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STAGEHAND PRO 3

REFERENCE MANUAL 1.1

Summary of Contents for Stagehand Pro 3

Page 2: ...Stagehand Pro 3 Reference Manual 11 20 Index...

Page 3: ...us display 2 Limit switch override buttons New 3 Brake test buttons 3 Mains power indicator 3 Branch circuit protection breaker New 3 VFD Keypad 3 USB commissioning port New 3 Rack mounting New 4 Ethe...

Page 4: ...it 12 Forward Limit 12 Limit Wiring Strategies 13 Speed Encoder 13 Position Encoder 14 Encoder Wiring Strategies 14 Single encoder 15 Dual encoders 15 Ethernet 16 Showstopper 17 OPERATION 17 Manual Op...

Page 5: ...ke Testing 26 Connecting to Spikemark 29 Setting the IP Address 29 Setting the Subnet Mask 30 Auto Tuning 30 Within Spikemark 31 VFD Keypad 33 Parameter Configuration 36 Keypad 37 Restore from USB 37...

Page 6: ...hand Pro 3 Reference Manual 11 20 Index Phone 46 Fax 46 Email 46 SPECIFICATIONS 47 Physical Specifications 47 Electrical Specifications 48 Mitsubishi VFD Parameters 49 PLC Ladder Logic 54 Wiring Diagr...

Page 7: ...2942 x2 We want your automation to succeed and we are eager to help you through any head scratching issues What s in the box Inside the box you should find A welcome card with a quick link to this ma...

Page 8: ...tor Knob When used with the jog buttons the knob will adjust speed from 0 100 It doesn t like to be spun super fast slow and steady is the best method The knob is also a button that can be used for ne...

Page 9: ...rotection breaker New A circuit breaker mounted on the front of the controller alleviates worries of a dangerous circuit overload The breaker also makes it easy to power down the controller without un...

Page 10: ...ht is that the VFD needs to be mounted vertically for proper ventilation To adhere to the manufacturer s mounting recommendations we had to make the case 8U tall As soon as we figure something better...

Page 11: ...feature in the Stagehand firmware that will record the encoder position to flash memory and then read that position if it loses power This bit of engineering obviated the need for a battery backup whi...

Page 12: ...has gone wonky and you need to wipe the drive s memory to start fresh More details follow later in this manual to explain the process INSTALLATION The Stagehand Pro 3 is designed to mount in a standa...

Page 13: ...nput Power The power inlet on the Stagehand is a 6 pin rectangular plug IRC 77mm X 27mm 16B 6P 35A 400V Male There are many manufacturers of these connectors our favorite is by ILME CPM 06 No matter t...

Page 14: ...t what s wrong with the power source Motor and Brake Power output connections for a motor and two brakes have been combined into a single 12 pin rectangular connector ILME CXF 4 8 or compatible Before...

Page 15: ...ed within 60ms of receiving power Under normal operation the motor brake is only engaged once the motor has come to a controlled complete stop The motor brake needs power to release If power is remove...

Page 16: ...nce our Pushstick deck winches do not have a load brake but our Spotline hoist does use a load brake Now that we have an understanding of the terminology the pin out of the Motor and Brakes connector...

Page 17: ...ed monitoring and one for positioning and three sets of limit switches forward reverse and ultimate are combined in one rectangular connector ILME CDDF 24 All limit switch signals require Normally Clo...

Page 18: ...lem with at least one of the primary limit switches The faulty equipment must be repaired and the Ultimate Limit must be mechanically reset before the Stagehand will allow motion Reverse Limit A norma...

Page 19: ...re a pair of conductors for each switch other times it may be better to reduce the number of conductors by sharing a common voltage source Both options are shown below Speed Encoder A set of quadratur...

Page 20: ...it may be a separate encoder For instance a scissor lift needs a speed encoder on the pump motor but the positioning encoder should be placed directly on the lift platform since the relationship betw...

Page 21: ...Stagehand Pro 3 Reference Manual 11 20 Page 15 of 56 Single encoder Dual encoders...

Page 22: ...Stagehand Pro 3 Reference Manual 11 20 Page 16 of 56 Ethernet...

Page 23: ...hat power will be removed from the motor and brakes instantly if the 24vdc Emergency Stop signal is interrupted Before you can move any motor you must connect the Stagehand to a Showstopper with a 5 p...

Page 24: ...the Forward Button While holding the Forward Button turn the Knob Clockwise slowly The brakes should release and the machine should begin to move The Position Encoder counts are displayed on the Statu...

Page 25: ...top the motor If you strike a forward limit while jogging forward you will have to release the forward jog button and then jog in reverse If you strike a reverse limit while jogging reverse you will h...

Page 26: ...hether the Stagehand is actively connected to Spikemark Connected means that the Stagehand has an active connection with a Spikemark computer Disconnected means that the Stagehand is not actively comm...

Page 27: ...e status display and in Spikemark Consult the Mitsubishi A700 manual for the exact fault description the error code is displayed on VFD keypad To clear a drive fault correct the cause of the fault and...

Page 28: ...ad to cycle through the instantaneous current in Amps and the voltage In particular using the display to check the current draw of the motor is a great way to verify whether the attached machine is ov...

Page 29: ...Stagehand Pro 3 Reference Manual 11 20 Page 23 of 56...

Page 30: ...Stagehand Pro 3 Reference Manual 11 20 Page 24 of 56...

Page 31: ...ne has traveled unexpectedly too far Time to stop evaluate what happened and make a correction However sometimes especially during load in or shop testing the limit is merely improperly set and it wou...

Page 32: ...t confirm that the brakes are mechanically operating correctly Since the Stagehand cannot confirm that both brakes are functioning mechanically and that neither has jammed in a released state very rar...

Page 33: ...or Brake should still be engaged and will hold the load If the suspended scenery slips down release the Load Brake button immediately Since the Motor Brake did not hold the load as expected that brake...

Page 34: ...ll manually release the Motor Brake The Load Brake should still be engaged and will hold the load If the suspended scenery slips down release the Motor Brake button immediately Since the Load Brake di...

Page 35: ...nd to control a hoist it may be convenient to manually release the safety brakes at times but it is not required Connecting to Spikemark Setting the IP Address When you are ready to write and run comp...

Page 36: ...the Knob Setting the Subnet Mask Stagehand Pro 3 also allows you to set the Subnet Address To unlock the subnet menu simply press and hold the jog wheel until the display shows the Set Subnet screen...

Page 37: ...he motor brake so the drive can sense the motor s reaction to applied power There are two methods available to execute the Auto Tuning procedure from within Spikemark 4 0 and higher or manually from t...

Page 38: ...Manual 11 20 Page 32 of 56 5 The Drive Auto Tune window will open a The current drive parameters are listed on the left under DRIVE VALUE b Make any changes to the parameters in the right hand column...

Page 39: ...o execute the auto tuning from the VFD keypad Although the procedure has quite a few steps it is straightforward if you follow this guide Turn off PLC mode governing the Brake Test circuitry using the...

Page 40: ...Stagehand Pro 3 Reference Manual 11 20 Page 34 of 56 o Scroll the wheel to find parameter P 414 o Press the SET button to adjust the parameter o Scroll down to the value 0 to turn off the PLC program...

Page 41: ...to the rated current of the motor 14A for 5hp o Set Parameter 71 equal to 3 This is the setting for a general purpose motor o Set Parameter 81 equal to the number of motor poles appropriate for the b...

Page 42: ...rameter P 414 o Press the SET button to adjust the parameter o Scroll down to the value 2 to turn on the PLC program o Press the SET button to accept the new value Restart the VFD by either cycling po...

Page 43: ...and press SET to save Without changing the value press SET to return to the parameter list To return to the parameter list discarding changes press ESC The photos below show the process Restore from U...

Page 44: ...n making or made tweaks to the stock parameters that you d like to save you can save your new parameter set to the USB storage device inside the Stagehand Pro 3 There are 99 available slots that can b...

Page 45: ...cceleration time Standard time to accelerate a movement 0 0 0 8 Deceleration time Standard time to decelerate a movement 0 0 0 9 Electronic thermal O L relay Current rating from the motor nameplate 17...

Page 46: ...ber Specifies the inverter station number 1 1 1 118 PU communication speed 4800bps 48 48 48 119 PU communication stop bit length data length Data length 8 bits stop bit 1 bit 0 0 0 120 PU communicatio...

Page 47: ...hat will trip an overspeed fault 20 20 20 331 RS 485 communication station number RS 485 Communication 1 1 1 332 RS 485 communication speed RS 485 Communication 48 48 48 333 RS 485 communication stop...

Page 48: ...999 9999 800 Control method selection 0 Vector control speed control 10 Sensorless Vector control 20 Volts Frequency control 0 0 0 802 Pre excitation selection servo lock 1 1 1 818 Easy gain tuning re...

Page 49: ...and set to 1 the display will flash between PRCL and 1 once set 9 Power cycle the VFD Now the VFD is in the default state from the factory Before you can use it again you must reload one of our param...

Page 50: ...ess the RESET button on the VFD keypad Confirm that there isn t a limit fault on the status display If so either move off the limit or use the Limit Override buttons to temporarily defeat it When runn...

Page 51: ...either intentionally or just bumped in passing Turn the knob until the cursor is blinking over the word CANCEL and then press the knob The motion controller will now be in normal mode and can jog the...

Page 52: ...If you call outside of normal business hours like during tech or pre show check or intermission please leave a message on the support voicemail We monitor it off hours and then draw straws to figure...

Page 53: ...Stagehand Pro 3 Reference Manual 11 20 Page 47 of 56 SPECIFICATIONS Physical Specifications...

Page 54: ...uto tuning is ineffective below 2HP Minimum Motor Speed 5Hz Maximum Motor Speed Hoisting 60Hz When hoisting the Stagehand Pro cannot be over sped because of the overspeed detection safety feature Maxi...

Page 55: ...ase frequency Set the frequency at the rated motor torque 50Hz 60Hz 60 106 60 7 Acceleration time Standard time to accelerate a movement 0 0 0 8 Deceleration time Standard time to decelerate a movemen...

Page 56: ...etting status Offline auto tuning status 0 not set 1 auto tuning initiated 2 auto tuning in progress 3 auto tuning completed See Stagehand Pro manual for instructions 0 0 0 117 PU communication statio...

Page 57: ...selection General output 9999 9999 9999 252 Override bias Percentage of analog signal to use for speed signal adjust this to overspeed motor 100 100 100 285 Overspeed detection frequency speed deviat...

Page 58: ...to tune motor 2 2 2 549 Protocol selection MODBUS RTU protocol 1 1 1 550 NET mode operation command source selection The RS 485 terminals are the command source when in the NET operation mode 1 1 1 55...

Page 59: ...ehand Pro 3 Reference Manual 11 20 Page 53 of 56 903 Terminal 2 frequency setting gain frequency C4 Enter the value on the Stagehand cabinet or refer to the manual for details on other methods TBD TBD...

Page 60: ...Stagehand Pro 3 Reference Manual 11 20 Page 54 of 56 PLC Ladder Logic...

Page 61: ...Stagehand Pro 3 Reference Manual 11 20 Page 55 of 56...

Page 62: ...Stagehand Pro 3 Reference Manual 11 20 Page 56 of 56 Wiring Diagram The next page has a reduced scale copy of the Stagehand Pro 3 wiring diagram...

Page 63: ...Stagehand Pro 3 Reference Manual 11 20 Page 57 of 56...

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