Daktronics Pro Series User Manual

PRO SERIES OPERATIONS & MAINTENANCE MANUAL

PRO SERIES OPERATIONS MANUAL

Daktronics Automated Rigging System

Manufacturers contact info

7200 Rawson Road

Victor, New York 14564

tel 866-486-7835 585-924-5000 fax 585-924-0545

email sales@daktronics.com

daktronics.com/rigging

TABLE OF CONTENTS

01 Safety Information 1

Warning, cautions, and notes

Electrical safety—general warning Included safety features Compliance with regulations EU declaration of conformity

02 General Information 5

Motor electronic variable frequency drive

Hoist assembly Pro Series Controller (VAC)

 Specications

USA VAC based models and applications VAC—Single purchase VAC—Double purchase European VAC based models and applications VAC—Single purchase VAC—Double purchase Dimensions of a standard unit

03 Theory of Operation 9

04 Administration 11

Password

Add user Remove user E-stops Deadman

05 Manual 19

Motor selection Motor info Hoist info screen Digital I/O screen Speed Set speed numerically Icon selection Up/Down Batten position indicator Upper target

TABLE OF CONTENTS i

Current position Alternate target Lower target Set/clear targets Clear target Setting targets Move to postion Auto up/down Curtain control Open target Current position Alternate target Close target Auto open/close

06 Grouping 29

Create group Name Modify group Modify menu Edit group Trim motor Joystick control Rename group Delete group

07 Cueing 35

Vocabulary Load cue sheet Delete cue sheet Create cue sheet Name Set cue 00.00 Add Cue sheet Number Title Motor/group Target Time/speed More Actions Create action Delete action Modify action More cues Delete cues Modify cues Run cues i-Batten Hide/show alert Alert box functions Clear fault Bypass Disable

PRO SERIES OPERATIONS MANUAL

08 Presets 53

Create preset Name preset Create Order controls Omit motor Move in list All Target controls Up/down Keypad UPR/LWR Joystick Delete preset Modify preset Modify screen Run preset

  Conrmpreset

Run screen Pause screen

09 Setup 63

Motor selection

Batten setup Restore factory setting Bypass i-Batten safety

  Conrm

Curtain setup Rename Speed Set speed numerically Up/down Batten position indicator Upper limit Current position Lower limit Set/clear limits Set upper/lower limits Clear upper/lower limits Move to position Auto up/down Icon selection Icon management Add category Add icons Delete icons Category management Edit category Delete category Curtain control

TABLE OF CONTENTS

iii

Open target Current position Alternate target Close target

10 Motor Restrictions 79

Disable motors Enable motors Order motors

11 E-Stop & Deadman Recognition 83

E-Stop display Deadman display

12 View 87

View display Numerical information Individual display Hoist info panel Digital I/O panel

13 Troubleshooting 91

14 Warranty 93

15 Maintenance 95

Periodic Inspections Recommended Supplies System Maintenance

16 Cue Sheets 105

01 SAFETY INFORMATION

Warnings, cautions and notes

All Warning notes contained in this manual indicate information that may endanger personnel.

WARNING

The Daktronics rigging system is designed to raise and lower theatrical equipment under the rated hoist capacity ONLY. This system is NOT designed to lift or lower personnel, and should never be used for that purpose.

Only trained and authorized personnel should be permitted to operate the Daktronics system. The unauthorized use, alteration, or use for purposes other than those for which it was designed may cause injury to persons, damage to the equipment, or create conditions which could lead to fatalities. All proper safety considerations must be observed. While operating the Daktronics rigging system, a spotter must be used in conjunction with the user at all times. The spotter must have a clear view of all moving elements while maintaining contact with the user. If an unsafe situation occurs, the spotter must immediately signal the user to halt all movements until the environment is cleared of any person or obstruction.

All installation and maintenance involving the Daktronics drive unit itself or the main electrical control cabinets will require trained personnel. Simple daily maintenance activities such as cleaning of the touchscreen and the VAC workstation may be carried out by the operators, and in most cases will be all that is needed once installed.

Electrical Safety—General Warning

WARNING

Before working on any of the Vortek hoists, the main electrical disconnect must be turned off and locked out according to OSHA regulations 29 CFR 1910.147.

The voltages used in the motor drive and master control panels can cause severe electrical shock and/or burns. Extreme care is necessary at all times when working with the motor drives. Only authorized personnel should carry out any installation, commissioning, or maintenance of the electrical systems. All drive systems have been tuned at the factory and will not require any additional alteration or adjustment by the owner’s personnel unless specifically authorized by a Daktronics representative.

SAFETY INFORMATION

Included Safety Features

i-Batten with Over-load and Under-load Protection

The i-Batten feature allows the authorized operator to preset sensitivity on the maximum and minimum loads a specific Vortek hoist will encounter. If the system detects a load outside the set range, indicating a possible problem, the unit will automatically stop all motion. It is strongly recommended that this feature be used in order to prevent any injury to personnel or damage to equipment.

Emergency Stop

A red Emergency Stop mushroom head push button is located on each VAC control station. Pushing the button will disable all motor drives connected through the specific VAC, and set all motor brakes. This will stop all motion of the attached loads on each Vortek hoist immediately, and inhibit further movement until reset.

The Emergency Stops should ONLY be used for real emergencies or when required to reset a motor fault if indicated on the VAC touchscreen.

Vortek Back-Up brake

This secondary mechanical braking system is designed to hold the rated load in the improbable case of a failure of the primary motor brake or gearbox. This system acts independently of any electrical inputs on the system.

Compliance with Regulations

The Daktronics system complies with the relevant European directives required for the CE mark, including:

98/37/EC: Machinery Directive

73/23/EEC: Low Voltage Directive

89/336/EEC: Electromagnetic Compatibility

Independent reviews/tests in support of above compliance

EN55022 Class A Radiated and Conducted Emissions

EN61000-4-2 Electrostatic Discharge

EN61000-4-6 Conducted Susceptibility

EN60950, 60204 Safety Review

Airborne noise emissions

Continuous A-weighted sound pressure levels at distances 40 feet from the Vortek hoist module, a typical distance for the operator VAC control unit to be located, do not exceed 70 decibels.

EU DECLARATION OF CONFORMITY

Manufacturer's name and address:

Daktronics, 7200 Rawson Road Victor, N.Y. 14564 USA

We declare under sole responsibility that the product:

Product Name:

Daktronics Automated Theater Rigging system

Product Description:

Automated Hoisting Equipment for theatrical venues

Product type/model:

Single Purchase: V_-12180, V_-1740, V_-14120, V_-2020, V_-0820, H_-22230, H_-4020,

EV_-0509, EV_-0607, EV_-0702, EV_-0901, EV_-0301, EH_-1012, EH_-1801

Double Purchase: V_-12180-2, V_-1740-2, V_-14120-2, V_-2020-2, V_-0820-2, H_-22230-2, H_-4020-2,

EV_-0509-2, EV_-0607-2, EV_-0702-2, EV_-0901-2, EV_-0301-2, EH_-1012-2, EH_-1801-2

*To reference the model list of pre-2009 hoist nomenclature, see Troubleshooting on p. 91.

Conforms to the following standard(s) :

EN 60204-1 Safety of Machinery/ Electrical Equipment for Machinery EN 60950 (ITE) Information Technology Equipment

EN 55022 Class A Product Specific Emissions

EN 61000-4-2 Electrostatic Discharge

EN 61000-4-6 Conducted RF Susceptibility

Following the provisions of the EU Machinery Directive 98/37/EC, EU Low Voltage Directive 73/23/EEC, and EU EMC Directive 89/336/EEC.

SAFETY INFORMATION

02 GENERAL INFORMATION

WARNING

The Daktronics hoist system is an automated rigging system meaning that the load is not counter-weighted. Each hoist can lift loads only up to the design capacity. Overloading will result in electrical overload protection shut down of the hoist and possible damage to rigging components.

Each hoist system consists of an integral electric motor driven reducer, directly coupled to a cable drum, which winds steel cables (wire ropes) leading over sheaves installed within the hoist assembly and along the structural steel of the building. The cables support battens for attaching the load. The battens can be lowered to within the specified trim above the stage floor to allow attachment of loads.

The Daktronics hoist system consists of three basic parts.

Motor electronic variable frequency drive

The Electronic Variable Frequency Drive and dynamic braking resistor for each motor is located in each Vortek motorized hoist. A local control panel is located on each hoist for programming and diagnostics by factory personnel. There is a reset-able circuit breaker located at each power point on the HV wireway. The rated twist-locking plug on each unit acts as the main high voltage disconnect along with its corresponding CB.

The Vortek batten hoists are not designed to raise and lower people. These hoists should NEVER be used for this purpose.

Hoist assembly (cable drum, load brake, limit switches and frame)

The Vortek hoist assemblies are mounted on the rigging steel at the top of the stage house. The gearmotor, helically grooved cable drum, support bearing and frame structure are all factory assembled and tested. Maximum upper height and minimum lower height are set by limit switches which are adjusted by factory-trained personnel during installation and commissioning of the system. A position encoder is located at the brake end of each hoist motor, attached directly to the motor shaft. Each hoist assembly is also equipped with a LOAD BRAKE, a unique safety feature provided exclusively by Daktronics. This unit is designed to engage automatically when the load is being lowered. This greatly reduces any possibility of a loaded batten to descend uncontrolled.

GENERAL INFORMATION

Pro Series controller

Control of all hoists is possible from the Daktronics VAC console. The hoists can be controlled individually, and operated at various speeds. Please see the Controls Operating portion of this manual for the operating procedures.

WARNING

If it is necessary to operate a hoist from a location where the operator's view of the moving load is obstructed, a second person must be used to observe the load and communicate to the operator.

Specifications

WARNING

THE FOLLOWING MODELS ARE VARIABLE SPEED AND DESIGNATED TO BE CONTROLLED THROUGH THE VORTEK AUTOMATION CENTER (VAC

The Vortek hoist must only be used with a maximum load equal to the capacity stated for your model below. Overloading the system may result in serious injury or an inoperable system.

). THE VAC IS A STAND ALONE AUTOMATION SYSTEM.

USA VAC® based models and applications

VAC - Single Purchase

MODEL NUMBER LOAD LBS (kg) SPEED FT/MIN (M/SEC)

V_-0820 0 - 800 (362) 0 - 20 (.1)

V_-12180 0 - 1200 (540) 0 - 180 (0.914)

V_-14120 0 - 1400 (635) 0 - 120 (.6)

V_-1740 0 - 1750 (790) 0 - 40 (0.203

V_-2020 0 - 2000 (900) 0 - 20 (0.101)

H_-22230 0 - 2200 (1000) 0 - 234 (1.2)

H_-4020 0 - 4000 (1814) 0 - 20 (.1)

VAC - Double Purchase

MODEL NUMBER LOAD LBS (kg) SPEED FT/MIN (M/SEC)

V_-0820 0 - 1600 (725) 0 - 10 (.05)

V_-12180-2 0 - 2400 (1080) 0 - 90 (0.457)

V_-14120 0 - 2800 (1270) 0 - 60 (.3)

V_-1740-2 0 - 3500 (1580) 0 - 20 (0.101)

V_-2020-2 0 - 4000 (1800) 0 - 10 (0.050)

H_-22230 0 - 4400 (2000) 0 - 117 (.6)

H_-4020 0 - 8000 (3628) 0 - 10 (.05)

Maximum travel distance is 65' (19.8 m) for Single Purchase Units, 32.5' (9.9 m) for Double Purchase Units.

European VAC® based models and applications

VAC - Single Purchase

MODEL NUMBER LOAD kg SPEED M/SEC

EV_-0301 360 0.10

EV_-0509 500 0.9

EV_-0607 630 0.7

EV_-0702 790 0.2

EV_-0901 910 0.1

EH_-1012 1000 102

EH_-1801 1810 0.1

VAC - Double Purchase

MODEL NUMBER LOAD kg SPEED M/SEC

EV_-0301-2 720 0.05

EV_-0509-2 1100 0.45

EV_-0607-2 1260 0.35

EV_-0702-2 1580 0.01

EV_-0901-2 1820 0.05

EH_-1012-2 2000 0.06

EH_-1801-2 3620 0.05

Maximum travel distance is 65' (19.8 m) for Single Purchase Units, 32.5' (9.9 m) for Double Purchase Units.

Dimensions of Standard Unit

• Average weight of self-contained hoist module is 600 lb (272 kg)

• Height = 19.35" (49.15 cm)

• Length = 12' 9" (3.9 m)

• Width = 9" (22.9 cm) -- 6" (15.2 cm) centers can be achieved by positioning self-containing hoist modules on opposite or opposing sides of the stage (stage right and stage left)

GENERAL INFORMATION

03 THEORY OF OPERATION

Each Vortek hoist is connected to the main high voltage power buss through a safety twist-locking plug. This plug brings in the main 3-phase power that is connected to the motor drive and motor brake located in each hoist assembly. Also connected to each Vortek hoist assembly through safety locking connectors are 24 V DC power, E-Stop circuit, and a computer network cable.

The motor drive controls all movements of the hoist. Each drive on each hoist contains programming to identify it to the network. This programming also includes but is not limited to maximum speed, acceleration, gear ratios and soft limits. Each motor drive monitors an incremental encoder, limit switches, i-Batten™ safety feature and emergency stop status. The incremental encoder is used for position control. The limit switches are used for maximum up and down travel. i-Batten safety feature is used for the detection of both an underload or overload condition. The emergency stop status is used to detect the operation of the emergency stop system.

Monitoring of each hoist is done over the network using a master drive. The master drive is located in the master drive cabinet typically at stage level. Included in the master drive cabinet are the master drive and the network hubs. A 24 V DC power supply that powers the network hubs and the E-Stop circuit is also located in the master drive cabinet.

The main Daktronics Pro Series controller (VAC) is comprised of a Pentium joysticks and E-Stop button. The VAC computer runs a proprietary Windows® based application that allows the operator to perform manual and programmable functions to any or all of the hoists connected to the system. The VAC is connected to the master drive and motor drives through an ArcNet™ based network operating at 2.5 Mbaud. During operation of the VAC, data is transmitted from the VAC computer through the network system to the master drive and distributed to the appropriate hoist drive. Likewise, data is received from each hoist drive through the master drive and to the VAC computer for display by the VAC operating software. The 24-volt dc E-Stop circuit is also connected to the E-Stop button located on the front of the VAC.

class computer, touch screen, keyboard,

THEORY OF OPERATION

Figure 4.1: Administration screen

04 ADMINISTRATION

The administration module (Figure 4.1) allows the user to change the system preferences according to their security level.

An operator may change their password.

An administrator may add users, change their password, or remove users at administrator level and below.

The screen on the top shows the operator level screen, while the screen on the bottom shows the administrator level screen.

On-screen assistance can always be found by touching HELP in the lower right corner.

Figure 4.2: Password screen

Password

Touch PASSWORD from the main menu to edit your password for the system.

Before your password can be changed, you must first enter your old password so the system can verify your identity.

Select the next field to enter by touching the field you wish to enter.

Enter your new password in the New Password field (Figure 4.2) and the Confirm field.

When the Old Password is correct and the New Password fields contain the same value, the ACCEPT button will light. Touch ACCEPT to confirm the change, or touch DECLINE to return to the main menu without changing the password.

ADMINISTRATION

Add user

From the main menu, Administrators may touch ADD USER to insert profiles of new users into the system. The New User screen (Figure 4.3) will display.

A profile consists of the new user’s name, password and user type (either Normal User, Administrator, or Factory).

A complete profile (Figure 4.4) of the new user must be entered before the Accept button will activate. Touch ACCEPT to confirm the addition of the user.

Figure 4.3: New User screen

Figure 4.4: New User screen with a complete profile filled in.

Figure 4.5: Remove User screen

Remove user

From the main menu, administrators may touch REMOVE USER to delete profiles of users out of the system. The Remove User screen (Figure 4.5) will display.

Select a user by touching their name. After selection the Accept button activates.

Touch ACCEPT to confirm the removal of the user and return to the main menu.

Administrators may only delete Administrators and Operator level users. Administrators can not delete Factory level users.

Figure 4.6: E-Stops screen awaiting selection.

E-Stops

From the main menu, administrators may touch E-STOPS to edit the names of multiple E-Stops for the system. The reason to do this is to specify the location of the activated E-Stop.

Select an E-Stop by touching its name.

13ADMINISTRATION

After selection the Change E-Stop Label field activates.

Type a new name for the E-Stop and touch ACCEPT to confirm the new name.

Figure 4.7: E-Stops screen awaiting the new name

Figure 4.8: E-Stops screen.

Figure 4.9 Label Deadman screen

Deadman

From the Administration module, (Figure 4.9) administrators may touch LABEL DEADMAN to edit the names of one or more Deadman switches for the system (Optional). This will help identify the Deadman switch location where multiple Deadman switches are required.

Select a Deadman switch to edit

After selecting a Deadman switch to edit, the Change Deadman Label field activates. Type a new name for the Deadman switch and touch ACCEPT to confirm the new name (Figure 4.10).

Figure 4.10: Change Deadman Label field

Figure 4.11: Deadman open window

Upon pressing the DEADMAN button, a window will open (Figure 4.11).

ADMINISTRATION 15

This window will list the name of any Deadman switch that is not depressed (Figure 4.12).

The Deadman button will change from red to green when the DEADMAN switch is pressed, allowing movement (Figure 4.13).

Figure 4.12: Deadman switches not tripped

All hoist movement will be inhibited and each move initiating button will be grayed out and unusable until the Deadman switch(s) is depressed (Figure 4.14).

Figure 4.13: Green button allows movement

Figure 4.14: Hoist movement inhibited

Figure 4.15: Move to Position control disabled

Move to Position control is also disabled while the Deadman switch is not pressed (Figure

4.15)

When the Deadman switch is depressed, control functionality will be restored, and grayed out buttons will once again be available. This function applies to all modules when the Deadman feature is enabled. (Figure 4.16).

Figure 4.16: Deadman functionality restored

17ADMINISTRATION

Figure 5.1: Manual screen

05 MANUAL

The Manual module (Figure 5.1) has two controllers, each of which controls a motor, group or curtain. After selecting which element to control, its speed, position, targets or icon may be changed.

Additionally, the controllers display the state of the i-Batten safety feature. If a weight change for the batten is detected, the Vortek will stop the motor from moving until the batten weight returns to normal.

If the safety feature is disabled for a motor or group, the controller will display a red slash over the i-Batten logo (see Figure 5.2).

On-screen assistance can always be found by touching HELP in the lower right corner.

Enabled Disabled

Figure 5.2: i-Batten status

19MANUAL

Motor selection

Select a motor by touching the yellow drop down button at the top of the menu as shown in Figure 5.3.

The dropdown menu expands to show a list of all available motors, with grouped motors shown in blue (Figure 5.4).

Move through the list by using the:

• Slider

• PgUp

• PgDn

Figure 5.3: Motor Select button

Touch the name of the desired motor or group to select it. It will highlight and both MOTOR INFO and CONFIRM will activate (Figure 5.5).

Touch CONFIRM to verify the selection. If there’s a need to find out more detailed information about the selected motor, touch MOTOR INFO.

Before touching CONFIRM, change the selection by touching a different motor name.

Figure 5.4: Motor Select screen

Figure 5.5: Motor selected

MOTOR INFO

When the MOTOR INFO button is touched, the Hoist Info screen is displayed (Figure 5.6).

Hoist Info screen

This screen has details about the

• Batten Weight

• Acceleration Rates

• Gear Ratio and Diameter

• Batten Position

• Motor Speed

• Operating Temperature

• Travel Distance

Touch the DIGITAL I/O button to display the Digital I/O screen (Figure 5.7) or touch

CONTINUE to return to the normal display.

Figure 5.6: Hoist Info screen

Figure 5.7: Digital I/O screen

Digital I/O screen

This screen displays:

• The last five trip codes

• Whether the motor is at the Upper / Lower Limit

• Whether an E-Stop is engaged

• Whether an Overload or Underload has occurred

• Whether the motor is healthy

• Whether the motor is not moving

• Whether the hardware Upper / Lower Limit is reached

• Whether a Homed Up / Down command has been completed

• Whether extreme operating temperatures have been encountered.

• Whether the motor’s power has been lost

Touch the HOIST INFO button to display the Hoist Info screen or touch CONTINUE to return to the normal display.

MANUAL 21

SPEED

The speed button is located under the Motor Select dropdown menu (Figure 5.8). To change the speed, touch and hold down the speed button. Slide it to the right to increase the speed of the selected motor, or left to decrease the speed.

Above the button, the current speed is shown on the left, while the maximum speed of the selected motor is shown on the right.

Set Speed Numerically

Touch the speed button twice quickly (double-click) to adjust the speed with greater accuracy,

The controller will display a keypad for manual entry (Figure 5.9). Enter the new speed value and touch

KEYPAD to confirm the entered value.

Figure 5.8:

Speed button

Icon Selection

The button for icon selection is located to the right of Motor Select (Figure 5.10). The icon for the selected motor appears here.

To change the icon, double-click the icon to display the Icon Selection panel (Figure 5.11).

Select a category by touching its name in the category list. The different icons available will display in the box on the right. Use the scroll bar to navigate through the icons. Choose an icon by touching it.

Touch DONE to confirm the selection, or CANCEL to leave the function without changing the icon.

Figure 5.9: Enter speed numerically

Figure 5.10: Icon Selection button

Figure 5.11: Icon Selection

UP / DOWN

These buttons raise or lower the batten. They are colored blue for up and green for down.

To move the motor, touch and hold an arrow key. When pressed, they divide into three areas (Figure 5.12).

Touch the MINUS (-) to decrease the speed, or to PLUS (+) to increase it while the motor is moving. The motor will stop moving when the button is no longer touched or the motor has reached its pre-set target position.

Figure 5.12: Up arrow depressed

Upper target

Current position

Alternate target

WARNING

If any problems arise during any hoist motions, depress the Emergency Stop button located below the monitor immediately and all hoist movements will stop.

BATTEN POSITION INDICATOR

This displays the batten position visually and numerically relative to its upper and lower target height. The batten upper and lower target values along with alternate targets (if any exist) are also displayed (Figure 5.13).

Upper target

This dark blue button shows the value for the upper target.

Current position

This light blue bar shows the position of the batten in relation to the targets. As the batten moves, this display will move as well.

Figure 5.13: Batten indicator

Lower target

Alternate target

This gray box is another target position. The VAC allows three of these per motor.

Lower target

This green button shows the value for the lower target.

MANUAL

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