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USER`S MANUAL - FLIR Systems

1. pins indicate payload pass through rated to three amps O Empty pins indicate control lines mapped to the pan tilt control board Video 2 signal Video 2 ground Pass Through 1 PTU CON Pan Tilt controller board BASE The base connector Notes 6 CAUTION DO NOT EXCEED MAXIMUM RATED PASS THRU AMPERAGES FUSE PAYLOADS AT RATED TRIP VALUES THE WARRANTY DOES NOT COVER DAMAGES DUE TO OVER CURRENTING 7 Channel A RS232 and Channel A TTL are mutually exclusive You may not connect to both of these ports simultaneously as they operate on the same port at different voltage levels 8 All communication directions refer to the host Specifically the TX lines represent that data is moving from the PTU Controller to the customer device and the RX lines represent that the data is moving from the customer device to the PTU Controller 9 The payload shield is to be terminated to the shield of your payload 10 Do not attempt to terminate to this line without first contacting FLIR Motion Control Systems 31 Networking PTU D48 User Manual Version 3 03 B Mechanical Drawings The D48 comes with a variety of mechanical bases and payload configurations Please refer to section 1 2 2 bracketing and mounting tables to determine which options are present on your pan tilt and reference the appropriate sections below B 1 Payload Mounting Pattern The DA8 may be used with a variety of payload bracket combinations please see section 3 8 f
2. position speed amp acceleration e On the fly position and speed changes e Self calibration upon reset e Power consumption can be controlled from host e ASCIl command mode for simplicity binary commands available for efficient program control e Constant current DMOS motor drives for increased performance and control e DC power input from an unregulated source e Flexible connectivity options Applications of the PTU D48 include e Mid and Long range Surveillance systems e Automated detection and tracking e Multi sensor perimeter monitoring systems e Thermal and IR cameras e Marine shipboard sensor systems e Harbor and Port Security e Border Security Law Enforcement e Highway Transportation Monitoring e Military special operations e Satellite communications systems e Microwave antenna systems passive active e Robotics amp computer vision This User s Manual provides information needed to set up and operate the PTU D48 unit The next section provides a brief overview to allow you to get started as quickly as possible More detailed technical information is provided in the remaining sections Accompanying this manual is a Command Reference manual which provides details on the protocol for communicating with the pan tilt Introduction PTU D48 User Manual Version 3 03 1 1 Ve ee a Important Safeguards and Warnings Please read these instructions prior to use Please keep these instructions access
3. see Sections 4 6 1 and 4 6 2 Careful testing can be used to determine the lowest power modes that assure your load can be moved and held without losing synchrony see Section 3 8 7 Networking The PTU lets you connect up to 127 PTUs to a single host computer port Your host computer can then address each PTU on the network as though the PTU were the only unit attached to the host In this way it is simple to migrate existing code developed for a single PTU to a network of PTUs controlled by a single host computer This section describes the basic installation and setup steps required to network your pan tilt units 7 1 Basic Networking Setup Steps The steps in networking your PTUs to your host computer are Sketch out the physical placement of your PTUs and host computer Assign a unique network ID number to each PTU Connect the PTUs and host computer to the PTU network CUPS SES Test the configuration by addressing each PTU by its unit ID and commanding and querying its attached pan tilt unit 7 2 PTU Network Connections Figure 5 illustrates how PTUs can be networked and connected to a host computer via its RS 232 port The networked communications all occur over RS485 serial The PC must use an RS232 to 485 converter and is considered the host of the network the host s TX RX pairs define the traffic directions Multiple pan tilts can then be attached as clients on the network and communicate in full duplex PTU D48 User Ma
4. side mount Video 1 2C s brackets Video 2 2C D100 Payload BKTO1 General Pass Through Lines 5C Payload Power 2C lt P PC Basic D300 Payload Pass Thru Connections Pan Tilt Control RS485 RS232 7C Video 1 2C Video 2 2C D300 Power 2C General Pass Through Lines 5C Payload Power 2C Optional Controls CHA RS232 CHB RS232 L __ WEE D300 Cable Figure 1 Pan Tilt System Overview PTU D48 User Manual Version 3 03 Quick Start The PTU D48 can be controlled from any host computer using the built in ASCII protocol described in the included Pan Tilt Command Reference Manual For high speed hard real time controls such as tracking a binary protocol is supported via a C Programmers Interface PTU CPI Drivers are also available in 3rd party software packages such as LabVIEW and digital video control systems 2 2 Installation Components Components supplied with this manual are e D48 User Manual this document e Pan Tilt Command Reference Manual e D48 Pan Tilt Unit e Payload Mounting Brackets Optional e Pan Tilt Break Out Cable DASAC CAB 25BO Optional e AC DC Power Supply D48AC APS 30V Optional 2 3 Basic Setup Steps The following outlines the basic pan tilt set up and installation steps Section 3 details each of these steps 1 Unpackthe D48 pan tilt Mount the pan tilt securely See section 3 1 for details on mounting 2 Es
5. 48 requires a 9 30VDC unregulated power source capable of 5 6A peak Less peak current is required if you do not use the higher motor current controls available see the Command Reference Manual To achieve the highest pan tilt unit performance use the highest motor voltage within the allowable range To achieve the quietest and smoothest pan tilt operation you can use a lower motor voltage e g 24VDC Please note that the resulting pan tilt torque depends on the input voltage 30 VDC providing the max torque and 9VDC providing the least torque When wiring your own power source failure to comply with wiring and AN power source requirements described in this manual can result in decreased unit performance or damage not covered under the limited warranty If you are providing your own DC power source the power source must never supply more than rated current and if so you must add a fuse in series with your DC power source For example when connecting to a vehicle battery or lighter plug you must fuse the incoming DC source Failure to properly fuse your input power source could cause overloading of internal protection devices pose a safety hazard or void product warranties 3 4 Shielding All wiring configurations for the pan tilt provide a shield pin at both the base and the payload on pin F This shield is attached to the housing of the pan tilt and is attached the D48 Power ground through an inductor on the main controller
6. DC power source to the D48 power input and a host computer connection to communicate and control the D48 The easiest way to wire into the D48 is to use the factory cable with breakouts for power and other connections model D48AC CAB 25BO and to use the factory power supply model D48AC APS 30V This allows you to plug in and run the D48 in minutes Or you can use the wiring diagrams in Appendix A to make your own cables that better suit your installation Connect an RS 232 or RS 485 cable between the D48 and a host computer When using the factory cable D48AC CAB 25BO standard RS232 connection DB9F is provided HyperTerminal built into Windows is the most commonly used communications program Communications parameters are 9600 baud no parity no handshaking See section 3 5 The D48 provides payload pass thru signals that connect between pins in the base receptacle to corresponding pins in the payload receptacle Additional pins in the payload receptacle provide other payload controls to the pan tilt controller board including auxiliary RS232 ports When attaching payload signals to the system care must be taken to adhere to all specifications for the pass thru signals such as maximum voltage and current levels 3 2 2 Wiring Options The D48 comes in a variety of wiring options to determine which option is present in your pan tilt visit section 1 2 2 under wiring and each wiring option is fully described in appendix A The
7. SFLIR Motion Control Systems COMPUTER CONTROLLED PAN TILT UNIT MODEL PTU D48 VERSION 3 03 REVISION DATE SEPTEMBER 2 2011 UsER S MANUAL 890C Cowan Road Burlingame CA 94010 e 650 692 3900 e FAX 650 692 3930 MCS flir com e www flir com MCS Pan Tilt Unit Model PTU D48 User s Manual September 2 2011 01991 2011 by FLIR Motion Control Systems Inc 890C Cowan Road Burlingame California 94010 650 692 3900 FAX 650 692 3930 www flir com mcs All rights reserved Protected under numerous U S Patents including 5463432 and 5802412 and patents pending No part of this book may be reproduced stored in a retrieval system or transcribed in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of FLIR Motion Control Systems Inc The information in this manual is subject to change without notice and except for the warranty does not represent a commitment on the part of FLIR Motion Control Systems FLIR Motion Control Systems cannot be held liable for any mistakes in this manual and reserves the right to make changes Table of Contents ED RONE A UON EU 5 1 1 Important Sateguards dnd Warnings ones se od a quo due cade 6 1 2 MOI eb mc D RE cU I AN DUE TED NOD RISE INS 7 1 2 1 Model Number OVeEVIB Wii 7 1 2 2 Model Number Breakdown anrcsan N N 7 1 3 Optional Modules
8. T Ka 9 2 AWK Sta akan bia acta naa eosque pe robo pa an ag Possess te Ba das bud pU Le pem situ ene ala na a aa a a dp a 10 2 1 SUSO OVEIVIEW carl 10 2 2 instalation COMPONEN ci A Eve Me are WIRE 11 2 3 Basic CUD St GDS a 11 s ihstallatioh ana Se TUD aaa 13 3 1 Panti MONINE ucc a ll e T 13 3 2 Wiring and CONNEGE OT Sis saa bui vers ra A DAGAN ON Aan A A AGA Gs ees E AGA Ng Aa ana A MuR aet 14 3 2 1 Mechanical OvervieW sssseessssssereessssreresssseressssrrrresssseressssrrressserrressssereesssereessseeeeressseeeee 14 3 2 2 WINE D DIDIS aaa as 15 3 3 RS A N a aa ga a tania NB tae NG D a oes 16 3 4 SA A e pO ES OO O da eens DG D aa KN A aan Sa 16 3 5 Serial Intertac esana Host Settings 3er escis ia aaa 16 3 5 1 R9232 Electrical Interface cas ue Aa RU EP ga doa E Re Vade ERE 16 3 5 2 R548 5 Electrical INTEN carac 17 3 6 Initial Powersup anmd Tes sapara E ad etel vei ia 17 3 7 Basic PaneTilt Unit Commands ii 18 3 8 MOURtUNE Your PAY lO dO iioii aa a ag Gb aana A A PvE bd uM La A 18 3 9 Payload Wiring CONNECTIONS uestros rau Geek Regen ia 19 4 Manesahd Hard StO DS sesto n e oe Ci p tae Lot ah s 19 4 1 dame e E 20 4 2 Mice Corm 20 4 3 FANG StODS E RETE T T Na a PN DANA BA AN GR a ANG een 20 5 A A a A DLL M a Na a aa DEM E M M ML AO 21 6 Special CONS UratION Cnm 21 6 1 HighsSpeed Opera HON iaa 21 6 2 Hien Payload OPE UN ina AS AAA 21 6 3 Battery Powered Operation cccccssscccsssecccscccssceceeececs
9. U D48 User Manual Version 3 03 Installation and Setup 3 Installation and Setup This section describes the basic installation and setup steps required to get your pan tilt operational as quickly as possible 3 1 Pan Tilt Mounting Figure 2 shows the mounting pattern for the PTU D48 The basic mounting pattern is four 1 4 20 socket head cap screws in a 3 375 85 725mm square pattern All four mounting screws should be used The mount strength must be able to hold the weight of the unit plus the payload plus any additional forces exerted on the system e g wind G forces A good rule of thumb the mount must support at least four times the combined weight of the payload plus the weight of the pan tilt e g a 25 Ib payload mounted to the D48 must support at least 205 lbs CAUTION FAILURE TO SECURE THE PAN TILT AND ITS PAYLOAD TO A SUFFICIENTLY STRONG MOUNTING CAN RESULT IN DAMAGE TO THE PAN TILT THE PAYLOAD OR POSSIBLE INJURY OR DEATH YOU MUST ENSURE THE MOUNTING IS CAPABLE OF HOLDING THE LOADS lt 3 379 gt R 0 41 4 20 3 375 1 1 y 3j Q gt E I Nl Y NL x 4X 0 257 Figure 2 Hole Mounting Pattern Installation and Setup 3 2 Wiring and Connectors PTU D48 User Manual Version 3 03 The standard D48 model is depicted below and has a base and payload connector for customer attachment The D48 ships with a variety of wiring options which may affect the
10. board It is important that the shield pin not be confused for a ground pin as its potential will vary from the ground Ideally at the base of the pan tilt pin F should be routed to a long rod embedded in the ground providing a genuine ground reference In lieu of this it would be acceptable to route pin F to the power ground through a surge protection device 3 5 Serial Interface and Host Settings Depending on the pan tilt s wiring configuration see section 1 2 2 wiring it may be equipped with just RS485 or with RS232 and RS485 communications In the case that both forms of communication are present it is important that you only terminate to one of these forms of communication as terminating to both will cause interference between the channels Regardless of which form of communication is used the host terminal or computer should be set to 9600 baud 1 start bit 8 data bits 1 stop bit and no parity Hardware handshaking and XON XOFF are not used The baud rate of the pan tilt is adjustable through software commands see the Command Reference Manual for instructions 3 5 1 RS232 Electrical Interface The RS 232 connections to the Pan Tilt are TxD pin 2 RxD pin 3 and GND pin 5 Since TxD and RxD assignments to pins 2 and 3 can vary on host computers try using a null modem if your initial connection does not work PTU D48 User Manual Version 3 03 Installation and Setup 3 5 2 RS485 Electrical Interface The RS 485 communica
11. connectors used and for which you should reference section 1 2 2 under the wiring heading to determine your wiring configuration and appendix A for more details on your specific pin out and connectors 3 2 1 Mechanical Overview ZA A 4E de Payload Receptacle NY N Base Receptacle Payload Receptacle The payload connector is a 19 pin circular connector complying with MIL standard MS3122E14 19S The appropriate mating connector shall comply with MS3126F14 19P the male version of the payload connector One of these connectors is shipped with each D48 and additional connectors may be ordered with the following part number e FLIR Motion Control Systems o D48 CABLEO1 19PMILC Base Receptacle At the base of the pan tilt is a receptacle The receptacle uses a 19 pin circular connector complying with MIL standard MS3122E14 19S This is identical to the payload connector Please see the payload connector for details about an appropriate mating connector PTU D48 User Manual Version 3 03 Installation and Setup Appendix A shows the specific pin outs for all of the available wiring configurations for the D48 Basic control requires that you connect a
12. ddition to optical electronic limits the D48 is capable of having hard mechanical limits installed as well These are only installable at the time of manufacture in either axis Please refer to section 1 2 2 under the hard stops header to determine which hard stops are present in your pan tilt PTU D48 User Manual Version 3 03 Resolution 5 Resolution The D48 unit is driven with stepper motors through a gear reduction The resulting motion on the drive shaft is 0 05143 per full step The controller has the ability to drive the stepper motors in micro stepping modes meaning that it can drive the motor between one half and as little as one eighth of one step at a time Thus in its finest resolution the pan tilt can be commanded in steps as small as 0 00643 per step This is the maximum resolution of the device 6 Special Configurations 6 1 High Speed Operation This section discusses how to improve high speed pan tilt unit performance for your load The primary factors that affect high speed operation are e Load weight weight distribution and dynamics e Desired upper speed limit e Rate of acceleration e The base start up speed e The voltage of the source power supply Use of the highest available voltage in the range 9 30VDC significantly improves axis speed and acceleration performance e The in motion power mode and stationary power mode e Multi axis dynamics Simultaneously moving the tilt and pan axes affects the forces ex
13. ed to the shield of your payload 5 Do not attempt to terminate to this line without first contacting FLIR Motion Control Systems 27 28 Networking PTU D48 User Manual Version 3 03 A 2 D48 Standard PLO2 Wiring Description Revision 1 00 1 26 2009 A 2 1 Overview The D48 may be configured with a variety of wiring configurations based on the customer s needs This includes the cabling in from the base as well as the cabling out to the payload This document describes the standard PLO2 configuration A 2 2 Scope This document covers the external wiring schematics for the D48 Pan Tilt with the PLO2 wiring option It is meant only for users of the standard D48 with the PLO2 configuration A 2 3 Revision Control Rev Date Description Author Reviewer 1 00 1 26 09 Initial Release KRS PTU D48 User Manual Version 3 03 A 2 4 Mechanical Overview amp A A F 4p Payload Receptacle NY N Base Receptacle Networking Payload Receptacle The payload connector is a 19 pin circular connector complying with MIL standard MS3122E14 19S The appropriate mating connector shall comply with MS3126F14 19P the male version of the payload connector One of these con
14. erted on the pan axis High speed operation tests should always begin on each axis in isolation When the best performance for each axis in isolation is understood high speed operation of simultaneous pan tilt axis movements can be performed An example configuration string for high speed operations is PA9000 TA9000 DS 6 2 High Payload Operation This section discusses how to improve high payload weight operation of the pan tilt The primary factors affecting payload capacity is the tilt axis as it forms a mechanical lever which is an efficient force multiplier The primary means to increase payload capacity are e Configure the pan tilt controller for increased motor current and torque An example configuration string to increase payload capacity is DF PA1000 TA1000 PB57 TB57 PMR TMR DS If your move duty cycle is less than 2096 you can alternatively use the highest move current settings and regular hold power settings of PMH TMH PHR THR e Move the payload center of gravity closer to the tilt axis e Usea higher voltage power source in the range 9 30VDC Networking PTU D48 User Manual Version 3 03 e Determine if the payload can be modified to lighten it 6 3 Battery Powered Operation The Pan Tilt Unit has been designed for battery powered operation Battery powered applications need to conserve power when possible The pan tilt unit has commands to control pan tilt motor power consumption while in transit and when stationary
15. es direct control of the pan tilt from an industrial joystick Quick Start PTU D48 User Manual Version 3 03 2 Quick Start The pan tilt unit provides direct serial control of all motion aspects of the device This may then be interfaced to a host computer for software control or directly to a joystick or proprietary controller FLIR Motion Control Systems provides various starter packages and OEM solutions for control and depending on the options present with your pan tilt you will want to refer to the following sections to get started For units ordered with a Geo Pointing Module PTU DGPM or an external joystick PT DCJ please refer to their respective manuals for quick start guides that include the use of the options The guide below is intended only for users wishing to power up their pan tilt and test direct communications from a host computer 2 1 System Overview Figure 1 shows a system overview The PTU D48 includes an integral controller and it accepts control commands from any host computer over serial RS 232 or RS 485 The basic D48 connections are D48 power from a DC power source and Pan Tilt Control via RS232 485 In addition to pan tilt control connections Payload Pass Thru internally routes payload signals such as video payload power and other payload connections from a single stationary connector in the PTU base to a single payload connector that moves with your payload Payload Pass Thru A Optional
16. estions about your payload mounting or load handling please contact Technical Support for further assistance e f your load passes the above pan and tilt axis load handling tests you are ready to begin controlling your load using the commands described in Section 4 3 9 Payload Wiring Connections The D48 provides payload pass thru signals that connect between pins in the base connector to corresponding pins in the payload connector Additional pins in the payload connector provide other payload controls auxiliary RS232 ports and TTL control Figure 2 shows this payload connector which is also a MIL C 26482 compatible receptacle 19 pins Appendix A 4 details the payload connector pin out Your payload connects to the payload connector via a male MIL C 26482 compatible plug e g PTO6A14 19P Appendix A 4 shows the payload connector wiring Pins highlighted in red indicate payload pass thru signals connected to corresponding pins in the base connector When attaching payload signals to the system care must be taken to adhere to all specifications for the pass thru signals such as maximum voltage and current levels 4 Vanes and Hard Stops The D48 utilizes high precision optical limit sensors that detect the presence of a mechanical limit vane to determine the device s home position and to act as an electronic lockout of undesired motion In addition to this electronic stop mechanism the D48 offers optional mechanical stops which will phy
17. fective product and provide new or rebuilt replacements at no charge Warranty repairs require the issuance of a repair authorization number from FLIR Motion Control Systems prior to the return of merchandise and the buyer assumes responsibility for freight charges After the one year period the purchaser must pay for all parts labor and freight This warranty does not cover any damage due to accident misuse abuse or negligence You should retain your original bill of sale as evidence of the date of purchase REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER FLIR MOTION CONTROL SYSTEMS SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY Some states do not allow the exclusion or limitation of incidental or consequential damages or allow limitations on how long an implied warranty lasts so the above limitations or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state
18. ible Please heed all warnings Please follow all instructions Installation should be done only by qualified personnel and conform to all local codes CAUTION These servicing instructions are for use by qualified service personnel only To reduce the risk of electric shock do not perform any servicing other than that contained in the operating instructions unless you are qualified to do so Use only mounting methods and materials capable of supporting at least four times the combined weight of the D48 pan tilt mounted payloads and cabling For outdoor use use only corrosion resistant hardware to fasten the mount and payloads e g Stainless steel screws The unit should not be installed in environments that present conditions beyond the environmental specification of the D48 Installation near heat sources such as radiators heat registers stoves or other apparatus including amplifiers can exceed the unit s temperature ratings Refer all servicing to qualified service personnel If the unit is damaged remove power immediately and contact FLIR Motion Control Systems 10 A readily accessible power disconnect shall be incorporated into the installation wiring CAUTION Removing power by pulling the plug can damage the PTU D48 11 Only use replacement parts recommended by FLIR Motion Control Systems PTU D48 User Manual Version 3 03 Introduction 1 2 Models Each D48 pan tilt has a model number on it located beneath the co
19. licensed radio communications service Class A Class A equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his her own expense Class B Class B equipment has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the u
20. mply with MS3126F14 19P the male version of the payload connector One of these connectors is shipped with each D48 and additional connectors may be ordered from us with the following part number e FLIR Motion Control Systems 650 692 3900 o D48 CABLEO1 19PMILC Base Receptacle At the base of the pan tilt is a receptacle The receptacle utilizes a 19 pin circular connector complying with MIL standard MS3122E14 198S This is identical to the payload connector Please see the payload connector for details about an appropriate mating connector 26 Networking PTU D48 User Manual Version 3 03 A 1 5 PLO1 Base Schematic Pin Destination Current TP Description PTU CON 1A RS485 TX PTU CON 1A RS485 RX PTU CON 1A RS485 RX PTU CON 3A D48 Ground PTU CON 3A D48 9 30 VDC PYLD 1A Shield PYLD 1A Video 1 Ground PYLD 1A Video 1 Signal PTU CON 1A RS232 Signal Ground PTU CON 1A RS232 TX PTU CON 1A RS232 RX PTU CON 1A RS485 TX PYLD 1A Pass Through 3 PYLD 1A Pass Through 2 PYLD 3A Payload Ground PYLD 3A Payload DC 0 30V PYLD 1A Video 2 Signal PYLD 1A Video 2 Ground PYLD 1A Pass Through 1 Blue pins indicate payload pass through rated to one amp Blue cross hatch pins indicate payload pass through rated to three amps Empty pins indicate control lines mapped to the pan tilt control board Shield pin a
21. nector TP Twisted pair PTU CON Pan Tilt controller board PYLD Base payload connector A B C D E F G H J K L M N p R S T U V Notes 6 CAUTION DO NOT EXCEED MAXIMUM RATED PASS THRU AMPERAGES FUSE PAYLOADS AT RATED TRIP VALUES THE WARRANTY DOES NOT COVER DAMAGES DUE TO OVER CURRENTING 7 The video lines have been specifically routed to have the least impedance of any payload lines and as such it is recommended you place any analog video lines along these payload lines 8 Twisted pairs are not twisted throughout the entire pan tilt but where raw wires are run internally for some distance these pairs are twisted together 9 All communication directions refer to the host Specifically the TX lines represent that data is moving from the PTU Controller to the customer device and the RX lines represent that the data is moving from the customer device to the PTU Controller 10 It is important that the shield line be terminated either to an appropriate system shield or through a large inductor to the D48 ground PTU D48 User Manual Version 3 03 Networking A 2 6 Payload Schematic Pin Source Current Description PTU CON 1A Pass Through 4 PTU CON 1A Pass Through 5 PTU CON 1A Pass Through 6 PTU CON 1A RS232 signal ground O Blue pins indicate payload pass through rated to one amp o Blue cross hatch
22. nectors is shipped with each D48 and additional connectors may be ordered from us with the following part number e FLIR Motion Control Systems 650 692 3900 o D48 CABLEO1 19PMILC Base Receptacle At the base of the pan tilt is a receptacle The receptacle utilizes a 19 pin circular connector complying with MIL standard MS3122E14 198S This is identical to the payload connector Please see the payload connector for details about an appropriate mating connector Networking PTU D48 User Manual Version 3 03 A 2 5 Base Schematic Pin Destination Current TP Description PTU CON 1A RS485 TX PTU CON 1A RS485 RX PTU CON 1A RS485 RX PTU CON 3A D100 Ground PTU CON 3A D100 9 30 VDC PYLD 1A Shield PYLD 1A Video 1 Ground PYLD 1A Video 1 Signal PTU CON 1A Pass Through 4 PTU CON 1A Pass Through 5 PTU CON 1A Pass Through 6 PTU CON 1A RS485 TX PYLD 1A Pass Through 3 PYLD 1A Pass Through 2 PYLD 3A Payload Ground PYLD 3A Payload DC 0 30V PYLD 1A Video 2 Signal PYLD 1A Video 2 Ground PYLD 1A Pass Through 1 Blue pins indicate payload pass through rated to one amp Blue cross hatch pins indicate payload pass through rated to three amps Empty pins indicate control lines mapped to the pan tilt control board Shield pin attached to housing and passed through to payload connector Pins arranged as they appear on a female socket con
23. nnectors on the rear of the base This model number can be used to derive which options are present on the particular unit This is important as different versions of the pan tilt will have different operations and the manual will cite this section frequently to determine the correct course of action for a particular unit 1 2 1 Model Number Overview The following table describes the format of the D48 model number and may be used to understand the option codes present on your unit Family Class Bracket Mount Wiring Color Stops Custom Vane D48 X X X X X X XX XX 1 2 2 Model Number Breakdown The following tables list the various options for a particular sub code of the model number The Family is the FLIR Motion Control Systems product family This manual only describes the D48 product other product families include the D46 D47 D100 and D300 pan tilt units Family D48 PTU D48 Pan Tilt Integrated Controller 9 30VDC input Includes mating connector for payload signals Does not include payload brackets power supply or cable harness The class describes any options relating to the motors or gears installed in the unit At this time the D48 is only offered with standard gears and motors Class S Standard speed and gears The D48 has dual attachment hubs which allow for a variety of standard payload bracket configurations Please see section 3 8 or more information Bracket S No brackets are included C Top mount bracke
24. nseceeenceeaencesaeeceseueceseueessescessuacessugecesens 22 E IN da o 22 7 1 Basic Networking Setup Steps aa 22 7 2 PTU Network Connections cccccccccsssssccccssessccccssesseeeccesseueececssuuseeseccsseussesecesauseeseesssauaeeees 22 A El cthical SPECICATION Saladas 24 A 1 DAS Standard PLOL Wiring DescriptlOT sooo as ise evan Oki RW v e UP UD V OU aaa a MEER NS 24 Bi Mechanical DEawWIDBS cedem ba ae ga a ev A dos iei eel cate ar TA 32 B 1 Pavioad Mounting Pattern da 32 B 2 D48 Dimensions with Standard Rear Plug Base ccoocccccnccncnncnnnonccnnoncnnnononncnncnnonoononarononanononanos 33 Regulatory MOMMA IN le 34 LECANORA 35 Table of Figures Feure LPan TUCSyStem OVERVIEW vaian a aean AA a a a cui ANANA BAN 10 Figure 2 Hole Mountne Patterns ainia alcatel latas 13 Figure o Bracketing ODORS iaa acid 18 Figure 4 Pan Tilt Rotational Orientation ooccccoccnncnnonnncncnnnnnnononarononononnnnnonnnnrononnrnnononrnnonnnnnnaronenarnnennnonos 20 Figure 5 PTU Network Configuration eese essa e sar essen na 23 PTU D48 User Manual Version 3 03 Introduction 1 Introduction The PTU D48 Pan Tilt Unit from FLIR Motion Control Systems provides fast accurate and durable positioning of cameras antennas lasers and other large payloads Some general features e Simple to command from any RS 232 or RS 485 terminal or computer e Payload capacity up to 15 lbs e Resolution of 0 006 degrees e Precise control of
25. nsmit and Receive Receive wires at each end of the multidrop wiring network 24 Networking PTU D48 User Manual Version 3 03 A Electrical Specifications Please reference section 1 2 2 and check your wiring configuration to determine which sub section is most appropriate for your unit A 1 D48 Standard PLO1 Wiring Description A 1 1 Overview The D48 may be configured with a variety of wiring configurations based on the customer s needs This includes the cabling in from the base as well as the cabling out to the payload This document describes the standard PLO1 configuration A 1 2 Scope This document covers the external wiring schematics for the D48 Pan Tilt with the PLO1 wiring option It is meant only for users of the standard D48 with the PLO1 configuration A 1 3 Revision Control Rev Date Description Author Reviewer 1 00 4 22 08 Initial Release KRS EF PTU D48 User Manual Version 3 03 A 1 4 PLO1 Mechanical Overview amp A A F 4p Payload Receptacle NY N Base Receptacle Networking Payload Receptacle The payload connector is a 19 pin circular connector complying with MIL standard MS3122E14 19S The appropriate mating connector shall co
26. nual Version 3 03 Networking RS485 Multi Drop TX Twisted Pair 1200 1 PAM NANA PARRA A 1200 1 1200 1 Jae I N N N N N N I N ZN I N N I N Joo N I N N DOOD DODD KK GTO NG NGT nS ASZ NG NGT OGG GRAY 12002 1 RS485 Multi Drop 9903 RS485 RS485 RX Twisted Pair RS485 TX RX RS232 lt gt RS485 Converter RS232 gt Figure 5 PTU Network Configuration Several issues are important to note when you make your own data cables First use a good quality cable Though a good quality telephone cord cable can be used use of a twisted pair cable is highly recommended A twisted pair whose impedance is about 100 is typically used for longer RS 485 runs The twisted pair provides good noise immunity owing to the relative signals used by the RS 485 standard For some applications the host computer may directly provide RS 485 full duplex I O In this case you may directly connect your host computer to the PTU network For computers with only RS 232 RS 485 connections may be simply made using an external RS 232 to RS 485 converter FLIR Motion Control Systems has tested qualified two converters ATEN IC 485S and Moxa A50 which both require a flipped RJ 12 connector such as a standard phone cord It is important to note that the network should be terminated using 120 1 resistors to protect against signal ringing on the network Termination is achieved by placing the resistors between the RS 485 Transmit Tra
27. or more information on the different brackets Regardless of which payload bracket combination you use the hole patterns and positions with respect to the hubs do not vary This is true regardless of which side mount bracket is used and whether a top mount bracket is present The following drawing fully dimensions the combination of two side mount brackets with a top mount bracket Please see section 1 2 2 under the bracket options to determine which brackets your unit has TBD PTU D48 User Manual Version 3 03 B 2 D48 Dimensions with Standard Rear Plug Base co CN D V E per aa hl TE T Se ur eH g mE ON E C J Dil uu exo A G d A He op KE ik EL e A EA S ANGE OL MBA 2 o 27 A Cn Networking MO lt a ee m 3 gt ON N pu O b mo 33 Regulatory Information PTU D48 User Manual Version 3 03 Regulatory Information Electromagnetic Interference EMI is any signal or emission radiated in free space or conducted along power or signal leads that endangers the function of a radio navigation or other safety service or seriously degrades obstructs or repeatedly interrupts a
28. pment Because of the heavy payload weights and high potential speeds supported by the PTU D48 it is very important that all guidance and instructions regarding payload mounting be followed carefully Figure 3 shows all of the possible arrangements of brackets Please refer to 1 2 2 under bracket to determine which brackets are included with your unit TBD Figure 3 Bracketing Options Payloads should be mounted as close to the Pan tilt housing as possible so as to position the center of gravity as close to the pan axis as possible In all cases care must be taken to ensure that the payload will clear the Pan tilt housing and surrounding objects throughout the full range of motion of the unit Though the PTU D48 unit is rated to a maximum load of 15 lbs the distribution of the load affects the actual load capable of being moved by the pan tilt unit The steps to determine whether your load and its positioning e g center of gravity are within the maximum load capacity and dynamics are e Mount your payload Side mount is preferred for heavier loads as it keeps the payload center of gravity closer to the tilt axis of rotation thereby minimizing torque requirements Ensure that the load is securely attached to the payload bracket e First move the pan axis through its range to test whether the pan tilt can handle the load e g enter dr pp2700 a pp 2700 a ppO A load that is too heavy or moved too quickly will cause the unit to lose synch
29. rees No stops are installed on the pan axis Custom configurations are unique codes developed to meet a customer s specific requirement These are not covered in the manual but rather are available by request Custom SS X Standard configuration does not modify the pan tilt in any way Vanes are used with optical limit switches in order to precisely calibrate the device s home position as well as to provide an electronic limitation on the range of motion These limits must be explored at the time of power up thus if you have any constraints on the limits of motion the vanes should reflect that Vanes S Pan 175 degrees Tilt 30 90 degrees PTU D48 User Manual Version 3 03 Introduction 1 3 Optional Modules In addition to the installed options on a D48 external modules may be added for additional functionality These are described below but are not covered in this manual For additional technical information on these options please see their respective data sheets manuals e Geo Pointing Module GPM PTU DGPM This module may be combined with any D48 configuration and provides a means to calibrate the 6 dimensional location of the pan tilt with the use of landmarks With this option the pan tilt can be commanded over Ethernet and a serial port so that the DA8 can be made to point at GPS coordinates rather than simple pan and tilt angles e Joystick Controller DJoystick PT DCJ This option provid
30. rol lines mapped to the pan tilt control board Red pins denote empty or reserved pins Notes Pin amp i ci4M e vzieir ix irioimimiogioimi Source PTU CON PTU CON PTU CON PTU CON PTU CON BASE BASE BASE PTU CON PTU CON PTU CON PTU CON BASE BASE BASE BASE BASE BASE BASE Current 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A 1A 3A 3A 1A 1A 1A Networking Description Channel A RS232 RX Channel A RS232 TX Channel B RS232 RX Channel B RS232 TX Channel B RS232 DTR Shield Video 1 ground Video 1 signal TTL OP2 Channel A TTL RX Channel A TTL TX RS232 signal ground Pass Through 3 Pass Through 2 Payload ground Payload DC 0 30 VDC Video 2 signal Video 2 ground Pass Through 1 PTU CON Pan Tilt controller board BASE The base connector 1 CAUTION DO NOT EXCEED MAXIMUM RATED PASS THRU AMPERAGES FUSE PAYLOADS AT RATED TRIP VALUES THE WARRANTY DOES NOT COVER DAMAGES DUE TO OVER CURRENTING 2 Channel A RS232 and Channel A TTL are mutually exclusive You may not connect to both of these ports simultaneously as they operate on the same port at different voltage levels 3 All communication directions refer to the host Specifically the TX lines represent that data is moving from the PTU Controller to the customer device and the RX lines represent that the data is moving from the customer device to the PTU Controller 4 The payload shield is to be terminat
31. rony and this will be accompanied by an audible rrrr sound from the PTU D48 User Manual Version 3 03 Vanes and Hard Stops pan tilt unit motors See section 6 2 for further information on configuration of the Pan Tilt for heavier payloads e f your load passed the pan axis load test you can then test the tilt axis load handling capability The center of gravity for top mounted payloads is further from the tilt axis of rotation and this may require more torque to move the load Move the tilt axis through its range of motion to test whether the pan tilt can handle the load e g enter DR TP 900 A TP600 A TPpO A load that is too heavy or moved too quickly will cause the unit to lose synchrony and this will be accompanied by an audible rrrr sound from the pan tilt unit motors e f your load fails the above pan or tilt axis load handling tests check Section 6 2 for further information Significantly faster or lower power control can be obtained via commands to the pan tilt unit The speed and acceleration of a mechanical system depends upon the inertial properties of your load The ability of the pan tilt unit to successfully move your load without losing synchrony depends upon the inertial load factors and their relationship to power supply voltage unit speed acceleration position motor torque etc Section 6 2 discusses how to configure pan tilt parameters to achieve more optimal pan tilt unit performance for your load If you have qu
32. ser is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Establish good grounding to the base connector e Consult the dealer or an experienced radio TV technician for help Caution Changes or modifications of this equipment not expressly approved by manufacturer could result in violation of Part 15 of the Federal Communication Commission s rules The FCC has prepared the following booklet How to Identify and Resolve Radio TV Interference Problems It is available from the US Government Printing Office Washington DC 20402 Stock Number 004 00 00345 4 FCC Notice According to 47CFR Parts 2 and 15 Subpart B Class A This device complies with FCC Part 15 Subpart B Class A of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must accept any interference received including interference that may cause undesired operations PTU D48 User Manual Version 3 03 Limited Warranty Limited Warranty FLIR Motion Control Systems Inc warrants this product against defects in material or workmanship as follows For a period of one year from date of purchase FLIR Motion Control Systems Inc will repair the de
33. sically restrict the motion of the pan tilt to pre specified limits Vanes and Hard Stops PTU D48 User Manual Version 3 03 4 1 Orientation Figure 4 shows the D48 from a top and side view and illustrates the orientation of each axis The positive direction on the pan axis is clockwise when viewed from above while on the tilt axis the positive direction is clockwise when viewed with the motors connectors facing to the right E C O Figure 4 Pan Tilt Rotational Orientation NOTE Figure 4 Depicts a D100 the orientation is the same for a D48 4 2 Vanes At power up the pan tilt will self calibrate the pan and tilt axes by moving from one extreme to the other and then returning to the devices home position This provides the absolute coordinate system for the pan tilt and all motion and location information is calculated based on open loop stepping of the built in motors Figure 4 illustrates the default values for these limits placed on the pan axis at 175 and on the tilt axis at 30 90 These vanes are configurable at the time of manufacture To determine which vanes are present in your pan tilt please refer to section 1 2 2 under the vanes header 4 3 Hard Stops In a
34. standard slip ring and connectors offer 19 termination pins at the base and at the payload as well as through the slip ring In all configurations the pan tilt needs to minimally consume seven of the connections at the base these are for power RS485 communications and shielding The following is a description of what each wiring option offers Option Description PLO1 Provides an alternate RS232 communication option for talking with the pan tilt head This is provided in addition to the RS485 lines and leaves 9 payload pass through lines These lines provide two video lines AC 1 set of power lines 2C and 3 general I O lines 3C In addition to these pass through lines the pan tilt controller provides two auxiliary serial ports to the payload connector which may be controlled with special commands to the pan tilt to control cameras or other peripherals without an added serial port See appendix A 1 for complete details PLO2 Standard wiring option and provides the maximum available pass through lines from the base to the payload These include two video lines AC 1 set of power lines 2C and 6 general I O lines 6C In addition to the pass through lines the pan tilt controller provides RS232 control to the payload allowing the pan tilt to be controlled by a module on the payload side as opposed to the base See appendix for complete details Installation and Setup PTU D48 User Manual Version 3 03 3 3 Power Sources The PTU D
35. sure that the left switch is set to T RTS RxON and that the right switch is set to DCE Finally connect the RS485 connector from the breakout cable into the adapter and provide power to the converter through the included wall wart Next bring up HyperTerminal built into Windows by going to start gt accessories gt communications gt hyperterminal If you are running Vista you will have to download this from http www hilgraeve com Once hyperterminal is open create a new connection with the following communications parameters 9600 baud no parity no handshaking See section 3 5 6 Provide DC power to the pan tilt When using factory cable D48AC CAB 25BO easy plug in power is provided by AC DC power supply model D48AC APS 30V Or you can obtain your own DC power source that better suits your installation See section 3 3 CAUTION Removing power by pulling the plug can damage the PTU D48 Power up the pan tilt If power is working the unit will go through a power up calibration At power up the pan tilt defaults to providing splash text on your terminal that will identify the unit configuration Pan tilt operation can then be tested by typing commands into your terminal program Section O describes some basic pan tilt commands to get you going Section 4 provides a full description of all pan tilt unit commands and queries You can now mount and wire your payload e g camera on the pan tilt unit see Section 3 8 PT
36. t is included only The mount options describe the base of the pan tilt which most often affects the height and mechanical foot print of the complete unit though all bases share the same four hole mounting pattern Mount S Standard rear plug base plate Introduction PTU D48 User Manual Version 3 03 The D48 has a variety of wiring options relating to the communications lines to the pan tilt controller as well as the number and arraignment of the pass through lines that run from the base to the payload through the slip ring For more information see section 3 2 2 or additional descriptions or appendix A for complete pin outs Wiring S PLO1 wiring includes RS232 and RS485 communications as well as 9 pass through connections E PLO2 wiring includes RS485 communications only as well as 12 pass through connections The D48 unit is available in a variety of colors The standard units come in black and other colors are available per the table listed below or by request Color S Anodize to MIL A 8625 TYPE II CLASS 2 Sandoval MLW Black with carbide black covers Optional hard stops may be installed at the time of manufacture these assure that the unit is not capable of exceeding the bounds at the hard stops Please note that the hard stops are actually installed just beyond the stated limits to allow motion up to the limits Please see section 4 3 for more details Stops S Standard configuration includes stops on the tilt axis at 220 deg
37. tablish wiring to the pan tilt The factory breakout cable makes this easy D48AC CAB 25BO providing connections for power communications and general payload pass through lines You can also make your own cables that better suit your installation 3 Check section 1 2 2 under the wiring description to determine which wiring option is available on the pan tilt If it is PLO1 or PLOS the pan tilt provides direct RS232 support If it is PLO2 or PLO6 you will have to connect through an RS485 converter if this is the case please skip to step 4 If the pan tilt is PLO1 or PLO5 please attach a standard RS232 cable between a host PC and the pan tilt s DB9F connector labeled RS232 After connecting the cable as in the picture to the left please skip ahead to step 5 11 12 Quick Start PTU D48 User Manual Version 3 03 Za 8 en Check section 1 2 2 under the wiring options to determine if your pan tilt is PLO1 or PLO6 if so you may attach the RS232 DB9f from the breakout cable directly to your computer if not please proceed with the rest of this step The pan tilt only provides RS485 422 communications thus to connect to a PC you will have to use the included RS232 RS485 converter Unpack e the converter and attach the DB25 to DB9 converter on one side and the four pin phone cable to the other side At the end of the cable attach the female to female adapter this is important as it rearranges the pins Make
38. te in your terminal program the baud rate of the pan tilt is configurable and may have been changed from its default of 9600 You are now connected to the pan tilt Enter the character for a complete listing of commands The next section describes some basic commands to help you get going and a full command description may be found in the command reference manual We suggest that you exercise the unit and become familiar with its operation and commands before mounting your payload e g camera as described in Section 3 8 Special attention should be paid to acceleration and speed commands and they should be set at levels appropriate to your payload weight and size Installation and Setup PTU D48 User Manual Version 3 03 3 7 Basic Pan Tilt Unit Commands Below are some pan tilt commands that will familiarize you with the pan tilt unit and its operation pp2500 tp 900 PS1900 ppo This sets the pan axis to position 2500 the tilt axis to position 900 the pan speed to 2500 positions a second and sets the pan position back home When operating the pan tilt unit the available command menu is printed when you enter the character A detailed description of pan tilt commands and queries may be found in Section 4 3 8 Mounting Your Payload The PTU D48 provides a flexible payload bracket system that can be configured in a number of ways to support a variety of payloads including cameras lasers antennas and other equi
39. tion to the pan tilt is full duplex and provides Tx Tx Rx and Rx connections for talking with the pan tilt These lines provide RS422 or RS485 voltage levels 3 6 Initial Power up and Test If you have the power source and Host computer connected described in Sections 3 3 and 3 4 you are ready to power up and test its operation Test and verify all cable connections and connector wiring before power up We suggest that you do not mount your payload e g camera until this initial installation is completed and tested 1 Using HyperTerminal or a similar terminal program configure the RS 232 485 serial port of the Host Computer to 9600 baud 1 start bit 8 data bits 1 stop bit and no parity Hardware handshaking and XON XOFF are not used You are now ready to power up the pan tilt unit and test its operation Apply power Upon power up introduction text should appear on your screen and the pan tilt unit should go through a reset cycle pan and tilt axes will cycle through their full range of motion This reset is completed when an asterisk appears If the unit did not reset properly recheck your power source and cabling If the unit went through its reset procedure but no text or garbled text appears on your screen then a Checkthat the host RS 232 RS 485 host port settings are correct see Section 3 4 b Check that the RS 232 RS 485 cable is correct for your host see Section 3 4 c Try a different baud ra
40. ttached to housing and passed through to payload connector Pins arranged as they appear on a female socket connector TP Twisted pair PTU CON Pan Tilt controller board PYLD Base payload connector A B C D E F G H J K L M N p R S T U V Notes 1 CAUTION DO NOT EXCEED MAXIMUM RATED PASS THRU AMPERAGES FUSE PAYLOADS AT RATED TRIP VALUES THE WARRANTY DOES NOT COVER DAMAGES DUE TO OVER CURRENTING 2 The video lines have been specifically routed to have the least impedance of any payload lines and as such it is recommended you place any analog video lines along these payload lines 3 Twisted pairs are not twisted throughout the entire pan tilt but where raw wires are run internally for some distance these pairs are twisted together 4 All communication directions refer to the host Specifically the TX lines represent that data is moving from the PTU Controller to the customer device and the RX lines represent that the data is moving from the customer device to the PTU Controller 5 Itis important that the shield line be terminated either to an appropriate system shield or through a large inductor to the D48 ground PTU D48 User Manual Version 3 03 A 1 6 Payload Schematic Y PD y ID O Ne NN M A BL A e Blue pins indicate payload pass through rated Y to one amp Blue cross hatch pins indicate payload pass through rated to three amps Empty pins indicate cont

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