Vinten HS-102P AutoCam manual

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HS-102PAutoCam™ Pan & Tilt Head

Operation, InstallationAnd Maintenance

(pn AB-300126 for sn 73xxxx002A - 101100)

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HS-102P Pan & Tilt Head

Safety

IMPORTANT!: Read the Safety Section starting on page 1-2 before installing or using this equipment, or attempting any adjustment or repair. This safety triangle is used in the manual to indicate important information. Read this information carefully to

avoid the risk of personal injury, injury to others, or damage to the equipment.

Warning LabelsVarious colored safety labels are attached to the AutoCam equipment to alert you to hazardous situations. The labels and their meaning are described below.

DANGER (with a red background) indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING (with an orange background) indicates a poten-tially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION (with a yellow background) indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION (with a yellow background, but without the Safety Alert symbol) indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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Critical Data For HS-102P

Mass (Weight) 17 lb (7.7 kg)

Maximum Load 35 lb (15.9 kg)

Maximum Pressure Not Applicable

Input Voltage 24 VDC Nominal

Input Current 0.75 Amp Nominal at 24 VDC1.0 Amp Peak

Date Of Manufacture 2000

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Technical SupportIf you are based in North, South or Central America and need technical support on the AutoCam system, contact Vinten Inc. at:709 Executive Blvd.Valley Cottage, NY 10989USA

Phone:1-888 4 VINTEN (1-888-484-6836) - Toll free in the U.S.A.+1 845-268-0100Fax:+1 845-268-0113

Or, if you are based outside of North, South or Central America, contact Vinten Broadcast Limited at:Western WayBury St. EdmundsSuffolk IP33 3TBENGLAND

Phone: +44 (0) 284 752121Fax: +44 (0) 284 750560

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WarrantyVinten, Incorporated (Vinten) warrants that its equipment shall be free of defects in material and workmanship for a period of twelve (12) months from the first date of installation, but no more than eighteen (18) months from date of shipment, and is extended only to the original purchaser. Vinten, at its option, will repair or replace defective components. Warranty covers only those defects that occur when the equip-ment is used in the manner described in the Operation, Installation, and Service man-ual. Vinten’s liability is limited to parts, material, and labor necessary to repair or replace equipment manufactured by Vinten. Any and all consequential damages are excluded. Consumable supplies and normal wear items are the customer’s responsi-bility and are not covered by this warranty.

The warranty is in effect only when equipment is operated, adjusted, and maintained in the manner described in the appropriate Operation, Installation, and Service man-ual. Modifications, service by non-authorized service personnel, failure to provide proper maintenance, and abuse and misuse of the equipment will void the warranty. Repairs not covered by this warranty will be billed for parts, labor, and expenses at the rates in effect at the time of service.

Warranty service and repair will normally be performed at the Vinten factory in Val-ley Cottage, New York, but may, at the discretion of Vinten, be performed on the cus-tomer site. It is the customer’s responsibility to contact Vinten and obtain authorization prior to returning equipment for warranty service. Returned equipment must include a Return Material Authorization (RMA) number, and a failure report describing the nature of the failure or complaint as well as the customer’s name, address, and a contact name and phone number.

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CopyrightThe Vinten Inc. AutoCam User Manual is copyrighted with all rights reserved. Under the copyright law, this manual may not be copied, in whole or in part, without written consent from Vinten Inc.

© 1998-2000 by Vinten Inc.

Disclosure Statement - AutoCam SystemThis document contains information proprietary to Vinten Inc. Except by written authorization from Vinten Inc., the information contained in this document shall not, in whole or in part, be disclosed to third parties, reproduced for any purpose, or used except for evaluation, operation and maintenance of equipment supplied by Vinten Inc. or Vinten Broadcast.

Manual OutlineThis manual covers the installation, operation and maintenance of the AutoCam HS-102P Pan/Tilt Head. See Chapter 1 for a detailed description of the contents of this manual.

Product Serial NumbersVinten AutoCam products are marked with unique serial numbers that include a 2 digit product identifier, a 4 digit serial number and a 2 character revision code. The format is AABBBBXXCD where:

This manual is applicable to products that have serial numbers 73xxxx002A where xxxx may be any 4 digit number.

AutoCamTM, Vinten Inc.TM and Lubricated Friction (LFTM) are trademarks of Vinten Inc. or Vinten Broadcast Limited.

Specifications and features are subject to change without prior notice.

(101100)

AA Product Identifier - 73 for the HS-102P

BBBB Serial number

XX Reserved for future use - currently 00

C Primary revision status - 0, 1, 2, 3 etc.

D Secondary revision status - 0, A, B, C etc.

Table of Contents

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HS-102P Pan & Tilt Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iiCritical Data For HS-102P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ivWarranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viDisclosure Statement - AutoCam System . . . . . . . . . . . . . . . . . . . . . . viManual Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viProduct Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

1 Safety & IntroductionSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Very Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2Customer Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2Safe Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2Operating Footprint And Safe Operating Zone . . . . . . . . . . . . . . . 1–3Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3Heads Can Start Unexpectedly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4Pinch Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4Sharp Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Manual Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5HS-102P Pan/Tilt Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6HS-102P Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8Touch Screen Controller Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8

ACP 1–8HCP 1–8LCP 1–8

MCS-4000 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8MultiController II System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8

2 OperationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2Power 2–2Data 2–2

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3 InstallationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

Tools You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

Mounting The Pan & Tilt Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4Mounting And Balancing The Payload . . . . . . . . . . . . . . . . . . . . . . 3–4

Lens Drive Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . 3–6Minimizing Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7Follow Pot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

Focus 3–7Zoom 3–7

Electrical Installation And Interconnection . . . . . . . . . . . . . . 3–10Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12

Zoom/Focus/Pan/Tilt Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12Zoom Clip 3–13Focus Clip 3–13Pan Clip 3–14Tilt Clip 3–14

Other Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15Baud Rate 3–15Pan/Tilt Direction 3–15Factory Test Switch 3–15

4 Maintenance And RepairIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Service Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2Avoid Damage From Static Electricity . . . . . . . . . . . . . . . . . . . . . . . 4–2Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4Checking Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4Checking Overall Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

Theory Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6Data Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6Command Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7Initialization Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7Servos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

Zoom and Focus Servos 4–7Pan and Tilt Servos 4–8

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Electrical Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10Surface Mount Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

Mechanical Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11HS-102P Disassembly/Reassembly . . . . . . . . . . . . . . . . . . . . . 4–12

Software Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12Board Troubleshooting And Replacement . . . . . . . . . . . . . . . . . . 4–12Belt Replacement And/Or Adjustment . . . . . . . . . . . . . . . . . . . . . 4–12 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12Optosensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12Anti Backlash Gear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14Software Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16

Preliminary Steps 4–16Replacing U1 4–16Reassembly 4–17

Removing The Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18Removing The CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–18Removing The Driver Board Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20Removing The Connector Plate And Harness . . . . . . . . . . . . . . . . 4–21Removing The Pan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22Removing The Tilt Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–24Removing The Tilt Tensioner And Tilt Belts . . . . . . . . . . . . . . . . . . . . 4–26The Tilt Anti-Backlash Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28

Checking The Anti Backlash Gear 4–28Powered Head 4–28Non Powered Head 4–28

Adjusting The Tilt Anti Backlash Gear Assembly . . . . . . . . . . . . . . 4–30Removing The Tilt Anti Backlash Gear Assembly . . . . . . . . . . . . . . 4–32Removing The Pan Tensioner And Pan Belts . . . . . . . . . . . . . . . . . 4–34The Pan Anti-Backlash Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–36

Checking The Anti Backlash Gear 4–36Powered Head 4–36Non Powered Head 4–36

Adjusting The Pan Anti Backlash Gear Assembly . . . . . . . . . . . . . 4–38Removing The Pan Anti Backlash Gear Assembly . . . . . . . . . . . . 4–39Installing The Pan Anti Backlash Gear Assembly . . . . . . . . . . . . . . 4–40Installing The Pan Belts And Pan Tensioner . . . . . . . . . . . . . . . . . . 4–42Installing The Tilt Anti Backlash Gear Assembly . . . . . . . . . . . . . . . 4–44Installing The Tilt Belts And Tilt Tensioner . . . . . . . . . . . . . . . . . . . . . 4–46Installing The Tilt Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–48Tilt Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–50

Checking Belt Tension 4–50Tilt Motor Belt 4–50

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Tilt Drive Belt 4–51Installing The Pan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–52Pan Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–54

Checking Belt Tension 4–54Pan Motor Belt 4–54Pan Drive Belt 4–55

Installing The Connector Plate & Harness . . . . . . . . . . . . . . . . . . . 4–56Installing The Driver Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–57Installing The CPU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–58Finishing Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–60

User Manual 1-1

1 Safety & Introduction

HS-102P Safety & Introduction

1-2 User Manual

SafetySafety issues including important warnings, risks and related topics are covered in this section of the manual. It is very important that this information be avail-able to all personnel who will work on or near the Autocam equipment.

Very Important Information

To avoid personal injury, always exercise caution when work-ing in the vicinity of energized heads as they can start to move without any warning.

Unless it is impossible to accomplish a task, you should always de-energize the head before working on any part of the head, the camera/lens, or any associated equipment.

Know the location of the power supply and its On/Off switch so that you can power down the head in an emergency.

Customer ResponsibilityIt is the customer’s responsibility to ensure that the workplace is safe. Make sure that you comply with local safety requirements for owning and operating robotic equipment. In normal operation, the remote controlled heads and payloads in an Autocam system can move suddenly and without warning. Since audible warn-ings are out of the question in normal television applications, it is recommended that only trained personnel be allowed to work in the active areas where the remote controlled heads and payloads are located. As part of the training, per-sonnel must be made aware of the hazards of working in a robot environment, including the specific hazards listed below. The forces are sufficient to cause personal injury, or injury to others and therefore, caution is essential.

Safe Working EnvironmentEach of the remote control heads should be within the view of the operator of the Autocam system at the control panel. Before and during remote operation, the operator must verify visually that the active area is clear. If personnel are too close to one of the heads that is about to move, the operator can prevent the motion from starting, or stop the motion after it has started.


User Manual 1-3

If the direct line of sight is obstructed in your installation, it is recommended that one or more viewing cameras (e.g. security type cameras) are installed to cover the active areas and allow the operator to view the entire work-space at all times.

Operating Footprint And Safe Operating ZoneThe operating footprint must take into account the overhang of any payload equipment mounted on the HS-102P. In particular, the payload element that pro-trudes the most defines the operating footprint area as the head pans and tilts.

If your operating practices require personnel to work less than 3 feet (1m) out-side the operating footprint, you must make sure that they are trained and are aware of the hazards of working in a robot environment, including the specific hazards listed below. The forces are sufficient to cause personal injury, or injury to others and therefore, caution is essential.

Warning SignsWarning signs should be displayed prominently in the workplace as a reminder to trained personnel, and a primary warning to untrained personnel and visitors. A typical sign might read:

WARNING:Robotic Heads & CamerasMove Suddenly Without Warning

Heads Can Start UnexpectedlyThe hazards associated with robotic camera systems are only slightly different than those associated with operating a camera under conventional manual con-trol. The speeds and camera weights are similar. The main difference is that with automation, the operator is normally not near the cameras, and it is more diffi-cult to verify that the area is clear. For personnel working on or near the robotic heads, they must be aware that the equipment can start moving unexpectedly.

All personnel should be trained and aware of the hazards of robotic heads, and the fact that they can move at any time. They must be trained on how far the heads and payloads can move, the speeds involved, and the need to stay back an appropriate distance.

Most adjustments to the camera and head, such as tilt balancing and camera video adjustments, should be made with the system de-energized. However, if adjustments are absolutely necessary while the head is powered, they should only be made by trained technical personnel familiar with the AutoCam robotics system. They must understand that the camera can move unexpectedly at any time, and must position themselves so that any motion would not cause them personal harm.


1-4 User Manual

When the robotic heads move, the speeds involved are fairly slow. However, the equipment is still capable of generating sufficient force to cause injury. There-fore, it essential that you exercise caution.

Any failure of the system could possibly cause one or more axes to move on their own, but the speeds and forces should not be noticeably greater than those encountered during normal use.

Power SwitchIf you need to disable a head in an emergency, or for any other reason, use the Power Switch on the power supply.

After clearing the cause for the emergency, or completing the maintenance task, turn the Power Switch back on.

Pinch PointsParticular care should be exercised around possible points where you could get pinched, such as the tilt cradle. Here, the forces can be somewhat greater, due to the short lever arm.

Sharp EdgesIf the lens, or other camera attachments have sharp edges that could cause injury, make sure they are padded or protected.


User Manual 1-5

Manual Outline

Chapter 1 This chapter discusses important safety issues and provides an overview of the HS-102P and typical applications.

Chapter 2 Step by step instructions for operating the HS-102P pan/tilt head.

Chapter 3 Step by step instructions for unpacking and installing the HS-102P pan/tilt head.

Chapter 4 Technical information including routine maintenance, circuit descriptions, calibra-tion, schematics and parts lists.


1-6 User Manual

HS-102P Pan/Tilt HeadKey Features

• 35 lb. (15.9 kg.) payload capacity

• Brushless servo technology

• Low cost

• Small profile

• High accuracy/speed

• Lightweight (17 lb. / 7.7 kg.)

The HS-102P is a light weight, servo pan/tilt head designed to support a wide range of camera and lens combinations up to a maximum payload of 35 lb (15.9 kg.). Its uses can include: following government proceedings; delivering dis-tance learning between campuses; documenting scientific meetings; and much more.

The HS-102P post head can be mounted to tripods, wall brackets, or may be inverted for suspension from the ceiling. The compact profile allows it to be used within existing wall cavities and other tight quarters.

The head is designed for payloads up to 35 lb. (15.9 kg.) and delivers high speed and accuracy in small spaces. The rigid mechanical design allows tight damping without oscillation or overshoot. High gain servos result in excellent accelera-


User Manual 1-7

tion (180°/sec2) smooth movement and position accuracy of 60 arc seconds (0.125” at 36 feet). The pan range of the HS-102P is 359° and the tilt range is ± 179°.

The HS-102P can be controlled by all AutoCam controllers including the ACP/HCP/LCP touch screen controllers, the MultiController II and MCS-4000.

HS-102P Specifications

Weight 17 lb. (7.7 kg.)

Payload 35 lb. (15.9 kg.)

Pan Range 359°

Tilt Range ± 179°(may be reduced by actual payload and mounting configuration)

Accuracy 60 arc secs

Angular Acceleration 180°/sec2

Angular Velocity 60°/sec

Height 8.75” (22.2 cm)

Width (including cradle) 12” (30.5 cm)

Depth 6” (15.2 cm)

Mounting Tripod/Pedestal/Wall/Ceiling

Servo Type 24 bit digital with brushless DC motor

Gear-train Type Self lubricating, anti-backlash


1-8 User Manual

Typical ApplicationsThe HS-102P pan and tilt head can be controlled by one of the AutoCam touch screen controllers, the MCS-400 or the MultiController II.

Refer to the User Manuals for your specific controllers for more information.

Touch Screen Controller SystemsUp to eight heads can be controlled by a single AutoCam touch screen controller as shown below.

ACPIf the system includes one or more servo pedestals, the ACP controller is used.

HCPThe HCP is used when there are no servo pedestals in the system.

LCPThe LCP is customized for Legislative (and similar) applications.

MCS-4000 SystemThe compact MCS-4000 can control up to four heads as shown below.

MultiController II SystemThe MultiController II can control up to six heads of mixed types, including the HS-102P. Refer to the User Manual for the MultiController II for more informa-tion.

Video Switcher

PS-102-4

PS-102-1

PS-102-4

PS-102-1

User Manual 2-1

2 Operation

HS-102P Operation

2-2 User Manual

IntroductionThe HS-102P has no external switches or controls. Operating procedures for controlling the head remotely are described in the User Manual for the specific controller in your installation.

IndicatorsTwo LEDs are located on the connector plate

PowerThe LED is on when DC power from the power supply is reaching the head.

DataThe LED is on when control data is reaching the head from the controller.

User Manual 3-1

3 Installation

HS-102P Installation

3-2 User Manual

IntroductionThis chapter describes the step by step procedure for mounting the heads, mounting and balancing the cameras and configuring the system for operation.

For proper performance of the equipment and to prevent personal injury it is critical that these procedures are followed.

Tools You Will NeedIt is recommended that you have the following tools available during the unpacking and installation:

• A set of right angle hex keys


User Manual 3-3

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3-4 User Manual

Mechanical InstallationMounting The Pan & Tilt HeadAttach the HS-102P head to its mount using the six screws provided (10-32 x.500 socket head cap screws) and tighten them securely with a 5/32” hex wrench. The screws must protrude 5/16” into the pan base of the HS-102P.

Mounting And Balancing The PayloadFor proper operation it is very important that the load is properly balanced mechanically with the center of gravity set exactly on the tilt axis.

1. Start with the tilt cradle level.

2. Position the camera on the tilt cradle and attach with bolts through the tilt cradle into the base of the camera. Leave the bolts just loose enough to be able to slide the camera backwards and forwards.

3. Mount the lens on the camera (if it was not already installed).

4. Mount any other ancillary equipment such as tally lights etc.

5. Slide the camera back and forth until the overall payload feels balanced and is centered about the tilt axis of the head. Tighten the bolts in the base of the camera.

6. Check the balance after the bolts are tightened. If necessary, loosen the bolts that hold the camera to the cradle and carefully push the payload in the desired direction. Retighten the mounting bolts and check again for proper balance. It is best to move the payload in small increments even though this may require several steps until the balance is achieved.

7. Once the back and forth balance is achieved, proceed with adjustment of vertical balance. Tilt the camera approximately 30 degrees upward and release it. If the camera stays in the same position when released, the pay-load is properly balanced.

8. However, if the camera continues to move upwards after you let go, the payload is mounted too high. On the other hand, if the camera moves back towards the horizontal position when you let go, the payload is mounted too low. Determine if you need to raise or lower the tilt cradle.

9. Mark the position of the camera on the tilt cradle so it can be re-installed in the same position. Remove the camera from the tilt cradle.

10. Note or mark the vertical position of the tilt cradle to make sure that you move it in the desired direction. Loosen the two 5/32” hex head screws and raise or lower the cradle as necessary. Tighten the screws securely.

11. Remount the payload and repeat step 7 to check the balance. Move the tilt cradle again if necessary until balance is achieved.


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Lens Drive Installation and SetupThe servo lens drive assembly is shown below.

ENG Lens Drive Assembly


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Minimizing BacklashWhen the lens drive is fitted, the eccentric mounts should be adjusted for mini-mum backlash. Advance the eccentric mounts to remove any excess play between the gears. However, do not set the mounts so close that the lens barrel is tight. Similarly, do not set the mounts so loose that the lens servo is not repeat-able. Find the happy medium. If you remove the drive from a lens, and then re-mount it on the same lens, no adjustment should be necessary.

Follow Pot AdjustmentThe positional information in the lens servo comes from the zoom and focus potentiometers. The wiper voltages provide the accurate feedback of position to the servo. It is important therefore, that the pot wipers move within the center of the pot’s travel for an end-to-end move of the lens. The method of adjustment is described below, but note that the resistance values quoted are for reference only, and may vary slightly from lens to lens. It is more important that the resis-tance values at each end of travel are symmetrical.

Focus1. Switch the lens Manual/Servo lever to Manual.

2. Loosen the two fixing screws “A” sufficiently to allow the focus pot gear to rotate free of the lens barrel, if required.

3. Measure the resistance of the focus pot pin #1 with respect to the wiper. Rotate the lens barrel to the end of travel in the far focus direction - the resistance should decrease. Lift the pot anti-backlash gear out of mesh and rotate the gear for a resistance of 300 ohms. Re-engage the pot with the lens focus barrel, advancing the ant-backlash gear by 2-3 teeth.

4. Connect the resistance meter to pin 3 with respect to the wiper. Rotate the lens barrel to the end of travel in the near focus direction - the resistance should decrease. Check that the resistance is approximately 300 ohms. Repeat steps 3 and 4 until the resistance readings at each end of lens travel are the same.

5. When symmetry is achieved, check that the anti-backlash gear is set cor-rectly and tighten the two fixing screws “A”.

ZoomThe anti-backlash gear on the zoom pot is meshed with the zoom motor gear. To rotate the pot shaft, loosen screw “B” and slide the pot gear out of mesh.

1. Loosen fixing screw “B” sufficiently to allow the zoom pot gear to rotate free of the zoom motor gear, if required.

2. Measure the resistance of the zoom pot pin #3 with respect to the wiper. Rotate the lens barrel to the end of travel in the telephoto direction - the resistance should decrease. Lift the pot anti-backlash gear out of mesh and rotate the gear for a resistance of 300 ohms. Re-engage the pot with the motor gear, advancing the ant-backlash gear by 2-3 teeth.


3-8 User Manual

3. Connect the resistance meter to pin 1 with respect to the wiper. Rotate the lens barrel to the end of travel in the zoom wide direction - the resistance should decrease. Check that the resistance is approximately 300 ohms. Repeat steps 2 and 3 until the resistance readings at each end of lens travel are the same.

4. When symmetry is achieved, check that the anti-backlash gear is set cor-rectly and tighten the fixing screw “B”.


User Manual 3-9



3-10 User Manual

Electrical Installation And InterconnectionInstallation instructions for the controller and associated equipment are provided in the User Manual for your controller.

1. Before connecting AC power to any of the equipment, check the labels on each piece of equipment to make sure that it is the correct voltage for your installation (i.e. 110 or 220 volts).

2. Install the rackmount power supplies up to 500 ft. (150 m) from their respective pan/tilt heads and connect AC power cables.

3. Connect the power/data cable from each power supply to its pan/tilt head.

4. Connect the cable from the lens drive assembly to the mating connector on the HS-102P.


User Manual 3-11



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ConfigurationZoom/Focus/Pan/Tilt CalibrationThe head clip parameters including the zoom and focus limits are set digitally and stored in non-volatile memory in the HS-102P. The factory default settings will allow approximately 25% of the full range of motion. This limited range allows you to confirm that they system is operational but will minimize the like-lihood of damage before the calibration is performed.

1. Use a 7/64” hex wrench to remove the eight screws that secure the cover of the HS102. Set the cover and screws aside for re-installation.

2. Locate the 10 position DIP switch package (SW1) and the momentary pushbuttons on the CPU board as shown below.

3. If you are in a poorly lit location, use switch SW1-1 (the left-most position) to turn on the lamp that is next to the DIP switches.

4. At the controller, disconnect the data cable for the head being calibrated. At the head, if the Data LED on the connector panel is “twinkling” (i.e. data is being received from the controller), you must not adjust the clip settings.

5. Power down the head by turning the power supply off. Turn the power sup-ply back on to initialize the head.

Lamp

MomentaryPushbuttons

SW1

SW4


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Zoom ClipNote that the lens servo gain and damping must be correctly adjusted so that there is little or no overshoot. Otherwise, the lens could still hit the end stops even if the clips are set correctly.

1. Slide the ZOOM-W switch (SW1-7) up. Make sure that the other 7 clip switches are down.

2. Use the momentary pushbuttons (+ and -) located to the left of the DIP switches to adjust the lens zoom angle until it is at the widest angle, just before hitting the end stop. The zoom ring moves slowly in this mode so you can zoom all the way wide until the ring stops moving (that is it runs into the end stop) and then back off slightly.

3. Slide the ZOOM-W switch down and the limit position will be stored in non-volatile memory.

4. Slide the ZOOM-T switch (SW1-8) up.

5. Use the momentary pushbuttons located to the left of the DIP switches to adjust the lens zoom angle until it is at the tightest angle, just before hitting the end stop. The zoom ring moves slowly in this mode so you can zoom all the way tight until the ring stops moving (that is it runs into the end stop) and then back off slightly.

6. Slide the ZOOM-T switch down and the limit position will be stored in non-volatile memory.

Focus Clip1. Slide the FOCUS-N switch (SW1-9) up. Make sure that the other 7 clip

switches are down.

2. Use the momentary pushbuttons located to the left of the DIP switches to adjust the lens focus ring until it is focused at the near limit, just before hit-ting the end stop. The focus ring moves slowly in this mode so you can wait until the ring stops moving (that is it runs into the end stop) and then back off slightly.

3. Slide the FOCUS-N switch down and the limit position will be stored in non-volatile memory.

4. Slide the FOCUS-F switch (SW1-10) up.

5. Use the momentary pushbuttons located to the left of the DIP switches to adjust the lens focus ring to infinity, just before hitting the end stop. The focus ring moves slowly in this mode so you can adjust it until the ring stops moving (that is it runs into the end stop) and then back off slightly.

6. Slide the FOCUS-F switch down and the limit position will be stored in non-volatile memory.


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7. Set the pan and tilt limits as described in the next section. Or, finish up by making sure that the lamp inside the head is off by sliding switch SW1-1 to the Down (Off) position. Replace the head cover, using the screws (6-32 x 0.250 socket head cap screws) removed earlier and tighten the screws with a 7/64” hex wrench.

Pan ClipAs viewed from behind the camera, counterclockwise (CCW) pan results in the lens swinging to the left.

The clips must be set when there is no data being sent from the controller. At the controller, make sure that the head you are working on is not selected. Verify that no data is being received at the head by confirming that the Data LED on the connector panel is glowing steadily. This means that the controller is con-nected, but not transmitting data. If the Data LED is “twinkling”, this indicates that data is being received from the controller and you must not adjust the clip settings.

1. Slide the PAN< switch (SW1-3) up. Make sure that the other 7 clip switches (positions #4 - #10) are down.

2. The momentary pushbuttons located to the left of the DIP switches are used to pan the head slowly pan to the left or the right. Use the pushbuttons to pan to the left and position the head at the desired limit of CCW travel.

3. Slide the PAN< switch down and the limit position will be stored in non-volatile memory.

4. Slide the PAN> switch (SW1-4) up.

5. Use the momentary pushbuttons located to the left of the DIP switches to pan the head to the right and position it at the desired CW limit.

6. Slide the PAN> switch down and the limit position will be stored in non-volatile memory.

Tilt Clip1. Slide the TILT< switch (SW1-5) up. Make sure that the other 7 clip

switches are down.

2. The momentary pushbuttons located to the left of the DIP switches are used to tilt the head slowly up or down. Use the pushbuttons to tilt the head to the desired limit of travel with the lens pointing upwards.

3. Slide the TILT< switch down and the limit position will be stored in non-volatile memory.

4. Slide the TILT> switch (SW1-6) up.

5. Use the momentary pushbuttons located to the left of the DIP switches to tilt the head to the desired limit of travel with the lens pointing downwards.

6. Slide the TILT> switch down and the limit position will be stored in non-volatile memory.


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Other Configuration SwitchesApart from the pan, tilt, zoom and focus clips already described, the HS-102P has two other configuration switches that are used to set the baud rate and the pan/tilt direction.

Baud RateSW1-2 sets the baud rate for the data communication. The rate is 2400 in the Down position and 19200 in the Up position. The position of the switch is read at power up. Therefore, set the switch with power off for the new setting to take effect when the head is powered up.

Pan/Tilt DirectionThe HS-102 can be mounted in a normal orientation (i.e. on a post or pedestal) or ceiling mounted with pan and tilt senses reversed.

SW4-1 sets the orientation - Down for normal mounting, Up for ceiling mount. The position of the switch is read at power up. Therefore, set the switch with power off for the new setting to take effect when the head is powered up.

Factory Test SwitchSW4-2 is used for factory test only. This switch must be in the Down (Off) posi-tion for normal operation.


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User Manual 4-1

4 Maintenance And Repair

HS-102P Maintenance And Repair

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IntroductionIn general, AutoCam is a highly reliable and stable product. Many of the mechanical components are sealed and permanently lubricated. The electronics are well ventilated and highly rated. The number of connectors is kept to a min-imum and the best quality connectors are utilized. All this adds up to a product that does not require much general routine maintenance.

Service PhilosophyServicing is supported at three levels by Vinten Inc. after the 12-month warranty period expires:

• On-site service may be contracted from Vinten Inc. or through the Sales Representative from which the system was purchased.

• Board-level replacement may be readily accomplished by station personnel, using stocked or ordered circuit boards.

• Component level replacement is feasible to some extent, by quali-fied station engineers or technicians, using the material in this chapter.

Service questions may be directed to factory service specialists at Vinten Inc. in Valley Cottage, NY, by phone at 1-845- 268-0100, or toll free (in the U.S.A.) at 1-888 4 VINTEN (1-888-484-6836). You can also fax Vinten at 1-845-268-0113. An emergency telephone service is available 24 hours a day, seven days a week using the 1-845-268-0100 or 1-888 4VINTEN numbers.

Avoid Damage From Static ElectricityTo avoid damaging your system with static electricity, make sure you are prop-erly grounded before touching any internal components. You can maintain grounding with a grounded wrist strap, or by periodically touching the bare metal of the chassis or the housing. Do not shuffle your feet on a carpet or any other surface that can produce an electric charge.


User Manual 4-3

Safety

WARNING! Service should only be performed by qualified personnel, who are familiar with the equipment. At some points inside the power supplies 120 (or 240) volts AC is exposed, with a danger of electrical shock.

WARNING! If you must work on a head that is powered up, place a large WARNING sign at the controller to alert other personnel that they should not attempt to use the system.

WARNING! Some tests are performed with the head pow-ered. There is always a danger that an unexpected motion could cause a head to strike or pinch you, causing physical injury. Always follow tagout procedures that meet local and

federal guidelines. Also, reread the Safety comments in Chapter 1 of this manual before working around a powered head.


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Routine MaintenanceAside from checking balance and overall operation periodically (once a week for example), the HS-102P pan/tilt head should require no other routine mainte-nance in the area of the motor drive and gear train.

Checking BalanceIt is recommended that you check the balance at least monthly to ensure proper operation and to reduce excessive wear on the drive train and potential overheat-ing. An unbalanced load may also affect servo operation and responsiveness. Unless the mounting screws are loose, the balance should only change if the camera is moved back and forth for some reason, or if the payload has been changed.

1. With no power applied to the head, support the camera and head in a hori-zontal position and feel if the payload is unbalanced (i.e. does it tend to tilt up or down when you let go).

2. If it is unbalanced, loosen the bolts that hold the camera to the cradle and carefully push the payload in the desired direction (forwards to counteract tilt up, or backwards to counteract tilt down). Retighten the mounting bolts and check again for proper balance. It is best to move the payload in small increments even though this may require several steps until the balance is achieved.

3. Once the back and forth balance is achieved, proceed with adjustment of vertical balance. Tilt the camera approximately 30 degrees upward and release it. If the camera stays in the same position when released, the pay-load is properly balanced.

4. However, if the camera continues to move upwards after you let go, the payload is mounted too high. On the other hand, if the camera moves back towards the horizontal position when you let go, the payload is mounted too low. Determine if you need to raise or lower the tilt cradle.

5. Mark the vertical position of the tilt cradle to make sure that you move it in the desired direction. Have two assistants support the cradle and payload as you use a 5/32” hex wrench to loosen the two screws that attach the cradle.

6. Raise or lower the cradle as necessary and tighten the screws securely.

NOTE: If you cannot access the cradle screws with the payload mounted, mark the position of the camera on the tilt cradle so it can be re-installed in the same position. Remove the camera from the tilt cradle and follow steps 5 and 6. Then mount the payload back onto the cradle.

7. Repeat step 3 to check the balance. Move the tilt cradle again if necessary until balance is achieved.


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Checking Overall OperationWhen you check the balance, it is a good idea to check the overall operation of the head. Use the controller to exercise pan, tilt, zoom and focus through their ranges. Make sure that the movement of the head is smooth and consistent.


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Theory Of OperationPower SupplyThe power to the head from the rack mount power supply is nominally +24 volts DC. The HS-102P head will operate satisfactorily over a fairly wide range of the “raw” DC power (18-36 V). The +5V, +15V and -15V supplies are all regulated internally from the input DC power.

The rack mount power supply is based on a Lambda 24V switching supply. If a problem is suspected, disconnect the head power/data cable and test the power supply using standard troubleshooting techniques.

Referring to the HS-102 CPU board schematic, the “raw” 24V enters the board via J5, is fused through 5A fuse F1 and then regulated by switching regulator U14 to generate the +5V for the digital circuitry. Linear regulator U15 regulates the 24V down to +15V for the analog circuitry. Switching regulator U13 gener-ates the -15V for the analog circuitry from the regulated 5V supply.

Data PathThe data bus is a 4-wire bi-directional 19200 baud RS-422 signal between the controller and the head via the power supply. Data is transmitted in data frames that are sent to and received from the head at 25ms intervals. Within each frame are command bytes for each servo axis. With RS-422 data, each side of the data line is the electrical mirror image of each other. Each should look like a TTL signal. A fault condition is indicated by identical signal phase on both lines, or one line stuck.

The HS-102P may be used with various Vinten controllers including the HCP-8000, LCP-8000, MCS-4000 and MultiController II. Depending on the control-ler used, the HS-102P baud rate is set with a DIP switch on the CPU board (SW-1, position 2). Using 19200 baud control with controllers that support the higher data rate results in more responsive operation.

Referring to the HS-102 CPU board schematic, the data bus enters the board via J5 and is coupled to the microprocessor U1 through the transceiver U2. The incoming data from the controller is connected to the data LED DS1 located on the connector panel. In normal operation, active data from the controller will cause the LED to twinkle. A steady on LED means that the controller is inactive (i.e. this head is not selected). A steady off LED means that there is a cable problem, or U2 has failed. Data from the microprocessor U1 is coupled through line driver U2 back to the controller.

Microprocessor U1 has a second data port that is coupled to U11, an RS232 transceiver IC. The RS232 bus is coupled through J3 to the Hi Density DSUB-26 connector on the housing. This RS-232 bus is used for optional CCU inter-faces and for the control of selected lenses that have built-in zoom and focus ser-vos that can be controlled serially.


User Manual 4-7

Command FunctionsFour command functions can be selected at the controller and used for special-ized control applications at the head such as lighting control, windshield wiper control for tower mounted cameras, or heater control etc. Three of the functions are on/off and the one is a momentary function.

The command functions from the controller are decoded in microprocessor U1 and coupled to an open collector driver U8. The four driver outputs are coupled off the board via connector J3 to the camera connector (Hi-density DSUB-26) on the housing. The command functions are found on pins 20, 21, 22, 23 of the camera connector.

For example, these command functions may be used to close 24V low current reed relays (or their equivalent) that are connected between these control pins and +24V on pin 14 of the 26 pin camera connector. A complete pin out list for this connector can be found in the Cable Interconnect Information section later in this chapter.

Initialization SensorsThe pan and tilt servos provide incremental control and therefore, at power up, the head must be initialized to a known repeatable starting point. Each axis has a shutter that is opaque for 180 degrees and transparent for 180 degrees. The shut-ter positions are detected by two optosensors whose outputs are connected to the microprocessor U1 via J1 and J4.

At power up, each optosensor detects either light (i.e. the shutter is transparent) or dark (the shutter is opaque). The state of each sensor determines which direc-tion the head must move in order to reach the start up initialization position - pointing straight ahead and level. Each axis moves in the appropriate direction until the transition from light to dark (or dark to light) is detected. The direction of movement is then reversed and the axis moves at slow speed until the transi-tion in the shutter is detected and motor power is turned off. When each sensor is at the transition edge of the shutter, the head is accurately located at the correct initialization point and is ready for normal operation.

Configuration SwitchesDIP switches SW1 and SW4 and momentary pushbuttons SW2 and SW3 pro-vide configuration and calibration control. Use of the switches is described in the installation section of Chapter 3.

ServosThe zoom and focus servos are analog while the pan and tilt servos are digital. Part of the servo circuitry for all four servos is located on the CPU board and the balance is located on the two identical Driver boards.

Zoom and Focus ServosThe zoom and focus servos are identical in operation. Referring to the CPU board schematic, microprocessor U1 decodes the zoom and focus demand posi-


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tions from the data bus and generates 16 bit servo demand signals that feed DA converter U4. The zoom and focus demand signals from U1 are in time multi-plexed format and the analog output of U4 is demultiplexed by U5 so that the focus and zoom demand voltages are sampled and held on C19 and C20 respec-tively. The demand signals are then buffered through U10 to feed the Driver boards. At this point, the demand signal ranges from -10V to +10V. The positive and negative reference voltages for the lens follow pots are also generated digi-tally by microprocessor U1, sampled and held on C17 and C18, buffered through U10 and coupled to the lens.

Referring to the Driver board schematic, the zoom/focus demand signal from the CPU board (between -10V and +10V) feeds U2 where the servo loop is closed by the feedback of the follow pot voltage and the motor tachometer signal through separate sections of U2. The tachometer feedback provides improved stabilization over the follow pot feedback alone. The lower section of U2 gener-ates a positional error voltage which couples through U5 to the motor power driver U6 and U7. The positive drive output from U6 passes through a self reset-ting polymer fuse F1. U5 provides a soft turn on at power up to prevent the zoom and focus motors from driving into the end stops.

The gain and damping characteristics of the analog servos are determined by fixed resistors R1 (gain) and R15 (damping) on the Driver boards. The factory values have been selected for optimum performance and should not be changed without consulting Vinten Inc.

Pan and Tilt ServosThe pan and tilt servos are identical in operation. Referring to the CPU board schematic, microprocessor U1 decodes the pan and tilt demand positions from the data bus and generates 16 bit servo demand signals that feed the digital servo controller U6 and U7. The servo loop is closed on the CPU board by feeding back the outputs of the quadrature encoders on the motors to U6. U6 compares the position demand signal to the encoder signals and generates a servo demand signal proportional to the required torque in the motor. The servo attempts to produce a motor velocity which is proportional to the position error. The actual motor velocity is subtracted from the position error to derive the velocity error. The servo controls the motor current to reduce the velocity error to zero by gen-erating the desired current (or torque) in the motor. U16 converts the parallel digital demand signal to a serial signal which is converted to separate analog pan and tilt demand signals by the DA converter U17. The outputs of U9 are bipolar demand signals from -12V to +12V which are coupled to the respective Driver boards.

U12 provides a power on reset for the microprocessor and for the digital servo control ICs. Crystal Y1 generates the clock signal for the microprocessor while crystal Y2 generates the clock signal for the digital servo.

Referring to the Driver board schematic, the circuit consisting of U2 and the four elements of U1 convert the bipolar demand signal into a Forward/Reverse signal at pin 3 of U3 and a unipolar demand signal from +1.5V to +4.1V at pin


User Manual 4-9

11 of U3. U3 is a pulse width modulator that generates the three phase drive sig-nals for the motor. U4 is the power driver that drives the motor. Resistor R10 acts as a current limiter to prevent excess current in the motor windings.


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Electrical RepairSurface Mount ComponentsReplacement of surface mount components should only be undertaken by trained individuals using tools specifically intended for these components. At a minimum you will need a clean, well lit work area, an illuminated magnifier, a fine soldering iron and fine, non-corrosive solder (.010” or.015” diameter). Using the wrong tools or incorrect techniques can cause problems rather than solve them. If in doubt, contact Vinten to arrange a board replacement.

Troubleshooting GuidelinesThe two driver boards in the HS-102P are identical. Therefore, if a problem occurs in just the pan or tilt axis, you can swap the driver boards to see if the problem moves to the other axis. If it does, the fault is in the driver board. Other-wise, the fault must be in the CPU board, the cabling, or one of the motor assem-blies.


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Mechanical RepairThe pan and tilt drive trains in the HS-102P head require no routine mainte-nance. However, over extended periods of operation, it is possible for one or more of the drive belts to stretch slightly. If this happens, you may see excessive backlash and/or sloppy operation. For example, the shot positioning may not be repeatable when a given shot is approached from each side. A tight belt on the other hand will probably result in jerky motion and/or excessive belt noise. In either case, check the belt tensions as described later in this chapter.

In the unlikely event of mechanical problems in the HS-102P, it is generally rec-ommended that the head be returned to the factory if possible. However, if this is not possible, the following disassembly and reassembly procedures can be used to repair the head in the field.


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HS-102P Disassembly/ReassemblyThe HS-102 is a very compact design and therefore, it is very important that the disassembly and reassembly steps be followed exactly. Otherwise, cables may be in the wrong position causing mechanical interference, premature wear, cable failure etc. If you do not have the correct tools, or if you have any doubts about having the time or the ability to undertake the following procedures, contact Vinten for assistance.

There are several potential reasons (including those listed below) for needing to disassemble the head - some more likely than others.

Software UpdateThe software resides in U1 on the CPU Board. To update the software the CPU Board must be removed from the head before the IC can be replaced.

Board Troubleshooting And ReplacementThe two driver boards are electrically identical. Therefore, if a problem is sus-pected in one board, the drivers can be exchanged to see if the problem follows the board.

Belt Replacement And/Or AdjustmentThe drive belts are extremely durable and a broken belt is unlikely. However, over extended periods of operation, it is possible for one or more of the drive belts to stretch slightly. If this happens, you may see excessive backlash and/or sloppy operation. For example, the shot positioning may not be repeatable when a given shot is approached from each side. A tight belt (which will probably result in jerky motion and/or excessive belt noise) is unlikely unless someone has inadvertently misadjusted the tension.

To adjust the pan belts, the three boards and the harness must be removed. To adjust the tilt belts, the pan motor must also be removed. To replace a belt, you must also remove the associated tensioner assembly.

Motor ReplacementThe brushless DC motors used in the HS-102P are extremely reliable and should not need to replaced in normal operation. The encoders (which are part of the motor assembly) are also very reliable, but if one should fail, the motor assem-bly must be replaced. Note that if a motor/encoder needs to be removed, it should be handled with care. Any sharp impact could fracture the glass encoder.

Optosensor ReplacementThe tilt and pan optosensors control the initial indexing of the head at power up. The tilt optosensor can be accessed after the three boards have been removed. However, to access the pan optosensor, the tilt drive components (tensioner assembly and anti backlash gear) must be removed.


User Manual 4-13

Anti Backlash Gear AdjustmentIt is very unlikely that the anti backlash gear will need adjustment or replace-ment. Even though the calibration steps are described in this manual, it is recom-mended that the head be returned to the factory if a problem is suspected in this area. You can do a simple test of the anti backlash gear operation without having to disassemble the head (page 28 and page 36).

Tools RequiredDifferent combinations of the following tools are required depending on the extent of the disassembly you need to do.

• A set of right angle hex keys including 3/32”, 7/64”, 9/64”, 5/32”, 5/64” - Note: For procedures that require the loosening of the pan motor drive belt tensioner, you may need a ball head 7/64” hex key if the right hand screw is partially obstructed by the tilt motor

• “Stubby” right angle 7/64” hex key (for removing the pan optosensor)

• Medium flat blade screwdriver

• Small flat blade screwdriver

• Small Phillips screwdriver

• 1/4” open end or box wrench

• Long tweezers (may be useful)

• E-clip pliers

• Pencil type tension gauge (0-10 Lb. range) to check belt tensions (Vinten part number 070104)

• PLCC IC extractor (Vinten part number 070111)

• HS-102 Belt Installation Tool (Vinten part number B0854AXA)

• HS-102 Anti Backlash Tensioning Tool (Vinten part number B0855AXA)


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Preliminary Steps1. Disconnect all cables from the HS-102. Mark the position of the camera on

the tilt cradle and remove the camera from the cradle.

2. Unless it is impossible, the HS-102 should be removed from its mount for disassembly on a workbench.

3. It is easier to work on the head if the tilt cradle is removed. Mark the posi-tion of the tilt cradle on the tilt hub. Use a 5/32” hex key to remove the two cradle mounting screws and spacers. Remove the cradle from the head.

4. Use a 7/64” hex key to remove the eight screws in the cover - see opposite. Set the cover and screws aside.

For the following steps, it is assumed that you have the HS-102 resting on a workbench with the tilt hub resting on the bench and the pan hub pointing

Tilt Cradle ScrewsAnd Spacers


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towards to you. All references in the text to left/right top/bottom etc. assume this orientation.

8 Cover Screws


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Software UpgradeU1 on the CPU Board will be replaced whenever there is a software upgrade. Although U1 is accessible without removing the CPU Board, attempting to replace the IC while the board is mounted in the housing places excessive strain on the board and circuit traces, resulting in circuit failure or intermittent prob-lems. Therefore, you should remove the CPU Board as described on page 18.

Preliminary Steps1. Remove the CPU Board as described on page 18.

Replacing U11. Observe the CPU Board and note that with the connectors on the left as

shown below, the upper left corner of U1 and its socket are keyed - the cor-ner is “clipped” on a diagonal.

2. Insert the tabs of the IC extractor tool into the upper right and lower left corners if the U1 IC socket. You will feel the tabs snap into place under the corners of the IC.

3. Lay the board on a resilient surface (for example a mousepad or something similar) and press down around the U1 socket to prevent the board from bending as you extract the IC. Press down on the tool and squeeze on the handle until you feel a “click” as the IC pops out of its socket.

4. Orient the replacement U1 so that the “clipped” corner is aligned with the upper left corner of the socket. Position your fingers on the back of the board behind the IC socket to prevent the board from flexing. Press down firmly on the IC with your thumbs to seat it firmly in the socket.

This CornerIs Keyed


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Reassembly1. Install the CPU Board as described on page 58.

2. Finish up as described on page 60.


4-18 User Manual

Removing The Circuit BoardsThere are three boards in the HS-102P head - the CPU board and two driver boards (one for Tilt/Focus and one for Pan/Zoom). The CPU board can be removed by itself for software updates or board replacement. The two driver boards and mounting bracket can then be removed as a single unit.

Removing The CPU Board1. It is recommended that you label each cable before removing it to simplify

the re-assembly. Disconnect the cables from J7, J6, J5, J4, J3, J2, J1 and DS1.

J6

J5

J3

J7

J4

J2

J1

DS1


User Manual 4-19

2. Use a 3/32” hex key to remove the four screws that attach the CPU Board.

3. Carefully lift the CPU board out of the head.

CPU BoardMounting Screws


4-20 User Manual

Removing The Driver Board Set1. Use a 3/32” hex key to remove the six screws that attach the board set to the

housing.

2. Carefully pull the board set out of the head until you can reach the connec-tors on the upper (Tilt/Focus) driver board.

3. Label and remove the cables from J1, J2 and J3 on the upper driver board.

4. Pull the board set a little further out of the head.

5. Label and remove the cables from J1, J2 and J3 on the lower (Pan/Zoom) driver board. Note that the Y cable assembly from the J3 connectors on the driver boards can be removed and set aside.

6. If you need to remove the individual driver boards, use a small Phillips screwdriver to remove the two screws that attach each board to the mount-ing plate.

Mounting Screws

J1

J3

J2


User Manual 4-21

Removing The Connector Plate And HarnessThe connector plate and harness must be removed (or at least unscrewed and repositioned) in order to adjust the tilt belt tensions, replace the tilt motor assem-bly, or perform other “low level” repairs.

1. Use a 5/64” hex key to remove the four screws that attach the connector plate to the housing.

2. Carefully remove the plate and slide the harness out of the housing.

Mounting ScrewsConnector Plate


4-22 User Manual

Removing The Pan MotorNote that when the motor/encoder needs to be removed, it should be handled with care. Any sharp impact could fracture the glass encoder.

The pan and tilt motor assemblies are similar but not interchangeable - the two motor and encoder mountings are mirror images of each other. Each assembly consists of the motor, encoder, flywheel, pulley and mounting block. In the event of a motor or encoder failure, the entire motor assembly must be replaced.

The pan motor can be removed without removing the boards. However, in this procedure (and the illustrations), the three boards and the cable harness are removed to simplify subsequent disassembly steps.

1. Remove the board set (page 20) and cable harness (page 21).

2. Use a 7/64” hex key to loosen the tensioner locking screws and slide the tensioner to the right. The motor belt is now loose. Note: you may need a ball head hex key for the right-hand screw if it is partially obstructed by the tilt motor assembly.

ScrewsPan Tensioner


User Manual 4-23

3. Hold the pan motor in place while using a 7/64” hex key to remove the pan motor mounting screws in the bottom of the housing.

4. Lift the pan motor out of the housing being careful to lift the belt off the motor pulley. Use tweezers or a small screwdriver if necessary, but make sure that you do not nick or damage the belt.

Mounting ScrewsPan Motor


4-24 User Manual

Removing The Tilt MotorNote that when the motor/encoder needs to be removed, it should be handled with care. Any sharp impact could fracture the glass encoder.

The pan and tilt motor assemblies are similar but not interchangeable - the two motor and encoder mountings are mirror images of each other. Each assembly consists of the motor, encoder, flywheel, pulley and mounting block. In the event of a motor or encoder failure, the entire motor assembly must be replaced.

This procedure assumes that the following components have already been removed: Tilt/Focus Driver Board (page 20), Pan/Zoom Driver Board (page 20), CPU Board (page 18), connector plate and harness (page 21). The pan motor does not have to be removed if the tilt motor is the only component you are replacing. However, see page 22 if you need to remove the pan motor.

1. Use a 7/64” hex key to loosen the tensioner locking screws for the motor belt and slide the tensioner towards the top of the housing. The motor belt is now loose. Re-tighten one of the locking screws to hold the tensioner in this position.

ScrewsTilt Tensioner


User Manual 4-25

2. Hold the tilt motor in place while using a 7/64” hex key to remove the tilt motor mounting screws in the tilt cradle side of the housing.

3. Lift the tilt motor out of the housing being careful to lift the belt off the motor pulley. If necessary, use tweezers or a small screwdriver to ease the belt off the pulley, but make sure that you do not nick the belt.

Mounting ScrewsTilt Motor


4-26 User Manual

Removing The Tilt Tensioner And Tilt BeltsIf you need to replace one of the tilt belts, adjust the anti-backlash gear, or replace a component in the tilt drive train assembly, the tilt tensioner must be removed from the housing. In addition, the tilt tensioner and tilt anti-backlash gear must be removed to access the pan tensioner, pan belts and pan anti-back-lash gear.

This procedure assumes that the following components have already been removed: Tilt/Focus Driver Board (page 20), Pan/Zoom Driver Board (page 20), CPU Board (page 18), connector plate and harness (page 21), pan motor (page 22), tilt motor (page 24).

1. Use a 9/64” hex key to loosen the two screws in the drive belt tensioner. Back off the tensioner to the end of its travel. Temporarily tighten one of the tensioner screws to make sure that the tensioner does not move.

2. Use a 7/64” hex key to remove the tilt optosensor assembly and cable.

ScrewsTilt Tensioner

Tilt OptosensorAssembly


User Manual 4-27

3. Locate the three screws in the tilt cradle side of the housing that attach the mounting posts of the tilt tensioner assembly. Use a 7/64” hex key to loosen each screw 2 or 3 turns.

The mounting posts are designed to be a tight fit in the recessed holes in the housing. As you ease the three posts out of the mounting holes take care to do it evenly so that the assembly is not distorted.

4. Push firmly on the hex key to ease a post out of its hole (or use a small hammer to tap gently on the hex key). Repeat this with the other two mounting posts.

5. Loosen each screw 2 or 3 more turns and repeat step 4 until all three posts are clear of their mounting holes.

When you remove the tensioner in the next step, be careful not to lose the small spacer between the anti backlash gear and the bearing in the tensioner assembly. This bearing may stay in its mount in the tensioner assembly, or may stay on the shaft of the anti backlash gear. If the bearing stays on the shaft, make sure that you do not lose the four beveled washers between the bearing and the bearing mount in the tensioner assembly.

6. Remove the screws and lift the tensioner assembly out of the housing.

7. Remove the tilt motor belt and the tilt drive belt. If you only need to replace one or both of the tilt belts, continue on page 46.

Tilt TensionerMounting Screws


4-28 User Manual

The Tilt Anti-Backlash GearIt is very unlikely that the anti-backlash gear will need to be adjusted. Unless a spring breaks, or you need to replace a part in the assembly, the anti-backlash gear should be left as shipped from the factory. If possible, return the head to the factory for repairs in this area.

The anti-backlash gear assembly uses a split gear arrangement where the two halves are forced to shift relative to each other by spring tension. The split gear mates with the final ring gear in the drive train and the spring loading forces the mating tooth space to be filled. When adjusted correctly, this arrangement elim-inates fixed backlash and backlash that varies with rotation. Changes due to wear and temperature are also eliminated. The net result is very accurate posi-tioning with or without direction reversal, and smooth overall operation with minimum vibration.

Checking The Anti Backlash GearThe proper operation of the anti backlash gear can be checked without disassem-bling the head (if the head can be powered). This test is not quantitative, but does give you an idea if further testing and disassembly is needed. This test can be performed with the head mounted in its normal location. Even on the bench, it is easier if the tilt cradle is attached for this test. It may also help to perform this test on more than one head to compare the head under test with a known good head and get a feel for normal operation.

Powered HeadIf you can apply power to the head, the servos will lock the head on both the tilt and pan axes and therefore, no disassembly is required for the test.

1. Apply pressure with a finger on the tilt cradle, first in one direction and then the other direction. If there is play (backlash) in both directions, it indicates a potential problem with the anti backlash gear (a broken spring for example).

2. In a head that is operating normally, you will feel the resistance of the servo in one direction, while in the other direction you will feel the resistance of the anti backlash assembly until the gear “unloads” (with about 1/32” of play) when your finger pressure overcomes the spring tension of the anti backlash gear.

Non Powered HeadIf the head cannot be powered, you will have to lock the tilt drive train manually. The three boards must be removed for this test.

1. Stall the first reduction stage of the tilt drive train (the large gear with six holes in it) by putting a finger through one of the holes.

2. Apply pressure with a finger on the tilt cradle, first in one direction and then the other direction. You will feel the corresponding torque on the stalled gear with your other hand. If there is play (backlash) in both direc-


User Manual 4-29

tions, it indicates a potential problem with the anti backlash gear (a broken spring for example).

3. In a head that is operating normally, you will feel the resistance of the stalled gear in one direction, while in the other direction you will feel the resistance of the anti backlash assembly until the gear “unloads” (with about 1/32” of play) when your finger pressure overcomes the spring ten-sion of the anti backlash gear.


4-30 User Manual

Adjusting The Tilt Anti Backlash Gear AssemblyThis procedure assumes that the following components have already been removed: Tilt/Focus Driver Board (page 20), Pan/Zoom Driver Board (page 20), CPU Board (page 18), connector plate and harness (page 21), pan motor (page 22), tilt motor (page 24) tilt tensioner (page 26).

1. Use a 7/64” hex key to loosen the 6-32 x .500 socket head cap screw in the locking collar allowing the tension to be released from the springs. Make sure that the springs do not come off the posts.

2. Slide the anti backlash tensioning tool through the connector plate opening and position it on the anti backlash gear so that the pins of the tool are on the counter-clockwise side of the spring posts. The arm of the tool should

Locking Screw

Tensioning SpringsTilt Anti Backlash


User Manual 4-31

be resting on the pan tensioner assembly as shown below so that the tool does not move when you tension the springs.

3. Rotate the anti backlash gear counter-clockwise to take up any slack in the tensioning springs without stretching them. Observe the position of the arm of the tool relative to the teeth of the anti backlash gear. Insert a 7/64” hex key in the locking screw, ready to clamp the locking collar.

4. Rotate the anti backlash gear counter-clockwise by six teeth relative to the arm of the tool. This applies the correct tension to the springs. Hold the gear in place and tighten the locking screw. Remove the tensioning tool.

Anti BacklashTensioning Tool

Locking Screw

Rotate GearThis Direction


4-32 User Manual

Removing The Tilt Anti Backlash Gear Assembly1. Use E-clip pliers to remove the E-clip and then remove the large spacer and

wavy washer from the idler shaft.

2. Pull the idler pulley off the shaft.


4. Remove the tilt anti backlash gear assembly from the housing.

Be careful not to lose the small spacer on the bottom end of the anti backlash shaft (between the split gear and the lower bearing in the housing).

Locking Screw

Tilt Idler

Gear AssemblyTilt Anti Backlash

SpacerWavy Washer

E-Clip


User Manual 4-33



4-34 User Manual

Removing The Pan Tensioner And Pan BeltsIf you need to replace one of the pan belts, adjust the pan anti backlash gear, or replace a component in the pan drive train assembly, the pan tensioner must be removed from the housing.

This procedure assumes that the following components have already been removed: Tilt/Focus Driver Board (page 20), Pan/Zoom Driver Board (page 20), CPU Board (page 18), connector plate and harness (page 21), pan motor (page 22), tilt motor (page 24) tilt tensioner (page 26), tilt anti backlash gear and idler (page 32).

1. Use a 7/64” hex key to remove the pan optosensor assembly.

2. Use a 1/4” open end or box wrench to loosen the pan drive belt tensioner. Slide the tensioner all the way to the left to loosen the belt. Temporarily tighten one of the tensioner screws to make sure that the tensioner does not slide back.

Pan OptosensorAssembly

Pan BeltTensioner Screws


User Manual 4-35

3. Locate the three screws in the bottom of the housing that attach the mount-ing posts of the pan tensioner assembly. Use a 7/64” hex key to loosen each screw 2 or 3 turns.

The mounting posts are designed to be a tight fit in the recessed holes in the housing. As you ease the three posts out of the mounting holes take care to do it evenly so that the assembly is not distorted.

4. Push firmly on the hex key to ease a post out of its hole (or use a small hammer to tap gently on the hex key). Repeat this with the other two mounting posts.

5. Loosen each screw 2 or 3 more turns and repeat step 4 until all three posts are clear of their mounting holes.

When you remove the tensioner in the next step, be careful not to lose the small spacer between the anti backlash gear and the bearing in the tensioner assembly. This bearing may stay in its mount in the tensioner assembly, or may stay on the shaft of the anti backlash gear. If the bearing stays on the shaft, make sure that you do not lose the four beveled washers between the bearing and the bearing mount in the tensioner assembly.

6. Remove the screws and lift the tensioner assembly out of the housing.

7. Remove the pan motor belt and the pan drive belt. If you only need to replace one or both of the pan belts, continue on page 42.

Pan TensionerMounting Screws


4-36 User Manual

The Pan Anti-Backlash GearIt is very unlikely that the anti-backlash gear will need to be adjusted. Unless a spring breaks, or you need to replace a part in the assembly, the anti-backlash gear should be left as shipped from the factory. If possible, return the head to the factory for repairs in this area.

The anti-backlash gear assembly uses a split gear arrangement where the two halves are forced to shift relative to each other by spring tension. The split gear mates with the final ring gear in the drive train and the spring loading forces the mating tooth space to be filled. When adjusted correctly, this arrangement elim-inates fixed backlash and backlash that varies with rotation. Changes due to wear and temperature are also eliminated. The net result is very accurate posi-tioning with or without direction reversal, and smooth overall operation with minimum vibration.

Checking The Anti Backlash GearThe proper operation of the anti backlash gear can be checked without disassem-bling the head (if the head can be powered). This test is not quantitative, but does give you an idea if further testing and disassembly is needed. This test can be performed with the head mounted in its normal location, or mounted to a post on the work bench. It may also help to perform this test on more than one head to compare the head under test with a known good head and get a feel for normal operation.

Powered HeadIf you can apply power to the head, the servos will lock the head on both the tilt and pan axes and therefore, no disassembly is required for the test.

1. Apply pressure with a finger to the housing (in the pan axis), first in one direction and then the other direction. If there is play (backlash) in both directions, it indicates a potential problem with the anti backlash gear (a broken spring for example).

2. In a head that is operating normally, you will feel the resistance of the servo in one direction, while in the other direction you will feel the resis-tance of the anti backlash assembly until the gear “unloads” (with about 1/32” of play) when your finger pressure overcomes the spring tension of the anti backlash gear.

Non Powered HeadIf the head cannot be powered, you will have to lock the pan drive train manu-ally. It is easier (although not essential) if the three boards are removed for this test.

1. Stall the first reduction stage of the pan drive train (the large gear with six holes in it) by putting a finger through one of the holes.

2. Apply pressure with a finger on the housing (in the pan axis), first in one direction and then the other direction. You will feel the corresponding


User Manual 4-37

torque on the stalled gear with your other hand. If there is play (backlash) in both directions, it indicates a potential problem with the anti backlash gear (a broken spring for example).

3. In a head that is operating normally, you will feel the resistance of the stalled gear in one direction, while in the other direction you will feel the resistance of the anti backlash assembly until the gear “unloads” (with about 1/32” of play) when your finger pressure overcomes the spring ten-sion of the anti backlash gear.


4-38 User Manual

Adjusting The Pan Anti Backlash Gear AssemblyTo make an adjustment to the pan anti-backlash gear, the head must be disas-sembled to remove the pan belt tensioner assembly - see page 34.

1. Use a 7/64” hex key to loosen the 6-32 x .500 socket head cap screw in the locking collar allowing the tension to be released from the springs.

2. Position the anti backlash tensioning tool on the anti backlash gear so that the pins of the tool are on the counter-clockwise side of the spring posts. The arm of the tool should be as far to the right as possible so that the stop screw in the arm is resting against the pan idler gear as shown below. This ensures that the tool does not move when you tension the springs.

3. Rotate the anti backlash gear counter-clockwise to take up any slack in the tensioning springs without stretching them. Observe the position of the arm of the tool relative to the teeth of the anti backlash gear. Insert a 7/64” hex key in the locking screw, ready to clamp the locking collar.

4. Rotate the anti backlash gear counter-clockwise by six teeth relative to the arm of the tool. This applies the correct tension to the springs. Hold the gear in place and tighten the locking screw.

Anti BacklashTensioning Tool

Rotate GearThis Direction

Locking Screw


User Manual 4-39

Removing The Pan Anti Backlash Gear Assembly1. Use E-clip pliers to remove the E-clip and then remove the large spacer and

wavy washer from the idler shaft.

2. Pull the idler pulley off the shaft.


4. Remove the pan anti backlash gear assembly from the housing.

Be careful not to lose the small spacer on the bottom end of the anti backlash shaft (between the split gear and the lower bearing in the housing).

Locking Screw

Pan Idler

Gear AssemblyPan Anti Backlash

SpacerWavy Washer

E-Clip


4-40 User Manual

Installing The Pan Anti Backlash Gear Assembly1. Place the small spacer on the lower end of the anti backlash shaft below the

split gear and insert the shaft into the bearing in the housing. Mesh the teeth of the split anti backlash gear with the teeth of the main drive gear as you fully seat the shaft in the bearing.

2. Install the idler pulley onto its shaft.

3. Secure the idler with the wavy washer, spacer and E-clip.

4. Adjust the pan anti backlash tension as described on page 38.

Small Spacer

Pan IdlerGear AssemblyPan Anti Backlash

SpacerWavy Washer

E-Clip

Split Gear


User Manual 4-41



4-42 User Manual

Installing The Pan Belts And Pan Tensioner1. Install the pan drive belt (the wider of the two belts) around the pan anti

backlash gear and the lower section of the idler.

2. Install the pan motor belt (the narrower of the two belts) around the upper section of the idler.

3. Install the spacer on the anti backlash shaft above the clamp.

4. Hold the bearing and beveled washers in place in the Pan Tensioner as you install it in the housing so that the anti backlash shaft slides into the bear-ing. If you have to reinsert the four beveled washers, make sure that they are oriented correctly - with alternating curvature as shown below.

5. Install tensioner assembly, holding the bearing in place until it is properly seated on the anti backlash shaft. At the same time, align the three mount-ing posts with the mounting holes in the housing. Make sure that the loop of the motor belt is to the right of the anti backlash shaft and does not get trapped between the tensioner and the anti backlash clamp. The belt must be inside the three posts.

6. Press down firmly to seat the tensioner assembly as far as you can.

7. Center the three mounting posts on their holes in the housing and install the three screws (6-32 x .500 socket head cap screw). Tighten each screw a couple of turns by hand. Be very careful that you do not cross thread the screws.

8. When you tighten the three screws you will pull each post into its recess in the housing. Therefore it is important that you tighten the three screws evenly, for example one or two turns at a time to prevent distortion. Use a

Washer #1Washer #2

Washer #3Washer #4

BearingBearing

Spacer

Anti Backlash Gear Clamp

Housing


User Manual 4-43

7/64” hex key to tighten all three posts completely while making sure that the pan motor belt does not get trapped between the tensioner and the idler.

9. Install the pan optosensor assembly on the pan tensioner and attach it with a 6-32 x .250 socket head cap screw.

Pan OptosensorAssembly


4-44 User Manual

Installing The Tilt Anti Backlash Gear Assembly1. Place the small spacer on the lower end of the anti backlash shaft below the

split gear and insert the shaft into the bearing in the housing. Mesh the teeth of the split anti backlash gear with the teeth of the main drive gear as you fully seat the shaft in the bearing.

2. Install the idler pulley onto its shaft.

3. Secure the idler with the wavy washer, large spacer and E-clip.

4. Adjust the tilt anti backlash tension as described on page 30.

Small Spacer

Tilt Idler

Gear AssemblyTilt Anti Backlash

SpacerWavy Washer

E-Clip

BelowSplit Gear


User Manual 4-45



4-46 User Manual

Installing The Tilt Belts And Tilt Tensioner1. Install the tilt drive belt (the wider of the two belts) around the lower sec-

tion of the idler and the tilt anti backlash gear.

2. Install the tilt motor belt (the narrower of the two belts) around the upper section of the idler.

3. Install the spacer on the anti backlash shaft above the clamp.

4. Hold the bearing and beveled washers in place in the Tilt Tensioner as you install it in the housing so that the anti backlash shaft slides into the bear-ing. If you have to reinsert the four beveled washers, make sure that they are oriented correctly - with alternating curvature as shown below.

5. Install the tensioner assembly, holding the bearing in place until it is prop-erly seated on the anti backlash shaft. At the same time, align the three mounting posts with the mounting holes in the housing. Make sure that the loop of the motor belt is to the right of the anti backlash shaft and inside the three posts.

6. Make sure that the motor belt is not trapped between the tensioner assem-bly and the anti backlash clamp or the idler. Press down firmly to seat the tensioner assembly as far as you can.

7. Center the three mounting posts on their holes in the housing and install the three screws (6-32 x .500 socket head cap screw). Tighten each screw a couple of turns by hand. Be very careful that you do not cross thread the screws.

8. When you tighten the three screws you will pull each post into its recess in the housing. Therefore it is important that you tighten the three screws

Washer #1Washer #2

Washer #3Washer #4

BearingBearing

Spacer

Anti Backlash Gear Clamp

Housing


User Manual 4-47

evenly, for example one or two turns at a time to prevent distortion. Use a 7/64” hex key to tighten all three posts completely.

9. Install the tilt optosensor assembly on the tilt tensioner and attach it with a 6-32 x .250 socket head cap screw.

Tilt OptosensorAssembly


4-48 User Manual

Installing The Tilt MotorNote that when you are installing the motor/encoder, it should be handled with care. Any sharp impact could fracture the glass encoder.

1. Make sure that the tilt motor drive belt is roughly centered on the large pul-ley and properly seated. The tensioner should be backed off to leave the open belt loop to the right - in the space where the tilt motor will be installed.

2. Slide the Belt Installation Tool (see page 13 for the part number) through the connector plate opening, below the tilt tensioner assembly. Slide the belt loop over the tool as shown below and hold the belt loop in place.

3. Slide the tilt motor down into position in the housing until the motor pulley is seated in the Belt Installation Tool.

4. Use tweezers or a small screwdriver to slide the belt off the tool onto the motor pulley as you remove the tool.

5. Move the motor in its final position.

6. Make sure that the belt is on the motor pulley and roughly centered on the idler and attach the motor with two screws (6-32 x .500 socket head cap

Tilt MotorBelt Loop

Belt InstallationTool


User Manual 4-49

screw) through the tilt cradle side of the housing. Use a 7/64” hex key to tighten the screws.

7. Slide the tensioner down to put a little tension on the belt and use a 7/64” hex key to temporarily tighten one of the tensioner screws. Rotate the idler pulley by hand through a couple of revolutions to make sure that the belt is correctly installed.

Note: If you do not have the Belt Installation Tool, loop the belt around the motor pulley and then turn the idler gear to align the belt. Then secure the ten-sioner.

8. Check the tensions of the tilt belt as described on page 50.

Mounting ScrewsTilt Motor


4-50 User Manual

Tilt Drive BeltsThere are two belts in the tilt drive train. The first stage belt from the motor to the idler (the tilt motor belt) is the narrower of the two belts - and the second stage belt from the idler to the anti backlash gear (the drive belt) is the wider of the two.

Checking Belt TensionThe belts in the HS-102P are extremely durable in normal operation if the belt tensions as set in the factory are maintained. In general, unless you specifically replace a belt, remove a motor or loosen a belt tension for some other reason, there is no routine reason to check belt tensions. However, if you notice an increase in belt noise, or if the positioning gets sloppy and non-repeatable, you should check the belt tensions.

It is essential that the tensions be set using a tension gauge (see page 13 for the part number). Trying to set the tensions by sight and feel is not satisfactory and will compromise the performance of the system.

The three boards, the pan motor and the cable harness must be removed to set the tilt belt tensions.

Tilt Motor Belt1. Use a 7/64” hex key to loosen the two tensioner screws and push the ten-

sioner downwards to apply tension to the belt.

2. Place the tip of the tension gauge on the lower tensioner screw as shown below. Apply 2.5 lb. of force with the tension gauge by pushing in the direction shown (roughly in line with the slot in the tensioner assembly). Tighten the upper screw while the tension is applied.

ScrewsTensioner

Apply Force InThis Direction


User Manual 4-51

3. Tighten the lower screw.

Note: The 2.5 Lb. of force is applied to the tensioner at an angle because the housing prevents you from applying the force directly in line with the locking screw. This results in a tension of approximately 1.0-1.5 Lb. of tension on the belt itself. At this relatively low tension, the motor belt can be deflected from side to side with light pressure applied close to the motor - this is normal.

Tilt Drive Belt1. Use a 9/64” hex key to loosen the two tensioner screws and push the ten-

sioner upwards to apply tension to the belt.

2. Place the tip of the tension gauge on the lower tensioner screw as shown below. Apply 6 lb. of force with the tension gauge by pushing in the direc-tion shown (roughly in line with the slot in the tensioner assembly). Tighten the upper screw while the tension is applied

3. Tighten the lower screw.

Note: The 6 Lb. of force is applied to the tensioner at an angle because the hous-ing prevents you from applying the force directly in line with the locking screw. This results in a tension of approximately 4.0-5.0 Lb. of tension on the belt itself.

ScrewsTensioner



4-52 User Manual

Installing The Pan MotorNote that when you are installing the motor/encoder, it should be handled with care. Any sharp impact could fracture the glass encoder.

1. Make sure that the pan motor drive belt is roughly centered on the large pulley and that the belt teeth are properly seated. The tensioner should be backed off to leave the open belt loop to the left - in the space where the pan motor will be installed.

2. Slide the pan motor down into position while hooking the belt over the motor pulley. Use your little finger though one of the large holes in the motor mounting block to hook the belt onto the motor pulley. It may help if you rotate the motor slightly from its mount position until the belt is on the pulley.

3. Position the motor in its final position.

Belt Loop ForMotor Pulley

InstallPan Motor


User Manual 4-53

4. Attach the motor with two screws (6-32 x .500 socket head cap screw) through the bottom of the housing. Use a 7/64” hex key to tighten the screws.

5. Make sure that the belt is on the motor pulley and roughly centered on the large pulley, slide the tensioner to the left to apply tension to the belt. While applying tension to the belt, rotate the large pulley by hand to make sure that the belt is seated properly.

Mounting ScrewsPan Motor


4-54 User Manual

Pan Drive BeltsThere are two belts in the pan drive train. The first stage belt from the motor to the idler (the pan motor belt) is the narrower of the two belts - and the second stage belt from the idler to the anti backlash gear (the drive belt) is the wider of the two.

Checking Belt TensionThe belts in the HS-102P are extremely durable in normal operation if the belt tensions as set in the factory are maintained. In general, unless you specifically replace a belt, remove a motor or loosen a belt tension for some other reason, there is no routine reason to check belt tensions. However, if you notice an increase in belt noise, or if the positioning gets sloppy and non-repeatable, you should check the belt tensions.

It is essential that the tensions be set using a tension gauge (see page 13 for the part number). Trying to set the tensions by sight and feel is not satisfactory and will compromise the performance of the system.

The three boards and the cable harness must be removed to set the pan belt ten-sions.

Pan Motor Belt1. Use a 7/64” hex key to loosen the two tensioner screws and push the ten-

sioner to the left to apply tension to the belt.

2. Place the tip of the tension gauge on the left hand tensioner screw as shown below. Apply 1.5 lb. of force with the tension gauge by pushing in the direction shown (roughly in line with the slot in the tensioner assembly). Tighten the right hand screw while the tension is applied.

3. Tighten the left hand screw.

ScrewsTensioner



User Manual 4-55

Note: At this relatively low tension (1.5 lb.), the motor belt can be deflected from side to side with light pressure applied close to the motor - this is normal.

Pan Drive Belt1. Use a 1/4” open end or box wrench to loosen two tensioner screws and

push the tensioner to the right to apply tension to the belt.

2. Place the tip of the tension gauge through the connector plate opening onto the left hand tensioner screw as shown below (the pan motor and tilt assem-bly have been removed for clarity). Apply 4 lb. of force with the tension gauge by pushing in the direction shown (roughly in line with the slot in the tensioner assembly). Tighten the right hand screw while the tension is applied.

3. Tighten the left hand screw.

ScrewsTensioner



4-56 User Manual

Installing The Connector Plate & Harness1. Feed the cables through the mounting hole in the housing. Route the CPU

J7 cable (two wires - red and black) and the two cables that connect to J2 on each driver board into the open space above the pan motor. Route the other cables that connect to the CPU board to the left of the pan motor.

2. Hold the connector plate in place and attach with the four socket head screws removed earlier. Use a 5/64” hex key to tighten the screws.

Mounting ScrewsConnector Plate


User Manual 4-57

Installing The Driver Boards1. Position the driver board set and mounting plate so that the cables can be

connected.

2. Route the CPU J7 cable (two wires - red and black) over the top of the driver boards near the J2 connector.

3. Connect the cables to J1, J2 and J3 on the lower driver board (Pan/Zoom).

4. Slide the assembly carefully into the housing making sure that the bottom of the boards does not hit the encoder cable on the pan motor.

5. Connect the cables to J1, J2 and J3 on the upper driver board (Tilt/Focus).

6. Line up the holes in the mounting block with the holes in the housing. Attach the mounting block with the 6 screws removed earlier. Use a 3/32” hex key to tighten the screws.

J1

J3

J2

Mounting Screws


4-58 User Manual

Installing The CPU Board1. Position the CPU board over the mounting holes and attach with the 4

screws removed earlier. Use a 3/32” hex key to tighten the screws.

CPU BoardMounting Screws


User Manual 4-59

2. Connect the cables to DS1, J1, J2, J3, J4, J5, J6 and J7.

3. Make sure that the cables will not interfere with the cover when it is installed.

J6

J5

J3

J7

J4

J2

J1

DS1


4-60 User Manual

Finishing UpAfter any of the preceding procedures, the final steps are the installation of the cover and the tilt cradle.

1. Attach the cover with the eight screws removed earlier. Use a 7/64 hex key to tighten the screws.

2. Install the tilt cradle in the position that was marked when you removed it and attach it with the two screws (10-20 x .750 socket head cap screws) and spacers removed earlier. Use a 5/32” hex key to tighten the screws.

3. Mount the head in its final location and recheck the horizontal and vertical balance as described earlier in this chapter.

HS-102P Index

I

AACP System 1–8Adjusting The Pan Anti Backlash Gear 4–38Adjusting The Tilt Anti Backlash Gear 4–30Anti Backlash Gear Adjustment 4–13Anti Backlash Gear, Adjusting 4–30Anti Backlash Gear, Checking 4–28, 4–36Anti-Backlash Gear, Pan 4–36Anti-Backlash Gear, Tilt 4–28Applications 1–8

BBacklash, Minimizing 3–7Balance, Checking 4–4Balancing The Payload 3–4Baud Rate 3–15Belt Adjustment 4–12Belt Replacement 4–12Belt Tension, Checking 4–50, 4–54Belts, Pan 4–54Belts, Tilt 4–50Board Replacement 4–12Board Troubleshooting 4–12

CCalibration

Focus 3–12, 3–13Pan 3–12, 3–14Tilt 3–12, 3–14Zoom 3–12, 3–13

Checking Balance 4–4Checking Overall Operation 4–5Checking The Anti Backlash Gear 4–36Circuit Boards, Removing 4–18Clip

Focus 3–13Pan 3–14Tilt 3–14Zoom 3–13

Command Functions 4–7Configuration 3–12Configuration Switches 4–7Configure

Baud Rate 3–15

Factory Test Switch 3–15Pan/Tilt Direction 3–15

Connector Plate And Harness, Installing 4–56Connector Plate/Harness, Removing 4–21CPU Board, Removing 4–18Critical Data For HS-102 iiiCustomer Responsibility 1–2

DData Path 4–6Disassembly 4–12

EElectrical Installation 3–10Electrical Interconnection 3–10Electrical Repair 4–10

FFactory Test Switch 3–15Features 1–6Focus Calibration 3–12Focus Clip 3–13Focus Servo 4–7Follow Pot Adjustment 3–7

HHCP System 1–8

IInitialization Sensors 4–7Installation

Balancing The Payload 3–4Electrical 3–10Lens Drive 3–6Mounting The Head 3–4Mounting The Payload 3–4

Installation, Mechanical 3–4Installing The Connector Plate/Harness 4–56

HS-102P Index

II

Installing The CPU Board 4–58Installing The Pan Anti Backlash Gear 4–40Installing The Pan Belts 4–42Installing The Pan Motor 4–52Installing The Pan Tensioner 4–42Installing The Tilt Anti Backlash Gear 4–44Installing The Tilt Motor 4–48Installing The Tilt Tensioner 4–46Installing Tilt Belts 4–46Interconnection, Electrical 3–10

LLCP System 1–8Lens Drive Installation 3–6Lens Drive Setup 3–6Lens Drive, Follow Pot Adjustment 3–7Lens Drive, Minimizing Backlash 3–7

MManual Outline 1–5MCS-4000 System 1–8Mechanical Installation 3–4Mechanical Repair 4–11Motor Replacement 4–12Mounting The Pan & Tilt Head 3–4Mounting The Payload 3–4MultiController II System 1–8

OOperating Footprint 1–3Operation 2–1Optosensor Replacement 4–12

PPan Anti Backlash Gear, Adjusting 4–38Pan Anti Backlash Gear, Installing 4–40Pan Anti Backlash Gear, Removing 4–39Pan Anti-Backlash Gear 4–36Pan Belts, Installing 4–42Pan Belts, Removing 4–34

Pan Calibration 3–12Pan Clip 3–14Pan Drive Belts 4–54Pan Motor, Installing 4–52Pan Motor, Removing 4–22Pan Servo 4–8Pan Tensioner, Installing 4–42Pan Tensioner, Removing 4–34Pan/Tilt Direction 3–15Pinch Points 1–4Power Supply 4–6Power Switch 1–4

RReassembly 4–12Removing Pan Belts 4–34Removing The Board Set 4–20Removing The Circuit Boards 4–18Removing The Connector Plate/Harness 4–21Removing The CPU Board 4–18Removing The Pan Anti Backlash Gear 4–39Removing The Pan Motor 4–22Removing The Pan Tensioner 4–34Removing The Tilt Anti Backlash Gear 4–32Removing The Tilt Belts 4–26Removing The Tilt Motor 4–24Removing The Tilt Tensioner 4–26Repair, Electrical 4–10Repair, Mechanical 4–11

SSafe Operating Zone 1–3Safe Working Environment 1–2Safety 1–2Sensors, Initialization 4–7Service Philosophy 4–2Servo, Focus 4–7Servo, Pan 4–8Servo, Tilt 4–8Servo, Zoom 4–7Servos 4–7Setup, Lens Drive 3–6Sharp Edges 1–4Signs, Warning 1–3Software Update 4–12

HS-102P Index

III

Software Upgrade 4–16Specifications 1–7Static Electricity 4–2Support, Technical ivSurface Mount Components 4–10Switches, Configuration 4–7

TTechnical Support ivTheory Of Operation

Command Functions 4–7Configuration Switches 4–7Data Path 4–6Initialization Sensors 4–7Power Supply 4–6Servos 4–7

Tilt Anti Backlash Gear, Installing 4–44Tilt Anti Backlash Gear, Removing 4–32Tilt Anti-Backlash Gear 4–28Tilt Belts, Installing 4–46Tilt Belts, Removing 4–26Tilt Calibration 3–12Tilt Clip 3–14Tilt Drive Belts 4–50Tilt Motor, Installing 4–48Tilt Motor, Removing 4–24Tilt Servo 4–8Tilt Tensioner, Installing 4–46Tilt Tensioner, Removing 4–26Tools Required 4–13Tools You Will Need 3–2Troubleshooting Guidelines 4–10Typical Applications 1–8

UUpdate, Software 4–12Upgrade, Software 4–16

WWarning

Customer Responsibility 1–2Operating Footprint 1–3Pinch Points 1–4

Power Switch 1–4Safe Operating Zone 1–3Safe Working Environment 1–2Sharp Edges 1–4Static Electricity 4–2Unexpected Motion 1–3, 1–4

Warning Labels iiWarning Signs 1–3Warnings 1–2Warranty v

ZZoom Calibration 3–12Zoom Clip 3–13Zoom Servo 4–7

HS-102P Index

IV


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