Will burt Positionit pi-35 User manual

PI-35 (P/N: 5467801) OPERATOR’S MANUAL

The Will-Burt Company

169 S. Main Street

Orrville, OH 44667

www.willburt.com

TP-5406201-B, July 2017

POSITIONIT PI-35

TP-5406201-B i

July 2017

Warranty

The Company will repair or replace, if in its opinion, any part of the Goods which shall prove faulty

by reason of defect in workmanship or materials relating to the Goods which shall arise within 3

years of delivery to the Customer for mechanical items, (excluding wiper arms and blades), and

2 years forelectrical items, provided that anysuchfault is notified inWriting to theCompanywithin

10 working days of the date on which such fault was, or ought, reasonably to have been

discovered and provided that the Goods or relevant part thereof, if so requested by the Company,

are returned carriage paid by the Customer to the premises of the Company.

All works pursuant to the Guarantee shall be carried out by the Company free of charge to the

Customer except, if the cost of such works shall be increased by reason of any use of the Goods

after any fault ought reasonably to have been discovered, such increase shall be paid by the

customer.

If the work required is a result of misuse of the Goods by the Customer or any use of Goods after

any fault has been discovered, this Guarantee is rendered invalid.

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Document History

Document Numbers

Dates

Remarks

TP-5406201-00

September 8, 2016

Initial Release

TP-5406201-A

November 21, 2016

Updated Figure 1-2. Updated Sections 2.7,

3.3.4.2, 3.4, and 7.

TP-5406201-B

July 19, 2017

Updated Section 1.6.1 and 1.5. Updated

Figures 1-1, 1-2, 1-3, 2-1, 2-2, 2-3, and 2-

14. Removed Top Level Drawing from

Section 7 and unnecessary drift

precaution.

 POSITIONIT PI-35 
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Table of Contents
Section 1 Introduction.......................................................................................................... 1-1 
1 Safety Precautions...........................................................................................................................1-1 
2 How this Manual is Organized .........................................................................................................1-1 
3 Additional Documentation................................................................................................................1-2 
4 Definitions of Terms and Symbols ...................................................................................................1-2 
5 Specifications...................................................................................................................................1-4 
6 Major Components...........................................................................................................................1-5 
6.1 Positioner..................................................................................................................................1-5 
6.2 Controller...................................................................................................................................1-6 
6.3 Power/Data Cable.....................................................................................................................1-7 
6.4 Positioner Power Supply...........................................................................................................1-8 
6.5 Step Up Converter ....................................................................................................................1-8 
6.6 Step Down Converter................................................................................................................1-9 
6.7 Barrel Connector (2.1 mm) .......................................................................................................1-9 
7 Quick Overview..............................................................................................................................1-10 
Section 2 Installation............................................................................................................ 2-1 
1 Pre-Installation Check......................................................................................................................2-1 
2 Installation Tools ..............................................................................................................................2-2 
3 Components.....................................................................................................................................2-2 
4 Unpacking ........................................................................................................................................2-2 
5 Mounting the Positioner ...................................................................................................................2-3 
6 Wiring the System............................................................................................................................2-4 
6.1 Positioner Plugs........................................................................................................................2-4 
6.2 Connecting Power and Controls...............................................................................................2-8 
7 Mounting the Payload ....................................................................................................................2-12 
8 Setting Presets and Electronic Limit Stops....................................................................................2-13 
Section 3 Operation.............................................................................................................. 3-1 
1 Pre-Operation Check .......................................................................................................................3-1 
2 Operation Tools................................................................................................................................3-2 
3 General Controls..............................................................................................................................3-2 
3.1 Keyboard...................................................................................................................................3-3 
3.2 Joystick .....................................................................................................................................3-3 
3.3 Menu Functions.........................................................................................................................3-4 
3.4 Presets......................................................................................................................................3-5 
3.4.1 Setting Presets with the Keyboard.....................................................................................3-5 
3.4.2 Recalling Presets with the Keyboard.................................................................................3-5 
3.5 Electronic Limit Stops ...............................................................................................................3-6 
3.5.1 Adjust Limit Stops with the Keyboard ................................................................................3-6 
3.5.2 Restore Limit Stops with the Keyboard..............................................................................3-7 
4 Unstowing the Positioner .................................................................................................................3-7 
5 Stowing the Positioner .....................................................................................................................3-8 
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 .........................................................................................................................1-2 
Figure 1-2 Positioner Directions................................................................................................................1-3 
Figure 1-3 Positioner.................................................................................................................................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....................................................................................................................2-3 
Figure 2-2 Positioner Mounting Hole Pattern............................................................................................2-4 
Figure 2-3 Positioner Plug Locations........................................................................................................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 

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Figure 2-14 Payload Mounting Hole Pattern...........................................................................................2-12 
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 
 

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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.

Safety Instruction –Lightning! Lightning protection is not part of this system. A proper means

of electrical grounding should be provided. Failure to observe this warning could result in death

or serious injury.

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.

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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.

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.

Safety Instruction –Impact Loading! Utilize a safety tether to secure the payload in the event

of impact loading. The tether should connect to the positioner mounting pedestal or other rigid

structure. Death or serious injury could result if proper precautions are not performed.

Equipment Damage! All persons installing and maintaining this equipment should be suitably

qualified and work to national and local standards and codes of practice.

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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.

Safety Instruction –High Pressure Spray! Do not expose the positioner to high pressure

spray. Equipment damage may occur.

 POSITIONIT PI-35 
TP-5406201-B 1-1 
July 2017 
Section 1 Introduction 
Review this manual in its entirety. Contact the Will-Burt Company with any questions before 
performing any procedure outlined in this manual. 
The PositionIt™system is a pan and tilt positioner system used as a platform for many different 
applications. This system is designed to remotely position a suitable payload and may be 
attached on top of a mast. 
This manual covers the following PositionIt: 
PI-35 (P/N: 5467801) 
The PositionIt does not currently support the following: 
GPS Control 
Infrared Remote Control 
RS-232 GUI Interface (customer supplied only) 
Mast Up / Down Control 
 
1.1 Safety Precautions 
Refer to the Safety Summary for precautions to be observed while installing, operating, 
maintaining, or troubleshooting this equipment. 
 
1.2 How this Manual is Organized 
This manual is organized into the following sections: 
Section 1 Introduction 
Section 2 Installation 
Section 3 Operation 
Section 4 Maintenance 
Section 5 Troubleshooting 
Section 7 Drawings 
 

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1.3 Additional Documentation

In addition to this manual, the controller ships with the controller manual. Reference this manual

for additional information on the function of the controller.

1.4 Definitions of Terms and Symbols

Throughout this manual, the following will be used:

General Terms:

Positioner refers to the PI-35 PositionIt

Controller refers to the default joystick controller (P/N: 5098901).

System refers to the entire positioner and Controller system.

Payload refers to the object or equipment being moved by the positioner.

Positions

Home (Figure 1-1) to refer to the factory set preset position [0] (zero) which is set to

move the positioner to the mid-point of both the pan and tilt. In this position, the tilt

platform will be horizontal, and the pan axis will be in the center position. In this position,

the rear of the positioner is the side facing the side egress on the mounting pedestal.

Note that the offset on the left of the positioner, as you face the side egress, is wider

than the offset to the right. The positioner ships in the home position.

Figure 1-1 Home Position

Side Egress

Note That the Left Offset

is Wider Than the Right

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Stowed refers to a customer-set preset position which the positioner moves the payload

to a desired pan and tilt position for travel or safe storage. The customer should set this

as preset [1].

Unstowed refers to a customer-set preset position which the positioner moves the

payload to a desired pan and tilt position from the stowed position. The customer should

be sure the positioner can be safely moved to this position from the stowed position

without causing damage. The customer should set this as preset [2].

Directions

When operating the positioner, directions are given as follows:

Home Position

Top Down View

Figure 1-2 Positioner Directions

When using the default joystick:

oPushing the joystick forward will tilt the positioner towards the rear

oPulling the joystick back will tilt the positioner towards the front

oMoving the joystick to the right will rotate the joystick clockwise

oMoving the joystick to the left will rotate the joystick counterclockwise

Symbols:

Characters inside < > as in <Success!> represent text that appears on the display

screen.

Characters inside [ ] as in [1] represent buttons or keys being used.

Arrows as in “▲, ►, ▼, ◄” represent the direction(s) the positioner is moving in. These

arrows are shown on the display screen of the default joystick controller (P/N: 5098901).

Side Egress

Left

Right

Front

Rear (Side with

Side Egress)

Left

Right

Rotate Clockwise

Towards Right

Rotate

Counterclockwise

Towards Left

Move Up From Front

Move Down to Front

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1.5 Specifications

Table 1-1 lists specifications for the positioner. Table 1-2 lists specifications for the default

joystick controller.

Table 1-1 Positioner Specifications

Functional Characteristic

Specification

Payload Capacity

35 ft.-lb. (47.4 Nm)

Overall Height

9.8 Inches (248 mm)

Overall Width

10.8 Inches (273 mm)

Approximate Weight

21 lb. (9.5 kg)

Operating Temperature

-4° to 122°F (-20° to 50°C)

Pan Axis

355° (± 177.5°)

Tilt Axis

180° (±90°)

Pan Speed (Proportional)

1 to 12° / Second

Tilt Speed (Proportional)

1 to 12° / Second

Backlash

<0.15°

Repeatability

<0.3°

Maximum Continuous Power

44 W

Maximum Continuous Current @ 24 VDC

1.85 A

Input Voltage

24 VDC

(Converters available for 12 VDC and AC power sources.)

Protocol

Pelco D used (Pelco P available)

Ingress Protection Rating

IP68 for dust and water intrusion

Baud Rate

2,400 bps

All dimensions and parameters are for reference only and are subject to change without notice.

Table 1-2 Default Joystick Controller (P/N: 5098901) Specifications

Functional Characteristic

Specification

Input Voltage

12 VDC

Rating Power

0.5 watts

Communication Interface

RS485

Communication Frequency

2,400 bps used (4,800; 9,600; 19,200 bps available)

Operating Temperature

32°F to 122°F (0°C to 50°C)

Dimensions (W x H x L)

5.4 x 4.2 x 6.6 in. (136 x 105 x 168 mm)

Weight

0.89 lb. (0.40 kg)

Protocol

Pelco D used

All dimensions and parameters are for reference only and are subject to change without notice.

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1.6 Major Components

The major components of the system are:

Positioner

Controller

Power/Data Cable

Positioner Power Supply

Step Up Converter

Step Down Converter

1.6.1 Positioner

The PI-35 pan and tilt positioner:

Is made of die-cast aluminum casing

Uses stainless steel fasteners

Has weather and dust proofing to an IP68 rating

Is designed to minimize backlash

Is configured to run on RS485 data using Pelco D protocol

Contains an internal tether to prevent the pan and tilt head from separating from the

mast in the event of an impact load separating the pan and tilt head from the base

Ships with the PositionIt PI-35 Operator’s Manual (this manual)

Figure 1-3 Positioner

Payload

Platform

Removable Plug

on Side Egress

Mounting Pedestal

Bottom Egress Hidden on

Underside of Mounting Pedestal

Base

Pan and

Tilt Head

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1.6.2 Controller

The default joystick controller (P/N: 5098901) (Figure 1-4):

Controls pan and tilt functions

Is Pelco D compatible

Has a joystick, LCD Screen and a keyboard

Has programmable presets

Has programmable electronic limits

Has speed control

Ships with the controller manual

Is not designed to handle inclement weather and should be kept in a protected

environment

Figure 1-4 Default Joystick Controller (Left: With Keyboard Cover On. Right: With Keyboard Cover Off.)

Joystick

LCD Screen

Keyboard

Cover

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1.6.3 Power/Data Cable

The power/data cable (Figure 1-5) consists of (2) power wires (16 AWG twisted pair) and (2)

control wires (22 AWG twisted pair). The cable ships with a straight connector (PT06W14-5S)

installed on one end and loose wires on the other end to allow for a Nycoil pull. The end with the

loose wires can be cut if the customer requires a shorter length.

Figure 1-5 Power/Data Cable

Table 1-3 provides the part numbers for the standard cables.

Table 1-3 Standard Cables

Will-Burt

Part Number

Length

5195401

150 ft. (45.72 m)

5195402

100 ft. (30.48 m)

5195403

75 ft. (22.86 m)

5195404

50 ft. (15.24 m)

5195405

25 ft. (7.62 m)

Alternatively, the 90° elbow connector (P/N: 213227; PT08E-14-5S(SR)) may be purchased

separately for use with customer supplied wires.

Power/Data Cable

(P/N: 000018-500-001)

Connector

(P/N: 213261)

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1.6.4 Positioner Power Supply

The positioner power supply (P/N: 208016) (Figure 1-6) is used in systems using 120 VAC

(50 or 60 Hz) or 240 VAC (50 or 60 Hz) to convert the AC power to 24 VDC input power for the

positioner. The power supply has short circuit, overcurrent, overvoltage, and over temperature

protections. It is an IP67 design and is suitable for dry, damp, or wet locations.

Figure 1-6 Positioner Power Supply

1.6.5 Step Up Converter

The step up converter (P/N: 208012) (Figure 1-7) is used in systems with 12 VDC input power

to step up the power to 24 VDC for the positioner.

Figure 1-7 Step Up Converter

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1.6.6 Step Down Converter

The step down converter (P/N: 208017) (Figure 1-8) is used in systems with 24 VDC input

power to step down the power to 12 VDC to power the default joystick controller if the AC power

supply supplied with the joystick is not used to provide power.

Figure 1-8 Step Down Converter

1.6.7 Barrel Connector (2.1 mm)

The 2.1 mm barrel connector (P/N: 5195601) (Figure 1-9) can be used to connect the controller

to the step down converter or 12 VDC power source.

Figure 1-9 Barrel Connector

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1.7 Quick Overview 
This section provides a quick overview of the system. Be aware of and follow all associated 
precautions when performing these procedures. 
To install the positioner (Section 2 ): 
1. Mount the positioner with (4) high-strength ⅜ in. or M8 stainless steel bolts and nuts. 
See Section 2.5 for additional detail and bolt pattern. 
2. Wire the positioner according to the schematic (Section 7). See Section 2.6 for additional 
detail. 
3. Mount the payload with appropriate hardware. See Section 2.7 for additional detail. 
To operate the positioner (Section 3): 
1. Attach the controller. 
2. Operate the positioner using the controller. See Section 3 for additional detail on the 
function of the default joystick controller (P/N: 5098901). 
3. If required, see Section 3.3.4 for information on how to use preset positions. 
4. If required, see Section 3.3.5 for information on how to adjust the electronic limit stops. 
The positioner ships from the factory with electronic limit stops set. There are no hard 
stops. 
 
 
 