General Documentation

Battery

Material Safety Datasheet & Test Report

Elios 2 has several flight modes which can be selected by the pilot. Each have their own properties and uses.

ASSIST is the default control mode, and must be engaged at the beginning of a flight. In this mode, several optical sensors around the drone will measure its distance and motion with respect to nearby objects. It uses this information to automatically remain perfectly stationary.

However, optical sensors have limited range, and the quality of their measurements can be reduced by dust, direct sunlight, or featureless surfaces.

In the ATTI flight mode, the pilot's inputs directly control the attitude of the drone and the optical sensors are not used. This control mode must be selected if the pilot notices erratic flight behavior due to the limitations of the optical sensors.

Some flight environments are more demanding on the stability system (and pilot) than others. You can use the difficulty assessment sheet to estimate the difficulty level in function of several environmental factors.

Elios 2 Cage pentagon replacement

Elios 2 Propellers replacement

Automatic update:

We have created a basic flight simulator to help pilots build and maintain their skills. This simulator runs on the Elios 2 tablet and can be used to familiarize yourself with the flight controls in a realistic setting.

Download and install the APK file onto the tablet, the app will be called "Elios Training". The installation requires an internet connection for a one time activation at first use.

When connecting the remote controller to the tablet via USB, the tablet will ask you to allow this app to connect to the DJI controller, you must press confirm to continue. The simulator might take a few moments to launch.

Basic diagnostic information is displayed on the four LED navigation lights of the ELIOS 2. A combination of blinking patterns and colors are used to transmit different types of information about the status of the drone.

Drone Idle

In flight

To check if your transmission system is 100% functional, please follow these checkpoints before each mission/flight:

1. Connect the system with a fully charged battery for the drone and for the Range Extender if you use one

   1. If you use a modified GCS ensure the antennas are correctly fitted

   2. If you use the Range Extender ensure the cables are correctly fitted

2. Place the GCS or Range Extender and the drone at the same level, the drone must be facing the GCS or Range Extender (drone antennas at the opposite side, red circles here below)

3. Leave about 3 meters (10 feet) distance, between the drone and the GCS or Range Extender
4. From Cockpit application, navigate to the Radio panel
5. From the Radio panel, focus on the left part of the 2 first lines

6. You need to confirm the RSSI1 consistency between LB1, RC1, LB2 and RC2

When verifying those values, gently move the antennas around on the RC or gently bend up and down, left and right the Range Extender cables near the GCS and near the Power Module to ensure no ware or false contact are existing.

Each time you move the cable or antenna keep holding them in position and confirm the RSSI¹ consistency.

If one of the values gets higher than 20dbm compared to the others you must consider the device as faulty.

In this case, stop immediately all operations with the Range Extender and/or the GCS and contact providing the serial number of the material and a screen shot of the radio panel showing the defect.

RSSI¹ = Received Signal Strength Indicator

The HDMI output can be connected to a secondary monitor for demonstration purposes, or in combination with higher brightness monitor when flying in direct daylight.

What you will need

• Android/IOS device with DJI GO app installed (DJI GO—for products before P4 version)

• USB Cable

• The remote controller

Instructions

1. When the controller has connected to the tablet, the blue camera button will appear in the main menu of the DJI GO app.

2. Go to the HD tab (Image transmission settings)

3. Make sure you have

The Elios and Elios 2 drones use DJI Lightbridge 2 transmission system, and as such require the DJI GO app to be used for some advanced operations such as:

Calibration ensures that the control sticks have correct center point and range, the status LED on the GCS unit will blink red and a beeping sound will be heard when calibration is necessary. The control sticks can be calibrated with the DJI GO app by following these steps:

• Install "DJI GO--For products before P4" on your personal device. We do not recommend, to install it on the provided tablet. Cockpit and DJI GO do not get along well.

• Connect the GCS to a device with DJI GO, turn on the GCS and launch DJI GO

• DJI GO will automatically detect the Lightbridge 2, press on the "Camera" button

Every Flyability drone comes with a complementary training, but for some users it is sufficient to go through a self-training process. The following documents are available for pilots wishing to go through self training.

This is a short theory presentation to introduce new users to the features of the Elios 2 drone.

Flight simulator: This simulator runs on the Elios 2 tablet and can be used familiarize yourself with the flight controls in a realistic setting. Download and install the .APK file onto the tablet, run the app, and connect the tablet to a controller. The tablet requires an internet connection for a one time activation at first use.

. These are designed to give new pilots hands on experience with flying the drone in a safe area before heading out into the field. The training box shown in the exercises can be created by cutting ca. 450mm diameter holes into a cardboard box. It serves to give an impression of the behavior of the drone in extremely confined spaces.

Drone Lighting: Configuration, Operation, and Best Practices

The ELIOS 2 drone features strategically placed light panels to enhance visibility in dusty environments. The main lights are positioned away from the camera and angled outward to minimize glare. A close-up light, located next to the camera, helps reduce shadows but should be turned off in large dusty areas to prevent blinding effects.

To manage lighting effectively, pilots can choose between automatic mode, where the close-up light activates within 90 cm of a surface, and manual mode, which requires full control over light operation. Proper use of these settings improves visibility and performance in challenging conditions.

Battery temperature management for optimal performance

Maintaining batteries within the ideal 20-25°C range is crucial for performance, especially in extreme climates. A built-in temperature sensor alerts users if the battery falls below 10°C or exceeds 40°C, with monitoring available in the Cockpit app.

For cold climates, store batteries in an insulated box, use a battery discharger for gradual warming, or place a hot water bottle inside. In warm climates, cooling can be achieved with a frozen water bottle wrapped in a towel. Proper temperature management ensures battery efficiency and longevity.

Drone Safety Precautions: Handling and Protective Measures

Spinning propellers pose a safety risk, but the ELIOS drone’s protective cage minimizes danger, allowing safer handling. To avoid injuries, wear gloves and hold the drone cage with flat hands.

Regularly inspect the cage for damage, as broken parts can have sharp edges and compromise protection. Following these safety guidelines ensures both user and drone safety during operation.

ELIOS 2 Stabilization System: Sensors, Control Modes, and Best Practices

The ELIOS 2 stabilization system allows precise hovering using optical and distance sensors instead of GPS. These sensors measure movement and distance but can be affected by dust, direct sunlight, and dark or reflective surfaces.

The default ASSIST Mode stabilizes the drone, but in dusty or featureless environments, the system may fail, requiring a switch to Attitude Mode for manual control. Pilots should clean sensors after each flight, practice Attitude Mode, and plan routes near textured surfaces for optimal stability.

Propellers Maintenance: Inspection and Replacement

The ELIOS drone propellers spin at up to 30,000 RPM, designed to deform upon impact, they can suffer wear from dust and dents from debris, leading to increased drag, vibrations, and motor strain.

To maintain performance, inspect propellers before every flight and replace them if deformations exceed 1mm.

Enhancing Comfort for Optimal Drone Operation

Pilots need full focus when flying indoor inspection drones. However, industrial settings can be uncomfortable, with standing positions and screen reflections affecting visibility and concentration.

To improve focus and reduce fatigue, pilots should bring a chair for comfort, use an umbrella to eliminate screen glare, and sit to maintain a stable posture. A relaxed position ensures better control, minimizing errors and enhancing inspection efficiency.

A beeping sound and red flashing LED can indicate the following errors:

• Low battery

• Stick calibration

• Hardware error

If the possibility of a low battery has been eliminated then the use of the "DJI GO" app is required the debug the issue further.

Important notice

What you will need

• Android/IOS device with DJI GO app installed (DJI GO—for products before P4 version)

• USB Cable

• The remote controller

Step by Step guide

• Deploy, connect the USB cable and turn on the GCS.

• Launch DJI GO app

• Once the Remote Controller Picture appears, tap on Camera.

• Tap on the bar at the top of the screen to display the cause of the error.

1. If calibration is required: follow the on screen instructions to perform the calibration.

2. If hardware error: The unit will need to be sent to Flyability for repairs or swapped out for a new unit. Please contact the

During visual inspections, all areas of interest must be systematically visited and filmed. A well defined and executed flight plan will help you get the most out of a flight by:

• Helping the preparation of the flight.

• Helping you identify local risks.

• Ensuring that all areas of interest are visited during the flight.

• Simplifying later analysis of the footage.

The correct process of flight planning and analysis will be demonstrated with a simple mission example where we will be inspecting 5 lamps on a hangar ceiling. In particular, we will show how Flyability Inspector and a Clapperboard can be used together to improve flight planning, execution and video analysis.

Planning

The first step is to draw a simple schematic of the flight area on front of the Clapperboard. Be sure to add relevant features such as:

• The items to be inspected

• Pilot position

• Obstacles or dangers

• The orientation of the building

An accurate sketch can help communicate what will be inspected during the mission, it also serves as a reference during the mission to determine what has already been inspected. After the mission, it can be used to identify the features on the video footage.

Before you fly, use the sketch to decide on the optimal flight path along all inspection items. Divide the mission into several flights if necessary. Numbering the inspection items allows each one to be referred to individually and unambiguously. This may appear trivial, but some missions involve hundreds of inspection items which all need to be individually identified and systematically visited.

Luckily, the "Hangar Lamps" mission is quite simple, the sketch will look something like this:

The north marker and the exit location are used to establish the orientation of the sketch. Clearly marked are the five lamps to be inspected, which are numbered accordingly. From experience, the pilot can estimate that two flights are needed to adequately inspect all five lamps. There are also some strings hanging from the ceiling which could entangle Elios. Take these factors into account when deciding how to approach the lamps.

Flight

Be sure to insert the Mission and flight name into the Cockpit app, this will simplify the later identification of the files in Inspector.

The reverse side of the clapperboard contains the flight list which should be updated before every flight. The numbers of the inspection items to be visited during that flight are written down.

Showing the clapperboard to the on-board camera at the beginning of every flight will later allow you to quickly identify which inspection items are visited in a particular video file. Remember: the camera only starts recording once Elios is armed.

At the beginning of flight 1. At the beginning of flight 2.

Be sure to mark a POI whenever you reach a numbered inspection item during a flight. This will mark the point in time where each lamp is shown on the video.

Analysis

Once all the flights are completed collect the video files (.MP4) from the CAM SD card and the .LOG files from the LOG SD card. It is useful to rename the files according to their flight number for easier reference. In Flyability Inspector, open the matching pair of files from any flight. You will be able to click on the POIs and jump towards the inspection items visited during that flight, simplifying post mission analysis by skipping to the interesting bits of the video.

For example in the image below, flight 2 is being analyzed. The POIs corresponding to lamps 3, 4 and 5 can be seen in the timeline. Each POI can be directly traced to a specific lamp, all thanks to careful flight planning and execution.

Gather information about the flight environment

Avoid unpleasant surprises by gathering as much information as possible about the flight environment before you are on site. Ask for blueprints, photos, or descriptions of the flight area. You should be able to answer the following questions:

Is the environment in which the Elios will be operated safe?

Drones are sensitive to its surroundings. The mission environmental conditions must be within the specifications listed in the user manual of the drone. Think about conditions such as: temperature, presence of water, wind speed, explosive atmospheres etc.

What Personal Protective Equipment (PPE) is needed for the operators?

Flyability drones are relatively safe to fly close to humans provided that adequate precautions are taken. The following PPE must always be carried:

• Eye protection

• Hearing protection

• Protective gloves

Also list the dangers posed by the presence of hazardous materials in the flight area, this might can range from corrosive chemicals to bio-hazards caused by untreated sewage.

You must be aware of the effects of flying in your working environment and prepare accordingly by taking additional measures. For example if the environment is dusty, wear respiratory protection.

Pilot Skill Requirements

Some flight environments are more demanding on the pilot than others. You can use the Mission difficulty assessment sheet to estimate the skill level of the pilot required. Bear in mind that the ELIOS2 is much less demanding to fly than the original Elios drone.

Prepare the Paperwork

Method Statement

The Method Statement (MS) lists all the different steps that will be performed during the inspection. It will also specify all the required equipment to fulfill the mission.

The “Method Statement – Template” document offers a template to establish your own:

An example of a filled in document can be found here:

This document will be required on most industrial sites, and is used to communicate the scope of your work to the local work coordinators.

Risk Assessment

The Risk Assessment (RA) is a document which breaks down the steps taken and specifying all the risks that can occur during the progress of the mission. It also states the mitigating measures that can be taken to limit the likelihood and/or consequences of a mishap.

The “Risk Assessment – Template” document offers a template to establish your own:

You can also download an example of a completed document here:

Do you have the proper flight authorization?

If you perform outdoor flights, depending on the area and on the country in which you will conduct your flight, you will need a specific authorization. Make sure that you satisfy all requirements of the Civil Aviation Authority to go ahead with your flight.

Note that in most countries, indoor areas are not in the civil airspace, so drone flights conducted inside are not regulated.

Flight Planning

Once the objectives and risks of the inspection are known, you should proceed with the flight planning stage. During visual inspections, all areas of interest must be systematically visited and filmed. A well defined and executed flight plan will help you get the most out of a flight. Flight planning and systematic inspection is covered in a .

Cockpit is the application used to pilot the Elios 1 and Elios 2 systems. Its main use is to allow the pilot to view the live video feed from the on board cameras, thus enabling FPV flights. In addition, different dashboards allowing precise monitoring of the of the system.

The app is designed and optimized for the tablets provided by Flyability (Samsung T580 and Active 2).

v1.7 January 2022

New features:

• Compatibility with new E2RAD sensor payloads (LOW, MID, HIGH level)

• When a battery error is detected the drone goes into Autoland mode and the tablet vibrates for 3 seconds to warn the pilot.

When planning inspections, it is important to be able to give an estimation of how much time is needed to inspect a certain asset. In this article we will discuss some of the variables which influence the duration of an inspection.

Generally speaking, a flight can be divided into two phases: transit to (and from) the inspection area inside the asset, and the inspection itself.

Transit

Transit time will depend on the distance to be travelled, and the nature of the environment. The pilot will not be able to fly as fast in a cluttered environment as in an open environment. For example, the top speed in the 'ASSIST' flight mode typically used in cluttered environments is 1.3m/s, which corresponds roughly to 80m per minute. In risky environments and even slower speed is recommended. In an open environment the 'ATTI' flight mode is more likely to be used, and the top speed is 4m/s, or 240m/minute.

The maximum controlled vertical speed of Elios 2 , whether going up or down, is also 1.3m/s, or roughly 80m/minute. It is also important to keep this in mind when determining the battery level needed to safely return from high areas, such as smoke stacks or boilers. This speed can be increased in 'Manual Thrust' mode, which allows the drone to climb at up to 10m/s and descend at almost free-fall velocity.

Remember that the cage offers protection from impacts at speeds up to 3.6m/s on flat surface, and 1.5m/s on sharp surfaces. Flying faster can get the job done quicker, but it comes at a significant risk.

Inspection

The time needed for the actual inspection depends on the size of the area to inspect, and the required detail of the inspection. Detail is often expressed in Ground Sampling Distance (GSD), which is the distance between two adjacent pixels, measured on the observed object. A GSD of 1mm/pixel means that one pixel on the image represents 1 mm in the real world. A smaller GSD means that smaller details will be visible in the image. For more information concerning GSD and camera resolution, we recommend reading .

To obtain a smaller GSD (more detail) you must fly closer to the object to inspect, the relation between these is linear. This in turn means that a smaller area is in the field of view of the camera at any given time, reducing the surface area that can be scanned in a given time. The white line in the following graph shows the relation between GSD, and the surface area which can be scanned per minute of flight:

In the case where the object is illuminated exclusively by the drone's on-board LED lighting, then the emitted light will be more concentrated when the drone is up close against it, and the object will appear brighter. In turn the shutter speed can be relatively high, up to 1/250th of a second. When flying far away from a surface then the light is distributed over a larger area, and the shutter speed can be as slow as 1/50th of a second. The reason that the maximum motion blur speed decreases as you fly closer to a surface, is because the distance represented by one pixel decreases faster than the shutter speed increases. This is especially the case at less than 2m from a surface, as shown in the detail view of the same plot:

v2.8 January 2022: New features:

• Compatibility with new E2RAD sensor payloads (LOW, MID, HIGH level)

• When a battery error is detected the drone goes into autoland mode and the tablet vibrates for 3 seconds to warn the pilot.

• LED blink patterns updated, they will now blink red in case of a battery warning or a critically low battery.

Bug fixes:

• Wifi streaming reliability improved

• Transmission status logging fixed

• Maintenance panel information no longer gets stuck in 'loading' status

v2.7 October 2021: New features:

• New Signal Strength indication

• The two indicators on the top left corner now indicate downlink and uplink RSSI instead of a quality indicator as it is more gradual and could prevent incidents in tricky environments such as sewers.

• Cockpit is now available in French, Spanish, German and Russian.

• Error codes added to warning messages.

Bug fixes:

• Fixed distance Lock bug in control mode 1

• False warning about exceeded number of battery cycles fixed

• Fixed memory leaks

v2.6 August 2021: New features (Elios 2 only):

• Integration with E2 RAD Radiation detector payload

• Battery SoC displayed up to 60 cycles. Battery too old displayed for 60+ cycles

Bug Fixes:

• "Old firmware" warning stays forever, even when drone is disconnected

• Camera switch toggled with no video after automatic switch to SD

• Cockpit not informing the user that the FW is not the right one with the current Cockpit version.

• Distance sensor text overlaps with imperial units when distance > 100

v2.5 November 2020: New Features (Elios 2 only):

• Photogrammetry flight mode now has grid lines overlaid to help with managing overlap during flight.

• New warnings to communicate about hardware issues in the transmission system.

• Added warnings to communicate that motors are approaching or have exceeded the maximum recommended replacement interval of 25 flight hours.

• Added warnings to communicate that the battery is approaching or has exceeded the maximum recommended lifetime of 40 discharge cycles.

Bug Fixes:

• Motor flight hours now also displayed correctly, even after 140 flight cycles.

v2.4 March 2020: New features (for Elios 2 only):

• Battery diagnosis menu panel to access BMS data

• New in flight battery status monitoring (temperature and internal resistance)

• Motor diagnosis and flight time data added to maintenance menu panel*

• Live video feed can be switched to composite (SD) if the HDMI (HD) feed fails camera SD card status icon on main screen shows remaining free space

Bug Fixes:

• Circular buffer implemented for backup recording to ensure it can always record

• Battery current draw now always correctly displayed

• No longer crashes when changing settings panel while initiating connection with drone

• No longer crashes when arming the drone

Camera

Latest firmware: v1.7 (January 2022)