UT Payload Quick Start Guide

Discover everything you need to know to get started with your Elios 3 UT Payload

Before Starting

Unboxing the Payload

When you have received your new UT Payload, make sure that the package is not damaged externally. If any substantial damage can be seen on the package, contact our customer support team before opening it.

Although it is protected, please do not use something sharp that could damage the Payload while opening the package.

Disclaimers

Carefully read the Elios 3 UT Payload User Manual and Quick Start Guide before managing the equipment and performing a flight. We also highly suggest that you take the available training provided to you by Flyability. See more here on how to update Inspector and here on how to update Cockpit. To update your drone simply connect it to your PC while connected to the internet and you will receive a pop-up prompting you to update your drone.

Pay attention. The Elios 3 UT Payload is a class 2 laser product. For more information please visit: https://www.lasersafetyfacts.com/labels2.html

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Software requirements

To operate the UT Payload you will need at least the 2024.07 update for the Elios 3 onboard software, Cockpit and Inspector, or any later update. To learn how to upgrade to the latest version click on this link.

Do not operate the Payload with any earlier version of the software! Only use the 2024.07 version or higher. This could otherwise corrupt your opened UT data.

Inspector is the software provided by Flyability to read and analyze the data collected by the Elios 3 UT drone. To smoothly download and work on Inspector 5 with the data captured from the UT Payload we suggest that you have a Desktop PC that matches the following requirements (or above):

Minimum	Recommended
Windows 11 64-bit	Windows 11 64-bit
Intel Core i5-1135 or AMD equivalent	i7-8750H @2.20GHz (6 cores)
16 GB RAM	16+ GB RAM
Iris Xe Graphics (Minimum tested)	Nvidia GTX 1050 or AMD RX 560
30 GB Storage	250+ GB Storage

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Setting up your Elios 3 UT drone

Mounting the UT Payload

The UT Payload is compatible ONLY with the Elios 3. Elios 1 and Elios 2 drones cannot be equipped with this Payload. You will need a Phillips screwdriver (not provided in the Elios 3 or UT box) and the Torque screwdriver supplied in the Elios 3 box (for motor replacements) to mount the UT Payload.

Watch this video to learn how you can mount your UT Payload on the Elios 3 drone:

IMPORTANT! Please check that the cables and tubes are correctly mounted outside the cage to avoid them falling into the propellers and make sure there is no dust before inserting the cable into the drone AUX port.

Adding ultrasonic couplant

Flyability provides you with a 25cl (8oz) bottle of couplant to get you started with UT inspections. The couplant is food-safe; you can find the datasheet here. We do not guarantee the integrity of the equipment if you use other types of couplant. The couplant operating temperature is between -51°C (-60°F) and 176°C (350°F). Adding water to the couplant may change the usable temperature range and it could freeze under 5°C/41°F conditions and damage the Payload.

To learn how to add couplant, watch this video:

To dispense couplant press and hold for a few seconds the AUX button on the remote controller. As long as you keep pressing the couplant keeps flowing. Most of the time you need less than a second to dispense enough couplant.

For safety concerns regarding the couplant provided to you by Flyability please refer to this safety sheet.

PLEASE NOTE: Repeated usage (normally >100 refills) or following a long storage period may block the smart syringe plunger. We recommend checking if the syringe functions correctly before each flight and changing it with a new one if necessary.

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Available training

Suggested training

We highly suggest that you follow some UT measurement training. When purchasing the UT Payload, basic online training is included to take you through the different components of the UT Payload and some basic knowledge on how to use it. You can receive the free training by contacting your sales representative or by contacting us at [e-mail].

It is also possible to purchase an Advanced OEM training option that will be provided in person by the Flyability training team or one of its resellers. If you are interested in purchasing the Oem UT training please contact us at: [e-mail].

PLEASE NOTE: Additional factors that directly affect the use and accuracy of ultrasonic equipment are beyond the scope of the UT Payload basic online training, Flyability OEM UT training, Quick Start Guide, and User Manual, which instruct in the setup and operation of the UT Payload within the Elios 3 drone system. The operator of the UT Payload mounted on the Elios 3 must be a well-trained UT inspector qualified by either their organization or another outside agency to the appropriate level of both theory and practical application of ultrasonics. Any issues concerning the UT data capture or analysis cannot be attributed to Cygnus Instruments or Flyability.

Required training

Cygnus Instruments has provided the UT technology within the UT Payload and recommends that users and operators of the UT Payload should have at least the following level of formal qualification:

• a minimum of UT “Level 1” (ASNT or PCN), under the supervision of Level 2 or Level 3 personnel

• when using Manual Gates to take measurements, the operator should hold a UT “Level 2” qualification

(References: ISO 16809 Clause 5.6; ISO 9712 Clause 6.1, 6.2.)

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Getting ready for your first flight

Preparation

Now that the UT Payload has been mounted, all the systems have been updated, you have read the user manual, you have taken the necessary training, and you have familiarized yourself with the new Cockpit interface you are ready for a test flight.

Make sure that you are in a safe environment for flying the drone, that no one is close to the take-off point, and that you have the correct protective gear. Also, be aware that an Elios 3 equipped with a UT Payload is more likely to get stuck or crash. To understand the risks associated with performing contact inspections with the UT Payload, it is suggested that you train in an easy open space environment where you can retrieve the drone if necessary.

Checklist before flying

Before you perform a UT flight, make sure you have done the following things:

1. Check that you have the correct probe and hood mounted on the drone

2. Make sure that the gauge is well-secured to the drone

   
3. Perform a probe gain compensation (watch this video to see how)
4. Perform probe zero (watch this video to see how)
5. Perform a calibration (watch this video to see how)
6. Take your first measurement not in flight by simply placing the probe in contact with a metallic surface. Make sure the A-scan appears clear on the screen

7. Adjust the arm in the correct position (watch this video to see how)

First test flight

You are now ready for your first Elios 3 UT flight. Turn on the drone and the remote control, wait for the UT Payload to be detected, and take off.

To perform a UT measurement while in flight, get close to the surface you want to inspect until the UT Payload magnetically locks onto the surface. Then dispense the couplant by pressing the AUX button. A measurement should appear on the screen.

If you are happy with the measurement, detach and move on to the next spot that needs inspecting. To make it easier to identify the measured spots in post-processing we suggest taking points of interest (POIs) every time you take a measurement.

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Correct use

Correct use of the UT Payload requires an appropriately trained and qualified UT inspector (see Required Training), identification of the correct equipment (UT Probe, Couplant, and test block) for the specific material, surface conditions and thickness range to be measured, and correct Calibration.

PLEASE NOTE: The UT Payload offers features that enable an expert operator to manually adjust the A-scan signal displayed, creating options for different measurements. This means that inaccurate measurement data can easily arise if the operator does not understand the manual adjustments or settings or is unqualified or inexperienced in interpreting the displayed information. Incorrect use of the UT Payload, incorrect Calibration, and/or incorrect data interpretation can result in inaccurate measurements and/or readings and possible serious financial loss, damage to components, and facilities, personal injury, and even death.

Neither Flyability, Cygnus Instruments Limited (Cygnus) nor any of its employees, suppliers, or representatives can be held responsible for improper use of the UT Payload, use of third-party probes, and/or inaccurate analysis and interpretation of data. The following are all of critical importance when using the UT Payload for accurate ultrasonic thickness gauging:

• Required Training
• A complete understanding of ultrasonic wave propagation

• Thorough reading and application of the User Manual and Quick Start Guide

• Proper UT Probe selection

• Good condition and correct zeroing of the UT Probe

• Proper cable length and Couplant selection

• Correct use of the appropriate test blocks for Calibration

• The process of complete and accurate Calibration of the UT Payload

• Correct sound velocity for the material being measured

• Assessment of environmental factors, which may affect the quality of contact between the UT Probe and the surface being tested, such as surface condition, sufficient Couplant, UT Probe stability, and surface contact time

• Proper storage and regular checks of all equipment

• Implementing all fixes and updates or upgrades prior to EACH use

The implementation of these factors is entirely outside the control of Cygnus Instruments and Flyability. It is the sole responsibility of the User to ensure that each and every one of these requirements is met to ensure proper use of the UT Payload.

In the absence of any negligence or other breach of duty by Cygnus, the use of the UT Payload is entirely at your own risk. Any claim relating to any part of the Elios 3 drone system should be referred to Flyability or Flyability Resellers in the first instance.

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Resource

Testing Elios 3’s spot thickness measurements' accuracy vs. manual devices

Please find and download this white paper here.