actuation.

Rotor head servos (links, bolts and correct actuation).

RPM sensor.

Transmission (belt tension & condition, gear teeth)

Engine + exhaust (check thoroughly for loose fittings and cracks (inboard side as well)).

Fuel tank(s) + fuel lines (check for lines perforations).

Clutch condition, drive belt.

Antennae (incl cables, connectors): Telemetry, GPS.

AP connectors: GPS, Main Connectors, ADS connectors. Rubber dampers (check for loose fittings or damage).

Wiring harness: check for wear and damage (especially loose or faulty connectors).

PCM connectors: Antennas, Main Connector, Servo Connectors, Power Connectors.

Camera gimbal condition (Check fittings).

Switch Box Main Battery (write down voltage value and balance). V. %

Switch Box Secondary Battery (write down voltage value and balance). V. %

Tail servo (links, bolts and correct actuation).

Tail rotor (links, bolts, blade grip tension).

Check Center of Gravity is aligned with the rotor.

Gcase (INTERNAL PILOT)

General condition / check for damage.

Confirm presence of Visionair’s dongle.

Check cables/connectors for general condition.

Check GCase Batteries (write down voltages). V. V.

Download maps and DEM for the mission if necessary.



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AT FLYING SITE

FUNCTIONAL CHECK (INTERNAL & EXTERNAL PILOTS)

Complete general airframe inspection. Refer to ‘Airframe Check’ in ‘Prior to Day Of Flight’ checks.

Detailed Mission briefing.

When applicable proceed with airfiled coordination procedures. Check OPS-P-SG A800 for detailed airfield coordination procedure.

Check dongle present and launch VISIONAIR.

Power on Switchbox (Use Ext.power to Charge Main Battery).

Use JOYSTICK switch to set MANUAL mode. Check absence of jittering and correct actuation in all servos.

Check map calibrated & DEM present.

Check alarms, only UAV ON GROUND and QD SENSOR FAIL must appear. Check speaker volume for audible alarms.

Check camera actuations & alignment (If present).

Execute Visionair Preflight-Checks: Start recording, GCS location, Landing site, Safety altitude ASL, QNH, Reset Mission and Set Bingo Time.

Verify correct AHRS attitude indication (physically move UAV pitch up / down / roll).

Check servo corrections (pitch, roll, yaw etc) by physically moving UAV.

Use JOYSTICK to move and check UAV control surfaces and Throttle Servo actuations.

Visually check swashplate level. Check ADS sensors: Cover/ blow over Pitot & Static ports separately. Observe sensor reading are Logical.

Check GPS altitude / position stable in VISIONAIR. (GPS Fixed minimum 6 satellites and GS < 1m/s)

Fuel up UAV: Check fuel Quantity Sensor Actuation.

Set FLIGHT PLAN (double check altitude / distance of all waypoints).

Move UAV to take-off location.

Prime carburetor pushing prime pump.

Check mode set to MANUAL and ensure throttle set to IDLE position (Internal P: Check Th% applied; Ext P: Check Carburetor Arm). Start engine.

POSITION & MAGNETOMETER CHECK: MAGNETOMETER: check for N E S W headings and absence of MAG Alarm.

Check alarms, only UAV ON GROUND, QD SENSOR FAIL & GROUND ALT LOW must appear.

Check or define Landing plans (Flight Plan editor).

Set/check FLIGHT PLAN (double check WPs: Altitude, Speed and Distance between all waypoints).

Ensure GCS location is correct (via GPS) – if not, enter manually.

Remove Ext. Power. Check voltages and all alarms clear (except QD, UAV ON GND, GROUND ALT LOW, CRITICAL

VOLTAGE). Alarms must be set to audible.

Check altitude, position, velocity indications and communication Statistics.

Pre-Take-off Mission Review.

Reset Mission Time.

External pilot must check trims are centered on the joystick and user switches are off.

Command TO and check generator voltage and RPMs reading are correct.

UAV READY FOR FLIGHT

MISSION COMPLETION AND UAV LANDING

POST-FLIGHT CHECKS (in addition to normal shutdown)

Stop the engine, switch off Switchbox.

Stop Recording Telemetry.

Shut off Visionair and flight PC. Ensure Gtrack/GS03/GCase Duo are disconnected.

Fill out Flight Log Follow Up & flight crew debriefing.

EP perform a complete mechanical check of the UAV. Refer to ‘Airframe Check’ in ‘Prior to Day Of Flight’ checks.

UAV READY TO STORE



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ANNEX 2: SINGLE OPERATOR PREFLIGHT CHECKLIST

GENERAL DATA ALPHA 800 serial number Engine serial number Log file number (Project/Flight nº/SN/date) Flight time Aircraft Take Off Weight

PRIOR TO DAY OF FLIGHT (AT BASE)

AIRFRAME CHECK

Rotor head (links, bolts, shaft play).

Main blades & blade grip tension.

Rotor dumpers (Check for strength and limited play).

Jesus bolt.

Lubricate pitch control mechanisms (if necessary). Check one way bearing correct actuation.

Rotor head servos (links, bolts and correct actuation).

RPM sensor.


Engine + exhaust (check thoroughly for loose fittings and cracks (inboard side as well)).

Fuel tank(s) + fuel lines (check for lines perforations).

Clutch condition, drive belt.

Antennae (incl cables, connectors): Telemetry, GPS.

AP & PCM connectors: GPS, Main Connectors, Servo Connectors, Power Connectors.

Silent-blocks (check for loose fittings or damage).

Wiring harness: check for wear and damage (especially loose or faulty connectors).

PCM connectors: Antennas, Main Connector, Servo Connectors, Power Connectors.

Camera gimbal condition (Check fittings).

Switch Box Main Battery (write down voltage value and balance). V. %

Switch Box Secondary Battery (write down voltage value and balance). V. %

Tail servo (links, bolts and correct actuation).

Tail rotor (links, bolts, blade grip tension).

Check Center of Gravity is aligned with the rotor.

Gcase

General condition / check for damage.

Confirm presence of Visionair’s dongle.

Check cables/connectors for general condition.

Check GCase Batteries (write down voltages). V. V.

Download maps and DEM for the mission if necessary.



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AT FLYING SITE

FUNCTIONAL CHECK

Complete general airframe inspection. Refer to ‘Airframe Check’ in ‘Prior to Day Of Flight’ checks.

Detailed Mission briefing.

When applicable proceed with aifield coordination procedures. Check OPS-P-SG A800 for detailed airfield coordination procedure.

Check dongle present and launch VISIONAIR.

Power on Switchbox (Use Ext.power to Charge Main Battery).

Use JOYSTICK switch to set MANUAL mode. Check absence of jittering and correct actuation in all servos.

Check map calibrated & DEM present.

Check alarms, only UAV ON GROUND and QD SENSOR FAIL must appear. Check speaker volume for audible alarms.

Check camera actuations & alignment (If present).

Execute Visionair Preflight-Checks: Start recording, GCS location, Landing site, Safety altitude ASL, QNH, Reset Mission and Set Bingo Time.

Verify correct AHRS attitude indication (physically move UAV pitch up / down / roll). Operator placement should be suitable for checking the Visionair display while moving the UAV.

Check servo corrections (pitch, roll, yaw etc) by physically moving UAV.

Use JOYSTICK to move and check UAV control surfaces and Throttle Servo actuations.

Visually check swashplate level.

Check ADS sensors: Cover/blow over Pitot & Static ports separately. Observe logical sensor reading.

Check GPS altitude / position stable in VISIONAIR. (GPS Fixed minimum 6 satellites and GS < 1m/s)

Fuel up UAV: Check fuel Quantity Sensor Actuation.

Set FLIGHT PLAN (double check altitude / distance of all waypoints).

Move UAV to take-off location. MANUAL mode must be enabled. Throttle at minimum and trim at 1/3.

Prime carburetor pushing prime pump.

Check mode set to MANUAL and ensure throttle set to IDLE position (Check Throttle% applied (10%-13%) & Carburetor Arm). Start engine.

POSITION & MAGNETOMETER CHECK. MAGNETOMETER: Check the correct reading of take off heading

Check alarms, only UAV ON GROUND, QD SENSOR FAIL & GROUND ALT LOW must appear.

Check or define Landing site (Flight Plan Editor).

Set/check FLIGHT PLAN (double check WPs: Altitude, Speed and Distance between all waypoints).

Ensure GCS location is correct (via GPS) – if not, enter manually.

Remove Ext. Power. Check voltages and all alarms clear (except QD, UAV ON GND, GROUND ALT LOW, CRITICAL

VOLTAGE). Alarms must be set to audible.

Check altitude, position, velocity indications and communication Statistics.

Pre-Take-off Mission Review.

Reset Mission Time.

Operator must check trims are centered on the joystick and user switches are off.

Command TO and check generator voltage and RPMs reading are correct. UAV READY FOR FLIGHT

MISSION COMPLETION AND UAV LANDING

POST-FLIGHT CHECKS (in addition to normal shutdown)

Stop the engine, switch off Switchbox.

Stop Recording Telemetry.

Shut off Visionair and flight PC. Ensure Gtrack/GS03/GCase Duo are disconnected.

Fill out Flight Log Follow Up & flight crew debriefing.

Perform a complete mechanical check of the UAV. Refer to ‘Airframe Check’ in ‘Prior to Day Of Flight’ checks.

UAV READY TO STORE



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ANNEX 3: RELEASE TO SERVICE PROCEDURE

TABLE OF CONTENTS Section 1 - Alpha 800 Post Maintenance/Storage Checklist and AP configuration.

1.1 General data .................................................................................................................. 104 1.2 Airframe inspection ........................................................................................................ 105 1.3 Wiring inspection ........................................................................................................... 106 1.4 GCS, GTrack and Visionair inspection.............................................................................. 107

Section 2 - On ground functional test 2.1 Power on check .............................................................................................................. 108 2.2 Mechanical setting ......................................................................................................... 109 2.3 Control surfaces & sensors checks .................................................................................. 110 2.4 Engine Test. ................................................................................................................... 111 2.5 Payload Checks (on ground) ........................................................................................... 112

Section 3 - Alpha 800 ATP at Flying Site 3.1 Magnetometer Calibration ............................................................................................. 113 3.2 Manual Flight Test .......................................................................................................... 114 3.3 Autonomous Flight Checks (no Payload) ......................................................................... 115

Section 4 – Alpha 800 Release to Service closing report and deviations. 4.1 Closing report ................................................................................................................ 116 4.2 Deviations found. ........................................................................................................... 116



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Section 1 - Alpha 800 Post Maintenance/Storage Checklist and AP configuration.

1.1 General data

Air Segment General data.

Alpha 800 serial number

Engine serial number

AP serial number

PCM serial number

Switch Box serial number

Alpha 800 empty weight no payload (including batteries)

Payload (Yes(type)/No – Weight Kg)

Dummy/Ballast (Yes/No – Weight Kg)

Ground Segment General data.

GCASE serial number

GCS 03 serial number

GTRAK (if applicable) Type & serial number

Visonair SW version

Checker Date Completed

Name Signature

Cross-Checker Date Completed

Name Signature



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1.2 Airframe inspection

Step by step procedure CHECK CROSS-CHECK Rotor head (links, bolts, shaft play)

Main blades & blade grip tension

Rotor dumpers (Check for strength and mobility)

Jesus bolt

Clean and lubricate pitch control mechanisms (if necessary)

Check one-way bearing correct actuation

Rotor head servos (links and bolts)

RPM sensor, fitting strength and clearance with magnets and main gear


Engine + exhaust (check for loose fittings and cracks)

Carburation: - High needle at 1.5 turn

- Middle needle at 1.5 turn

Fuel tank(s) + fuel lines (check for lines perforations and

contamination)

Clutch condition, drive belt pulley

Antennae (incl cables, connectors): Telemetry, GPS, Video, Magnetometer (if present)

AP connectors: GPS, main connectors well positioned and fixed

Silent-blocks (check for loose fittings or damage)

Wiring harness: check for wear and damage (especially loose or faulty connectors)

Camera gimbal condition

Main Battery pack (write down voltage value)

Second Batterie pack (write down voltage value)

Tail servo (links and bolts)

Tail rotor (links, bolts, blade grip tension)

Check Center of Gravity is aligned with the rotor

Check identification stickers and plates: - ID plate with correct SN and return reward message is placed

on Switch Box base holder - Switch Box SN sticker on top - Tail tube stickers with Alpha 800 SN on both sides - Engine SN sticker - PCM SN sticker


Name Signature


Name Signature



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1.3 Wiring inspection

Step by step procedure CHECK CROSS-CHECK All cables must be protected from sharp frame edges, corners

and moving parts. No loose cables.

Servo cables are correctly routed and secured. Have appropriate length. No interference with main rotor gear.

GPS cable is correctly routed and have appropriate length

Power cables (Generator, main & secondary) are correctly

routed and have appropriate length. Connect them to Switch Box if disconnected.

Antennae cables are correctly routed and have appropriate

length

Tail cables (GPS antenna and tail servo) are secured with cable ties and protectors every 70 mm

Main wiring harness is correctly routed, secured and protected.

Connectors are in good condition. Check no vibrations are induced into the AP.

Every cable is correctly identified with its serial number

All cables are correctly routed and protected.


Name Signature


Name Signature



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1.4 GCS, GTrack and Visionair inspection

Step by step procedure CHECK Launch USER TOOLS GCS 0X

Check joystick calibration

Check joystick switches

GTrack: Command 30° Pan and check PTU moves properly

GTrack: Command 30° Tilt and check PTU moves properly

GTrack: Activate Auto function, check that antenna moves towards the

Alpha 800 as it moves in both horizontal directions If the Gtrack follow the helicopter in the opposite direction, check that the GCS03

has the correct hardcode for D47 or D100 according to customer configuration

Close USER TOOLS (GCS 0X)

Check dongle present and launch VISIONAIR

Check map calibrated & DEM is present

Check Visionair layout

Check Visionair: - Data source

- Misc (check Disable AP mode changes while on ground & Audible high

priority alarms)

- Units

- Gauges

- FP rules

- Alarms

- Batteries

- Gamepad calibration (if proceed)

- AHRS config

Close Visionair


Name Signature


Name Signature



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Section 2 - On ground functional test

2.1 Power on check 1. Charge GCS and Alpha 800 batteries and connect all necessary items (cables, joystick, etc.) 2. Ensure no other GCS is powered on. 3. Power on aircraft and ground control station (GCS). Be ready to shut power down if necessary.

Step by step procedure CHECK Check dongle is present and launch VISIONAIR

Check servos operation and absence of jittering

Check power consumption is around 13W (±5W) maximum when on

standby and MIMO on and Radio at max power and no payload installed

Servo Configuration. Engage Pure Manual mode. Make sure: - Tail & Engine: No mechanical limit is reached but are well adjusted to them.

- For all possible control’s combination, make sure electrical consumption

doesn’t overpass in 50% idle servo’s consumption.

- Cyclic plate keeps pitch & roll inclinations along all collective values.

Battery voltage reading is correct


Name Signature


Name Signature



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2.2 Mechanical setting

1. With the UAV and the GCS powered on, open User Tools and click the HELI PURE MANUAL MODE

2. Put the helicopter on a leveled surface. 3. Angles are measured on the main rotor blades. 4. Check and record the mechanical setting of the UAV 5. Close User Tools

Tools needed:

- Caliper - Electronic level - Aluminum plate - Blades pitch measuring tool

COLECTIVE (tolerance = +/-0.5º)

Step by step procedure CHECK

-3.5º for 10% throttle from AP telemetry

+7.5º for 50% throttle from AP telemetry

> +12º for 90% throttle from AP telemetry

SWASH-PLATE (tolerance = +/-0.5º)

Step by step procedure CHECK Check that without manual command swash-plate remains horizontal and

rise collective to achieve 0º on main rotor blades. Form this position check angles

6.5º for minimum elevator (blades perpendicular to aircraft)

6.5º for maximum elevator (blades perpendicular to aircraft)

6.5º for maximum aileron left (blades longitudinal to aircraft)

6.5º for maximum aileron right (blades longitudinal to aircraft)

TAIL

Step by step procedure CHECK 6.5 to 7.0 mm for neutral yaw stick position, measured from rotor hub to

pitch slider. (Save a screenshot on annexes)

Commanding full yaw (left and right), verify that tail pitch slider reaches

both path ends but does not make contact with the limits.


Name Signature


Name Signature



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2.3 Control surfaces & sensors checks 1. Install gamepad if proceed.

Step by step procedure CHECK Check customer’s dongle present and launch VISIONAIR

Power on Alpha 800. Check absence of jittering and correct actuation in all

servos

Check alarms, only UAV ON GROUND and QD SENSOR FAIL must

appear

Verify correct AHRS attitude indication (physically move UAV pitch /

down / roll)

Check servo corrections (pitch, roll, yaw etc.) by physically moving UAV

Use JOYSTICK switch to set MANUAL mode

Use JOYSTICK to move / check UAV control surfaces

Visually check swashplate level

Check GPS altitude / position stable in VISIONAIR

Fuel UAV, check for leakage and correct filling of both tanks

PCM sensors check - RPM (Move rotor by hand)

- Temperature (EHT & CHT)

- Fuel quantity

- Voltage

- Current

Defuel UAV

Close Visionair


Name Signature


Name Signature



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2.4 Engine Test. 1. Remove Main and tail rotor’s blades 2. Start the engine

NOTE: at idle temperature must remain constant and around 65-70º. Standard needle set up is: 1+1/2 (high needle) 1+1/2 (low needle)

3. Undergo engine break in if needed. 4. Install Main and tail rotor’s blades

Step by step procedure CHECK Fuel UAV, check for leakage and correct filling of both tanks

Check engine CAN’T start at 0% throttle. Change servo calibration if needed

Check Engine CAN start at middle trim. Change servo calibration if needed

Check for correct engine functionality. Tune carburation if needed

Check rpms measurement (never rev higher than 1400 – 1500 rpm)

Check for Correct generator voltage generation

Shut down the engine

Check for loose fittings, pulleys etc.

Install main and tail rotor blades.

Defuel UAV


Name Signature


Name Signature



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2.5 Payload Checks (on ground) Perform a functional test with the payload.

1. Switch on the HC and GCS. Wait for communication.

2. Switch on the payload and the specific software if applies.

3. Perform functional test using specific software or Visionair software


Power up GCS

Power up HC

Check communication status

Power up payload

Run specific software for payload if applies

Perform functional test of payload

Power off system.

Internal Pilot Date Completed

Name Signature



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Section 3 - Alpha 800 ATP at Flying Site

3.1 Magnetometer Calibration 1. Power on HC and GCS. 2. Open Visionair. 3. Wait 10 minutes until GPS position is accurate and almanac is stored on AP. 4. Start recording. 5. Perform magnetometer calibration. 6. Stop recording and save the log file.

Step by step procedure CHECK Check that after calibration magnetic sensor module is constant +-15 m

Gauss for all orientations and all payload configurations

Check for N, S, E and W headings (+-6º)

Check GPS operation (speeds must remain below 1 m/s)

200 m radio range test

Check GCS antenna correct aiming to the helicopter

AHRS stable and heading not changing with engine RPMs


Name Signature

External Pilot Date Completed

Name Signature



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3.2 Manual Flight Test

1. Remove payload and install counterweigh 2. Fuel UAV main tank with ¾ of its capacity 3. Perform preflight checklist SOP 4. Perform a short flight as described on procedure below checking all the functionalities of the

UAV 5. Stop recording and save the log file.

Step by step procedure CHECK Check rpms at manual mode are between 1250 and 1350,

and throttle commanded is over 40%

Check for vibration peaks: - Az between 0G and -2G

- Ax & Ay between 1 and -1

Engage Hover mode

Check GOV RPMS are between 1200 and 1250 rpms

Check for commanded rudder near 0% in hover Mode


Name Signature


Name Signature



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3.3 Autonomous Flight Checks (no Payload)

1. Remove payload and install counterweigh 2. Fuel UAV main tank with ¾ of its capacity 3. Perform preflight checklist SOP 4. Perform a complete flight as described on procedure below checking all the UAV modes 5. Install payload


Activate GTrack auto functionality (if applicable)

Auto take-off

Fly short flight plan (Cruise speed, 40m altitude)

Fly to

Hover

Gamepad control if applicable

Auto land


Name Signature


Name Signature



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Section 4 – Alpha 800 Release to Service closing report and deviations.

4.1 Closing report Notes and briefing of the Release to Service:

4.2 Deviations found.

Deviations or malfunctions Corrective action

Quality Manager. Date Completed

Name Signature

pilot’s operating hand ook alpha 800 · ahrs attitude and heading reference system ads altitude...

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