Will Burt PositionIt PI-150 User manual

PI-150 (P/N: 5061001) AND PI-75 (P/N: 5191201)
OPERATOR’S MANUAL
(PI-150 shown)
The Will-Burt Company
401 Collins Blvd
Orrville, OH 44667
www.willburt.com
TP-5129001-J, January 2022
© 2022 The Will-Burt Company

POSITIONIT PI-150 AND PI-75
TP-5129001-J i
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Warranty
Will-Burt warrants its PositionIt™ to be free from defects in material and
workmanship for a period of two (2) years, with such time period running from the
date of shipment by Will-Burt. Will-Burt shall not be responsible for any damage
resulting to or caused by its products by reason of failure to properly install,
maintain or store the product; use of the product in a manner inconsistent with its
design; unauthorized service, alteration of products, neglect, abuse, accident, or
acts of God. This warranty does not extend to any component parts not
manufactured by Will-Burt; provided, however, Will-Burt’s warranty herein shall not
limit any warranties by manufacturers of component parts which extend to the
buyer.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, AND
NO REPRESENTATIONS, GUARANTEES OR WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO, A WARRANTY OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR NON-
INFRINGEMENT ARE MADE BY WILL-BURT IN CONNECTION WITH THE
MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE,
DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS
WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY ON BEHALF
OF WILL-BURT.
Claims for defects in material and workmanship shall be made in writing to Will-
Burt within thirty (30) days of the discovery of defect. Failure to provide notice as
required hereby shall be conclusive evidence that the product was in conformity
with the warranty, and Will-Burt shall be released from any and all liability relating
to the product. Will-Burt may either send a service representative or have the
product returned to its factory at Buyer's expense for inspection. If judged by Will-
Burt to be defective in material or workmanship, the product will be replaced or
repaired at the option of Will-Burt, free from all charges except authorized
transportation.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE
IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF WILL-BURT WHETHER
IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL
NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS
OPTION, ANY PRODUCT OR PART FOUND BY WILL-BURT TO BE DEFECTIVE
IN MATERIAL OR WORKMANSHIP. WILL-BURT SHALL NOT BE LIABLE FOR
COST OF INSTALLATION AND/OR REMOVAL, OR BE RESPONSIBLE FOR
DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY
NATURE.

POSITIONIT PI-150 AND PI-75
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Document History
Document Numbers
Dates
Remarks
TP-5219001-00
July 8, 2015
Initial Release.
TP-5219001-A
July 31, 2015
Added Section 1.7.
Updated positioner name. Updated Table
1-1, Section 1.6.3 and Section 7.
Simplified menu function references
throughout Section 3. Removed Section 5
Reference. Move old section 5.2 tables to
Table 5-3 and Table 5-4.
TP-5219001-B
August 11, 2015
Added Section 6. Updated sections 1.4,
1.6.3, 3.3.4, and Section 7. Minor
formatting changes throughout manual.
TP-5219001-C
March 21, 2016
Updated sections 1.4, 1.6.1, 1.6.3, 1.6.6,
2.6.2, 3.3.4.2, 3.4, 3.5, 6.1, 6.2, and 7.
Updated Table 3-2 and Table 3-3. Minor
formatting changing throughout manual.
TP-5219001-D
July 22, 2016
Updated Section 2.1
TP-5219001-E
November 21, 2016
Updated Sections 3.3.4.2 and 3.4.
TP-5129001-F
May 11, 2017
Updated manual part number.
TP-5129001-G
July 21, 2017
Updated Section 3.3.5.1.
TP-5129001-H
July 31, 2017
Updated Warranty.
TP-5129001-J
January 12, 2022
Updated Standard Cables

POSITIONIT PI-150 AND PI-75
TP-5129001-J iii
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Table of Contents
Section 1 Introduction.......................................................................................................... 1-1
1.1 Safety Precautions...........................................................................................................................1-1
1.2 How this Manual is Organized .........................................................................................................1-1
1.3 Additional Documentation ................................................................................................................1-2
1.4 Definitions of Terms and Symbols ...................................................................................................1-2
1.5 Specifications...................................................................................................................................1-4
1.6 Major Components...........................................................................................................................1-5
1.6.1 Positioner..................................................................................................................................1-5
1.6.2 Controller...................................................................................................................................1-6
1.6.3 Power/Data Cable.....................................................................................................................1-7
1.6.4 Positioner Power Supply...........................................................................................................1-8
1.6.5 Step Up Converter ....................................................................................................................1-8
1.6.6 Step Down Converter................................................................................................................1-9
1.6.7 Barrel Connector (2.1 mm) .......................................................................................................1-9
1.7 Quick Overview..............................................................................................................................1-10
Section 2 Installation............................................................................................................ 2-1
2.1 Pre-Installation Check......................................................................................................................2-1
2.2 Installation Tools ..............................................................................................................................2-2
2.3 Components.....................................................................................................................................2-2
2.4 Unpacking ........................................................................................................................................2-2
2.5 Mounting the Positioner ...................................................................................................................2-3
2.6 Wiring the System............................................................................................................................2-4
2.6.1 Positioner Plugs........................................................................................................................2-4
2.6.2 Connecting Power and Controls...............................................................................................2-8
2.7 Mounting the Payload ....................................................................................................................2-12
2.8 Setting Presets and Electronic Limit Stops....................................................................................2-13
Section 3 Operation.............................................................................................................. 3-1
3.1 Pre-Operation Check .......................................................................................................................3-1
3.2 Operation Tools................................................................................................................................3-2
3.3 General Controls..............................................................................................................................3-2
3.3.1 Keyboard...................................................................................................................................3-3
3.3.2 Joystick .....................................................................................................................................3-3
3.3.3 Menu Functions.........................................................................................................................3-4
3.3.4 Presets......................................................................................................................................3-5
3.3.4.1 Setting Presets with the Keyboard.....................................................................................3-5
3.3.4.2 Recalling Presets with the Keyboard.................................................................................3-5
3.3.5 Electronic Limit Stops ...............................................................................................................3-6
3.3.5.1 Adjust Limit Stops with the Keyboard ................................................................................3-6
3.3.5.2 Restore Limit Stops with the Keyboard..............................................................................3-7
3.4 Unstowing the Positioner .................................................................................................................3-7
3.5 Stowing the Positioner .....................................................................................................................3-8
3.6 Transportation..................................................................................................................................3-8

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Section 4 Maintenance ......................................................................................................... 4-1
4.1 Routine Maintenance .......................................................................................................................4-1
4.2 Replacement Parts...........................................................................................................................4-1
Section 5 Troubleshooting................................................................................................... 5-1
5.1 Troubleshooting Guide.....................................................................................................................5-1
5.2 Restoring Factory Defaults...............................................................................................................5-3
5.2.1 CamID.......................................................................................................................................5-3
5.2.2 MonID........................................................................................................................................5-3
5.2.3 Protocol.....................................................................................................................................5-4
5.2.4 Baud Rate .................................................................................................................................5-5
Section 6 Appendix............................................................................................................... 6-1
6.1 Communications Bridge Board Interface (optional).........................................................................6-1
6.1.1 Electrical Connections ..............................................................................................................6-1
6.1.2 Wire the Bridge Board Interface................................................................................................6-1
6.1.3 Set Stow and Unstow................................................................................................................6-3
6.1.3.1 With a Push Button Controller............................................................................................6-3
6.1.3.2 With a Toggle Switch Controller.........................................................................................6-3
6.2 Panel Mount Controller Assembly (optional)....................................................................................6-4
Section 7 Drawings............................................................................................................... 7-1
Table of Figures
Figure 1-1 Home Position (PI-150 Shown)...............................................................................................1-2
Figure 1-2 Positioner Directions (PI-150 Shown)......................................................................................1-3
Figure 1-3 Positioners...............................................................................................................................1-5
Figure 1-4 Default Joystick Controller.......................................................................................................1-6
Figure 1-5 Power/Data Cable....................................................................................................................1-7
Figure 1-6 Positioner Power Supply .........................................................................................................1-8
Figure 1-7 Step Up Converter...................................................................................................................1-8
Figure 1-8 Step Down Converter ..............................................................................................................1-9
Figure 1-9 Barrel Connector......................................................................................................................1-9
Figure 2-1 Rear of Positioner (PI-150 Shown)..........................................................................................2-3
Figure 2-2 Positioner Mounting Hole Pattern............................................................................................2-3
Figure 2-3 Positioner Plug Locations (PI-150 Shown)..............................................................................2-4
Figure 2-4 Carefully Pull Out the Removable Plug, Gasket, and Attached Wires....................................2-5
Figure 2-5 Quick Connect.........................................................................................................................2-5
Figure 2-6 Remove the (4) Bolts Securing the Plug Plate........................................................................2-6
Figure 2-7 Remove Plug Plate and Gasket ..............................................................................................2-6
Figure 2-8 Pull the Wires out the Bottom of the Positioner.......................................................................2-7
Figure 2-9 Secure the Gasket and Removable Plug to the Bottom Egress .............................................2-7
Figure 2-10 Secure the Plug Plate and Gasket to the Side Egress..........................................................2-8
Figure 2-11 Powered with 12 VDC ...........................................................................................................2-9
Figure 2-12 Powered with 24 VDC .........................................................................................................2-10
Figure 2-13 Powered with VAC...............................................................................................................2-11

POSITIONIT PI-150 AND PI-75
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Figure 2-14 PI-150 Payload Mounting Hole Pattern...............................................................................2-12
Figure 2-15 PI-75 Payload Mounting Hole Pattern.................................................................................2-13
Figure 3-1 Keyboard Keys ........................................................................................................................3-3
Figure 3-2 Menu Screen ...........................................................................................................................3-4
Figure 5-1 Start Up Screen.......................................................................................................................5-3
Figure 5-2 Menu Screen ...........................................................................................................................5-4
Figure 5-3 Protocol Setup Screen.............................................................................................................5-4
Figure 5-4 Dome Screen............................................................................................................................5-4
Figure 5-5 Keyboard Setup Screen ..........................................................................................................5-5
Figure 6-1 Contact Closure.......................................................................................................................6-2
Figure 6-2 Panel Mount Controller (P/N: 4270601) ..................................................................................6-4
Table of Tables
Table 1-1 Positioner Specifications............................................................................................................1-4
Table 1-2 Default Joystick Controller (P/N: 5098901) Specifications.......................................................1-4
Table 1-3 Standard Cables.......................................................................................................................1-7
Table 2-1 Tools and Materials Recommended for Installation .................................................................2-2
Table 3-1 Tools and Materials Recommended for Operation...................................................................3-2
Table 3-2 Limit Stop Adjustment Numbers ...............................................................................................3-6
Table 3-3 Default Limit Stop Numbers......................................................................................................3-7
Table 5-1 Troubleshooting the Positioner.................................................................................................5-1
Table 5-2 Troubleshooting the Controller .................................................................................................5-2
Table 5-3 Resetting the Protocol ..............................................................................................................5-4
Table 5-4 Resetting the Baud Rate...........................................................................................................5-5
Table 6-1 Contact Closure Wires..............................................................................................................6-2

POSITIONIT PI-150 AND PI-75
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POSITIONIT PI-150 AND PI-75
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Safety Summary
This section describes safety information for the PositionIt and its default joystick controller.
These are recommended precautions that personnel must understand and apply throughout
installation, operation, maintenance, and troubleshooting. Be sure to read and understand the
entire manual before performing any procedure outlined in this manual.
SIGNAL WORD DEFINITIONS
Warnings highlight an essential operating or maintenance procedure, practice, condition,
statement, etc., which, if not strictly observed, could result in injury to, or death of, personnel or
long-term health hazards.
Cautions highlight an essential operating or maintenance procedure, practice, condition,
statement, etc., which, if not strictly observed, could result in damage to, or destruction of,
equipment or loss of mission effectiveness.
Note: Notes highlight an essential operating or maintenance procedure, condition, or statement.
GENERAL SAFETY INSTRUCTIONS
The following are general safety precautions that are not related to any specific procedures.
These are recommended precautions that personnel must understand and apply throughout
installation, operation, maintenance, and troubleshooting. Additional precautions which apply to
specific procedures and steps may be listed with the procedure or step to which they apply.
Electrocution Hazard! Do not touch live wires. Make sure all power has been disconnected
prior to performing installation or maintenance. Make certain that the area is free of overhead
power lines and other unwanted sources of electricity. Do not operate the system during an
electrical storm. Follow OSHA safety regulations when working near energized power lines. Be
sure to allow sufficient clearance on all sides of the mast to allow for side sway. Death or
serious injury could result if proper precautions are not performed.
Resuscitation! Personnel working with or near high voltages should be familiar with modern
methods of resuscitation. Such information may be obtained from the Bureau of Medicine and
Surgery, United States Navy.
Pinch Point Hazard! Keep clear of moving parts. Be sure to stay clear of the positioner during
operation. Moving parts can crush and cut resulting in serious injury.

POSITIONIT PI-150 AND PI-75
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Crush Hazard! Do not stand directly beneath the positioner or payload. Be certain payload is
properly installed and secured. In locations or areas where the risk of injury occurs, or any part
of the assembly may become detached or fall for any reason, a strong safety chain or wire
hawser should be attached between the equipment and the mounting surface. At all times,
normal safety precautions must be employed. Death or serious injury could result if positioner
fails suddenly.
Safety Equipment! Helmets or hard hats, eye protection, gloves, and safety shoes or combat
boots must be properly worn while working in the deployment area. Death or serious injury
could result if proper safety equipment is not properly worn.
Trained Personnel Only! Installation, operation, and maintenance to be performed by trained
and authorized personnel only. Death or serious injury could result if proper installation,
inspection, operation, and maintenance procedures are not observed.
Lifting Hazard! Manually lifting over 55 lb. (25kg) is prohibited. In the UK, all lifting equipment
must be thoroughly examined annually by a competent person according to the Lifting
Operations and Lift Equipment Regulations 1998. Equivalent regulations exist in other EU
states.
Safety Instruction –Remote Control! The equipment is subject to remote control and may be
operated at any time. Persons working on the equipment should take appropriate precautions to
ensure that any unexpected movement does not occur as this could lead to injury.
Equipment Damage! All persons installing and maintaining this equipment should be suitably
qualified and work to national and local standards and codes of practice.
Equipment Damage! Each positioner contains a 1.85 amp self-resetting circuit breaker to
protect the PC board. Do not disassemble the positioner side plates, or separate from the
pedestal. Doing so will break the environmental seal and potentially cause improper stop limit
settings. This will void the warranty.