Input voltage: 220Vac
Output voltage: 400Vdc (30Vdc compensation)
Peak power: 6000W
Weight: 13.5kg ± 0.5kg
Dimensions: 380mm x 350mm x 230mm (L x W x H)

Rope length: 50M-110M,Default 100m

Includes tethered box, onboard module, battery clip, carbon plate

AF-NG4-100M Product Manual V1.0

The AF-NG4-100M UAV tethered box can be combined with airborne modules to form a tethered system, which is compatible with multiple UAV platforms. This tethered system mainly includes a retraction winch, a tethered box body, and integrates a tethered cable and an integrated tethered ground power supply. It mainly provides wired power supply, information transmission, and cable retraction/release functions for tethered UAVs. The retraction winch mainly consists of a system box body, a main frame, a cable storage reel, and a control circuit.

1. Main Parameters

This tethered system solves four major limitations of multi-rotor industrial UAVs:

1. Flight Time: After connecting to the tethered platform, multi-rotor UAVs are no longer limited by battery capacity and can complete long-duration continuous fixed-point flight tasks in specific scenarios.
2. Safety: In special areas such as restricted flight zones, crowded places, and flammable/explosive areas, tethered UAVs can minimize risks while performing tasks.
3. Usability: The tethered UAV can be easily operated with only basic flight skills.
4. Support for High-Power Mounting: A high-power power output interface is reserved at the airborne end, allowing the UAV to carry higher-power loads.

Features

• (1) Simple operation: One-key activation of high-voltage output and one-key automatic wire rewinding.
• (2) No modification to the UAV is required; it can be used by directly installing the airborne module.
• (3) Bulk customization of shell color and text language is supported.
• (4) Customizable optical fiber communication.

2. User Instructions

2.1 Tethered Box Panel Description

1. Main Power Air Switch: Serves as the main switch for all electrical systems, including the tethered box control power supply and the tethered main power supply.
2. Main Power Switch Button: The switch button for supplying power to the UAV's power system. When pressed, the system's high-voltage DC is energized, outputting 400V DC high voltage to power the UAV's airborne power supply.
3. Main Power Switch Indicator Light (integrated in the ring light of the main power switch button): Used to indicate the power supply status of the tethered box.
4. LCD Display Information:
   • Output Voltage: Displays the current DC voltage output by the ground power supply.
   • Output Current: Displays the current DC current output by the ground power supply.
   • Output Power: Displays the current power output by the ground power supply.
   • Input Voltage: Displays the current DC voltage input to the ground power supply.
   • Note: Retained as original (possible input error): Ca y Output 400.526; Cutput Pute 000.041A 0016.43 W; Vetuag Temperature 18°C 00:00:18 235.700v

2.2 Wiring Instructions

1. Use the power cord provided with the assembly to connect the municipal power supply or generator to the tethered box: Plug one end directly into the tethered box socket, and the other end can be connected to the municipal power supply or generator via an adapter plug.
2. The high-voltage cable output of the tethered box uses an XT90 connector. Connect the cable to the UAV's airborne power supply (as shown in the figure below) and secure the load-bearing hook (the load is borne by the pull wire of the load-bearing hook).

Figure: Connection Diagram of XT90 Connector and Load-Bearing Hook

2.3 Operation Instructions

1. Start the generator and plug the aviation plug into the tethered box. (You can pull the plug firmly to check if it is securely connected.)
2. During operation: First, turn the torque adjustment knob to the minimum position, then toggle it up to turn on the air switch. The system will be energized, and the display on the panel will light up. Observe the display—there will be no voltage output from the tethered device at this point.
3. Take out the cable, turn on the UAV remote controller, hang the cable hook, plug in the cable plug, power on the UAV battery, and connect the cable plug to the generator.
   When the UAV is ready to take off: Turn the torque knob to the minimum or add a small amount of torque (in windy conditions), and pull the cable out using the UAV. Ensure the cable remains straight during the UAV's flight. (Before the UAV takes off, manually pull out approximately 10 meters of cable; the pulling speed should not exceed 1 m/s—excessive speed may cause failures in the internal tension system.)
4. Unlock the remote controller and let the UAV take off. (After takeoff, ensure the UAV flies within ±30 degrees of the vertical direction of the wire retraction/release machine.)
5. When power supply to the UAV is needed: Press the "Main Power Switch" button to activate high-voltage power supply. At this time, the cooling fan of the tethered box starts working, the "Main Power Operation" indicator light stays on, and the display shows the current output voltage, output current, and output power of the cable's main power. When the system is loaded and current flows, the indicator light switches to a breathing flash mode—this means the UAV is being powered.
   Recommendation: Turn on the main power when the UAV has taken off 5 meters or when its propellers start rotating.
6. UAV Landing: (After the UAV completes its task and begins descending, it is recommended to land the UAV first before starting wire rewinding to avoid pulling the UAV during rewinding.)
7. When the UAV descends to 5 meters above the ground: Turn off the main power (to prevent unavoidable reverse electromotive force impact on the airborne module) and land the UAV smoothly. In case of any accident during operation, first turn off the main power switch to cut off the high-voltage DC power.
8. Wire Rewinding:
   • Option 1: After the UAV lands, adjust the torque knob clockwise from low to high.
   • Option 2: Set the torque to an appropriate value at the start to maintain a constant tension on the cable. The UAV will pull the cable during pay-off and hover; stop rewinding when the UAV is at 5 meters height.
   To prevent accidental electric shock during rewinding of the remaining cable, manual rewinding is also allowed. (When pulling the cable with power on, wear insulated gloves for personal protection. In case of electric shock, it is considered improper operation, and the customer shall bear all consequences.)
9. Finally: Turn off the main power switch, unplug the power cord, cut off the UAV battery power, disconnect the tethered cable from the airborne power supply, release the load-bearing hook, and restore the device to its original state.

2.4 Precautions

• 1) Before use, place the device as level as possible to ensure it is in a relatively balanced state.
• 2) Operators must wear insulated gloves to prevent accidental electric shock.
• 3) When adjusting the speed control knob, turn it slowly from low to high; do not suddenly set it to the maximum.
• 4) After rewinding/pay-off operations, wind the power cord neatly and store it in the box—do not drag it on the ground.
• 5) During use, do not drag the tethered cable on the ground to avoid fraying. Check the ground for stones or other sharp objects to prevent the cable from being cut.

Note: This tethered device box is equipped with a manual wire rewinding crank as standard, which can be used for manual rewinding in emergency situations (e.g., power-off conditions). The tethered box comes with an aviation case by default.

3. Product Maintenance & Warranty Service

3.1 Storage and Transportation

When transporting the tethered power supply box, mandatory shock absorption treatment is required. If this is not done, loose internal screws are considered a normal occurrence.

3.2 Maintenance

1. Inspect and maintain the tethered power supply every 50 take-offs/landings or 20 operating hours to ensure its normal operation.
2. Check whether any components of the tethered power supply have been subjected to strong impacts, and verify that all moving parts still operate smoothly.

Key Inspection Items

• 1) Cable Inspection: Carefully check the entire length of the tethered cable for outer skin damage, exposed armor layers, excessive bending, or bent/contaminated connector pins. This is the most critical step.
• 2) Interface Cleaning: Disconnect all electrical connectors, check and clean dust and moisture from the interfaces to ensure they are dry and clean.
• 3) Lamp Body & Module Cleaning: Wipe the lamp body and the shell of the power supply module with a dry soft cloth to ensure ventilation holes are not blocked.
• 4) Standard Storage: Wind the cable neatly for storage, avoid small-radius bending, and store it in a cool, dry place.

3.3 After-Sales Service

(1) Warranty Period

• Duration: 1 year (calculated from the date of goods shipment).
• Coverage: For non-human-caused faults during the warranty period, the manufacturer will promptly provide maintenance guidance or replace the product with a new one.
• For human-caused damage: The manufacturer will charge a labor fee of 10-20% of the original product purchase price.

(2) Warranty Scope

Failures caused by material defects or production process issues under normal usage conditions.

(3) Non-Warranty Scope (Paid Maintenance Required)

• Damage caused by human error (e.g., impact, falling, extrusion, water ingress, electric shock) or accidents.
• Cable damage (wear, crushing, tearing, burning): Tethered cables are vulnerable parts in complex environments; damage from dragging, rolling, or animal bites is not covered.
• Faults caused by unauthorized disassembly, modification, or maintenance without the company’s approval.
• Damage caused by force majeure (e.g., natural disasters).
• Products beyond the warranty period.

Safety Reminder

The tethered lighting system involves high-voltage electricity and flight safety. Non-professionals are strictly prohibited from disassembling or maintaining it independently. Any unauthorized operation may cause serious safety accidents and invalidate your warranty eligibility.