AccuPoint Positioner AP-50 / AP-100 Installation ... · AccuPoint Positioner AP-50 / AP-100 ....

AccuPoint Positioner AP-50 / AP-100

Installation, Operation & Maintenance Manual

The Will-Burt Company 169 South Main Street Orrville, Ohio 44667 Tel:+1 330-684-7015 www.willburt.com Revision 11, December 2013

AP-50 / AP-100 Positioner

Page ii

REVISIONS HISTORY:

Revision 07, MARCH 2007: Initial Release

Revision 08, MARCH 2009: Added AP-25

Revision 09, DECEMBER 13, 2012: Replaced AP-25 with AP-50

Revision 10, SEPTEMBER, 2013: Corrected TOC, paragraph, figures, tables, and page numbering

Revision 11, DECEMBER, 2013 Removed references to a 24 VDC, AP-50 (24 VDC is not supported on the AP-50). Also updated warranty page.


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AccuPoint® Warranty

Will-Burt warrants its AccuPoint® 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.


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TABLE OF CONTENTS CHAPTER 1 INTRODUCTION ............................................................................................................. 1-1 1.1 Safety Precautions ....................................................................................................................... 1-1 1.2 Description ................................................................................................................................... 1-1 1.3 Reference Data ............................................................................................................................ 1-2 1.4 AccuPoint Controllers ................................................................................................................... 1-2 CHAPTER 2 INSTALLATION............................................................................................................... 2-1 2.1 Tools and Materials required for Installation ................................................................................ 2-1 2.2 Unpacking .................................................................................................................................... 2-1 2.3 AccuPoint Orientation .................................................................................................................. 2-1 2.4 Mounting the Positioner ............................................................................................................... 2-2 2.5 Wiring the Positioner .................................................................................................................... 2-3

2.5.1 Wire / Cable Sizing ............................................................................................................. 2-3 2.5.2 AccuPoint 24 VDC & 115 VDC Connector Wiring ............................................................... 2-4 2.5.3 AP-100 AC Connector Wiring ............................................................................................. 2-4 2.5.4 Minimum Number of Wires for Positioner Cable .............................................................. 2-5

CHAPTER 3 Operational Check ......................................................................................................... 3-1 3.1 Operational Check........................................................................................................................ 3-1 3.2 Setting pan/tilt limits ..................................................................................................................... 3-2 CHAPTER 4 OPERATING INSTRUCTIONS ....................................................................................... 4-1 4.1 Theory of operation ...................................................................................................................... 4-1 4.2 Operating the AccuPoint Positioner ............................................................................................. 4-2

4.2.1 Potentiometer Operation (AP-25 and AP-100) .................................................................. 4-2 4.2.2 Signal Switch Operation (AP-100 only) .............................................................................. 4-2 4.2.3 Emergency Stow (AP-100 only) .......................................................................................... 4-2

CHAPTER 5 MAINTENANCE AND SERVICE INSTRUCTIONS ........................................................ 5-1 5.1 Scheduled Maintenance ............................................................................................................... 5-1

5.1.1 Lubrication ......................................................................................................................... 5-1 5.1.2 Cleaning .............................................................................................................................. 5-1 5.1.3 Inspection and Maintenance ............................................................................................. 5-1

CHAPTER 6 Troubleshooting............................................................................................................. 6-1 6.1 Troubleshooting Guide ................................................................................................................. 6-2


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LIST OF ILLUSTRATIONS Figure 1-1 AccuPoint Positioner (AP-100 shown) ........................................................................ 1-1

Figure 1-2 Mating Connector (included) ....................................................................................... 1-1

Figure 2-1 AccuPoint Pedestal Bolt Pattern .................................................................................. 2-2

Figure 2-2 DC Connector Pinout ...................................................................................................... 2-4

Figure 2-3 AC Connector Pinout ...................................................................................................... 2-4

Figure 3-1 AP-100 Pan/Tilt Limit Cams ........................................................................................... 3-4

Figure 6-1 Pan Backlash Adjustment .............................................................................................. 6-1

Figure 6-2 Tilt Backlash Adjustment ............................................................................................... 6-1

LIST OF TABLES Table 1-1 Reference Data............................................................................................................. 1-2

Table 2-1 Will-Burt Cable Options .................................................................................................. 2-3

Table 2-2 Number of Wires Required ............................................................................................. 2-5

Table 6-1 Troubleshooting Guide ................................................................................................... 6-2


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SAFETY SUMMARY

SIGNAL WORD DEFINITION

Per the ANSI Z535.4 standard, the following signal words and definitions are used to indicate hazardous situations:

DANGER indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices, or situations that could result in equipment damage.


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GENERAL SAFETY PRECAUTIONS

The following are general safety precautions that are not related to any specific procedures and therefore do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance

Electrocution Hazard! Contact with high voltage will result in death or serious injury. Observe general safety precautions for handling equipment using high voltage. Do not locate or operate mast near electrical lines, cables or other unwanted sources of electricity. Do not operate positioner in lightning. Be certain electrical cables are undamaged and properly terminated. Always disconnect power before performing service, repair or test operations.

Safety Instruction - Read Manual! Failure to follow operating instructions could result in death or serious injury. Read and understand the operator’s manual before using the mast.

Tip Over Hazard! Positioner tip over could result in death or serious injury. Do not operate in high winds. Operate on level ground only. Stand clear of positioner and positioner payload during operation. Be certain positioner is level and secure before and during installation, operation and maintenance.

SPECIFIC SAFETY PRECAUTIONS

The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this publication for emphasis. These are recommended precautions that personnel must understand and apply during specific phases of installation, operation and maintenance

Safety Instruction - Trained Personnel Only! Death or serious injury could result if proper inspection, installation, operation and maintenance procedures are not observed. Installation, operation and maintenance to be performed by trained and authorized personnel only. Proper eye protection should be worn when servicing the mast.

Health and Safety Hazard! Solvent used to clean parts is potentially dangerous. Avoid inhalation of fumes and also prolonged contact to skin.


Page viii

The following are safety precautions that are related to specific procedures and therefore appear elsewhere in this publication for emphasis. These are recommended precautions that personnel must understand and apply during specific phases of installation, operation and maintenance.

Safety Instruction-Operation! For outdoor use only. Do not use in areas that have been classified as hazardous as defined in Article 500 of the National Electric Code.

Crush Hazard! Death or serious injury could result if mast fails suddenly. Do not stand directly beneath the positioner or its payload. Be certain payload is properly installed and secured.

Fire Hazard! Cleaning solvent, used for maintenance, is flammable and can be explosive resulting in death or serious injury. Do not smoke. Use cleaning solvent in a well-ventilated area. Keep cleaning solvent away from ignition sources. Always store cleaning solvent in the proper marked container.

Relocation Hazard! Relocating the mast during operation or after extension could result in death or serious injury. Do not relocate the positioner during operation or while extended. This applies especially to positioners installed on masts mounted to vehicles. Operate the positioner only if the vehicle is stationary and the vehicle engine is off.

Mounting Structure Hazard! Mounting payload into a positioner unable to resist the forces generated from customer-specific loading scenario could result in death or serious injury and could damage the positioner. Before operation, be certain positioner is capable of resisting forces generated from all loading and environmental conditions, including, but not limited to, mast size and weight, payload size and weight, sail size, wind speed, guy line arrangement, support bracket or roof line location and base plate assembly.


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Electrocution Hazard! Do not touch live wires. Death or serious injury could result.

Safety Instruction – Operation! Make sure all power has been disconnected prior adjustments / maintenance.

Safety Instruction -Trained Personnel Only! Only trained and qualified personnel should perform installation, adjustments, and servicing. Only a properly trained and qualified certified electrician should perform electric installations and service.

Safety Instruction – Operation! All operators must read the Operation section of this manual and be properly trained

Entanglement Hazard! Tangled cables can cause equipment damage. Ensure control cables are not tangled and are free to pay out as mast is extended.

Safety Instruction – Operation! Do not operate the positioner during an electrical storm.

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.


Page 1-1

INTRODUCTION CHAPTER 1

This manual covers: operation, maintenance, troubleshooting, repair, and installation instructions for the AccuPoint Positioner. The unit was designed to be installed on an ENG truck in the Broadcast industry for the purpose of positioning a microwave antenna (AP-100) or camera (AP-25). It can, however, be used in virtually any application where the requirements do not exceed the unit’s specifications (refer to section 1.3 for reference specifications).

Safety Precautions 1.1

Refer to the Safety Summary for precautions to be observed while operating or servicing this equipment.

Description 1.2

The AccuPoint Positioner is an adjustable pan/tilt system and may serve as a platform for many different applications. The AccuPoint Positioner may be attached on top of a self-erecting, extensible mast.

This pan/tilt positioner is designed to remotely position a suitable payload (AP-100 not to exceed 100 lbs mass / 45 kg or 100 ft-lbs / 135 Nm of torque; AP-50 not to exceed 50 lbs mass / kg or 50 ft-lbs / 67.8 Nm of torque) to any degree of azimuth from 0 to 450 or degree of elevation from 0 to 180. Refer to Figure 1 for identification of the major components of the AccuPoint Positioner

Figure 1-1 AccuPoint Positioner (AP-100 shown)

Figure 1-2 Mating Connector (included)


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Reference Data 1.3

Model Number AP-50 AP-100 Voltage Options 12VDC 24VDC/115VDC/115VAC

Dimensions (WxHxD) 12.25” x 12.5” x 9.25”

311mm x 318mm x 235mm 12.25” x 12.75” x 9.25”

311mm x 324mm x 235mm Weight 31Lbs / 14.1kg 37Lbs / 16.8kg

Maximum Load 50Lbs / 13.6kg 100Lbs / 45.4kg Maximum Tilt Torque 50ft-lbs / 67.8 Nm 100ft-lbs / 135.6 Nm

Pan Speed (adjustable) 0.25 to 11deg /sec 0.25 to 11deg /sec Pan Rotation Range 430 degrees 430 degrees

Tilt Speed (adjustable) 0.1 to 5deg /sec 0.1 to 5deg /sec Tilt Angle (from

top/level) ± 90 degrees (180 deg

travel) ± 90 degrees (180 deg

travel) Temperature Limits 0° to 130°F (-18° -- 54°C) 0° to 130°F (-18° -- 54°C)

Duty Cycle 50% intermittent

20 mins. continuous 50% intermittent

20 mins. continuous

Potentiometers Optional (for Stow/Unstow)

Optional (for Stow/Unstow)

Stow Switches n/a Optional on 115VDC

Table 1-1 Reference Data

AccuPoint Controllers 1.4

The AP-Chief and AP-100 can be controlled with an AccuPoint controller. The AccuPoint controller is a self-contained digital control device that provides both local and remote control of industry-standard pan/tilt units. These AccuPoint controller provide basic pan and tilt control as well as automatic stow and unstow positioning when used with pan/tilt units equipped with pan and tilt sense potentiometers. Each AccuPoint controller must be ordered with the specified control voltage that matches the requirements of the pan/tilt unit with which it is to be paired. Refer to the Controller literature for more details.


Page 2-1

INSTALLATION CHAPTER 2The Positioner has been designed to provide for ease of installation. This section of the manual provides the procedures that must be followed to insure a successful installation. Be sure to read and understand the entire installation procedure before you begin.


Tools and Materials required for Installation 2.1

SAE Wrenches Hex Keys/ Allen Wrenches Screwdrivers Torque Wrench

Wire cutter/ stripper Crimping tools Soldering kit Level

Unpacking 2.2

Unpack the AccuPoint pan/tilt and the mating connector. Check to make sure all parts are included in the package. Check for any damage from shipping and report it immediately to the shipping company if damage has occurred.

AccuPoint Orientation 2.3

For installation purposes, the AccuPoint has been marked to indicate the front of the unit. The front of the unit is identified by an “F” that has been stamped into each side plate. The cover that is closest to the “F” stamp is the front of the unit.


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Mounting the Positioner 2.4

Select a mounting location that will allow for full pan and tilt movement that is free of obstructions. Be sure to take other external factors, such as wind or ice loading for example, when selecting a mounting location. Make sure that these external factors do not overload the pan/tilt unit. Install the included pedestal gasket to the bottom of the pedestal. Connect your AccuPoint to the top of the mast with high strength stainless steel bolts and nuts (5/16” bolts for AP-100, ¼” bolts for AP-25). There are 4 holes equally spaced. See Figure 2-1 for pedestal bolt pattern.

Figure 2-1 AccuPoint Pedestal Bolt Pattern


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Wiring the Positioner 2.5

2.5.1 Wire / Cable Sizing

The standard cables used and their wire sizes are shown in the following table:

Will-Burt P/N

No.Conductors/AWG

34625 7/20

34502 12/20

4819601 4/16 & 8/20

Table 2-1 Will-Burt Cable Options

The 6 wires that run to the AccuPoint (5 wires for DC version) to power the motors should be large enough to provide acceptable operation. When the controller is located farther away from the positioner, heavier gauge wire will be required to ensure adequate operation. The wires used for the potentiometers (optional) should be shielded and can be #24 AWG or thicker if the total length is less than 1,000ft (300m). It is recommended that the minimum wire size of 24 AWG is used for the Stow switches if the total wire length is less than 1,000 ft (300m).

NOTE: For 24VDC positioners, use Will-Burt P/N: 4819601 (16AWG motor wires), to reduce voltage drop to the positioner.


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2.5.2 AccuPoint 24 VDC & 115 VDC Connector Wiring

The DC power for the AccuPoint Positioner is supplied through a 17-pin MIL-type (MIL-DTL-5015) connector located on mounting pedestal. The mating connector is a MS3102R20-29-P or equivalent, Will-Burt P/N: 213025. Wires need to be soldered to the appropriate pins depending on the AccuPoint model and installed options. See Figure 2-2 for pin configuration.

Note: There are no internal fuses in the AccuPoint positioner. Fuses must be installed on the control side of the installation to ensure safety in the event of a malfunction; 2 Amp slow-blow fuse is recommended.

Figure 2-2 DC Connector Pinout

2.5.3 AP-100 AC Connector Wiring

The AC power for the AP-100 Positioner is supplied through a 14-pin MIL-type connector located on the mounting pedestal. The mating connector is a MS3102R20-27-P or equivalent (Will-Burt item no 213027). Wires need to be soldered to the appropriate pins depending on configuration; see Figure 2-3.

Note: There are no internal fuses in the AP-100 positioner. Fuses must be installed on the control side of the installation to ensure safety in the event of a malfunction. 2 Amp slow-blow fuse is recommended.

Figure 2-3 AC Connector Pinout


Page 2-5

2.5.4 Minimum Number of Wires for Positioner Cable

There are a minimum number of wires required to operate the positioner. Refer to Table 2-2 for minimum wires required for the various options.

Table 2-2 Number of Wires Required

Pan/Tilt ModelNumber of Wires

Required for Motors115 VAC 6115 VDC 524 VDC 512 VDC 5

Optional Accessories (on some models)Potentiometers 4 additional wiresSignal Switches 2 additional wiresLEDs 2 additional wires


Page 3-1

Operational Check CHAPTER 3

Ensure that all wiring connections are tight and appropriately connected. Make sure the area around the pan/tilt is clear so no damage will result from unexpected movement.

Power-on Check 3.1

• Apply power to the Accupoint.

Note: The LEDs on the AP-100 (bottom of the housing) should illuminate if they were connected during installation.

• When the pan left control is pressed, the positioner should rotate counterclockwise direction.

• When pan right control is pressed, the positioner should rotate clockwise direction.

• When tilt up control is pressed, the platform should rotate upwards.

• When the tilt down control is pressed, the platform should rotate downwards.

NOTE: If the pan or tilt location is at a limit, the unit may not pan or tilt in one direction. To verify that the unit is operating properly, press the pan or tilt button in the opposite direction to move the unit off of the limit cam. Then try the function that was not working and verify that it operates properly. If optional potentiometers or stow switches are installed, verify that those functions are working properly.


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Setting pan/tilt limits 3.2


There are 4 cams that activate limit switches and shut off the pan and tilt motors. These cams are adjustable. When adjusted, they will increase or reduce travel.

The two pan limit cams are shown in Figure 5 Detail B for the AP-100. The top cam, when adjusted to the right, will reduce the travel in the clockwise direction (when looking down on the platform). The bottom cam, when adjusted left will reduce travel in the counterclockwise direction (again, when looking down on the platform).

Do not turn the top cam to the left past the flat on the bottom cam – this could cause damage to the unit.

The two tilt limit cams are shown in Figure 5 Detail A for the AP-100. The cam on the left, when adjusted up, will reduce the tilt travel towards the front of the unit. The cam on the right, when adjusted down, will reduce travel towards the back of the unit.

Safety Instruction – Operation! Make sure all power has been disconnected prior to performing internal adjustments/maintenance.

Before adjusting the cams, make sure the power to the pan/tilt is turned off.


Page 3-3

To adjust the PAN limits, use the following procedure:

1. First remove the cover on the front of the unit to provide access to the limit cams. To remove the cover, loosen the screw(s) on the face of the cover. The screws are captivated and intended to remain attached to the cover when the cover is removed.

2. Next, using a 1/16” allen wrench, loosen one set screw on the top pan cam (clockwise limit) 2-3 turns and then loosen the second set screw on the same cam just enough to allow the cam to spin freely.

3. With the Allen wrench still in the set screw, adjust the cam to the desired location and tighten the set screw.

4. Test the new limit location by replacing the cover, powering the unit and panning until it stops. If further adjustment is necessary, repeat steps 1-3 until the desired limit is set.

5. Repeat steps 1-4 to set the bottom cam (counter-clockwise) limit.


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To adjust the TILT limits, repeat steps 1-4.

When programming any positions from the controller, like the home position, do not program these positions at the same position as the PAN and TILT limits set above.

Figure 3-1 AP-100 Pan/Tilt Limit Cams


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OPERATING INSTRUCTIONS CHAPTER 4

• All operators must read the Operation section of this manual and be properly trained. • Keep personnel clear of positioner during operation. • For outdoor use only. Do not use in areas that have been classified as hazardous as

defined in Article 500 of the National Electric Code. • Do not use in the presence of flammable gases or liquids such as paint, gasoline or

solvents. Do not use in areas of limited ventilation or where high ambient temperatures are present. Contact with combustible materials can cause ignition resulting in fire or explosion.

• Before operating, make certain that the area is free of overhead power lines and other unwanted sources of electricity. Be sure to allow sufficient clearance on all sides of positioner so that there are no collisions.

• Do not move vehicle until payload has been securely.

Theory of operation 4.1

The AccuPoint Positioner operates using two internally mounted gear motors that drive a heavy duty steel worm gear powertrain. The gear motors are connected to the worm shaft with stainless steel chains (AP-100) or belts (AP-25). There are four cams (two for the pan, two for the tilt) and they activate limit switches. When the cams trip the snap action switch, power is interrupted to the motor and rotation cannot continue in that direction. The pan rotation is limited to 450° and the tilt rotation is limited to 180°.

The pan worm gear is fixed to the pedestal and the rest of the unit rotates around the fixed pedestal. Both the pedestal and the tilt platform rotate on two sealed ball bearings. Likewise, the tilt worm gear is fixed to the tilt platform and the platform rotates around the central housing.

In addition, four ultra-bright LEDs are installed in the AP-100. If wired during installation, these LEDs provide verification that the unit has power to it and allows for greater visibility when mounted on a mast or other distant location.

The AccuPoint also has optional potentiometers (AP-25 and AP-100) and optional stow switches (AP-100). These are designed to give the operator desired position feedback from a remote location. Detailed functionality is discussed in the next section.


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Operating the AccuPoint Positioner 4.2

Under normal operating conditions, when power is applied to the pan and tilt motors, the unit will pan or tilt in the desired direction. The unit will only pan or tilt until one of the limit switches is activated. Then the power will be interrupted and motion will not continue in that direction. The pan and tilt axes are designed to move at different speeds. There is no speed adjustment in the positioner. If variable speed is desired, this must be accomplished using a separate controller.

4.2.1 Potentiometer Operation (AP-25 and AP-100)

If the optional potentiometers are installed, there are two potentiometers inside the unit – one to indicate pan position and the other to indicate tilt position. The potentiometers have an attached spur gear that rides in the worm gear. This enables the potentiometer to change as the unit pans or tilts.

4.2.2 Signal Switch Operation (AP-100 only)

The signal switches are internal magnetically activated switches. These are only installed on the tilt axis, not the pan. The switches are fixed on the inside of the housing and are tripped by a magnet that is installed on the back side of the tilt worm gear. There is no adjustment available for these switches. They are fixed and activate when the tilt platform is within 10°of being all the way to the front of the unit or all the way to the back of the unit. Each switch is wired to close to a ground connection. To wire these switches, simply make a connection between each stow switch and ground.

4.2.3 Emergency Stow (AP-100 only)

In the event that power is not available to operate the positioner, the pan and tilt functions can be operated manually using the following procedure:

1. Make sure there is no power applied to the unit. If the pan and tilt functions are not working, this does not necessarily mean that there is no power to the unit.

2. Remove the front cover.

3. Insert a large flat head screwdriver into the slot on the end of the worm shaft and manually pan or tilt the unit by turning the screwdriver.

4. Move the unit to the desired location and replace the front cover.


Page 5-1

MAINTENANCE AND SERVICE INSTRUCTIONS CHAPTER 5

This section describes routine maintenance procedures and general service information. Refer to Section 5 for exploded views of the AccuPoint Positioner and the accompanying Tables with item descriptions and part number, which may be used for ordering replacement parts.

Scheduled Maintenance 5.1

5.1.1 Lubrication

AccuPoint positioners should be cleaned and lubricated on a regular basis to insure smooth operation and to prolong life. This maintenance should be performed every 3-6 months depending upon local environmental conditions and frequency of use. Signs that cleaning and lubrication are needed can be:

• Erratic pan and tilt of the positioner

• Noisy operation of the positioner

• Pan and tilt functions moving abnormally slow

If any of these signs are present, refer to 4.2.3 for inspection and maintenance procedures.

5.1.2 Cleaning

The exterior of the Positioner should be wiped down periodically to remove dirt and road grime using a soft cloth or sponge and a mild solution of soapy water.

5.1.3 Inspection and Maintenance

A. Exterior

1) Finish:

Examine for signs of damage to exterior finish. If there are any areas showing scratches or damage to the exterior finish, ensure that they do not affect the integrity of the unit and aren’t deep enough to allow water to enter the inside of the housing.

2) Wiring:

Examine the exterior wiring harness for signs of cracked insulation, frayed or pinched wires and loose connections. If any of these things exist, repair them immediately.


Page 5-2

3) Mounting:

Check to make sure all of the mounting bolts are secure. If any of them appear loose, tighten immediately.

4) Other hardware:

Check to make sure that none of the exterior hardware is loose. If anything appears loose, tighten it using the appropriate tool.

B. Interior

1) Wiring:

Examine the interior wires for signs of cracked insulation, frayed or pinched wires and loose connections. If any of these things exist, repair them immediately.

2) Loose hardware:

Check to make sure that none of the interior hardware is loose. If anything appears loose, tighten it using the appropriate tool.

3) Cleanliness:

Remove any foreign material such as dust, dirt or chips which can acts as an abrasive in gear lubricant and reduce gear life. If there are visible metal chips inside the unit, look to find out where the chips came from and determine whether there is an additional problem that needs to be addressed.

4) Gear lubrication:

Visually check the gears for worn teeth, poor alignment and chips. Lubricate the worm gears every time the unit is opened. Re-grease the gears with a low temperature grease. Use a small brush to apply the grease to the worm gear. Rotate the worm gear using a large flat head screwdriver to manually rotate the worm shaft. As the gear is turned, apply grease to all teeth on the worm gear.

5) Bearings:

Ball bearings are sealed and lubricated for life. The four tapered roller bearings in the worm carriers should be lubricated with synthetic grease.


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6) Motors:

Replace if excessive wear is visible or motors are not functioning properly.

7) Chains (AP-100 only):

Check to make sure the chains remain adequately lubricated. If they appear dry, lubricate them with low viscosity oil.

8) Chain adjustment:

The AP-100 positioner is equipped with an automatic chain tensioner. As the chain stretches from normal operation, the chain tensioner will take up the slack. There is no need to tighten the chains.

9) Backlash (AP-100 only)

Check for unwanted movement (looseness) in either pan/tilt drives. Use the following procedure for reducing unwanted backlash in the pan drive.

1. Make sure all power is off to the unit.

2. Remove the payload from the positioner platform. The unit must be unloaded to adjust the backlash.

3. Remove the front cover.

4. Loosen the four (4) bolts (shown in Figure 7) that hold the worm block to the base. Only loosen by about one turn each.

5. Turn the set screw on the side of the unit a quarter turn clockwise to move the worm block closer to the worm gear.

6. Check the backlash and turn the worm shaft with a large flat head screwdriver to make sure it still turns freely. If the worm is binding with the gear, back the set screw off until there is no binding

7. Re-tighten the worm block screws.

To remove the backlash in the AP-100 tilt drive, follow steps 1-6, but refer to Figure 8.


Page 6-1

Troubleshooting CHAPTER 6

A quick visual inspection of the unit might reveal if the problem is mechanical or electrical.

1) Open the housing covers and check if there are loose sprockets, slipped or broken chains.

2) Visually inspect the circuitry for any short circuits or bare wires.

Figure 6-1 Pan Backlash Adjustment

Figure 6-2 Tilt Backlash Adjustment


Page 6-2

Troubleshooting Guide 6.1

The following table shows some possible issues and the trouble-shooting sequence.

Symptom Root Issue Trouble-shooting sequence

Pan and tilt motor will not respond 1. Broken or loose motor wire lead 2. Faulty motor

1. Reconnect wire lead 2. Replace motor

Pan limits fail to work Damaged or inoperative pan switches

Replace pan switches

Tilt limits fail to work Damaged or inoperative tilt switches

Replace tilt switches

Pan or tilt limit is not at the correct position

Pan and tilt limits are not set correctly.

Reset the limits (See Section 2.8 for setting pan/tilt limits)

No power to Positioner Wrong power supply Check if the correct power is supplied according to the positioner model.

No power to Positioner Connector wires not adequately connected

Re-solder the wires according to the pinout diagram. (See Section 2.5.3 &2.5.4 for DC and AC connector pinouts)

Positioner has power but fails to pan/tilt

Connector wires soldered incorrectly


Positioner has power but pan/tilt in the wrong direction

Connector wires soldered incorrectly


Table 6-1 Troubleshooting Guide

AccuPoint Positioner AP-50 / AP-100 Installation ... · AccuPoint Positioner AP-50 / AP-100 ....

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